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techtalk:evo:engmech01 [2019/07/29 13:35]
hippysmack [Comparing 03-04 Style Front Mounts]
techtalk:evo:engmech01 [2019/08/16 21:47] (current)
hippysmack [91 and Up Models (5 Speed)]
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 |  Crank pin boss washer (5608) ((photos by Hippysmack)) ​ || |  Crank pin boss washer (5608) ((photos by Hippysmack)) ​ ||
 |{{:​techtalk:​evo:​engmech:​crank_pin_boss_washer_1_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​crank_pin_boss_washer_2_by_hippysmack.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​engmech:​crank_pin_boss_washer_1_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​crank_pin_boss_washer_2_by_hippysmack.jpg?​direct&​300|}}|
 +
 +From '91 to '03 the Crankshaft/​Flywheel was balanced according to the engine size, either for 883 pistons or 1200 pistons. From 2004-later, the flywheels are balanced to be between the weight of the 883 & 1200 pistons. ((http://​hammerperf.com/​883conversions.shtml)) This is one reason why riders would use Wiseco pistons in early (pre-2004) 883 to 1200 conversions - the Wiseco 1200 piston & pin was closer to the weight of the 883 combination rather than the 1200 piston & pin from HD.
 +
 +\\
 +
 ====== Crank Pin ====== ====== Crank Pin ======
 Crank pin (23960-80a) used from L81-03. \\ Crank pin (23960-80a) used from L81-03. \\
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 ====== Pinion Shaft ====== ====== Pinion Shaft ======
  
-===== Removing the pinion shaft nut =====+===== Removing ​/ installing ​the pinion shaft nut =====
  
 To remove or install the pinion gear nut, \\ You'll need to lock the pinion gear from moving while turning it. \\ To remove or install the pinion gear nut, \\ You'll need to lock the pinion gear from moving while turning it. \\
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 {{techtalk:​ref:​tools:​grindlock_tool_2_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) {{techtalk:​ref:​tools:​grindlock_tool_by_aswracing.jpg?​direct&​300|}} ((aswracing of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1618841&​page=4)) ((photo by aswracing of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1920827&​highlight=pinion+gear+locking+tool)) {{techtalk:​ref:​tools:​grindlock_tool_2_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) {{techtalk:​ref:​tools:​grindlock_tool_by_aswracing.jpg?​direct&​300|}} ((aswracing of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1618841&​page=4)) ((photo by aswracing of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1920827&​highlight=pinion+gear+locking+tool))
  
-  * Once the pinion shaft nut is removed, the pinion gear may or may not slide off by itself. \\ You can use a gear puller to remove it if it is stuck on.+  * Once the pinion shaft nut is removed, the pinion gear may or may not slide off by itself. \\ You can use a gear puller to remove it if it is stuck on. \\ 
 +  * It's very important to hold the crank still from the cam side (not the primary side) when torquing the pinion nut. ((aswracing of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1666277)) \\ If you for example put the bike in gear and hold the rear brake and torque on the nut, you run the very real risk of knocking the crank out of true. \\ It's not designed to transmit torque from one side to the other and it tries to twist the crankpin connection. 
 +  * In respect to the key shearing, it's a very common issue particularly when heavy valve springs are used. \\ However, it shouldn'​t be the one thing that keeps the gear from spinning. The clamp load should do that. \\ The caption in the second pic below describes the fix: \\ Loctite red and 70ft-lbs instead of the factory specified 50ft-lbs. You won't have this issue again. \\  
  
-{{:​techtalk:​evo:​engmech:​removing_the_pinion_gear_by_grind.jpg?​direct&​300|}} ((photo by ~Grind~'​ of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1448694))+{{:​techtalk:​evo:​engmech:​removing_the_pinion_gear_by_grind.jpg?​direct&​300|}} ((photo by ~Grind~'​ of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1448694)) {{:​techtalk:​evo:​engmech:​pinion_key_nub_by_aswracing.jpg?​direct&​250|}} ((photo by aswracing of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1666277))
  
 ===== Pinion Gear Runout ===== ===== Pinion Gear Runout =====