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


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#766 rockerdan

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Posted 19 February 2016 - 05:02 PM

Now slide the Jshaft back into place, being very careful that the chaincase end SHIM does not fall off....and as you slide Jshaft across, now looking in behind, you can slide the 1/4" drive extension you left hanging there, back into the HOLE in end of Jshaft where top gear bolt goes, and once in the hole, you can help feed the Jshaft into the top gear, getting the splines to line up.  

 

Once the Jshaft splines line up on chaincase side and the bearing is laying into pocket,  I take a block of 2x4 on the secondary end of Jshaft, and tap on the end of 2x4  wood block with a hammer setting the Bearing into the pocket nice and firmly. 

 

.....

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Edited by rockerdan, 19 February 2016 - 05:45 PM.


#767 rockerdan

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Posted 19 February 2016 - 05:12 PM

Once the Jshaft and bearing are set into their pocket against the new shim....we can start to lock things down.

 

Start with the bearing retainer bracket...take the two washers(which add up to 3mm) and place them between the bracket and frame, which will shim out the bracket the correct 3mm distance.

 

Install the 13mm nylock nut and tighten down the bracket.

 

 

 

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

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Edited by rockerdan, 19 February 2016 - 05:13 PM.


#768 rockerdan

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Posted 19 February 2016 - 05:17 PM

Now go over to the chaincase side....and use BLUE loctite on the Bolt for the top gear.

 

Tighten down top gear bolt to 35 ft lbs.

 

Reinstall your rubber cap and vent tube in behind plastic clip away from Muffler.

 

Tighten your chain finger tight, then tighten lock nut.

 

 

 

...........

 

 

 

 

post-75199-0-28091100-1455031776.jpg

 

post-75199-0-71793200-1455037105.jpg


Edited by rockerdan, 19 February 2016 - 05:19 PM.


#769 rockerdan

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Posted 19 February 2016 - 05:25 PM

Original measurement was approx 37mm.....now with shim kit closer to 40mm, and makes a huge difference on the dogleg in the belt when running it up on stand, very happy now with how it all looks when running it up on stand.....Videos to come once done uploading.

 

Dan

 

 

 

post-75199-0-41238400-1454280341.jpg

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Edited by rockerdan, 19 February 2016 - 05:47 PM.


#770 sleddingfarmer

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Posted 19 February 2016 - 05:38 PM

Someone should pay you to do these threads. Be it the forum, or the manufacturer. You should be getting paid!

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#771 rockerdan

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Posted 19 February 2016 - 05:50 PM

Someone should pay you to do these threads. Be it the forum, or the manufacturer. You should be getting paid!

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LOL....haha

 

Lucky for me time in winter is plentiful, and I just have always loved modding/wrenching all my toys and if I can document it all, its just that much better. I like coming back and being able to see exactly what I did and when!  lol

 

The Vrod forums were alot of fun when I ripped that down day one from new and custom built it.

 

Dan



#772 BCX

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Posted 19 February 2016 - 06:17 PM

i would be kind of curious to see if there was a difference in belt/clutch temps before and after



#773 rockerdan

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Posted 19 February 2016 - 06:31 PM

1st video discussing the 40mm spec and alignment procedure....

 

 

 

Here is the 2nd video I made with sled running up on stand showing belt at 40mm spec...I wish I had done a video BEFORE with the 37mm dogleg to show the difference,  but trust me it was huge and now is straight.

 


Edited by rockerdan, 19 February 2016 - 06:33 PM.


#774 rockerdan

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Posted 19 February 2016 - 06:59 PM

VENTING Part 1      

 

Note: For lower side vents by PDP click here for Venting Part 2: http://www.dootalk.c...new/?p=17359481

 

Always helps to have a cooler running clutch. Not too mention my feet cook and sweat so bad on the 4s compared to the etec, I might need to get some cheapo boots! haha

 

I had bought these vents way back in the fall before winter was even here, mostly cause many guys here said venting is pretty much a must on these sleds, and with the XS being even tighter, and my leaner side panels I felt it was a smart thing to do. Im kinda anal about the looks and cutting up a new sled, so I chose to stick with a frogskin on the rear side to keep it looking as good as possible(I realize they wont vent as well) 

 

On the front side I chose Extreme Vents as I thought they looked the best, and are very durable and great customer service. http://www.xtremeairvents.com/17.html

The front Shock tower vents are pretty easy, they come with a template and then i used a holesaw to cut, then i cut the entire hole out with snips.

 

Unbolt shocks so you can get at holes with drill....and get the rivet gun in there.

 

 

.........

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Edited by rockerdan, 07 November 2016 - 03:20 PM.


#775 rockerdan

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Posted 19 February 2016 - 07:02 PM

Clutch side shock tower vent....

 

.......

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#776 rockerdan

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Posted 19 February 2016 - 07:05 PM

Clutch Guard, plastics removed.....Drilled out for direct air flow in line with Shock tower Vent and out the backside.

 

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

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Edited by rockerdan, 19 February 2016 - 07:09 PM.


#777 rockerdan

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Posted 19 February 2016 - 07:14 PM

Muffler side shock tower vent.....

 

..........

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#778 rockerdan

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Posted 19 February 2016 - 07:18 PM

Above knee flares drilled and covered with frogZskin....the leaner side panels have a smaller flare/lip here.

 

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

 

F0025web.jpg

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Edited by rockerdan, 13 October 2016 - 05:59 PM.


#779 rockerdan

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Posted 19 February 2016 - 07:20 PM

the frogskins look nice....and when holding hand over them, there is a ton of heat coming out....so its better then nothing for sure.

 

........

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#780 rockerdan

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Posted 19 February 2016 - 07:28 PM

Clutch Temps

 

The combination of Venting and better alignment really brought temps down...before I could not touch anything without burning hand right away even at medium speeds. I never took any reading then but i do know I can now touch everything, and many things are not even hot at all now.

 

I ran the sled WOT down my lake for approx 3 miles, mild day today at +2c and about 8 inches of heavy wet snow on lake, so this was a good test for hot clutches and would have fried me before.

 

1st pic is clutch cover of Pb80, cool to touch.

 

2nd pics of outer sheave of secondary, also much cooler then before.

 

........

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Edited by rockerdan, 19 February 2016 - 07:29 PM.





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