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techtalk:evo:engmech01k [2019/11/12 04:53]
hippysmack [Before removing the primary cover]
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 ====== ====== 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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 {{:​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 ​to gain access to the clutch basket mounting nut. \\+===== 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 piece of cardboard with 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 drawing ​of the primary cover on 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 ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​29955-06-clutch-install?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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