4.21 Primary Cover

PRIMARY COVER                                                                                                                   4.21

PREPARE                                                           3.   Install primary cover.

1.   Remove main fuse. See             POWER    DISCONNECT             a.      Rotate clutch actuator (2) counter-clockwise.
     (Page 8-4).
                                                                       b.      Align and install primary cover (7) to engine.
2.   Disconnect clutch cable. See CLUTCH CONTROL                       c.      Rotate clutch actuator (2) clockwise to set cover (7)
     (Page 3-82)                                                               in place and to engage the clutch mechanism.

3.   Drain engine oil. See REPLACE ENGINE OIL AND FILTER               d.      Install screws (1).
     (Page 2-7).
                                                                  4.   See Figure 4-53. Tighten screws in sequence.
4.   Remove center stand (if equipped). See CENTER STAND
                                                                       Torque: 94-115 in-lbs (10.6-13 N·m) Primary cover
     (Page 3-111).
                                                                       screws

5.   Remove radiator mounting screws and position radiator
     away from oil cooler. Support as needed. See RADIATOR
     (Page 7-18).

     a.    Do not disconnect coolant hoses.

6.   Remove exhaust header. See EXHAUST SYSTEM
     (Page 6-37).

REMOVE

Primary Cover
1.   See Figure 4-52. Remove screws (1).

2.   Remove primary cover (7).

3.   Remove and discard gasket (3).

Oil Baffle                                                             1.      Screw(10)
                                                                       2.      Clutch actuator
1.   See Figure 4-52. Remove screws (4, 6).
                                                                       3.      Gasket
                                                                       4.      Screw, short
2.   Remove oil baffle (5).
                                                                       5.      Oil baffle
                                                                       6.      Screw, long
INSTALL                                                                7.      Primary cover
                                                                                     Figure 4-52. Primary Cover
          FASTENER                     TORQUE VALUE
Oil baffle screws                  80-97 in-lbs  I
                                                9-11 N·m
Primary cover screws              94-11 5 in-lbs I 10.�13 N·m

Oil Baffle
1.   See Figure 4-52. Install oil baffle (5).

2.   Install screws (4, 6).
     Torque: 80-97 in-lbs (9-11 N·m) Oil baffle screws

Primary Cover
1.   See Figure 4-52. Clean grove in primary cover (7) from all
     residual oil and debris.

2.   Install new gasket (3) to primary cover (7).

                                                                            Figure 4-53. Primary Cover Torque Sequence

94000784                                                                                                                         4-49
DISASSEMBLE                                                               1413189

                            NOTE
Clutch actuator upper and lower bearings are NOT serviceable.
Replaced the complete cover if they are worn.

1.   See Figure 4-54. Remove spring (5) from clutch actuator's
     detent (1).

2.   Remove clutch actuator (2).

3.   Remove and discard seal (3).

ASSEMBLE

1.   See Figure 4-54. Lubricate and install new seal (3) onto
     clutch actuator (2).

2.   Install clutch actuator.

     a.    Position spring (5) into alignment with clutch actuator
           (2).

     b.    Install clutch actuator (2).

     c.    Lock spring (5) into clutch actuator's detent (1).

     d.    Other end of spring (5) is anchored against the
           primary cover's casting.
                                                                            1.      Detent
                                                                            2.      Clutch actuator
                                                                            3.      Seal
                                                                            4.      Upper bearing
                                                                            5.      Spring
                                                                            6.      Lower bearing
                                                                                        Figure 4-54. Clutch Actuator
                                                                     COMPLETE

                                                                     1.     Install exhaust header.         See   EXHAUST SYSTEM
                                                                            (Page 6-37).

                                                                     2.     Install radiator. See RADIATOR (Page 7-18).

                                                                     3.     Install center stand bracket (if equipped). See CENTER
                                                                            STAND (Page 3-111).

                                                                     4.     Service engine oil. See REPLACE ENGINE OIL AND
                                                                            FILTER (Page 2-7).

                                                                     5.     Connect clutch      cable.   See      CLUTCH   CONTROL
                                                                            (Page 3-82)

                                                                     6.     Install main     fuse.    See    POWER     DISCONNECT
                                                                            (Page 8-4).

4-50                                                                                                                       94000784