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techtalk:evo:elec02b [2019/11/13 23:11] hippysmack [Removing the stator] |
techtalk:evo:elec02b [2020/08/31 03:48] hippysmack [Remove shift lever] |
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Drain the primary fluid, loosen or remove the clutch cable and loosen the primary chain adjuster. \\ | 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. \\ | The engine below is a 98 XL1200S that has been upgraded to 1250 with a Buell XB crankshaft and respective engine sprocket. \\ | ||
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====== Before removing the primary cover ====== | ====== Before removing the primary cover ====== | ||
- | Remove shift lever. \\ | + | \\ |
+ | ===== Remove shift lever ===== | ||
+ | |||
+ | 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: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)) \\ | {{: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)) \\ | ||
- | Remove the rubber seal behind the lever. \\ | + | Remove the rubber spacer 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)) \\ | {{: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)) \\ | ||
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+ | ===== 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. \\ | ||
+ | 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. \\ | ||
+ | |||
+ | {{: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)) \\ | ||
+ | |||
+ | |||
+ | ===== Clutch cable ===== | ||
The clutch cable is best removed from the cover. \\ | The clutch cable is best removed from the cover. \\ | ||
Line 50: | Line 76: | ||
{{: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)) \\ | {{: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)) \\ | ||
- | Remove the derby cover and the clutch ramp assembly. \\ | ||
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- | {{:techtalk:evo:priclutch:adjusting_clutch_1_by_hippysmack.jpg?direct&300|}} \\ | ||
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- | {{: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)) \\ | ||
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- | {{: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)) \\ | ||
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- | {{: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 ===== | + | ====== Loosen and remove the primary cover ====== |
- | Loosening the primary chain adjuster takes the pressure off the primary chain from the cover. \\ | + | |
- | 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. \\ | + | |
- | + | ||
- | {{: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)) \\ | + | |
- | + | ||
- | ===== 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 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. \\ | Loosen the primary cover screws but don't completely remove them to allow oil to drain into a bucket or catch pan. \\ | ||
Line 106: | Line 114: | ||
There are also several 4 and 5 speed [[techtalk:ref:tools116#engine_and_clutch_sprocket_locking_tools|primary locking tool examples]] in the tool section. \\ | There are also several 4 and 5 speed [[techtalk:ref:tools116#engine_and_clutch_sprocket_locking_tools|primary locking tool examples]] in the tool section. \\ | ||
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. \\ | ||
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- | {{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. \\ | The threads should have previously been assembled with red Loctite. \\ | ||
Line 118: | Line 124: | ||
The clutch basket has left hand threads (lefty tighty-righty loosy) \\ | The clutch basket has left hand threads (lefty tighty-righty loosy) \\ | ||
- | {{:techtalk:evo:engmech:removing_engine_sprocket_and_clutch_hub_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:removing_engine_sprocket_and_clutch_hub_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | + | {{techtalk:ref:tools:primary-brasshinge-lock.jpg?300|}} ((photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?t=53268)) {{: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. \\ | ||
Line 132: | Line 138: | ||
If the chain gets tight, move the clutch basket out some more and go back to the sprocket. \\ | 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. \\ | DO NOT DROP THE ENGINE SPROCKET. The magnets can crack or break off and that's a different problem. \\ | ||
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- | {{:techtalk:evo:engmech:removing_engine_sprocket_and_clutch_hub_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
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However they come off is fine as long as they are not dropped. \\ | 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:engmech:removing_engine_sprocket_and_clutch_hub_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:removing_engine_sprocket_and_clutch_hub_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | + | {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
+ | |||
+ | {{: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. \\ | 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. \\ | Cover them to keep dirt / debris off them until they are ready to go back on. \\ | ||
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- | {{:techtalk:evo:engmech:removing_engine_sprocket_and_clutch_hub_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech: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. \\ | 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_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)) \\ | ||
+ | |||
+ | {{: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)) \\ | ||
+ | |||
- | {{:techtalk:evo:engmech:removing_engine_sprocket_and_clutch_hub_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech: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_11_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: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_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: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)) \\ | ||
\\ | \\ |