Andrews 30T Pulley Install

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Jun 15, 2013 | 01:11 AM

#61

Ratbob

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Joined: May 2008

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From: Newberg OR

My picture is of my bad clutch hub that has been pressed out of my clutch pack so that I could press in a new part. Your clutch pack comes apart into several pieces. What I am showing is the Clutch Hub that is pressed into the clutch basket. Can't see it in your picture, you can see the splines from the bottom, underneath the primary chain gears. It's the part of the clutch pack that is closest to the tranny. Pull the compensator and clutch pack back off, run your finger around the splines. If they're broken they'll just fall right out. You're probably OK but it doesn't hurt to check. I've seen several pictures just like this around the forums.

Jun 15, 2013 | 06:41 AM

#62

HD Pilot

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From: N Texas

Quote:

Originally Posted by Ratbob

While it's off, take a look at the splines inside the clutch hub. The 1st 3/8 inch of splines were broken off. Good luck with that 2 1/4 inch nut!

Here is what got me concerned, your second sentence makes it sound like you see damage in my pics. There is no "check to see" etc. So I looked at everthing, that a viewer could possible see in my pics and found nothing.

Just a wording thing that has me up at 6 am trying to figure out - ughh. But with your last post, I understand - I'll wait until my son can help me, so he can hold everything while I look at the clutch assemble from the back side and check it out. My bike only has about 2600 miles on it, so surely....

Jun 15, 2013 | 11:19 AM

#63

Ratbob

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Joined: May 2008

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From: Newberg OR

Quote:

Originally Posted by alansummrs

Here is what got me concerned, your second sentence makes it sound like you see damage in my pics. ....

Sorry Alan, I was referring to the damage on MY clutch hub, my bad.

At that low mileage you should be fine, but it's worth a look since mine is not just an isolated incident. Again, sorry for not being very clear the 1st time.

Jun 15, 2013 | 11:43 AM

#64

Bone11B

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Joined: Dec 2008

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From: Texas Nomad

About to tackle this as well...so I will be following.
I got a leak from behind the pulley from transmission, so I figured nows the time to replace it to a 30T.
Nice job so far..

Jun 15, 2013 | 03:08 PM

#65

HD Pilot

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From: N Texas

Quote:

Originally Posted by Ratbob

It's all good Ratbob, I knew that you were looking out for me, I was just afraid something was broke. Anyway, had a good look - all is well, not sure if this pic is very good for seeing:

Jun 15, 2013 | 03:38 PM

#66

HD Pilot

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From: N Texas

Installed the new Compensating sprocket bolt: 100 ft lbs, then loosen 1 turn, then 140 ft lbs. Installed the left handed Clutch hub nut: 75 ft lbs. Installed the clutch release plate, locknut, and retaining ring, then adjusted the clutch - there are a lot of threads on adjusting the clutch so I wont go into that - pretty easy. Installed the primary chain tensioner: 21-24 ft lbs and cut off the tie strap that kept it compressed.

Jun 15, 2013 | 03:59 PM

#67

mud

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From: the 50s & the 60s

Quote:

Originally Posted by alansummrs

Thought I would post up my parts and tool list for those who might be considering this mod. There are different options available as others have mentioned with the 30T pulley choice.

I will update this list as I continue to buy everything needed.

Parts

Andrews 30 T Transmission Pulley: # 290306 $118 Amazon

Barnett Heavy Duty Clutch Spring: # 502-00-01008 $34 ebay

Transmission Sprocket nut: $10 HD#35241-06
I'll get this in case the breaker bar does not work and I have to cut the nut off.

1 qt Primary Chaincase Oil + O-ring: $12 HD SYN3

Clutch Inspection Seal: $5 HD#17369-06

Primary Chaincase cover gasket: $31 HD#60547-06

Primary Chaincase sealing fasteners(5): $15 HD#786A

Crankcase gasket(has the 2 dowels): $14 HD#34934-06

Compensating Sprocket bolt: $6 HD#3368

Starter Housing O-ring: $4 HD#27444-00Y

Tools

Big Torque Wrench, CDI 1/2" 30-250 ft-lbs: $ 118 Amazon The biggest torque I see in the procedures is 140 ft-lbs.

Big Breaker Bar, 3/4" Tekton 40" long and a 3/4" F to 1/2"M adapter: $64 Amazon
If you have a nice electric impact wrench, you can skip the breaker bar.

Transmission Sprocket locking tool: $66 ebay

2 1/4" Mainshaft Sprocket wrench: $73 ebay

Primary Drive locking bar: $15 ebay

Belt Tension gauge: $25 ebay

All these prices include shipping. Obviously, a lot of you may already have some of the tools and some of them will be useful for other mods.

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good write up Alan.

tower gasket??
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Jun 15, 2013 | 03:59 PM

#68

HD Pilot

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From: N Texas

Reinstalled the Primary chaincase cover: 150 in lbs in sequence.

Put in about 39 oz of SYN3, was nice having seen the level before install. HD SM recommends 40 oz "dry" and after this mod I think the "dry" number is close.

Finished off by adjusting belt tension, reinstalling belt guard, debris deflector, battery tray, battery, and seat.

I meant to keep track of how many extra turns I made on the belt adjustment but forgot, but thinking about it, I think it was about 3 full turns.

Anyway, all done except adjusting my speedometer through my PV. I'll report back on that adjustment, and how the new pulley feels - but wouldn't you guess, it has been raining here!

Last edited by HD Pilot; Jun 15, 2013 at 08:27 PM.