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Rockerdan's 1200X Build thread---Lots of technical info on the new


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#646 rockerdan

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Posted 09 February 2016 - 09:57 AM

Using the secondary tool tightened into the Jshaft.....slide items on in the correct order....

 

-Plastic washer

-compression spring

-plastic washer

-helix

 

-start to snug down secondary tool

 

...........

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Edited by rockerdan, 09 February 2016 - 09:57 AM.


#647 rockerdan

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Posted 09 February 2016 - 10:00 AM

**Important-- Take note of the Helix ramps. Most brands will have their Logo or some sort of stamp at the correct ramp for roller to be in. It is the ramp with the curved bottom.

 

Compress the secondary tool pushing helix into secondary, making sure roller is in correct ramp location.

 

.........

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Edited by rockerdan, 09 February 2016 - 10:01 AM.


#648 rockerdan

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Posted 09 February 2016 - 10:06 AM

Using one hex bolt from behind, line up one hole to get helix lined up with the bolt holes.....I then use blue loctite on all 4 helix bolts and tighten them down equally in cross/cross pattern.

 

Now remove the secondary tool completely as Helix is done.

 

Reinstall the belt adjuster with large flat washer first against helix, be sure it is oriented correctly.

 

 

......

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Edited by rockerdan, 09 February 2016 - 10:09 AM.


#649 rockerdan

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Posted 09 February 2016 - 10:31 AM

Secondary & JackShaft Removal

 

To get at the Rear motor mount to shim it, we need to remove the Secondary clutch and Jackshaft to have room.

 

Start the process by removing the rubber plug at top of chaincase(where you add chaincase oil) and then remove the bolt.

 

..........

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Edited by rockerdan, 09 February 2016 - 10:32 AM.


#650 rockerdan

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Posted 09 February 2016 - 10:39 AM

Now go around to the secondary side, behind the secondary you see the Bearing, remove the bearing retainer nut with 13mm ratchet wrench. Dont drop the nylock nut!

 

move the bearing retainer out of the way, the clamp around the brake line is not an issue.

 

........

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Edited by rockerdan, 09 February 2016 - 10:40 AM.


#651 rockerdan

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Posted 09 February 2016 - 10:44 AM

With Bearing retainer bracket removed....I use a 1/4" drive LONG extension.....I slide extension into the chaincase end of Jshaft, the 1/4" drive fits perfectly into the threaded hole of Jshaft end at chaincase. Now tap on the extension with a hammer, and this will drive out the Jshaft and bearing from the frame on PTO side. My sled is new so it popped out with a couple hits, older sleds will be tougher, and I recommend using some anti-seize or abit of grease when reinstalling jShaft bearing into frame.

 

.........

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Edited by rockerdan, 09 February 2016 - 10:46 AM.


#652 rockerdan

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Posted 09 February 2016 - 10:49 AM

When pulling out the Jshaft....leave the 1/4" drive extension laying thru the chaincase top gear, the gear will not fall but I just leave the extension laying in there to be sure.

 

With Jshaft out, this is a good time to install helix HEX bolts, so you can then swap helix anytime you want without any special tool or ever removing Jshaft again.

 

Also a good time for SHIMMING the secondary if you have previously found your alignment to be too low.

 

 

..........

Attached Files


Edited by rockerdan, 09 February 2016 - 10:51 AM.


#653 rockerdan

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Posted 09 February 2016 - 11:45 AM

Installing PB80

 

Clean off the crank shaft PTO end and be certain it is free of any oil or grease ect.....needs to be dry and clean.

 

Install clutch onto crank, Add some anti-seize to the bolt threads and insert specific pb80 length bolt and conical washer(in correct orientation) and thread in tight by hand.

 

Using a torque wrench and the PB80 holding tool, torque down the clutch to 80-90 ft lbs.

 

.........

Attached Files


Edited by rockerdan, 09 February 2016 - 11:46 AM.


#654 rockerdan

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Posted 09 February 2016 - 11:56 AM

Reinstall Jshaft and secondary.....clean out bearing socket on frame(at bearing retainer) and add some grease or anti-seize here.

 

Reverse procedure, sliding the jshaft thru the pto frame and across. Then from the chain side, push the 1/4" extension into the threaded hole on Jshaft, then you can help guide the Jshaft into the chaincase and top gear. If the chain is tight, this can make it more difficult to get Jshaft into the top gear, but mine was loose enough and went right in.

 

Once you have it into case and top gear..take a block of wood(2x4) and place it over PTO end of Jshaft, and tap it a few times with hammer to set the jshaft bearing into the frame fully so its bottomed out into frame.

 

TIP: Dont forget the SHIMS if your alignment was off.

 

 

 

.........

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Edited by rockerdan, 09 February 2016 - 12:12 PM.


#655 rockerdan

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Posted 09 February 2016 - 12:04 PM

Apply blue loctite to top gear bolt and install.(holding brake will help to stop gear from turning)

 

install the black rubber plug into top of chaincase.

 

Reinstall the bearing retainer bracket, and the 13mm nylock nut behind secondary.

 

........

Attached Files


Edited by rockerdan, 09 February 2016 - 12:10 PM.


#656 rockerdan

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Posted 09 February 2016 - 12:11 PM

Clutches all installed..

 

Gates belt on

 

...........

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Edited by rockerdan, 09 February 2016 - 12:15 PM.


#657 rockerdan

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Posted 09 February 2016 - 12:18 PM

Cooling the PB80

 

Many things to do to aid in clutch cooling....I have some vents and other things to install but for now I had the hood off and decided to use the wrap I had since it looks like I wont be adding a header til later on. So i decided to wrap stock pipe.

 

Remove the stock pipe.

.......

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#658 rockerdan

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Posted 09 February 2016 - 12:20 PM

Thermo-Tec wrap and some SS ties. 2" x 50ft part number 11002.

 

............

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Edited by rockerdan, 02 October 2016 - 12:10 PM.


#659 rockerdan

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Posted 09 February 2016 - 12:21 PM

All wrapped up...

 

..............

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#660 rockerdan

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Posted 09 February 2016 - 12:24 PM

Next I decided to remove the plastic section off the metal belt guard.....Just drill out rivets and remove.

 

I also removed all the foam on left side panels.....using a blow dryer to heat up the glue on backside of foam will allow it to peel off cleanly.

 

Venting to come among some other ideas I am kicking around.

 

Dan

 

..........

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Edited by rockerdan, 09 February 2016 - 12:25 PM.





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