Getting it all back together

[Chicknstripn]

This goes out to those of you that have removed your crank or transmission. First the manual calls for a shirt detent tool when reinstalling the flywheel. The tool goes into the right crankcase and holds the little mechanism in place that actuates the neutral sensor. Or something like that. Anyway is this tool really necessary?
AND when installing the flywheel, is the crankshaft alignment tool really necessary?

 

[d_adams]

Anyway is this tool really necessary?

No, I did it without the tool, but it would be much easier with it. It's not super difficult to accomplish.

 

[Chicknstripn]

Adams you're the man when it comes to fabrication and maintanence SO I guess I should be able to get it all back together without TOO much trouble. Thanks for the reply.

 

[Chicknstripn]

That leads me to my next question..... ....what's a good alternative for the HD special assembly grease or whatever the manual calls for?

 

[gbalias]

assembly lube


you can use a metric socket (i forgot the size, maybe 9-10mm) for the neutral detent. or, you can assemble the cases about 85%, then use a pick or screwdriver to position the neutral location.

when you get it together, youll see what i mean.

 

[Chicknstripn]

Ok. Thanks for the tips. The assembly lube... .... Is that something I can just find at my favorite AutoParts store?

 

[gbalias]

Yup

 

[Chicknstripn]

Ok. So I'm seriously stalling on my rebuild. Here's why... ...when I installed my crank and put the crank case halves back together the spacer, on the stator side of the crank, just fell right out. It's the spacer that goes between the out put shaft and the output shaft seal.
Now I'm stalling cause I can't figure out if this is normal. I've done a little research and only found one place in the service manual that addresses this spacer. It's in the section that addresses replacing the out put shaft oil seal. And in this section it states that if the spacer is removed then the oil seal needs to be replaced.
My oil seal was not leaking prior to the rebuild and only had about 5k before I had to split the cases to chase my transmission problem.
Any advice or guidance is greatly appreciated.

 

[rchuff]

Your best bet would be to replace it don't think you would want to pull it a part again because it is leaking . If you replace you know it will not leak. (piece of mind).

 

[Chicknstripn]

I was thinking the same thing. Only thing holding me back is the fact that I don't have the special tools required to seat the stinking seal.
AND I definitely NEVER want to rebuild this thing AGAIN!
Anyone on here have any experiance doing an out put shaft oil seal without the required tools?

 

[mrlogix]

not familiar with the XB's but typically a seal install tool is a hollow metal tube that the O.D. is the same as the O.D. of the seal being installed. The I.D. of the tube is larger than the unprotected seal lip. The purpose of the tool is to allow the seal to be inserted (pressed or lightly tapped into the seal retaining bore without cocking at an angle. Without knowing or seeing the actual application the tube (tool) length needs to be long enough to slip over the end of the crankshaft so it can be pressed on or tapped with a hammer with out hitting the crankshaft end. If your going to tap it into place lightly lube (3in 1 oil, WD40, etc.) the crankshaft surface so the seal lip slides over the crankshaft until the seal casing (metal shell) is in contact with the seal bore. Slide the tool/tube over the crankshaft and LIGHTLY tap around the tube end diameter evenly to start the seal into the bore. Be careful not to get the seal going in at an angle. Once the seal is started evenly into the bore you can TAP a little harder evenly around the end of the tube or put a flat piece of metal against the end of the tube so the hammer taps are moving the seal in evenly until the seal seats (usually when the seal casing surface is flush with the seal bore top surface) wa la. Done. Sounds more complicated than it actually is. Wish I had pic's to help make sense of it. Hope this helps.

 

[Chicknstripn]

I have downloaded a service manual so I can see how the seal and tool combo work.
I appreciate your response but the seal on an xb does not make contact with the crank shaft. It does make contact with the spacer that came out of place during this rebuild process. The OD of the seal seats into the crankcase, the inner diameter of the seal makes contact with the OD of the spacer and the inner diameter of the spacer makes contact with the crankshaft. At least that's what it looks like.
Also, I've read some threads about people using DIY tool to seat their seals and to find that they seated the seal too far in the crank case. Thus the seal made contact with the case bearing and wound up needing to be replaced within a few hundred miles.
Anyway, I'll figure this out.
Thanks for the responses. I do appreciate others opinions experiance views and tips

 

[Chicknstripn]

So I can't find how MY seal would be replaced.
I'm totally hung up on this one part o my rebuild.
Here's what makes mine a little different. I had my bottom end, an 07, modified to fit an 08 crank. I tried down loading the 09 manual off of buell mods but something is wrong with the file and it does not work.
The 07 output shaft oil seal and spacer are press fit only. My modified bottom end has a snap ring retaining the seal.
Anyone have experience with this on an 08 bottom end?
I sent an email to the company that performed the mod but haven't heard back from them.
Any help is greatly appreciated