If you are still awake right now you need to knock out the starter seal



The new uprated seals have two springs, one either side....the small one goes towards the starter





I got Dr Phil to put the chainguards and shock absorber back on while I got the inner primary ready for reassembly





Replace the inner primary and be careful on two counts...1: line it up sweet so you don't snag that new IPB seal and 2: jiggle it to make sure it fits on the tranny and motor before you do the mounting bolts up, it slips on perfectly when it is aligned properly.....don't be tempted to close any gaps by tightnening the bolts

Torque the inner primary bolts to 22ft/lbs and bend the tabs back onto the heads





Refit the jackshaft and spacer



Tighten the jackshaft bolt (don't overdo it, its not very big) and bend the tab washer back onto the head.....turn the bike on and test the that the starter pinion flies out when you press the starter button



Replace the drive components in one hit



Red Loctite the crank nut and torque to 160 ft/lbs



Do the same with the clutch nut but torque to 75 ft/lbs





Make sure you remove the Delrin block before you replace the outer primary!!!!!!!!!



Wind in the clutch cable adjuster fully prior to adjusting the clutch



Replace the pushrod and the adjuster plate and then adjust clutch so that the plate is still just able to move behind the circlip



Adjust the primary chain as per the manual



Fit new gasket



Don't forget the two little sticky gaskets, clean where they go with contact cleaner or petrol before fitting them



Here is one already fitted and the other thread waiting for the gasket



Now go to part 4

 

Part 4 https://www.hdforums.com/forum/evo-c...01-pt-4-a.html