Differences

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--- techtalk:evo:engmech01k [2019/11/12 04:17]
hippysmack created
+++ techtalk:evo:engmech01k [2024/01/03 17:15] (current)
hippysmack [Loosen and remove the primary cover]
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 ====== 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. \\
+Drain the primary fluid, loosen or remove the clutch cable and loosen the primary chain adjuster. \\
+===== 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)) \\
+Remove the rubber seal behind the 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)) \\
+===== 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)) \\
+===== 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_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)) \\
+===== 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. \\
+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. \\
+{{: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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/29955-06-clutch-install?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)) \\
 \\

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