Preface
At around the 150K km mark (90K miles), I felt it was time to replace the
secondary belt and the primary chain on my '98 FLTRI (Road Glide). With
the help of a friend, I had rebuilt the motor's top end the previous
winter. During that previous year's work I made a photo and audio log of
what was done and placed the record on a Web page at
Evolution Top End Rebuild. Several
people told me, later on, that they appreciated that, so I'm doing it again -
this time documenting the process of removing the outer and inner primary and
changing the belt and chain.
What I have done is taken digital pictures of the disassembly and assembly
process and present them below for your information. Since my digital
cameral can record audio with each image, I have added commentary to each
picture. In some cases the audio portion is quite important; mentioning
aspects that I need to keep in mind when it comes to reassembly and for the
next time I do the job.
I have placed a link under each picture that you can click to hear the
audio commentary. You can also click on each image to get a
larger, high-resolution view.
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Removing front floorboard pin
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Removing passenger floorboard bracket
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(click for larger view)
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(click for larger view)
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Removing top floorboard bracket bolt
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Top floorboard bracket bolt direction
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(click for larger view)
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(click for larger view)
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Removing lower floorboard bracket bolt
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Upper and lower bolts, floorboard bracket
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(click for larger view)
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Removing rear shifter lever
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Removing outer primary bolts
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(click for larger view)
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Outer primary cover removed
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View of starter mounting bolts
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Starter mounting bolts removed
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Removing clutch adjustment face plate
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(click for larger view)
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Removing clutch hub bolt
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Removing chain adjuster top nut
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(click for larger view)
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Main shaft nut removal
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Chain adjuster and wood blocking
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(click for larger view)
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Disassembly of compensating sprocket
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Removing main sprocket and clutch
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(click for larger view)
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(click for larger view)
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Chain removed, pinion shaft view
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Disassembly of starter pinion gear
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(click for larger view)
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Main shaft sleeve and spacer
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Bending tabs holding inner primary bolts
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(click for larger view)
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(click for larger view)
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Removal of outer bolts, inner primary
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Shifter rod disassembly
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(click for larger view)
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(click for larger view)
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Inner primary bolts and their sizes
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Starter jackshaft bushing orientation
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(click for larger view)
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(click for larger view)
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Inner primary removed
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Left Side Exhaust Removal
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(click for larger view)
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Loosening axle nut
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Backing off adjusters
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(click for larger view)
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Removing swingarm nut
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Swingarm disassembly
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(click for larger view)
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(click for larger view)
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Rubber mount wear
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Backing off swingarm shaft
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(click for larger view)
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Shock lower bolt removal
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Repositioning cross-over pipe
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(click for larger view)
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Swingarm bracket removal
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Rubber mount disassembly
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(click for larger view)
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Shock top bolt removal
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Debris deflector removal
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(click for larger view)
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Belt removal
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Removing clutch diaphram spring retainer
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(click for larger view)
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(click for larger view)
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Removing clutch pressure plate
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Removing clutch friction plate
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(click for larger view)
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(click for larger view)
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Removing clutch steel plate
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Removing clutch damper spring
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(click for larger view)
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(click for larger view)
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Removing narrow friction plate
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Measuring clutch friction plate wear
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(click for larger view)
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(click for larger view)
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Compensating sprocket gear wear
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Clutch hub gear wear
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(click for larger view)
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(click for larger view)
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Loosening rear brake calipre
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Removing rear brake calipre
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(click for larger view)
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(click for larger view)
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Rear wheel removed
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Swingarm bracket removal
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(click for larger view)
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(click for larger view)
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Swingarm bracket bottom bolt problem
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Planned solution to bolt problem
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(click for larger view)
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View of frame and case support on lift
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Okay, I give up. Loosen exhaust.
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Old right-side rubber mount
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(click for larger view)
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(click for larger view)
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Rubber mount removed
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Replacing inner primary dust covers
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(click for larger view)
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(click for larger view)
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