Harley Davidson FXS Shovelhead Repairs [7] - Primary, Starter and Clutch Removal

In this episode of the project we will continue on with the removal of the primary, primarily in support of the removal of the engine so that it can be sent off for a bottom end rebuild. I will note that this model is a dry clutch belt driven setup so it will be a bit different than conventional models, but nothing terrible.

This begins with the removal of the outer cover, which in my case is simply there to stop rocks from getting in or fingers from getting chewed up. Its not oil tight. My gasket is only for vibration dampening,

A combination of Belt and oil residue is an unwelcome sign of things to come, nothing terrible, for now, but we continue onward as I assemble a quick pressure plate stay to remove the clutch as one unit. Everything with regard to clutch and friction plates seemed ok save some glazing. Once empty, a special tool is used to loosen the primary bolt. I'm not proud, I should have the correct tool on hand JIMS #2316.

To remove the pulley requires pullers, luckily I had that and it came off without issue. for the Nut in the back, locking tabs are hammered up and keeping in mind reverse thread it is loosened and placed right back on. This requires another special tool for removal. After removal, there is a key on the spline that needs to be removed and saved. That covers all of the inner primary internal contents.

This brings up to the starter solenoid, removed with two bolts, allow the sliding out of the Bendix. The remaining pieces for the starter can be left alone. I stop and do a quick check that the transmission mounting bolts are not loose before proceeding with any further steps, nothing crazy, just not loose.

At this point the starter is removed, two bolts secure it, one from inside the inner primary , the other side via a long extension from the other side of the bike. Following this, the safety wire inside the inner primary is cut and removed, along with all of the bolts inside the inner primary. This also includes two external bolts of the primary going into the engine.

With a few light taps, the primary is separated from the bike to reveal some unfortunate findings. Notably, a serious leak around the transmission area as well as an oil leak around the engine area including a belt misalignment.

Looks like there is a lot of work ahead...




#shovelhead #amf #harley #restoration #repair

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