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EVO: Engine Mechanicals - Sub-01K


Removing the 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.

Before removing the primary cover

Remove shift lever.

1) 2)

Remove the rubber seal behind the lever.

3) 4)

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

5) 6) 7)

8) 9) 10)

Remove the derby cover and the clutch ramp assembly to gain access to the clutch basket mounting nut.


11) 12) 13)

14) 15) 16)

17) 18) 19)

Loosen the primary cover screws to allow oil to drain in a bucket / catch pan.
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.

20) 21)

Loosening the primary chain adjuster takes the pressure off the primary chain from the cover.


1) , 2) , 3) , 4) , 5) , 6) , 7) , 8) , 9) , 10) , 11) , 12) , 13) , 14) , 15) , 16) , 17) , 18) , 19)
photo by Hippysmack
20)
photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130
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