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techtalk:evo:priclutch02 [2022/08/14 05:32] ixl2relax [Primary Chain - Tensioner] |
techtalk:evo:priclutch02 [2024/01/06 04:46] (current) hippysmack |
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| ====== Primary Drive Design ====== | ====== Primary Drive Design ====== | ||
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| The Primary Drive is responsible to transfer the crankshaft rotations (generated from the pistons, rods & flywheel) thru the Clutch to the Transmisison. The engine sprocket transfers engine power into the primary chain which turns the clutch assembly. The clutch assembly, when engaged, transfers engine power into the transmission on the mainshaft. (The transmission gears, along with final drive sprockets and chain or belt, transfers that engine power to the rear wheel.) | The Primary Drive is responsible to transfer the crankshaft rotations (generated from the pistons, rods & flywheel) thru the Clutch to the Transmisison. The engine sprocket transfers engine power into the primary chain which turns the clutch assembly. The clutch assembly, when engaged, transfers engine power into the transmission on the mainshaft. (The transmission gears, along with final drive sprockets and chain or belt, transfers that engine power to the rear wheel.) | ||
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| On the 1994-2003 cover, the primary chain inspection cover is still round using two screws to mount it.\\ | On the 1994-2003 cover, the primary chain inspection cover is still round using two screws to mount it.\\ | ||
| - | But, the clutch adjustment cover is the large Derby Cover (4-bolt) that allowed the Ball&Ramp assembly to be removed without removing the cover. | + | But, the clutch adjustment cover is the large Derby Cover (4-bolt) that allowed the Ball&Ramp assembly to be removed without removing the cover. The 'bump' of the cover where the starter is mounted is flat-topped. |
| - | Note: The primary cover from '94-'03 can be retro fitted back to 1991-93 models, but the Ball&Ramp assembly must be changed to the '94-'03 version. As mentioned above, the '94-'03 models use the large derby cover which will also be needed. The internal clutch parts are the same back to 1991 and the clutch cables are compatible (but need to be checked for length). The primary cover gasket is the same for 1991-2003 models.((http://xlforum.net/forums/showthread.php?t=952523)) | + | Note: The primary cover from '94-'03 can be retro fitted back to 1991-93 models, but the Ball&Ramp assembly must be changed to the '94-'03 version. As mentioned above, the '94-'03 models use the large derby cover which will also be needed. The internal clutch parts are the same back to 1991 and the clutch cables are compatible (but need to be checked for length). The primary cover gasket is the same for 1991-2003 models.((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/106167-primary-cover-swap?t=952523)) |
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| + | With the Rubbermount models, starting in 2004-later, the cover has a rectangular primary chain inspection cover, held in place by two screws. The clutch adjustment cover is the large Derby Cover, but it is mounted with 6 bolts. The 'bump' of the cover where the starter is mounted is rounded at the top.\\ | ||
| - | With the Rubbermount models, starting in 2004-later, the cover has a rectangular primary chain inspection cover, held in place by two screws.\\ | ||
| - | The clutch adjustment cover is the large Derby Cover, but it is mounted with 6 bolts.\\ | ||
| The polished covers on the 2004-2005 models have the same part number, 25430-04, but the 2006-later engines use part number 25430-06.\\ | The polished covers on the 2004-2005 models have the same part number, 25430-04, but the 2006-later engines use part number 25430-06.\\ | ||
| __IMPORTANT NOTE:__ The 2004-2006 covers may all have the same Internal Casting # 34951-04 which can be confusing, because the shifter shaft is different in 2006-later.\\ | __IMPORTANT NOTE:__ The 2004-2006 covers may all have the same Internal Casting # 34951-04 which can be confusing, because the shifter shaft is different in 2006-later.\\ | ||
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| Over the years, the primary cover has been available in different finishes (polished Aluminum, rough Aluminum, Chrome, Black, etc.) with different part numbers for those variations. | Over the years, the primary cover has been available in different finishes (polished Aluminum, rough Aluminum, Chrome, Black, etc.) with different part numbers for those variations. | ||
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| + | \\ | ||
| + | |||
| + | ====== Quad-Ring - Clutch Inspection Cover ====== | ||
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| + | From 1994-later the Clutch Inspection Cover (AKA: Derby Cover) has had a sealing ring, often referred to as the Quad-Ring. It is circular, but its cross-section profile is not round like an o-ring, but rather four-sided flat. The quad-ring P/N is 25463-94A.\\ | ||
| + | See discussion at https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/183554-clutch-cover-gasket?t=1974683 | ||
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| + | {{:techtalk:evo:priclutch:94-up-quad-ring-1-baby883.jpg?600|}}{{:techtalk:evo:priclutch:94-up-quad-ring-2-baby883.jpg?400|}} | ||
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| | Primary Chain Adjuster - 1986-1990 - Parts Obsolete\\ Primary Chain Adjuster - 1991-2003 - 39975-90A (upgrade in 2001+)\\ Primary Chain Adjuster - 2004-later --- uses 40039-02C | | | Primary Chain Adjuster - 1986-1990 - Parts Obsolete\\ Primary Chain Adjuster - 1991-2003 - 39975-90A (upgrade in 2001+)\\ Primary Chain Adjuster - 2004-later --- uses 40039-02C | | ||
| - | |**1986-90 Primary Chain Tensioner Parts**\\ \\ 39973-86 - Steel Carrier Plate\\ 40018-86 - Pivot Stud\\ 40019-86 - Spring for Tension\\ 39966-80 - Pad against Chain\\ 3250 ------- Threaded Stud - for Adjustment|{{:techtalk:evo:priclutch:primary_chain_tensioner_spring_installed_by_yochstein.jpg?direct&320|}}((photo by Yochstein of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=1980020))| | + | |**1986-90 Primary Chain Tensioner Parts**\\ \\ 39973-86 - Steel Carrier Plate\\ 40018-86 - Pivot Stud\\ 40019-86 - Spring for Tension\\ 39966-80 - Pad against Chain\\ 3250 ------- Threaded Stud - for Adjustment|{{:techtalk:evo:priclutch:primary_chain_tensioner_spring_installed_by_yochstein.jpg?direct&320|}}((photo by Yochstein of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/184451-primary-chain-adjuster-spring-install?threadid=1980020))| |
| - | | 91-later XLH Primary Chain Tensioner - Manually Adjustable ((photo by Gcram399 - http://xlforum.net/forums/showthread.php?t=1661362 & GophersAndCheese - http://xlforum.net/forums/showthread.php?t=619960)) | | + | | 91-later XLH Primary Chain Tensioner - Manually Adjustable ((photo by Gcram399 - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/154758-primary-side-tear-down?t=1661362 & GophersAndCheese - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/83129-ragerbuilt-jockey-shift-for-04?t=619960)) | |
| |{{:techtalk:evo:priclutch:primarychainadjuster-91-later.jpg|}}| | |{{:techtalk:evo:priclutch:primarychainadjuster-91-later.jpg|}}| | ||
| - | |{{:techtalk:evo:priclutch:primarychainadjuster-compoldnew.jpg|}}| {{:techtalk:evo:priclutch:primarychainadjuster-nut-7804.jpg?200|}}\\ 1991-later Sportsters\\ Primary Chain Adjuster Nut\\ **P/N 7804**\\ This nut has a special\\ extended nylon face((http://xlforum.net/forums/showthread.php?t=1047928)) which\\ seals against the Primary Cover\\ \\ **TO PREVENT LEAKS**\\ Avoid Common Nylon Insert Nuts | | + | |{{:techtalk:evo:priclutch:primarychainadjuster-compoldnew.jpg|}}| {{:techtalk:evo:priclutch:primarychainadjuster-nut-7804.jpg?200|}}\\ 1991-later Sportsters\\ Primary Chain Adjuster Nut\\ **P/N 7804**\\ This nut has a special\\ extended nylon face((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/111331-primary-adjuster-leak?t=1047928)) which\\ seals against the Primary Cover\\ \\ **TO PREVENT LEAKS**\\ Avoid Common Nylon-insert Nuts | |
| - | | Upgrade 39975-90A should be used in place of 1991-2000 stock Chain Tensioner.\\ 2001-2003 models had the -90A part as factory OEM stock. ((photo by aswracing - http://xlforum.net/forums/showthread.php?t=1627892)) | ::: | | + | | Upgrade 39975-90A should be used in place of 1991-2000 stock Chain Tensioner.\\ 2001-2003 models had the -90A part as factory OEM stock. ((photo by aswracing - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/150329-what-stator-rotor-brand?t=1627892)) | ::: | |
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| ^Nut Description^Nut Size^Tightening Torque^Where^^Notes| | ^Nut Description^Nut Size^Tightening Torque^Where^^Notes| | ||
| - | |**Engine Sprocket Nut (Crankshaft)** |||||| | + | |**Engine Sprocket Nut (Crankshaft) **, right hand threads all years. |||||| |
| |1991-1997 Models|1-1/8" Nut| 150-165ft-lbs |at Rotor Assy|| *HD Tech Tip 211 – September 16, 2005\\ Flywheel Sprocket Shaft Nut Torque Update\\ The flywheel (engine) sprocket shaft nut torque\\ for 2004 & later Sportsters and 2003 & later\\ Buell XB models has been changed.\\ The torque has been increased from 190-210\\ to 240-260 ft lbs. Remember to clean the\\ threads and generously apply LOCTITE\\ Threadlocker 262 (red) onto the threads of\\ the engine sprocket shaft. | | |1991-1997 Models|1-1/8" Nut| 150-165ft-lbs |at Rotor Assy|| *HD Tech Tip 211 – September 16, 2005\\ Flywheel Sprocket Shaft Nut Torque Update\\ The flywheel (engine) sprocket shaft nut torque\\ for 2004 & later Sportsters and 2003 & later\\ Buell XB models has been changed.\\ The torque has been increased from 190-210\\ to 240-260 ft lbs. Remember to clean the\\ threads and generously apply LOCTITE\\ Threadlocker 262 (red) onto the threads of\\ the engine sprocket shaft. | | ||
| |1998-2003 Models|1-1/8" Nut| 190-210ft-lbs |at Rotor Assy|| ::: | | |1998-2003 Models|1-1/8" Nut| 190-210ft-lbs |at Rotor Assy|| ::: | | ||
| |2004+ Models|1-1/8" Nut| 240-260ft-lbs* |at Rotor Assy|| ::: | | |2004+ Models|1-1/8" Nut| 240-260ft-lbs* |at Rotor Assy|| ::: | | ||
| - | |**Transmission Main Shaft Nut (Clutch Hub)** (1991-later) |||||| | + | |2017 Models|1-1/8" Nut| 250ft-lbs ((Tomcatt of the XLFORUM)) |at Rotor Assy|| ::: | |
| - | |Left-hand Threads!!|1-3/16" Nut| 75ft-lbs |at Clutch Hub||Use only 2 or 3 drops of RED threadlocker\\ on this nut| | + | |**Transmission Main Shaft Nut (Clutch Hub)** |||||| |
| + | |1991-Later Models \\ Left-hand Threads!!|1-3/16" Nut| 75ft-lbs |at Clutch Hub||Use only 2 or 3 drops of RED threadlocker\\ on this nut| | ||
| + | |2017 Models \\ Left-hand Threads!!|1-3/16" Nut| 50ft-lbs ((Tomcatt of the XLFORUM)) |at Clutch Hub||Use only 2 or 3 drops of RED threadlocker\\ on this nut| | ||
| If you can, use regular six-sided sockets which are less likely to slip and round off the edges of the nuts. Impact-type sockets may be too thick to fit. Metric equivalents that my work are 28mm and 30mm sockets. | If you can, use regular six-sided sockets which are less likely to slip and round off the edges of the nuts. Impact-type sockets may be too thick to fit. Metric equivalents that my work are 28mm and 30mm sockets. | ||
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| - | {{techtalk:ref:tools:primary-brasshinge-lock.jpg?350|}} ((photo by Scuba10jdl (2002 883>1250) http://xlforum.net/forums/showthread.php?t=53268 - Post#98)) {{techtalk:evo:priclutch:primary-nuts.jpg?500|}} ((photo by IXL2Relax - 1994 883>1200)) | + | {{techtalk:ref:tools:primary-brasshinge-lock.jpg?350|}} ((photo by Scuba10jdl (2002 883>1250) https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/32092-bottom-end-noise-and-the-primary-drive-sprocket-nut?t=53268 - Post#98)) {{techtalk:evo:priclutch:primary-nuts.jpg?500|}} ((photo by IXL2Relax - 1994 883>1200)) |
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| They are less likely to slip and round off the edges of the nuts. Impact-type sockets are likely too thick to fit. \\ | They are less likely to slip and round off the edges of the nuts. Impact-type sockets are likely too thick to fit. \\ | ||
| - | {{:techtalk:ref:tools:engine_sprocket_removal_-_installation_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:ref:tools:clutch_nut_removal_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) \\ | + | {{:techtalk:ref:tools:engine_sprocket_removal_-_installation_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/169896-2000-883-stator-replacement?t=1823130)) {{:techtalk:ref:tools:clutch_nut_removal_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/169896-2000-883-stator-replacement?t=1823130)) \\ |
| Normally when loosening or tightening these nuts, you will need to **lock the hub & sprocket** - Do not wedge the chain. \\ | Normally when loosening or tightening these nuts, you will need to **lock the hub & sprocket** - Do not wedge the chain. \\ | ||
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| A closed 4" BRASS hinge also works well to lock the sprockets and then you can use a pull bar and sockets / socket wrench. \\ | A closed 4" BRASS hinge also works well to lock the sprockets and then you can use a pull bar and sockets / socket wrench. \\ | ||
| - | {{techtalk:ref:tools:primary-brasshinge-lock.jpg?300|}} ((photo by Scuba10jdl (2002 883>1250) http://xlforum.net/forums/showthread.php?t=53268 - Post#98))\\ | + | {{techtalk:ref:tools:primary-brasshinge-lock.jpg?300|}} ((photo by Scuba10jdl (2002 883>1250) https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/32092-bottom-end-noise-and-the-primary-drive-sprocket-nut?t=53268 - Post#98))\\ |
| The threads should have previously been assembled with red Loctite. \\ | The threads should have previously been assembled with red Loctite. \\ | ||
