I'm preparing my nV65 Sabre so I can beef up the clutch spring. This snap ring groove needs to be wider for an added diaphram clutch springs. This grove needs to be wider by the width of the extra spring thickness.
That's a .015 thick Harbor Freight saw blade and mandrel. It takes about 4 cuts to widen that grove by about 60 thousandths. What you going to do if you don't have a lathe.
V65 Sabre's and Magnas have a weak clutch. They have Diaphram type springs so beefing up the spring isn't easy. So I figured I'd try doubling those springs..... I put those slits in the second spring to weaken it.
This abrasive saw mad quick work of partially slotting the diaphram spring.
This is my latest spring weakening procedure. I slotted it to within a 1/4 inch of the OD. My earlier slotting didn't weaken the spring quite enough. The clutch lever was too hard to pull. Spring needs to be weaker yet...try 3/16"
Using the drill press as a hand press, I was able to feel how much I had weakened the slotted spring VS an unaltered spring. It was considerable.
This is a V65 Sabre or Magna transmission in a cut-a-way trany case. It allows me to see just how far into each gear the slider dogs go.
Sixth gear engagement on the left 2 gears shows that those slider and 6th gear dogs only go in less than an 1/8th inch. Those dogs do show a slight undercut from the factory.
This is 5th gear and slider engagement is more than 3/16th inch. This shows me that this shaft could be shimmed more to the right. Or the shift barrel could be moved to the left somehow.
The 2 gears on the left are 1st & second gear. That slider's engagement can be assessed with this trany gig.
View of 1, 2, 3, &4th...4th on the right.
That's 2nd gear slider on the left. It clearly shows that the engagement is shallow and that it would be the most likely gear to pop out of gear, and benefit most from undercut gear and slider engagement. It's not obvious in this photo, but can be seen in this Jig.
Next is 4th gear engagement at the top of this photo, and it looks pretty good...these bike hardly ever pop out of 4th gear.
I cut some more panels out of my trans jig so I can see more of what's going on. Good view of the shift drum action. 5th & 6th gears on top there away from the pinion shaft.
Another angle, 1st and second near the pinion gear and 3rd & 4th on the pinion shaft away from the pinion gear
that's a view of 1st and 2nd on the left and 3rd and 4th on the right.
The next 3 pics are of a 1st gen Sabre or Magna that has a professional undercutting job done to this transmissions gear dogs.
6th gear on left...5th gear on right
those are second gear dogs with undercutting.
2th gear with all the Dog drive holes undercut except that one on the right.
undercutting of the drive holes was simple with the drill press set on high speed. A consistent angle was accomplished by using the Allen wrench as a prop.
I have a spacer under the right side of the board so that that gear is on an angle. That allows the grinding wheel to undercut the gear dog on that slider.
Undercutting has to be done to both sides of all four dogs.
The board is on an angle that provides the grind angle of 3 degrees.
Undercutting of the slider dogs was done freehand using an abrasive cut off saw.
I put the trans in and am buttoning up the rest of the parts that make it a complete engine.