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techtalk:evo:engmech01k [2019/11/12 06:51] – [Remove the clutch ramp assembly] hippysmacktechtalk:evo:engmech01k [2024/05/18 19:27] (current) – [Loosen and remove the primary cover] hippysmack
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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. \\
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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 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. \\ 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. \\ They will need to be replaced back in the same holes from which they were removed. \\
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 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)) \\ 
 + 
 +====== Installing the Cover ====== 
 +Torque specs are in the FSM but torque sequence is not. In order to get the best seal and keep the cover from warping, it should be torqued in sequence. \\ 
 +Torque spec is 80-100 in/lbs. Suggested torque sequence is in the pic below. \\ 
 +**NOTE**: using too much torque on these bolts has been known to strip the bolt heads and crack primary covers. \\ 
 + 
 +If you are using a clicker type torque wrench, it's best not to on these small torque values. \\ 
 +Clicker type torque wrenches have a habit of giving false results. In that case, just use the "snug plus a nudge" method with the sequence in the pic below. \\ 
 +Snug all the bolts in sequence first, then use the same pressure "nudge" on the second pass. \\ 
 +As this method will not tighten all the bolts the same, you'll have to use "feel" to know when to stop. \\ 
 + 
 +If you are using a beam type torque wrench, use the sequence below to get to the torque spec. \\ 
 +This is a proven sequence that will pull all the bolts up evenly without distorting the cover. \\
  
 +{{:techtalk:evo:engmech:1991-2003_sportster_primary_cover_torque_sequence_by_hippysmack.jpg?direct&400|}} ((photo by Hippysmack)) \\
  
  

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