Renegade Installation Instructions

Transcription

Renegade Installation Instructions
For 1990 to PRESENT EVO AND TWIN CAM SOFTIAL
2007.001
Tauer
Machine
www.tauermachine.com
4/7/2007
Page 1 of 37
Tauer Machine Renegade Installation Instructions
For 1990 TO Present Evo and Twin Cam Softails
Important Safety Warning:
When installing a Tauer Machine Belt drive you should have the bike securely fastened in an upright
position with access to the primary drive. When working with the primary drive you should disconnect the
battery to prevent any shorting of the battery.
If the procedures are not within your capabilities, or if you do not have the correct tools, have your
authorized Tauer Machine Dealer perform the installation of the belt drive.
Section 1 – Important Information before installation.
Section 2 -- Tools Needed to complete installation.
Section 3 – Disassembly of the stock primary
Section 4 – Installation of Tauer Machine Open Belt primary
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Section 1 Important Information before Installation
1. Proper installation of Tauer Machine open belt primary must be installed by a qualified
mechanic, if improper installation occurs the warranty and liability will be void.
2. Fill out warranty card and return it to Tauer Machine at 1043 Southbend Ave, Mankato,
MN 56001 as soon as possible. Failure to send in the warranty card will void warranty.
3. Disconnect battery.
4. No. oiling of the clutch plates. This is a dry clutch setup. Intend to run dry.
5. Be sure not the pinch belt. Premature belt breakage can be cause by pinching belt.
6. Aftermarket starters and transmission must be fitted before installation occurs. In some
cases if the starter and transmission don’t align proper this cause the jackshaft to be off
or misaligned.
7. Aftermarket frames can cause many misalignment issues. Be sure to prefit everything
before completely bolting together. Follow instructions to be sure everything is align
properly. Belt tracking and premature belt wear can be caused by misalign components.
8. If you are changing out a enclosed primary to an open belt system. You will now hear
all the noises that the oil and the enclosure baffled before. It is normal to hear clutch
noise.
9. Before installation be sure you have the correct motor plate. The motor plates are label
with a 78 (780) and 813. For Evo motors a 78(780) motor plate will work and for Twin
Cam you should have a 813 number stamped on the motor plate. This number can be
found under the starter block on the motor plate. In order to know the differenence the
Evo motor and transmission are not connected. Where as the Twin Cam motors are
bolted directly to the transmission. (Remember this manual is for Softails only) Along
with the motor plate being different so are the pulley sets. Be sure that you have the
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right pulley set with the correct motor plate. Pulleys for the Twin Cam sets are label on
the back of the pulley with a hand engrave 813.
Section 2
Tools Required for Installation
If changing out an enclosed primary a special bearing race puller is needed.
1. American allen wrenches
2. ½” Impact wrench
3. Dead blow hammer
4. Snap ring pliers
5. American socket set (3/8”set with ratchet and extensions)
6. 1-1/4” socket for rear clutch hub
7. 1-1/2” socket for compensating sprocket nut
8. 1-5/16” TM’s front pulley nut
9. Flat screw driver or small flat chisel
10. Blue and Red Thread locker
11. Channel Locks Pliers
12. Shims for the front pulley
13. Anti-seize
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Section 3
Disassembly of a stock primary
Step 1 Remove oil from primary
Remove Oil from enclosed primary.
Remove the drain plug under the enclosed primary. Be sure to have a oil
pan under the plug to catch the oil.
Allow the oil to run into oil pan.
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Step 2 Remove outer primary cover
Start removing outer primary cover. Using 3/8” ratchet with ¼” allen
socket. Their should be 9 total socket head cap screws to remove.
Remove the outer primary cover. Lightly tap using a dead blow hammer
will help you break the gasket seal. You will not need the gasket for an
open primary setup.
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Remove the outer primary cover and put to the side.
Remove gasket and put to the side.
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Step 3 Remove Clutch hub snap ring.
Using a snap ring pliers remove the snap ring holding the clutch
adjustment screw plate in place.
Remove the alutch adjustment plate and screw as one piece.
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Step 4 Remove clutch hub
Using a ½” impact with a 7/8” socket. Back off the clutch hub nut.
NOTE: THIS NUT IS LEFT-HANDED !!!!
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Step 5 Removing the sprocket nut and compensating assembly.
Using an ½ impact and 1-1/8” socket to loosen the crankshaft nut.
RIGHT HANDED THREADS !!!
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Remove the compensating sprocket nut, the compensating sprocket cover assy and the
sliding cam.
Step 6 Remove primary chain and sprockets.
Slide both the front sprocket and the clutch hub off at the same time.
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Put off to the side.
Step 7 Removing the starter jackshaft.
Using a screw driver or small chisel bend locking tab open.
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Using a channel lock and 5/16” socket loosen the stater jackshaft
bolt and remove.
Remove bolt and pinion gear.
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Remove the jackshaft assembly
Step 8 Remove the inner primary plate.
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*** First thing is to loosen the starter from the inner primary plate.
Just pull it back enough so the inner primary can be removed.
Picture N/A (Be sure the battery is disconnected before you start this step)
Using a screw driver or small chisel bend the locking tabs to allowing the
bolts to be able to be loosen.
Loosen 8 ---- 5/16” Cap screw and remove the bolts. 4 on the motor and 4 on the
transmission.
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Remove inner primary plate and set aside.
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Remove O-ring from the motor. This O-ring is not needed for an open belt
primary.
Remove the bearing race from the transmission input shaft. If this is not
completed the motor plate will not slide together correctly. Using a TM bearing
race puller (TMPL-100) this can be achieved easily.
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Part # TMPL-100
You are now ready to install a Tauer Machine Open Belt Drive.
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Section 4 – Installation of Tauer Machine open belt primary
This section is for proper installation of a Tauer Machine Renegade open belt primary
on to a stock Evo or Twin Cam 1990 to Present Softail models.
With the original primary removed you are ready to install a Tauer Machine open belt
primary. NOTE: For Evo style motors you need to loosen both the motor and the
transmission bolts in order to install the motor plate correctly. If this is not done
properly the belt can produce excessive noise and the belt will track incorrectly. You
can also break the motor plate if you tighten the motor plate without doing this
procedure. Also after tightening the motor plate bolts to the motor and transmission
you need to check to see if the motor and transmission are sitting flat on the mounts. If
they are not that means the frame is twisted and you need to shim the space between the
motor or transmission in order not to put excessive pressure on the motor plate. Custom
Frames have more potential of not having the motor mount or transmission mount
welded in correctly. Be sure you check this out carefully in order for proper installation
of the belt drive.
Shown here is a Twin Cam. You can see that the motor and transmission are bolted
together. There is no need to loosen the motor for these models.
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Step 1
Install Rotor Cover and Motor plate
Put a small amount of anti-seize on the input shaft in order to keep the the
input shaft for rusting the bearing and shaft together. This allows the
disassembly easier. Slide the motor plate into position. Be sure that the
surfaces are mating completely between the motor and motor plate and the
transmission and the motor plate.
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Using the back side of a hammer or a dead blow hammer to help slide the
bearing over the input shaft might be necessary. This is a tight slip fit.
Some Aftermarket transmission don’t have the tolerance held the same as
Harley Davidson and can be tight. It should slip on easily and if it doesn’t
don’t force it on. Keep in mind that it is a tight slip fit and any
misalignment can cause it not to slip on.
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Find the motor bolt kit (TM3005-K)
Motor Plate Mounting Kit
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Kit includes drawing above.
Install the 5/16-18 by 2 ½ “ long bolts into the transmission. Notice we
remove the starter block from the motor plate. Do not tighten just snug
them up for now. Total of 4 screws.
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Install 5/16-18 by 1 ¼ “ long Socket head cap screws into the motor. Total
4. Do not tighten just snug them up for now.
After all the bolts are in evenly tighten. Check to make sure that all the mating surfaces
are tight and check the frame mounts to ensure there are no gaps. If you find gaps with
the frame you need to make shims or washers to take up the gaps. Now after you’re sure
that everything is tight you can back out the bolts and put blue thread locker on the
bolts and tighten them evenly. After tightening up the motor plate you can now tighten
the motor and transmission to factory torque specs. Again we are mounting to a Twin
Cam applications and loosen the motor and transmission is not necessary.
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Install the 9/16-12 set screws into the 4 motor holes using blue thread locker. These set
screws were added for protection from the motor bolts from backing out and dropping
into the belt while it’s running. This can destroy the belt and the pulleys. Now the
chrome caps (JT-0312-CAP) can be put in the two motor bolts outside the belt in the
front. These are for dress-up.
In this picture you can see 4 steel inserts where the belt guard gets mounted. These are
designed for easy installation in the event that you break a stand-off screw. You can just
replace the insert instead of trying to drill out the motor plate. We also offer a insert
with 3/8-16 threads in it. These would be used if a larger covers. If the original 5/16-18
screws are breaking frequently.
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Install the rotor cover onto the main crank shaft. You can see we use the original
washer between the rotor and rotor cover. In some cases it is necessary to put the rotor
cover on first then the washer depending on the thickness of the rotor. Be sure to have
the polished side out. This can be achieved by tipping the cover under the devil point
and slip onto the shaft. When the front pulley is tighten down it will tighten up this
cover.
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Step 2
Install Starter
Install the starter back into its position and retighten using blue thread-locker.
Step 3
Install starter jack shaft.
Install the jack shaft using blue thread locker on the bolt. There is two bolts included in
the kit for both ¼-20 and 10-32 threaded starters.
Install jackshaft.
next slide the spring in.
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Install pinion gear.
Install the bolt. Using blue thread locker be sure that the lock washers are on
first then put the anti spin lock washer with the splines engaging into the shaft.
Note: when tightening be sure the anti spin lock washer is not sitting on top of the
splines. They need to be engaged. Bolt may loosen if this is not engaged.
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Step 4
Setting the alignment of the two pulleys.
First assemble the front pulley with the steel adapter. Do not install roll pins until
you set the pulley alignment. Put front pulley onto the crank shaft and the clutch hub
onto the transmission shaft. Check alignment if necessary you might need to flip the
steel insert around and try it that way and or use washers to space the front pulley to
achieve the correct alignment. Remember you might need to pull the clutch hub on with
an impact to ensure that the clutch hub is completely on the transmission shaft. In some
aftermarket transmission they stop the splines short on the input shaft and you need to
use an impact to pull the clutch hub onto the transmission input shaft. You are not
forming all the splines the clutch hub has a taper in the back so you only form a small
part of them. You will need to use a puller (TMCP-100) to remove the clutch hub. Once
you set the pulley alignment you can assemble the front pulley. In doing this be sure
that the lock washers for the 5/16 Socket head cap screws are in place. If you don’t use
the washer the bolts will extend pass the steel insert. Then when you tighten your front
pulley these bolts will only tighten on these 3 points. The aluminum rotor cover will
wash out and causing the front pulley to come loose. Be very sure these bolts don’t
extend pass the steel insert. Once you have the proper alignment of the pulleys you can
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assemble the front pulley and splined steel adapter. Using red thread locker on the 5/16
bolts. Drive the roll pins into position.
Step 5
Install rear clutch hub.
Remove the outer ring these are not tighten from the factory. This allows you to put the
belt on after the clutch hub is tightened.
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Install clutch hub using Red thread locker on the splines. Just slip it onto the
transmission input shaft and remove the
Using the left handed nut and red thread locker supplied with the kit. Tighten the clutch
hub onto the transmission shaft using an impact. Torque the clutch hub nut to 70-90
foot pounds.
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Step 6
Installing front pulley and belt
Install the belt and front pulley. Don’t completely put the belt onto the clutch hub once
you have the front pulley on the crank shaft you can work the belt on. Tapping with
your hand can get the belt to slide into place. Install the front pulley nut using red thread
locker. Tighten using an impact. Torque the front nut to 150-165 foot pounds.
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Step 7
Installing outer ring
Install the clutch hub outer ring using blue thread locker and tighten to 9 foot pounds.
Step 8
Installing starter block
Install starter block using anti-size or grease on the bushing the comes in contact with
the pipion gear. Tighten 5/16-18 bolt 1 ½ “ long using blue thread locker.
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Step 9
Installing pressure plate and clutch adj screw.
Install pressure plate and line up holes with hole in the inner pulley. Put anti-size on the
shoulder bolt before installing. Tighten bolts evenly around the pressure plate until they
are completely tight.
Kit comes with 9 springs and 9 shoulder bolts.
In most applications start with 6 springs and go to 9 if clutch slippage happens.
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Use a small amount of grease on the end of the adjustment screw which has the radius
in it. This will come in contact with the push rod. It is only for start up once the bike uis
running there is a small amount of transmission oil that get inside the input shaft to keep
it lube.
To adjust your clutch you need to thread the adj screw in until you feel it get tight using
tour hands. Then back the screw off about ¾ to 1 turn then tighten the jam nut to lock
in place.
TM suggest if you are using a hydraulic clutch you will need to adjust after 500 miles
or sooner. Once the fibers are seated you should be able to find a good setting for your
clutch. This comes from not having as mush throw as a cable set-up. Cable will give
you about .125” where some aftermarket hydraulic clutches have only .050 to .060
throw. Not allowing the clutch to open as much. This can cause dragging.
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Step 10
Installing outer guard.
Install the stand-offs using blue thread locker on the inner and outer bolts.
The outer guard is revisable so you can have the Tauer Machine logo out or just plain.
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Completed Install
Shown with coil spring clutch
Shown with diaphragm clutch
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Renegade Installation Instructions

Transcription

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