Differences

This shows you the differences between two versions of the page.

Link to this comparison view

Both sides previous revision Previous revision
techtalk:evo:priclutch02 [2023/06/23 16:21]
hippysmack [Sprocket Torquing]
techtalk:evo:priclutch02 [2024/01/06 04:46] (current)
hippysmack
Line 3: Line 3:
  
 ====== Primary Drive Design ====== ====== Primary Drive Design ======
- 
 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.)
  
Line 24: Line 23:
 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. 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))
  
 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 '​bump'​ of the cover where the starter is mounted is rounded at the top.\\
Line 40: Line 39:
  
 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.\\ 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 http://​xlforum.net/​forums/showthread.php?t=1974683+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
  
 {{:​techtalk:​evo:​priclutch:​94-up-quad-ring-1-baby883.jpg?​600|}}{{:​techtalk:​evo:​priclutch:​94-up-quad-ring-2-baby883.jpg?​400|}} {{:​techtalk:​evo:​priclutch:​94-up-quad-ring-1-baby883.jpg?​600|}}{{:​techtalk:​evo:​priclutch:​94-up-quad-ring-2-baby883.jpg?​400|}}
Line 51: Line 50:
 | 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)) ​ | :::  |
  
 \\ \\
Line 123: Line 122:
  
 \\  ​ \\  ​
-{{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))
  
 \\ \\
Line 140: Line 139:
 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. \\
Line 147: Line 146:
 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. \\