K9 Rebuild/Upgrade

[82ndAirborne]

Also, I tried inserting two short Bolts to pull the Rotor off...couldn't do it. So, installed two long Bolts with large washers...came off with ease!

 

[kickstart]

Ok...here we go with Primary swap. So, I'm looking at picture 2, I would like to remove the clutch basket as a single unit.

(From my manual)
CLUTCH BASKET/ENGINE SPROCKET/PRIMARY CHAIN-REMOVAL AND INSTALLATION
I see a Retaining Ring holding the Throwout bearing. The manual skips right over removing this and goes straight to removing the clutch hub Nut. I assume this is a simple oversight and I'll find the nut behind the bearing. Is this correct?

You need to remove the weight on your Ignition key.

 

[SKOGDOG]

Three thoughts on the stator plug: obsessively clean the housing, use high quality sealant and allow a day to cure. Sounds like you’re good for all 3.

 

[82ndAirborne]

Three thoughts on the stator plug: obsessively clean the housing, use high quality sealant and allow a day to cure. Sounds like you’re good for all 3.

Can I insert the plug and afterward Seat the Stator, or does it need to be fully seated BEFORE inserting the plug? There's not alot of finger room once it's fully seated.

 

[Rottweiler]

You need to remove the weight on your Ignition key.

Looks like he hooks it to a spark plug wire.

 

[82ndAirborne]

Though I would lay out the parts for the Inner Primary, Starter...etc. Basically make sure I have everything. So, opened up the box on the starter and started to pull it out of the plastic. OMG...it's deeply scratched all around the back housing. Looks like someone tried installing it with a chain saw! I know Donna will replace it but yet another unexpected delay. If it didn't show I would go ahead and use it but this is the exposed end and it's scratched all the way around...even the back side of the lip. Crap!

 

[82ndAirborne]

Huh—-my K9 also leaks a dribble of trans oil when I pull the clutch but my trans never requires any oil to be added. See if there is any end play in the input shaft—it should be rock solid. Check your trans oil level. Im in FL this weekend and don’t have access, but I think the clutch inner hub is sealed by a rubber inner lip on the transmission seal. When you remove the hub and spline (#21) from the transmission input shaft, it allows a bit of oil to seep out. Bet $10 your trans input seal is ok and the seepage normal.

You're correct...Seal (orange looking in pic 1) I see now that when I put the clutch hub back on it will push the seal back in on the shaft. The larger outer seal is not leaking. However, since I already ordered the kit I may as well use it. Also, I can't finish the project now anyway because of the starter. So, I'll just clean things up.

I bought Grade 8 Bolts for the lower Motor Mounts and then had them chromed. I installed 3, but couldn't get to the 4th because of the primary. Got it now. Pic 2

 

[82ndAirborne]

Looks like he hooks it to a spark plug wire.

No, it's just hanging down...it's a BIG Dog key ring...Think I got it from Curtis. You think it'll damage my key switch?

 

[HMAN]

No, it's just hanging down...it's a BIG Dog key ring...Think I got it from Curtis. You think it'll damage my key switch?

Keep it clipped to ur sparkplug. Not enough weight to do any damage.

 

[82ndAirborne]

Though I would lay out the parts for the Inner Primary, Starter...etc. Basically make sure I have everything. So, opened up the box on the starter and started to pull it out of the plastic. OMG...it's deeply scratched all around the back housing. Looks like someone tried installing it with a chain saw! I know Donna will replace it but yet another unexpected delay. If it didn't show I would go ahead and use it but this is the exposed end and it's scratched all the way around...even the back side of the lip. Crap!

Ah...think I know how that starter Housing got trashed. Someone already mounted this on the Primary. I was just reading a post on the Rotor/Stator install, sometimes requiring a little grinding on the fins. If they were doing this on concrete, with the starter mounted...well...you get the picture. It would have to be something like this to scratch both back and sides.

 

[82ndAirborne]

Huh—-my K9 also leaks a dribble of trans oil when I pull the clutch but my trans never requires any oil to be added. See if there is any end play in the input shaft—it should be rock solid. Check your trans oil level. Im in FL this weekend and don’t have access, but I think the clutch inner hub is sealed by a rubber inner lip on the transmission seal. When you remove the hub and spline (#21) from the transmission input shaft, it allows a bit of oil to seep out. Bet $10 your trans input seal is ok and the seepage normal.

Look what I found reading the Chapter you emailed to me...(Note at top)! So...nothing to worry about. I think I'll replace the two seals anyway since I already ordered the kit. Looks like the one on the shaft just slides on; the larger seal I believe I can just gently press it in.

 

[Snuffy]

I hang mine from the plug wire also and have for many years on several bikes. Never had any issues.

 

[82ndAirborne]

Well, I was wrong about how that new starter got scratches. I thought someone had mounted it already, scratched it up, then returned it. Donna was looking through the starter boxes (5), and all were scratched in the same place. Also, they (BigDogPartsKingpen) make the billet nose for the starter, then have a guy put them on. He decided he didn't want to do it anymore. Donna is going to send the billet nose along with the best starter she can find. So, I'll have to wait on that. I just got back from Kentucky yesterday so I haven't done anything to the bike for two weeks. I did manage to go to the machine shop while I was there and have them fabricate a set of Tribal Grips that match my Pegs. They called today and said I should get them tomorrow evening. Worked a few hours today, mostly polishing the bottom front where the motor Mounts are. I've still got some pitting. Really hard on the bach to polish that out.

 

[82ndAirborne]

Received my Tribal Grips last night. I think they did an amazing job. They were more expensive than I anticipated but the Machine shop explained some of the complications involved. They had to build a jig/tool so this added to the hours. I'm very happy with the results. The plastic inserts that go to the stock Grips will go inside, I thought this would eliminate any vibration rattle. Spent a couple more hours polishing the front of the motor and Forward Control Mounting Brackets. I'd like to get everything perfectly smooth again, no pitting. This will be my only chance before the Ceramic Coating is applied.

 

[82ndAirborne]

Let's hope they fit. I'm a little concerned about the length at the top of the Grips, where the Button Control Brackets wrap around them. We'll see how it goes. If they're off I'll just have to get them remade. Hey, I've gone this far, just a little more to get to the finish line! Remember, ALL THE WAY!

 

[82ndAirborne]

Got a couple more hours in this morning trying to polish out the small pits. I saw an aluminum polish on a video from Andrew's website. He had an engine and tranny all polished up. Though I would give it a try. It feels a little more abrasive than the Mother's Polish...hard to tell for sure. However, seemed better on removing the pits. Starter is on the way...probably Tuesday. I'll have to swap out the nose when it gets here then I'll be ready to start reassembly of the primary.

 

[82ndAirborne]

I just realized that although the Grips are the same length, because of the tapered end on the Tribal, it may bottom out on the handlebar. So, I know I can trim 1/2" off, does anyone know if this will be necessary?

 

[HMAN]

Stick the grip on and see where it lands compared to the OG. Sharpie should tell the tail.

 

[Snuffy]

You won’t know until you try

 

[82ndAirborne]

Ok. If I have to trim a little off the bar no big deal. Looks like 3/8 or 1/2 at the most.