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| techtalk:evo:elec02b [2019/11/14 00:31] – [Remove the clutch release assembly] hippysmack | techtalk:evo:elec02b [2024/01/03 01:26] (current) – hippysmack |
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| ===== Remove shift lever ===== | ===== Remove shift lever ===== |
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| The bike below has forwards but if you have mid controls, they'll be behind the (2) 5/16" bolts on the bottom middle of the cover. \\ | The bike below has forwards but if you have mid controls, they'll be behind the (2) 5/16" bolts on the bottom middle of the cover. \\ |
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| {{: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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| Remove the rubber seal behind the shift lever. \\ | Remove the rubber spacer behind the shift lever. \\ |
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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)) \\ |
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| ===== Remove the clutch release assembly ===== | ===== Remove the clutch release assembly ===== |
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| Remove the derby cover and the clutch ramp assembly. \\ | Remove the derby cover and the clutch ramp assembly. \\ |
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| {{: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)) \\ | {{: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)) \\ |
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| ===== Clutch cable ===== | ===== Clutch cable ===== |
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| The clutch cable is best removed from the cover. \\ | 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. \\ | 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. \\ |
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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)) \\ |
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| ====== Loosen and remove the primary cover ====== | ====== Loosen and remove the primary 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. \\ |
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| {{: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)) \\ | {{: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)) \\ |
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| {{: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)) \\ | {{: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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| ====== Remove clutch adjustment assembly ====== | ====== Remove clutch adjustment assembly ====== |
| Inspect the bearings / race for smooth operation and / or damage. The circlip is reusable as long as it's not bent / warped. \\ | Inspect the bearings / race for smooth operation and / or damage. The circlip is reusable as long as it's not bent / warped. \\ |
| {{:techtalk:evo:priclutch:removing_clutch_adjustment-bearing_assembly_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_adjustment-bearing_assembly_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | {{:techtalk:evo:priclutch:removing_clutch_adjustment-bearing_assembly_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_adjustment-bearing_assembly_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
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| ====== Remove the engine sprocket / clutch basket ====== | ====== Remove the engine sprocket / clutch basket ====== |
| See also [[techtalk:ref:tools139|Replacing Stator Magnets]] in the tools section of the Sportsterpedia. \\ | See also [[techtalk:ref:tools139|Replacing Stator Magnets]] in the tools section of the Sportsterpedia. \\ |
| 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. \\ |
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| {{: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)) \\ |
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| 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. \\ |
| There are also several 4 and 5 speed [[techtalk:ref:tools116#engine_and_clutch_sprocket_locking_tools|primary locking tool examples]] in the tool section. \\ | There are also several 4 and 5 speed [[techtalk:ref:tools116#engine_and_clutch_sprocket_locking_tools|primary locking tool examples]] in the tool section. \\ |
| 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. \\ |
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| {{techtalk:ref:tools:primary-brasshinge-lock.jpg?300|}} ((photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?t=53268)) \\ | |
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| The threads should have previously been assembled with red Loctite. \\ | The threads should have previously been assembled with red Loctite. \\ |
| The clutch basket has left hand threads (lefty tighty-righty loosy) \\ | The clutch basket has left hand threads (lefty tighty-righty loosy) \\ |
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| {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | {{techtalk:ref:tools:primary-brasshinge-lock.jpg?300|}} ((photo by Scuba10jdl of the XLFORUM 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)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
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| The engine sprocket and clutch hub should be removed as one unit. \\ | The engine sprocket and clutch hub should be removed as one unit. \\ |
| If the chain gets tight, move the clutch basket out some more and go back to the sprocket. \\ | If the chain gets tight, move the clutch basket out some more and go back to the sprocket. \\ |
| DO NOT DROP THE ENGINE SPROCKET. The magnets can crack or break off and that's a different problem. \\ | DO NOT DROP THE ENGINE SPROCKET. The magnets can crack or break off and that's a different problem. \\ |
| | However they come off is fine as long as they are not dropped. \\ |
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| {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
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| However they come off is fine as long as they are not dropped. \\ | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_5_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:evo:priclutch:removing_engine_sprocket_and_clutch_hub_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
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| {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_5_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | |
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| Make sure you already have a place to put them and a clear walking path before removing them from the engine. \\ | Make sure you already have a place to put them and a clear walking path before removing them from the engine. \\ |
| Cover them to keep dirt / debris off them until they are ready to go back on. \\ | Cover them to keep dirt / debris off them until they are ready to go back on. \\ |
| {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_8_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | |
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| Slip the primary cover back on and stuff rags in the openings when not working inside the engine to help keep out dirt / debris. \\ | Slip the primary cover back on and stuff rags in the openings when not working inside the engine to help keep out dirt / debris. \\ |
| | {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_8_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
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| {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_9_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_9_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
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| ====== Remove the stator ====== | ====== Remove the stator ====== |
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| {{:techtalk:evo:elec:removing_the_stator_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:elec:removing_the_stator_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | {{:techtalk:evo:elec:removing_the_stator_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:elec:removing_the_stator_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) |
| {{:techtalk:evo:elec:removing_the_stator_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | {{:techtalk:evo:elec:removing_the_stator_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
