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I’m sorry for that. TH-cam pulled the audio due to a copyright infringement with music I was playing in the background. I don’t know how to correct it.

@@garygiglio6359 yeah I don't know. Maybe there's a way to at least put in the closed captions for what you said

Hey brother, I taught myself how to TIG weld and I started repairs on the case I’ve split the motor I’ve torn everything down. I haven’t produced video in quite some time but I’m going to try to start again this winter. I’ll let you know when I post my very next video, it’s probably going to be covering, some of the repairs I’ve already done and showing the new primary shut up with a custom compensator and extended case as to allow for more oil. Thank you for your comment. I appreciate your time and attention.

Once I tore it all down, I found that one of the four bolts in the transmission trap door came out my fault. I must’ve neglected to put retaining compound on it.

The best way to repair those would be to TIG weld them, you are correct. I am currently in the process of doing just that. I have another video showing some catastrophic damage to the primary side case. I purchased a TIG welder and taught myself how to use it. I will be posting footage of those repairs soon.

Mine were tig welded and held up fine

I was playing some music in the background and TH-cam considered it “copyright infringement and cut the soundtrack

It’s a 1968 XLCH 55.

I plan on posting a video covering up to date repairs and outlining the plan moving forward. The last year or so has us barely catching our breath. The shop is up and functioning but it’s been slow moving. I appreciate you taking the time to watch and contact me. I will post within the next couple of weeks. Thanks again.

@@garygiglio6359 thank u

Thank you for watching, I appreciate the optimism. I bought all the replacement parts and a TIG welder and started the repairs. It has been a while since I’ve done any work on it, Covid and a move of residence has killed any progress. I plan on posting video of the progress soon. Thanks again.

Thank you, I have started repairs in the middle of moving and as soon I’m settled in I will post more video.

Thanks brother, I think one of the transmission door bolts came out and got caught up in the chain and sprocket.

@@garygiglio6359 I saw that in your second video. that makes sense.

Thank you Brother, I appreciate that.

WOW… do you know what he wants for it?

@@garygiglio6359 I will check. Has orig tank and seat but other tank and seat on it now. In north Carolina garage.

I saw something like that too… got me thinking. Someone referred to it as “divorcing the transmission “ There’s a good chance of going in that direction. I’m going to get back to the bike project soon, I’m in the middle of 68 corvette project now. Thanks for your interest and your comments, I appreciate you taking the time.

I did wind up splitting the cases after-all. I agree with you on it being the proper way to go.

@@garygiglio6359 I do a lot of crankcase repair, if I can help in any way let me know. I saw that damage and my mind immediately began thinking about how I'd repair it.

Bet that Stroker sounded amazing. I started repairs on the case and have all the replacement parts as well. I talked the wife into a TIG welder and all the kit to go with it. The Rona has interrupted progress but I’ll be back at it soon. I will record and post where I’m at in the repairs in a few weeks. Thanks for checking me out and your comments Brother… cheers.

@@garygiglio6359 I have an Aerospace Machinist background with metal fab experience. TIG has always been a favorite. Retired, I sure do miss the equip I had access to at work. Cast alum is porous and saturates with oil, big-time contaminate : ( I have made vibratory cleaning tanks (2) powered by palm sanders with sanding pad removed (regulated by router speed control) and used Purple Power for my cleaning agent. AWESOME results!! Need to build 1 more, big enough for the larger right side case to fit. Another project...

Thank you Brother, I appreciate your encouragement

Thank you for your kind words. The primary chain was diamond brand but it was not the chain that failed on its own. After further break-down I found one of the transmission trap door bolts missing. That bolt came loose and got caught up in the chain causing it to break along with some teeth on the main sprocket and the clutch basket. I have a second video that covers the missing bolt. Thank you for watching. I appreciate your time and attention. I have made some repairs to the case and plan to share the continued repairs and modifications thus far in a video or two coming soon. Thanks again.

@@garygiglio6359 hopefully everything works out for you, what caused the bolt to come loose like that??? Was it caused by under tightening or no lock tight??

@@Johnclark300 it was completely my fault. I failed to use a retaining compound on that bolt. The last time I rebuilt the transmission I used thread inserts for all four trap door bolts and thought I locked them down. There was as no evidence of retaining compound anywhere in or around that bolt hole.

You are welcome Scott. I have a digital manual that I use, I could try emailing you files from it. I also use the resources from “The XL Forum”. I joined years ago and it has been a great resource for information. Keeping an old Ironhead alive takes a village. I would love to help if I can.

I bought the springer front from DNA through EBay along with the shock. The shock is important for a solid feel. I read a lot of negative reviews of DNA springer front ends but I have been very happy. It’s been 10 years with it and no issues. The bars are standard drag bars with 6” rise.

The plates are made from 1-1/4x1/8in. flate stock cut to 3-1/2in. long. The spacers are 3/4in. round stock cut to 1-1/2in. long and I am using 1/2in. grade 8 bolts 2-1/2in.long. The holes are 1/2in.drilled 3/4in. on center from each end.

Thanks bro

I took an old friction disc and steel disc and bolted them together as to replicate Harley part; 97175-55 "Clutch Lock Plate" I then took some 1-1/4 flat stock and 11/16 tube stock to replicate Harley part; 97200-55 "Sprocket Locking Link" You can reference these tools on page 4T-2 in your service manual. I hope I answered your question. I appoligize for the delay in answering you, your question went to my "Spam" folder.

"Locking Tool"; The plates are made from 1-1/4x1/8in. flate stock cut to 3-1/2in. long. The spacers are 3/4in. round stock cut to 1-1/2in. long and I am using 1/2in. grade 8 bolts 2-1/2in.long. The holes are 1/2in.drilled 3/4in. on center from each end. The "Clutch Basket Lock" is made by simply bolting together 1 old friction disc and 1 old clutch plate. The two bolted together when placed into the clutch basket locks the outer basket to the inner clutch hub. When using the two tools together you immobilize the entire primary drive as to loose or tighten the PTO nut and/or the clutch hub bolt.

Thank you Brad, I appreciate you taking the time to comment.

Thank you

It turned out that the reason I could not get constant measurements was that the main-shaft was bent. The play in the shift pawl was inconsequential. I replaced the main-shaft and the transmission functioned properly. Thank you for your question. I hope I was helpful.

Yep , same here.