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Karata open primary install

Discussion in 'How-To' started by bdm7250, Jun 18, 2017.

  1. bdm7250

    bdm7250 Guru
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    Quick write up on installing the Karata 4" open primary. There are install instructions in my Dropbox https://www.dropbox.com/home/Big Dog but I took a few pics and will run through the install quick in case it may help someone else out. Had great advise/assistance from Dentdude, Ker and staffy, thanks a bunch for everything. :old2:
    Part 1: deconstruction
    Drain primary and remove outer
    IMG_8497.JPG
    Loosen the clutch cable on the downtube, remove the clutch rod cover, and remove the clutch rod. I removed my exhaust, takes very little time and gives you more room and less chance to damage anything.
    IMG_8494.JPG
    Take off the side covers and remove the two starter bolts.
    IMG_8496.JPG
    Pull the starter back away from inner primary
    20170609_171924_resized_1.jpg
    Remove the diaphragm spring (4 bolts) and loosen primary chain tensioner.
    image1.JPG
    Remove motor and clutch hub nut, please remember the clutch hub nut is left hand thread.
    IMG_8498.JPG
    Slide everything off the tranny and motor shafts
    image1.JPG
    Remove the eight inner primary bolts and remove the inner primary
    image1.JPG
    Be sure to remove all gasket material from motor and trans, also now is a great time to clean the tough to reach spots. Remove any excess thread locker from motor and trans shafts, good cleaning of each.
     
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  2. bdm7250

    bdm7250 Guru
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    Part 2: Install
    Dry fit motor plate and pulleys, you may need to loosen trans mount bolts. You want to check alignment of the pulleys with a straight edge.
    20170609_180147_resized_1.jpg
    FullSizeRender.jpg
    Check your motor plate at trans and motor with a feeler gauge, everything must be aligned precisely. There is no need to put the belt on at this point, I just wanted to see how difficult it was, plus I was a tad excited to see what it looked like.
    Once satisfied everything I'd aligned, pull it all back off and start wet assembly. Blue loctite on the motor plate bolts and cap screws, and a healthy serving of red loctite on the trans and motor shafts, please note that both shafts get a spacer behind the motor plate, and the trans shaft spacer is directional (tapered end goes in). Torque both shaft nuts to spec (remember, motor shaft is right hand thread and trans is left handed) use the nuts that are supplied by Karata.
    Re-install your starter, I removed the o-ring as it's not needed.
    Remove the clutch rod shaft seat from your stock throwout bearing, and install in the Karata throwout with the stock snap ring. Install your clutch plates, friction plate first, once all plates are in align your pressure plate with grooves in pulley (so it correctly seats on last friction plate) I didn't do this first time so it caused me some needless aggravation.
    20170610_123503_resized.jpg
    20170610_122135_resized.jpg
    20170610_123115_resized.jpg
    I am using the gold clutch springs, they provide plenty of pressure and clutch pull is very easy, use blue loctite when installing..
    Now install the belt, it is a tight fit but goes on by hand without needing to pry, the last half inch I used a soft head rubber mallet .
    20170609_220756_resized.jpg
    Install outboard bearings, use blue loctite.
    20170609_222615_resized_2.jpg
    20170609_223453_resized_2.jpg
    And install outboard bearing support using blue loctite
    image1.JPG
     
    #2 bdm7250, Jun 18, 2017
    Last edited: Jun 18, 2017
  3. FrankBDPS

    FrankBDPS Well-Known Member

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    Nice work. That outboard plate looks great.
     
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  4. Hirter6Pack

    Hirter6Pack Not Quite A Guru

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    Very cool. Great reference :old2:
     
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  5. BWG56

    BWG56 Guru

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    Nice write up Doug:old2:
     
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  6. Dakota

    Dakota Well-Known Member
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    :agree:
     
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  7. Big D Florida

    Big D Florida Well-Known Member
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    X2 :old2:
     
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  8. PROFLYER

    PROFLYER SWOLE
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    Sweet! I love the sound of those!
     
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