early valkyrie assembly manual

8/10/2019 Early Valkyrie Assembly Manual

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VATKYRIEKIT

T@)

TIBERFABDivis ion of Velocidad, nc .


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VALKYRIEKIT CTINSTRUCTIONANUAL

I/ GENERAL INTRODUCTION

2/ CONSTRUCTION'IATERIALS

3I ACQUIRIiIGCOFIPONENTSspension and s teer tng

b. Csrvalr t ransaxlee . V-8 englne and bel lhouslngd. Other naJor nechanlcal conponents

4/ ASSEMBLINGHE ENGINE/TRANSAXLENIT

5/ IHSTALLINGTHE FRONTSUSPENSION

aasenbly

NSTALLING HE ENGINE/TRANSAXLE/REARUSPENSION

?/ COMPLETING HE CTIASSIS REPARATIOITIo. Hyclraul lc sYston

b. FueI systenc. Shlf t l lnkaged. Cool lng sycten

8/ MOUNTIiIG HE BODY

9/ MOUilTING LECTRICAL OMPOiIEiITS U'IRING

r0l INSTALLIt{GutlND0uls frJD 00Rs

11/ FI ' I I ISHII{GTHE INTERIOR - UPHOLSTERY

12/ FTNI5HINGTHE EXTERIOR PAINTING

PARTS LISTOPTI0t '15 IST


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I / I fTITRODUCTIONO THE UALKYRIEKIT

Flber?ab flret ln t roduced the Ualkyr la concept to the pub-l fc fn- lni ?al l otn 1966 ln the ?ore of the UALKYRIE tl0 GT auto-roULi" . The 500 GT ls a conplete ly f lnlshed vohlcta Lncorporat-i ; ;- ; iantra l ly- loeated, 500 horaepouer engl ,ne , a t lo" epead z-F

tr insaxlc , foi l r-ohaEl lndependant euapcnelon and dige brakaat; loppeO sif" r l th a poahl al l - leather ln ter lor_and-a sleskr ul t ra-conl inBosary GT body. The 500 GT 1g undoubtedly tho. fas teat pro-duct loi r aut6nobl la ever nade aval lable to the gencral publ le --t t le a leo one o? the noct baaut t?ul . Tha prlce of the GT 5001g 112 '500.

S12r500 fer a ear cueh as the 508 GT eantrot be cenalderedunrraaoniUla , eapeel ,a l ly rhen a conpat ison la lade betreen thlapr lce and th6 prleea of-s lnl lar vehlclee ("g. , t . F0RD GT-40it l l?r?00, e tc . ) . Regardleaa of thg rat lonalc for thfu pr lce ,1t renalna, horcveD, bryond the budgete of al l but the noct av .d

el t buffs .I t lc rsal ,zcd, by Flber?abrs tcehntcal a ta l ' f r that rueh of

the coet of the Ualkyr le 500 rcs ldcs ln labor expendl turoe andthe eostg of tho apcclal ly-pr lparrd onglne and geatrbox -- el l r in-ate theae htgh-cost l tene 6ti-r t ,he pr lee o? the Ualkyr le 19-a gn-l f lcant ly reduced. Thc lsr pr lce of the VALKYRIEKIT .- f1tf95 --t t accolbl tehed ln thta nannetr l ie .1 by t radlog Flber?abrs pl t tor l -nel and bverhead ehargee ?or your t lme and by maklng provl , r longtn the kt t declgn for the uae of s tandard astorot lvc colponenteauppl led by you.

Uhereac the 500 GT ls a conpleted | aad as a resul t expenalve;

rachlne, thc UALKYRIE IT Lg conpleted by you at the expense of -yous t l is and for the eoat ol ' the kl t and a tandardr r radl ly aYal , l -iUte englna, runnl ,ng-gaat and euspensl .on componente . In pa[ t l ,cu-lar1 th- UALKYRIE IT tncludaa the fol lor lng:

l . Specla l rcctangulat - tube frane (St x 2r x .083r"sfr x L-L/2" x.083 'and 2n x 2" x .085r 's teel tyb-tng r t th l /8" e teel -p1ate guaset re tnforcementa) .

2 . The VALKYRIE ody conplete r l th coneole daehr ln-tegral f loorpan r l th nolded- l ,n sEats , and rheel-ecl l lnner_panela .

3 . Uindshlold and teat - l l .ndon glaes .

4 . Specla l adapter conponents rhlch a l loc you to u-tillze the Chevrolet 283/32? cuble-lnch eng .nc*and Chevrolet Corvalr t raneaxlee and roat suspen-clon (poet 1964) and Corvalr f ront suspeneions .

t Ford 2Bg CID englnes nay be uaed ln speela l -" order kl ts .

2


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I l INTRODUCTIT]TO THE UALKYRIEKIT - COIITINUED

Hencer you ptovlde only your t lne and creat lvl ty and aboutS450 (average) of rnaJor autonot lve suspension and po$er conponentsln excess of the purchaee pr lce of the Valkyr le Kl , t .

Flgure I ehora an overal l v leu of al l the components ln theValkyr le kl t and Flgure 2 shors , ln deta l l , Jus t the conponenteof the Corvalr- to-UB adapter kl t rhlch conea r l th ths Valkyr le .( t t l s ln tereat lng to note ln Flgure 2, the dl fferences ln lengthand dlaneter betraen the Corvalr s tandard trangnlselon lnput ghaf t25n long and the epecla l Flberfab ghaf t shorn. By el lnlnat lng theneed for the long, f lexlble s tandard shaf t , Flberfabrs adaptat lonof thc Corvalr t rangaxle 1g capable of handl lng algnif lcant ly notetorque than the or lglnal Corvalr conf lgurat l ,on. - - I t ron 265 lb-f traxl ,nun for s tandard Corval . r up to 375 lb-ft for the FlbsrfabUalkyr le get-up) .

FIGURE2

FIGURE 1

3


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2/- ._CQNSTRUCTToItJAIf AL5

The typtcal lnvehtory of toole found ln nost hone lork-shopa ul1l probably auff lce to coaplete your Ualkyr le Klt .A f ,orenost cr l ter lon ln al l Flberfab deslgns ls that assenblyprocedures should not be bae on the uae of any r 'exot l ,c t r cut-t tng, fas tenlng, e t t nEthodg not readlI aval lable to thehon6, utrouuy-t ipa" but lder, Tt tere-a- iFFF'ose lnstances , ofcourse , uhen for example , arc t t te ldlng mlght be preferred tobol t lng -- ln no lns tance, hou.ever, ls an exot lc technlquerequlred nor ul l l the u8s of a home workshop al ternat lve com-promlse the tnt i l r l ty o? your f lnlshed Ualkyr le .

The lol loulng tabulat lon of tools and natErla ls ls bagedon Flberfabts factory assenbly procedures and exper lcnce.I teng eonsl ,dered e,esent la l are l l s ted apar t f rom those l tensthat are s lmply hE[FffE t ime-savtng (Out nhose funct loncan bs dupl lcate i fTlff iF 'e essent la l l tems) .

HAfiID OOLS-

- - -Essent la l

-/fr

dr lve sockets : 5 /16 ' , , s /8 , , , ? /16 'n , L/2, , ,9 / 16" , 5/8" , LL/L6" , 3/ 4"

3/8" dr lve ratchet-handleCorblnat lon ulrencheE (open-end and box-rnd coo-

blncd) : 3/9"r 7/16", l /2 , , 9 /16", 5/8"Standard screcdr luer medlum bladePhl l l lps sotesdr lver nedlum bladeStra lght-edgeDrt l l5 (nlg6-gpeeo steel) : L/8" , 3/L6", L/4" ,

5/L6", 3/8" , ? /16", l /2"

Fl les z L. /4" dlameter round-l '1 le , f la t rood raspTapsz L/4"-2CI, s /LGn -tgl l lsc : hacksaw, eenter-punch, knlfe , hanmer,

put ty-knlfe

drlve extenslons: 3n and 6rl"Fop-11y"9 ' gun hose uorkehop var le ty ($C.gS)72t ' c teel ruleElectr ical ternlnal cr inping tool and nlre-

gtr lpper hone ruor[shop var le ty ( iz .sa1Set o |} uood-worklng (hlgh-speed steel not requlrad)

hole gau,sr g.r I /2" , I" , 2n,3trDla gona 1-cut t lng-pl lersnChannel- lockn pl lereJack stands

POIIERTOOLS-F---- - -- Essentla1

-Tfe-dfFlc dr t l l r L/4" capacl tyHeIP| 'u l-Tl6tr lc dr l l l : L/2" capacl ty'^ ' Sabre sat

Rotary sander /gr lnderHydraul lc | ' loor-Jack

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2/ c0NsTRUcrIoN mATERIALS C0{TINUED

COIiISTRUCTIOITIATERALS

ff ied nachlne bol ts and nuts z L/4" ) 5/L6",3/A"

,7

16"Asgorted uashetg and locklng-uashersSandpaPer: asgor ted coaase and flne gr l te#L6 AUIGlre: 300 feet#LO AUJG lre : 50 feetSl l lcone gaals connon typas a le Rubber Sealant

by the l laeklenburg-Duncan Qgrpany- of 0kla-hbna Ct tyr Dor-Cornlng DC ?50 sealant 'General Electr lc sealant , e tc .

Pal ,n t , Pr lmer r thlnnerHelPfuI-.@y adhesl-ve klt

Epoxy Put tV/?Ll ler

Crlrnp-on rr l . re ternlnals t r lng- ternlnals andprees-on fenale termlnalsAssor ted- length 'pop" r lvets and backlng oashersAcetone


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3. ACQUIRING OMPONENTS

This gect lon ls prfuaar l ly an annotated par ts l ts t ofna. for nechanlcal components requlred to conplete your Valkyr leFTt: Gcneral ly there ate two sources for each l ten, vl ,z . , aChevrolet (or in sone cases , Ford) par te depot ot auto lreck-

lng yards the la t ter repreaents the most economlcal sourcetby far. Arrangenents can usual ly be nade ut th reputable autorreckere to supply a "packagc-deal" lncludlng a l l the par tsyou regulre along sl th eome form of guarantee o | ' thel r ugablecondl t ton.

In the locale ol Flber?abreputable autonobl , le dlsnant lers ate l l s ted ln a publ lcat loneal led the PARTS L0CATOR. The PARTS LOCATORs lseued monthlyand contalns extcnalve l ls ts of al l the crecked autonobl lesln yards throughout Northarn Cal l , fornla . l t los t l lkelyr s lnl larpubl lcat lonc exis t ln your area and rould asgls t you stgnlf l -cant ly t f you chooge to ut t l lze Used par ts . Fot your referencetthe PARTS 0CAT0R ddrese ls :

PARTS LOCATOR1696 Washlngton AvenueSan Leandro, Cal l?ornla 915??

The naJor componentc of ln tErest .areI . Corvalr t ransaxle/ rear suspenslon2, U-8 onglne3. Corvalr f ront suspenslon

An exact deacr lpt lon of theae conponent groups ls glven bslos .

CORVAIR RAiISAXLE/REARUSPENSIONO ln the UalkYrle , le corpos-ed o?r

I. The dlfferent la l / r tng and plnlon houelng2, The gaarbox3. Trlo ix les (four unlvereal-Jotnts)4 . Tro forged-s teel suspenslon l lnks5. Tro s tamped-s teel suapenslon l tnk hangers6. Tro shock absorbers7. Tuo gtanped-s teel radlus-arn/bear lng carr lers /

hub assenbl tes8. Tro rheelr /brake asEemblles9. Tro col l spr lngs

Theee coaponente (ag plc . tured ln Flgure 3) conprlse thstota l 1965 Corvalr t rangaxle/ rear suspenslon unl t leas bel l -houslng and englne credlss . The 1966-6? unl ts a le ldent lcalr t th t ie execpi lon that the gcarbox ls blgger (f -s /g ' longer)and eontalna "beef lerr r qears . (WHEttA VALI(YRIE IT oRDER 5PLACED HE YEAROF THE CORVAIRGEAREOX O BE USEDFIUSTBESPECIFIED).


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3. AC0UIRING onp0NEl ' lTs cow

I f yqu purchase a used trans-axle/ rear suepensl .on be sure

to check the rubber bushlngsfor s lgne of deter lorat lontthe axles and etanPed-s teelconponents for dentsr thedlfferent la l and gearbox.houslngs for gouges and/otcracks and the shock abgor-bera for s t l ffncss .

CORUAIRRCIItITUSPENSION/STEERINGSSEMBLYnt susPenslon/s tcer-

lno assernbly can be renoved from the corval r chass la a3 a cof i -p iEtJ- | J ; ia - i fnply by loosentng and removlng about-a dozen bol ts .?n" bas lc f ronl ius iens lon closs- l renber lg sho$n ln F |gure .4-

notc tha t Jugt fbur bol ts re ta ln th ls ent l re unl t . To th lsbaelc s t ructurE are at tached '

l . Rtght and lef t uppes ' rA-ot l ler t2. Rtqht and lef t lsner suspenst 'on l tnks(f"t" I and 2 ate s tanpbd etael par te)

3 . Tco spr lngs4. Tco ghock-abeorbers5. Tno forged tra l l tng al086, Rlght and lef t splndles7, Rfqht and lef t hubs and bear lnge8. Rfght and lef t backlng-pla teg and brakes9. Rlght and lelnt brake drums

Up to and lncludlngbol t bol t -pat tern . In1965 the pat tern waechanoed to f lve-bol t( f roi t and reat) . The1960r 61 and 62 Corvalrshave no ant l - rol l bars .In 1963 a 5/8" bar(#3?83523) rras made a-val lable as an oPt l 'on.All 1964r 's sero equlP-ped ul th 3/4" bars andslnce 1965 the ant l - ro11bars have been L3/I6" ln

dl .aneter.

--TI6T'RE 5

1965 Corvalr Rear SusPen-s lon/Transaxle Untt

1964 the hubs and sheels have a four-

IJ .GURF.4 Corval r Front Suspenglon,


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3. ACQUIRING of ' |P0NEilTs qq[TINUED

asscnbly lc conposed oftThe steer lng box and ahaf tRlght and lef t s teer lng arma at tached to

the splndlesIdler at r and at tachnenti; ; adJustable- length drag- l lnks ( t le-rods)Tle-barassenbly ls rsnoved by detachlng the ldlcr

box fron the I ' lame.

The steer lngI.2 ,

3 .4 .5 .

The s teer lngarn and steer lng

N$TE: Throughout thlg sect lon re have been speaklng olthe Corvalr s teer lng box. Should you deslre anopt lnun steer lng rat lo , the Corvet te St lngraysteer lng box can be used.

If a used front suspenslon/eteer lng assenbly ls to beused, check the rubber buehlnge lor deter lorat lon ' the s tanp-ed pir tg for dents and tha sr lvals and bat l -Joints fPt free 'yet snug, operat |on. To ver l fy that thg suspenslon has not6een sei i re iy ntureakedtr heck closely the four cnol tnlnbtrnount lng hol ie thege holes should be soyqi l lo elongatcd 'and thei should be separated by 2?-I /2"(*-L/I6") l"gl r lghtglde to- lef t glde. Alao, e tght across the tops of the shockabcorbets , f rorn eide- to-s ldei to see that the croasnenbsr lsnot t r lg t6d shock absorbei topc a1 'e eeparated 34-3/d"( +-1/8" ) .

u-8 ENGINEANDBELLHoUgIiIGslgned to nost readi lY acccPt aChevrolet 2$7327 cublc lnch dlsptacenent (CtO) engine orat ternat tvely ' , a Ford 289 CID englno g se99l91 or,der. The;itt.ri"

-n9fn6s

have been available sfrcE-T95fafid-Ec qulte

""""i ,o obfatn fron dealers , engl ,ne re-bul ldere (fn ghort -

Ufoif forn) or f rom rreckers . The horseporer lange of the2A3/l27 ser les of eng .nes le 185 Hp to 360 Hp the la t teri ig i6" betng the naxlnum reconmendEd or appl lcat lon to theCorvalr t tanaaxle .

A typlcal Chevrolet 32? 9ID' . V-8 9n91T' ul th apPlo-pr ta t i U6if-nouslng at tached le ihosn ln Flgure I on the

; ; ; i -oaoe. (Note i leo the nount tng of the clutch elave-"ii i"i""l .

i t re Pour-bol t pat tern i t the aear of the bel l -f r6usfng iho"n ln Flgure 5 ls th? only pat tern gul table foruee ct ih the Ftberf ib adapter pla tes both Chevrolet cas t -l ron and dle-cagt alunlnurn be1l-houslngs have thlE pat tern .


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3. ACQUIRING OMPONENTS CONTINUED

If purchase o? a uged enqlnefron a srecker ls contenBlat-Bd, have thc sel ler run thaenglne bel 'ore you buy lt

N0 Rul t l , i lO BUY Incldental -Ly, a good source of qual l tyenglnes and englne conponentsla tha Sears Catalog SalesDepar t r rnt .

FIGURE5A Typlcal Chevrolet32? CID U-8 Englnetdt th Bel lhouslng

Rclerbar tol .2 .3 .4 .5 .6 .

lnc lude ln your englne purchase ,The s tar ter notorAn a l ternator or genera torClutehClutch covsrThror-out bear lng and thros-out bcar lng arnThroo-out bcar lng gulde , typa T89B-6 (nake ur thc mount tng f lange lor th lc Aulde ft tssnugly ln thr hole tn thc r lar of the bel l -houctn

OTHER 'IAJOR ECHANICAL OMPONEI{TS

No other naJog mechanlcal conponents are requlred to con-pht t yous UalE' f iTi Klt . Sone "bi ts and placesn ats :

l . Brake and clutch pedal assotnbly re reconnendtrDual Prndulun Pedalgro lnroa Honest Char ley, Chat-tanooga, Tennessea. Honest Char leyrs par t nunbrls ?8?04 ' .

2 . Front englne nountg the Ualkyr lc frane lg dg-s lgned to aceept the Hurgt "Unlversal Englne l lounts ."

3 . Rear t ransnlss lon nounts the Valkyr le tear covr

plate (eee Flgure 2) ls deslgned for-use r l th t rot33ft3i'+3:l3lo?' ::13",:[:ll']il"[,?3ll:4. Clutch r lave cyl lnder -- ' 195?-1960 Ford F-100

bruck (Wagner-Lockheed #FD-24288) .Thr l tgt above lc not an axhauct lve l lgt of al l other eon-

ponents requlred to conplete yout Valkyr le . 0thcifnot a t r tc t lynechanlcal , conponents are nent loned throughout the text thatfol lors . Al l conponent raqulrencntg, horuever, are gunnar lzedln a par ts-Tfs t a t the and of thege lnatruet lons .

, , ,

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4/ ASSETIELIiIGHE ENGIiIE/TRANSAXLENIT

The assenbly of the anglne/ t ransaxle uni t l s acconpl lshedln gcveral s taPs:

1 . Preparat lon of the cnglne

2, Ins[al la t lon of the Ftberfab drlvc-chaf t3 . Preparat ion of the toal . hanger-p, fg :4 . Assenbly of the cnglne/gcar box/dtfferent ta l

ln to a slngle unl t

Er{GINE REpARATIoFff i you have he englne ready- to-ggr 19. '

ths en-srne ;::i;"i"'pi"pliJo'i-r;"i :iii;il: 1:l-:;-;li- llt3"*::1/oH;;;"; : ; i ; ' r [ ."5-#;;-be"n ins ta l led , the s ta t lc t ln lne . h?" been

| t - - - - l

set , e tc . several tasks remain beiore the englne. unl t ls ready[o-u" coupfeO to the transaxle . l low the ] furs t f ront notor mountsrrouf ct be ' a t tact red. The clutch plate_ and clutch cover should beingtal led. nnJ inc bat l -houelng should_be at tached rt th thc thros-

out bcar lnq and arn t

FIGURE6 CEARBOXNITIAL DIS-AS5EMBLY

#z

SHIFTINGFORKRODS

DETEfIITHOLE

#t

I NSTALLATIN 0F THq-I-I-EE-E qBEIVE-SHAFTgtne/ t ransaxlc ls Probab-ly ths most tSorous

- t"p

ln urrrort te ths-Valkyr le t(1t . I t 1s lnthls s tep tnat - l t re s tandard Cor.val r-gearbox iput-gear ls replac-ed by tha "p" . i i r l lpg -eear, / shaf t -nanufactured

by Flberfab '(NoTE: Thare ' i ; - ; l lO.OO ficor :L-cn?rge" dded to thc pr lce-of t l"Valkyr le Kl t .

-neturnthc Corvat r- tn iu t -qq9q (sonet lnas rcferred

to as the "cfutcf r l63L"; i - to-FiU"rfab 'anO-$10.00 cl I1be refunded

to you) .

10

SHIFTIiIG FORKS


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a/ ns_semeurNcHr eNqtNr/ tRnNsnxteNlt

The fol loulng sgquence of operat l .ons should be usad tocomplete the gear /shaf t lns ta l la t l 'on.

I . Separate the gearbox and dlfferent la l houslng b_v e-

movlng thefour re ta lnlng bol ts threaded lnto the

dlfferent la l houslng.

Z. Remove he gearbox front cover pla te (s lx bol tst95.r.

four bol ts 166, ,6?) l -TF'e gear (wtth the spl lned hub)dlrect ly under thls covr ls the gear to be leplaced.

3 . Remove he gearbox slde covet pla te (e lght bol ts t65,sevsn bol ts

- t 66, ' 6?)-The 1966-67 gcarboxes have theshlf t tng ?orks and rods a t tached to the slde covelpla te ana they ale removed t l l th the platc . The 1965gearboxes have the shlf t lng forks 9nd rods separatcFrom the slde cov.r and they nust be removed as dEs-

cr lbed ln sect lons 4-8 below.Looklng through the slde openlng (see Flgure 6) ,4 , Drlve out the rol l -plns whleh eecurs the shlf t lng

forks to the shif t lng fork rods tf the plns fal lln to the cas, they can be retr leved subsequent ly.

5 . Remove he pluq from the detent hole (seeand extract the detent and spr lng not lng

Flgure 6)the order

ln uhlch they are removed.

SHIFTINGFORKROD#3SH FT I NGFORKROD

#zFIGURE?

GEARBOXEfi'D-TTEtr

. SHIFTINGROD

l l


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4/ AssEmBLING HE ENGINE/TRANSAXLENIT

6. Drlve shif t lng-fork rod #I conplete l ,y out of the case .

? . Drlve shtf t lng-fork tod #2 (see Flgure ?) to the posl-t lon shoon |n Flgure 6. . Do not renove the lod bacause t re ta lng detent bal ls and spr lngs at the front of theeaEg.

8. Renovs the tuo shtf t ing-forks .

9 . Renove the snap-s l .ng froo the hub of thc lnput-gear.

10. Ramove he lnPut-gear bear lng by tapplng tt out of thccaae and sl ldtng lt over thc lnput-gear hub.

l l . Renovc thc output-3haf t (see Flgure 8) bcar lng ln 1t9reta lner (fgeS output-shaf t bear ing re taLners ar t held

lnplace by t ro snap-r lngs . 1966-67 rata lners ala

Dalnta lned ' ln posl t lon r l t t r locklng tabs) . As the re-ta lnsr leavee the eaee 3o r t I I the naln ehaf t takecaDe to renov the sraln ehaf t and lnput-gcar as a unl t .

LZ. Notc the locat lon and orlenta t lsn o? thc brass synchro-nech cons adJacent to tha Lnput-gaat . t lor- ITEFdrar thcthc lnput-geir f rom tha oraln shaf t . Do thls over aclean i"g Sacause a number ol ' naedla bear lngs ut l l fa l lout o? thc lnPut-gaar hub.

FI6URE BSTANDARD AIN SHAFT& FIBERFAts NPUT GEAR/SHAF

OUTPU-TSHAFTBEAR NG

OUTPUTSI{AFT

SYNCHRO-R NG

L2


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e/ lssemeLtr ' leHr eilct t{VrnnNsnxLEt' l t t

I5 . Col lect a l l the needls bcar lngs -: thera are tuo robsof neeOfes-El thln the. input-gcar hub. Coat the lnsldaof thE Flberfab gear /shaf t hub r t th as "s t lcky" 9Deas6

""you trave avel iabl 'e . Noryplacc the needles ln the

hub 'uet nq tt t" grBaso to hold thom ln posl t lon thetuo role-ghould be ful l r wl th no gaps '

14. 511de the synchro r1n9 on the maln shaf t ln to the Po-s l t lon

"nornln Ftgure 8. Placs the braas synchro

con ln tho tnPut glar /shaf t '

15. Naxt , ver.y careful ly lnser t thc maln shaf t and the ln-put-gear7 ' tn i i i ln to ' the gearbox case ae ghoun 1n f tglure g.

-irrou"thc aear /snif t carefur ly. o avold dropplng

the aynchro cone or dis lodlng lhl needle bcarLngr.gt ing ' tho-"n"f t" togethcr and lnto al lgnment . Inser t

tho noss of thE naln ehaf t ln tothe ncedlc clusterc ln

ln the gear /shaf t hub.

FIGURE

GEARBOXHOWING@LE

INPUTGEAR/SHAF

MANSHAFT

16. Inecr t the maln sha?t bear lng ra ta lner lnto placcln thc aearbox. s l lp the lnput-gear bear lng ovcr

the geai /shaf t and f1t9 t l re gearbox. If the bcar-lnga-"""t . -propcr ly t t lndlcates the naln sha?tand q"arl"["i[-ftuir" been propesly matcd. Rclnsta l lthe Sear ing reta lnars both bear lngs '

1? . Relngtal l the shlf t tnq forks ?nd roda 'and the sldecovst Plate . Usc I nls gaskct '

lB. goi t tho gearbox to the dlfferent ta l houslng.

Thls coopletes the lnsta l la t lon of the lnput gear /shalFt '

13


15/56

4/ ASSEITIBLINGHE ENGINE/TRANSAXLENIT

PREPARATIOIIIF THE REARHANGER LATE

The R.ar hangcr pla tc cones to you as shonn ln Flgure 2 t ls the cast lng cl th thc labal "FIBERFAB." Although h"

hanter-pla tc ls "as cast f ' uhtn del lvcrcd, l t l s t rans?olmedtnto a f lnlshed par t e lnply by drl l l lng ten holcs .

Flrs t , dr l l l and taP the rectangular bossce sueh that theBulck Dynai tot subbcr nountg can be aff lxed to thclr bot ton sur-facea. The mountg arc at tachcd by bol t lng through thr l r ncta lnount lng feet 3/A" bol ts ar appropria te . Now placc thrhanger f ta tc ovtr thr r. tal of tha transaxlc , engaglng. thP 1.3"0.0: I fb o? the transaxle ln thc 13" I .D. r3coss n the backsutfact 'of thc plate . A119n the contouts o? the platc s l th the

"ontour"of thc transaxlc . . Drl l l thc hanger pla te for a t tach-

ncnt to thr t rancaxla uslng tha transaxls as a dr t l f Jfg

agaln 3/6" bol ts are approprla te ,Flnal ly, thc tr7l t6 n-ahaPcd

riar support l s bol tsd to thn rubbcr mounts .

Thc tasks lnvolvcd ln prepar lng and nount lng the r tarhangcr pla tc are sunnar lzGd plctor la l ly ln Flgure 10. Notetha[ thl rear support 1g not ra lded or bol tcd to thr ?raneunt l l the ent l rc i l r lve- t rETt ' ls ln posl t lon.

FINAL DRIUE-TRAINA5SEMBLY

Flgura 10 shors an exploded vlgur of thg englncr /bel l -houslngl to- t ransaxle intarfaca. Rafcrr lng to thls Flgurc --thc Flber?ab adaPtcr pla tc ls bol tad to the front of thc

gearbox casr. Thls Jolnt rcqulres no gaskct but should bc6oated r l th a non-haidonlng gaskct ccnant . Note that the holesiabel led r213 and 4 arc uied subsequcnt ly f9 bol ts ln to thcbcl lhouclng :- hole I should have n hol t ln l t before thc a-daptcr 1s 6t tacheO ptroanent ty to . th .* . gearbox bccause once at-ta thment ls conplete , aectss to this hols lg lnpalred.

Placc thc T898-6 thror-out (T/g) brar tng guldc mount lngf lange ln the rct t t3 n thc adapter- pla te . (Tlo. of ths holcEfn- l f ,e i langc ct l l requlre gl lght clongat lon r l th a f t la tfa r65 transixlc ls used ont hole requlres modlf icat lon wltht56- t6? transaxles) . Paes four 5/16"-18 bol ts a t leas tt- t /2, ' long thrbugh the mount ing f lange, throuqh the adapter

pf"i" anct into tha giarbox cast . Nq*' pass h" remalnLng bol ts( for rES cases: tEo 'S/16"-18, turo l /a"- tA and one 7/L6"-L4iff at leaet l -L/4" tbng for t66r t6? cas6s four 3/8"-16at lcas t L- t /A" long) through thc adaptcr lnto the gcarboxcase and t lghten al l bol ts .

l4


16/56

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early valkyrie assembly manual

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