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Jules’ favorite bike 1928 101 Scout

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  • #91
    Dave and Eric,
    The clutch hub tool is handy, I’ve used it on 3 Sport Scouts and this 101. The hub part is some sort of plastic, I don’t know what the material is, maybe Delrin? The handle is just flat stock and there are 2 thread inserts pushed into the plastic. It looks to be easy enough to make, but I actually bought this at a meet years ago, I think at the time it was like $20 or so. I mean, between time and material I couldn’t make it for that, so done deal.

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    • #92
      It’s been a busy 3 weeks or so, getting stuff ready for Oley and selling my Indian 4 I had my hands full, so now back on the 101. At Oley I did pick up my refurbished magneto…

      IMG_3157.jpeg

      So that’ll be ready when the time comes.

      Next up I’ll start with something easy, the transmission cover.

      IMG_3156.jpeg

      Got everything apart now to clean and reassemble…

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      • #93
        The Magneto looks great who rebuilt it for you?
        AMCA # 3233

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        • #94
          This guy…

          IMG_3168.jpeg

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          • #95
            Well, nothings easy. I started going thru the trans tower and didn’t like what I found…

            IMG_3174.jpeg

            Got a bit of wear here…

            IMG_3175.jpeg

            And the casting is cracked, likely cause the cap was loose and the shifter shaft was wobbling back and forth winds up bell mouthing the journals

            IMG_3176.jpeg

            And messing up the bushing

            IMG_3178.jpeg

            Lucky for me I have more parts in the stash and I’ll need a different tower, cap and end bushing.

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            • #96
              Here are some pictures of the new assembly after it was cleaned up…

              IMG_3180.jpeg IMG_3181.jpeg

              Much better, nice and snug.

              Ready for assembly

              IMG_3182.jpeg

              And back together

              IMG_3184.jpeg ​​​​​​ IMG_3185.jpeg

              For you purists out there yes, the cap should be held on with threaded studs and nuts and I used hex head screws. First off the correct studs use 1/4-24 nuts, and I don’t have too many of those obsolete sized nuts, and I have plenty of 1/4-20 screws. I get it that studs and nuts are better if that part is going to be assembled and disassembled a lot, which I don’t see the cap for the shifter shaft being removed too often. Besides, later Chiefs used screws on the cap so I figured that’ll be fine, it’s not going to be judged or anything. I will use studs and nuts to mount the tower to the trans case, even then I bought new studs 1/4-20 in the case and 1/4-28 for the nuts.

              Next up the primary drive…

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              • #97
                That looks great Joe! Nice to have a few parts laying around, too. And it's also encouraging to see that Greers is gradually adding to their selection of 101 parts and that they're now able to supply those 1/4-20/1/4-24 studs for the cover.
                Pisten Bully is Harry Roberts in Vermont.

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                • #98
                  Primary time…..

                  IMG_3206.jpeg IMG_3205.jpeg

                  They needing a good cleaning, obviously…

                  IMG_3213.jpeg

                  Inner pretty much done. While cleaning I noticed…

                  IMG_3214.jpeg IMG_3215.jpeg

                  It’s been welded on….but looks fine I think.

                  Next up cleaning the outer…

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                  • #99
                    Well, not so fast. I’ve been pondering this inner primary and I’m not thrilled with the welded area after all. The mating surface still shows a crack

                    IMG_3245.jpeg

                    Jules used Permatex on the covers, I got a new gasket and I suppose I could JB Weld over the crack and smooth it out to hopefully prevent any leak, but I have other inners so maybe I should use one.

                    I was also thinking what caused the break there that needed to be welded, and I think I figured it out. There isn’t much clearance between the cross over lever and the primary case…

                    IMG_3217.jpeg IMG_3218.jpeg

                    These are pictures of a 101 racer Jules built. You can see the “modification “ made to the case to accommodate the head of the screw on the lever. Other inner primaries that I have show a similar “modification “

                    IMG_3219.jpeg

                    Here is one (top) compared to my cleaned up one (bottom)

                    IMG_3220.jpeg

                    And here is another.

                    I need to do more investigating, but I’m learning toward using a different inner.

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                    • Well, decided to use the original inner anyway. Moving on to the outer.

                      IMG_3253.jpeg IMG_3254.jpeg

                      Looking better….

                      IMG_3255.jpeg

                      But I found this…

                      IMG_3256.jpeg

                      Yep, crack….shooooottttt…..
                      Can be fixed, but I want a timely solution so find a better one…

                      IMG_3257.jpeg
                      No crack, so I’ll use it.

                      And in case you are wondering, as I was, that hole in the boss goes up through the thread. So I figure it was drilled there by Jules to get some oil to lubricate the clutch worm? Did it contribute to the crack?

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                      • Moving on to the idler gear….

                        IMG_3261.jpeg

                        Cleaned up

                        IMG_3262.jpeg

                        Looks good

                        IMG_3271.jpeg

                        I checked the play, even though I couldn’t find a value in the 101 R&O manual. I found an article about rebuilding a high mileage 101, and they measured the play at like .028”, and they decided it was good enough. I got .025”, so I guess I’m good to go.

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                        • Moving on, mating the engine and trans…

                          IMG_3279.jpeg IMG_3280.jpeg

                          Nothing seems to be binding, I did the paper thru the gears check and it looks good


                          IMG_3282.jpeg

                          Next up the clutch…

                          IMG_3283.jpeg

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                          • I assume the paper thru the gears just checks binding only without checking excessive play? Is excessive play a concern? Thanks, I'm not an Indian guy, just trying to see other methods that might help me in checking Harley gear setups. Enjoy your updates!
                            Bob Rice #6738

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