EVO: Engine Mechanicals - Sub-01K

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====== EVO: Engine Mechanicals - Sub-01K ======
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====== 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 =====

{{: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)) \\

Remove the rubber seal behind the lever. \\

{{: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. \\
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. \\
Retract the cable connection fully to allow slack on the inner braided wire. \\
{{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\

{{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:adjusting_-_removing_clutch_cable_6_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\

Remove the cable holding clip (if used) and any wire ties etc. that may be holding the cable to the frame. \\

{{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_7_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\

Remove the clutch lever from it's bracket by removing the retaining ring (circlip) underneath and pivot pin from the top. \\
Then pull the lever from the bracket, swing the cable wire through the slot in the bracket and remove the plastic cable pin. \\

{{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_8_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_9_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_10_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ 

Then pull the clutch cable down thru the trees and lay it out in front of the bike. \\
Use a 1/2" open end wrench to loosen the cable connector at the primary cover and then you can most likely twist the cable to loosen the threads. \\
This method will help keep the cable straight so as to not cross thread it making it more safe for re-installing the cable later. \\

Be careful not to damage the O-ring on the part of the cable that comes out of the cover. \\
Inspect the O-ring and replace it if needed. \\

{{: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 clutch ramp assembly =====

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

{{:techtalk:evo:priclutch:adjusting_clutch_1_by_hippysmack.jpg?direct&300|}} \\

{{:techtalk:evo:priclutch:adjusting_clutch_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack))  {{:techtalk:evo:priclutch:adjusting_clutch_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack))  {{:techtalk:evo:priclutch:adjusting_clutch_4_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack))  \\

{{:techtalk:evo:priclutch:adjusting_clutch_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_ramp_assembly_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_clutch_ramp_assembly_2_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 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. \\

{{: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)) \\

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



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Trace: • REF: Tools - 147 • EVO: Engine Mechanicals - Sub-01K • REF: Engine Mechanicals - Sub-05I • REF: Engine Mechanicals - Sub-01I • REF: Tools - 136 • EVO: Engine Mechanicals - Sub-03B • IH: Engine Mechanicals - Sub-04A