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techtalk:evo:engmech01k [2019/11/12 04:22] hippysmack |
techtalk:evo:engmech01k [2019/11/13 01:47] hippysmack [Removing the Primary Cover] |
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====== EVO: Engine Mechanicals - Sub-01K ====== | ====== EVO: Engine Mechanicals - Sub-01K ====== | ||
\\ | \\ | ||
- | ====== Removing the Primary Cover ====== | + | ====== Removing 91-03 Primary Cover ====== |
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. \\ | 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. \\ | ||
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. \\ | ||
- | ====== Before removing the primary cover ====== | + | |
- | Remove shift lever. \\ | + | ===== Remove shift lever ===== |
{{: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)) \\ | ||
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{{: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)) \\ | ||
+ | |||
+ | ===== Clutch cable ===== | ||
The clutch cable is best removed from the cover. \\ | The clutch cable is best removed from the cover. \\ | ||
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If you have to remove the cable connection or the cover completely from the engine, removing the cable is the easy part. \\ | 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. \\ | 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 | + | 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_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)) \\ | {{: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 derby cover and the clutch ramp assembly to gain access to the clutch basket mounting nut. \\ | + | 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)) \\ | ||
+ | |||
+ | ===== Remove the clutch ramp 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_1_by_hippysmack.jpg?direct&300|}} \\ | ||
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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)) \\ | {{: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)) \\ | ||
+ | ===== 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. \\ | ||
- | Loosen the primary cover screws to allow oil to drain in a bucket / catch pan. \\ | + | The primary cover has (14) 1/4" and (2) 5/16" Allen head screws of various lengths. \\ |
- | Some of the screws are different lengths and need to be placed back in their respective places. \\ | + | They will need to be replaced back in the same holes from which they were removed. \\ |
- | You can use a piece of cardboard with a sketch drawn of the cover as to where the bolts go. \\ | + | 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. \\ |
+ | Then put them into the cardboard in the proper orientation 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. \\ | 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)) \\ | + | {{: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)) \\ |
- | + | ||
- | Loosening the primary chain adjuster takes the pressure off the primary chain from the cover. \\ | + | |
+ | {{: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)) \\ | ||
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