Differences
This shows you the differences between two versions of the page.
Both sides previous revision Previous revision Next revision | Previous revision Next revision Both sides next revision | ||
techtalk:evo:elec02b [2019/11/10 03:43] hippysmack [Before removing the primary cover] |
techtalk:evo:elec02b [2019/11/14 00:31] hippysmack [Remove the clutch release assembly] |
||
---|---|---|---|
Line 6: | Line 6: | ||
The stator is in the primary compartment behind the engine sprocket. \\ | The stator is in the primary compartment behind the engine sprocket. \\ | ||
You'll have to remove the primary cover, engine sprocket ** *and* ** the clutch basket to access the stator. \\ | You'll have to remove the primary cover, engine sprocket ** *and* ** the clutch basket to access the stator. \\ | ||
- | Before removing the primary cover, you'll need to drain the primary fluid, loosen the clutch cable, remove the clutch ramp and loosen the primary chain adjuster. \\ | + | Before removing the primary cover, you'll need to remove the shift lever bracket (or mid foot pedal bracket if applicable), linkage and derby cover. \\ |
- | The shifter shaft, linkage and mid foot pedal bracket (if equipped) will also need to be removed. \\ | + | Drain the primary fluid, loosen or remove the clutch cable and loosen the primary chain adjuster. \\ |
+ | The engine below is a 98 XL1200S that has been upgraded to 1250 with a Buell XB crankshaft and respective engine sprocket. \\ | ||
====== Before removing the primary cover ====== | ====== Before removing the primary cover ====== | ||
+ | \\ | ||
+ | ===== Remove shift lever ===== | ||
- | Loosen the clutch cable. \\ | + | The bike below has forwards but if you have mid controls, they'll be behind the (2) 5/16" bolts on the bottom middle of the cover. \\ |
- | {{:techtalk:evo:priclutch:06_clutch_removal_9_by_cjburr.jpg?direct&200|}} ((photo by cjburr of the XLFORUM)) {{:techtalk:evo:priclutch:06_clutch_removal_10_by_cjburr.jpg?direct&200|}} ((photo by cjburr of the XLFORUM)) {{:techtalk:evo:priclutch:06_clutch_removal_11_by_cjburr.jpg?direct&200|}} ((photo by cjburr of the XLFORUM)) \\ | + | |
- | Loosen the primary cover screws to allow oil to drain in a bucket / catch pan. \\ | + | {{:techtalk:evo:engmech:removing_primary_cover_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:removing_primary_cover_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
- | Some of the screws are different lengths and need to be placed back in their respective places. \\ | + | |
- | You can use a piece of cardboard with a sketch drawn of the cover as to where the bolts go. \\ | + | |
- | You can punch the holes with a screwdriver, insert the screws for holding and it makes reassembly less of a headache. \\ | + | |
- | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_1_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:ref:tools:primary_cover_screw_holder_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=49915)) \\ | + | Remove the rubber seal behind the shift lever. \\ |
+ | {{:techtalk:evo:engmech:removing_primary_cover_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:removing_primary_cover_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | ===== Remove the clutch release assembly ===== | ||
+ | |||
+ | Remove the derby cover and the clutch ramp assembly. \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:adjusting_clutch_1_by_hippysmack.jpg?direct&300|}} \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:adjusting_clutch_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_clutch_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_clutch_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:adjusting_clutch_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_ramp_assembly_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_ramp_assembly_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:removing_clutch_ramp_assembly_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_ramp_assembly_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_ramp_assembly_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | ===== Loosen the primary chain adjuster ===== | ||
Loosening the primary chain adjuster takes the pressure off the primary chain from the cover. \\ | Loosening the primary chain adjuster takes the pressure off the primary chain from the cover. \\ | ||
- | {{:techtalk:evo:priclutch:primarychainadjuster-91-later.jpg|}} ((photo by Gcram399 - http://xlforum.net/forums/showthread.php?t=1661362 & GophersAndCheese - http://xlforum.net/forums/showthread.php?t=619960)) | + | Hold the stud with a 1/4" Allen wrench and use a 7/8" open end wrench to loosen the tightening nut. \\ |
+ | Once the nut is loose, unscrew the stud until it bottoms out to loosen the chain adjuster. \ | ||
+ | This is easier done before removing the cover since the engine holds the assembly in place. \\ | ||
+ | If you don't loosen this before re-installing the cover, it will be more difficult to install the cover later. \\ | ||
- | ====== Removing the primary cover ====== | + | {{:techtalk:evo:engmech:removing_primary_cover_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:removing_primary_cover_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
- | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_2_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) \\ | + | |
- | ====== Removing the engine sprocket / clutch basket ====== | ||
+ | ===== Clutch cable ===== | ||
+ | |||
+ | The clutch cable is best removed from the cover. \\ | ||
+ | It's awkward to handle and keep the cover out of the way while you remove the sprocket / clutch basket and work on the stator. \\ | ||
+ | However, for this application, you could simply leave it on and hang the cover from the bike once removed. \\ | ||
+ | If you have to remove the cable connection or the cover completely from the engine, removing the cable is the easy part. \\ | ||
+ | It's easy to cross thread the cable in the primary cover if the cable isn't stretched out to keep it from binding up when installing. \\ | ||
+ | To remove the clutch cable, detach both ends as shown below and any holding clips and/or wire ties. \\ | ||
+ | Retract the cable connection fully to allow slack on the inner braided wire. \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | Remove the cable holding clip (if used) and any wire ties etc. that may be holding the cable to the frame. \\ | ||
+ | |||
+ | {{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | Remove the clutch lever from it's bracket by removing the retaining ring (circlip) underneath and pivot pin from the top. \\ | ||
+ | Then pull the lever from the bracket, swing the cable wire through the slot in the bracket and remove the plastic cable pin. \\ | ||
+ | |||
+ | {{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_8_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_9_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_10_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | Then pull the clutch cable down thru the trees and lay it out in front of the bike. \\ | ||
+ | Use a 1/2" open end wrench to loosen the cable connector at the primary cover and then you can most likely twist the cable to loosen the threads. \\ | ||
+ | This method will help keep the cable straight so as to not cross thread it making it more safe for re-installing the cable later. \\ | ||
+ | |||
+ | Be careful not to damage the O-ring on the part of the cable that comes out of the cover. \\ | ||
+ | Inspect the O-ring and replace it if needed. \\ | ||
+ | |||
+ | {{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_12_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_13_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | |||
+ | ====== Loosen and remove the primary cover ====== | ||
+ | Loosen the screws will most likely result in an oil leak. So, first, put an oil drain bucket or catch pan under the engine. \\ | ||
+ | Loosen the primary cover screws but don't completely remove them to allow oil to drain into a bucket or catch pan. \\ | ||
+ | |||
+ | The primary cover has (14) 1/4" and (2) 5/16" Allen head screws of various lengths. \\ | ||
+ | They will need to be replaced back in the same holes from which they were removed. \\ | ||
+ | So, their proper location will need to be marked upon removal. You can make a drawing of the primary cover on a piece of cardboard. \\ | ||
+ | Remove them one at a time and then put each into it's respective place in the cardboard as removed from the cover. \\ | ||
+ | You can punch the holes with a screwdriver, insert the screws for holding and it makes reassembly less of a headache. \\ | ||
+ | |||
+ | {{:techtalk:evo:engmech:removing_primary_cover_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:removing_primary_cover_8_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:ref:tools:primary_cover_screw_holder_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=49915)) \\ | ||
+ | |||
+ | {{:techtalk:evo:engmech:removing_primary_cover_9_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:removing_primary_cover_11_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:removing_primary_cover_10_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | |||
+ | |||
+ | |||
+ | ====== Remove clutch adjustment assembly ====== | ||
+ | Use circlips pliers to remove the circlip and the adjuster assembly simply falls out of the clutch hub. \\ | ||
+ | Inspect the bearings / race for smooth operation and / or damage. The circlip is reusable as long as it's not bent / warped. \\ | ||
+ | {{:techtalk:evo:priclutch:removing_clutch_adjustment-bearing_assembly_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_adjustment-bearing_assembly_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | ====== Remove the engine sprocket / clutch basket ====== | ||
+ | See also [[techtalk:ref:tools139|Replacing Stator Magnets]] in the tools section of the Sportsterpedia. \\ | ||
+ | |||
+ | Loosen the nuts / bolts holding the engine sprocket and clutch basket on. \\ | ||
+ | The engine sprocket has right hand threads and the clutch basket has left hand threads. \\ | ||
A reversible impact wrench has been used successfully to remove both the engine sprocket and the clutch basket nut. \\ | A reversible impact wrench has been used successfully to remove both the engine sprocket and the clutch basket nut. \\ | ||
However, it's been debatable whether you can accurately install them back to proper torque without using a torque wrench instead. \\ | However, it's been debatable whether you can accurately install them back to proper torque without using a torque wrench instead. \\ | ||
- | However, you remove the nuts, use regular six-sided sockets. \\ | + | Whichever way you remove them, use regular six-sided sockets. \\ |
They are less likely to slip and round off the edges of the nuts. Impact-type sockets are likely too thick to fit. \\ | They are less likely to slip and round off the edges of the nuts. Impact-type sockets are likely too thick to fit. \\ | ||
+ | |||
+ | {{:techtalk:ref:tools:engine_sprocket_removal_-_installation_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:ref:tools:clutch_nut_removal_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) \\ | ||
Normally when loosening or tightening these nuts, you will need to **lock the hub & sprocket** - Do not wedge the chain. \\ | Normally when loosening or tightening these nuts, you will need to **lock the hub & sprocket** - Do not wedge the chain. \\ | ||
Line 39: | Line 115: | ||
A closed 4" BRASS hinge also works well to lock the sprockets and then you can use a pull bar and sockets / socket wrench. \\ | A closed 4" BRASS hinge also works well to lock the sprockets and then you can use a pull bar and sockets / socket wrench. \\ | ||
- | {{:techtalk:ref:tools:engine_sprocket_removal_-_installation_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:ref:tools:clutch_nut_removal_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{techtalk:ref:tools:primary-brasshinge-lock.jpg?300|}} ((photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?t=53268)) \\ | + | {{techtalk:ref:tools:primary-brasshinge-lock.jpg?300|}} ((photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?t=53268)) \\ |
+ | |||
+ | The threads should have previously been assembled with red Loctite. \\ | ||
+ | Using a propane torch (on the nut or bolt only) will heat up and melt / soften the Loctite somewhat to make removal easier. \\ | ||
+ | Remove both fasteners holding them on before attempting to remove either. \\ | ||
+ | Big socket wrenches or pullbars give you a lot more leverage to make removing the fasteners less strenuous. \\ | ||
+ | |||
+ | **Note**: \\ | ||
+ | The engine sprocket has right hand threads (lefty loosy-righty tighty) \\ | ||
+ | The clutch basket has left hand threads (lefty tighty-righty loosy) \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
The engine sprocket and clutch hub should be removed as one unit. \\ | The engine sprocket and clutch hub should be removed as one unit. \\ | ||
+ | Both have to come out together to some point since the chain will tighten and neither will budge at that point. \\ | ||
+ | Once they are both moved out far enough, you may be able to get one or the other to come off without the other. \\ | ||
Once the sprocket and clutch basket is removed, you can gain access to the mounting screws for the stator. \\ | Once the sprocket and clutch basket is removed, you can gain access to the mounting screws for the stator. \\ | ||
- | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_5_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) \\ | + | You'd think both should slide off at this point. \\ |
+ | However, the magnets on the engine sprocket are very strong and will keep a good amount of pressure toward the engine until it's moved out so far. \\ | ||
+ | Pull the clutch basket out as far as possible and then maneuver your fingers both hands under the engine sprocket. \\ | ||
+ | Rock it side to side while pulling outward. \\ | ||
+ | Slowly you can rock it out enough to get your fingers under it to move it out far enough to release the force generated by the magnets. \\ | ||
+ | If the chain gets tight, move the clutch basket out some more and go back to the sprocket. \\ | ||
+ | DO NOT DROP THE ENGINE SPROCKET. The magnets can crack or break off and that's a different problem. \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | However they come off is fine as long as they are not dropped. \\ | ||
+ | |||
+ | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_5_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | Make sure you already have a place to put them and a clear walking path before removing them from the engine. \\ | ||
+ | Cover them to keep dirt / debris off them until they are ready to go back on. \\ | ||
+ | {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_8_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | Slip the primary cover back on and stuff rags in the openings when not working inside the engine to help keep out dirt / debris. \\ | ||
+ | |||
+ | {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_9_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | |||
+ | |||
+ | ====== Remove the stator ====== | ||
+ | |||
+ | {{:techtalk:evo:elec:removing_the_stator_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:elec:removing_the_stator_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
+ | {{:techtalk:evo:elec:removing_the_stator_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
- | ====== Removing the stator ====== | + | {{:techtalk:evo:elec:removing_the_stator_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) |
+ | {{:techtalk:evo:elec:removing_the_stator_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
+ | {{:techtalk:evo:elec:removing_the_stator_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
- | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_7_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_8_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_6_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) \\ | + | {{:techtalk:evo:elec:removing_the_stator_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) |
+ | {{:techtalk:evo:elec:removing_the_stator_8_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
+ | {{:techtalk:evo:elec:removing_the_stator_9_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | {{:techtalk:evo:elec:removing_the_stator_10_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
+ | {{:techtalk:evo:elec:removing_the_stator_11_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
+ | {{:techtalk:evo:elec:removing_the_stator_12_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
- | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_9_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) \\ | + | {{:techtalk:evo:elec:removing_the_stator_13_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) |
+ | {{:techtalk:evo:elec:removing_the_stator_14_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
+ | {{:techtalk:evo:elec:removing_the_stator_15_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | {{:techtalk:evo:elec:removing_the_stator_16_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
\\ | \\ |