Karata open primary install

Energy One
bdm7250

bdm7250

Guru
Supporting Member
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.
 
bdm7250

bdm7250

Guru
Supporting Member
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
 
Last edited:
Ivica88

Ivica88

New Member
bdm7250 said:
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
View attachment 46077
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.
View attachment 46078
Take off the side covers and remove the two starter bolts.
View attachment 46079
Pull the starter back away from inner primary
View attachment 46080
Remove the diaphragm spring (4 bolts) and loosen primary chain tensioner.
View attachment 46120
Remove motor and clutch hub nut, please remember the clutch hub nut is left hand thread.
View attachment 46121
Slide everything off the tranny and motor shafts
View attachment 46122
Remove the eight inner primary bolts and remove the inner primary
View attachment 46123
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.
Click to expand...
bdm7250 said:
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.
View attachment 46124
View attachment 46127
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.
View attachment 46128
View attachment 46129
View attachment 46130
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 .
View attachment 46131
Install outboard bearings, use blue loctite.
View attachment 46132
View attachment 46133
And install outboard bearing support using blue loctite
View attachment 46134
Click to expand...
Does this karata open primary available on the market? Btw very nice install explaining
 
Snuffy

Snuffy

Active Member
Karata.com also look at the karata intimidator series drives. Might get lucky. There are also some on here more knowledgeable about what the offset is and such. Search the threads.
 
Last edited:
Snuffy

Snuffy

Active Member
Funny how this comes up every few months. No one searches the threads. Yes it looks cool as hell but not without the lions share of problems. I’m pretty sure nobody is making this for the big dogs anymore but hey you might get lucky. Good luck
 
Mikeinjersey

Mikeinjersey

Well-Known Member
Ivica88 said:
Thanks for responding,I look up the threads and I see everyone is looking for open primary but no positive results
Click to expand...
I think I read somewhere that the original owner's daughter has taken over the business. I may be confusing that but this website came up . Give it a try. https://www.karata.com/intimidatorbigdog.htm
Sorry! I just called the number at Karata and the message was that the owner had passed away and the drives were no longer available.
 
Last edited:
Ivica88

Ivica88

New Member
Mikeinjersey said:
I think I read somewhere that the original owner's daughter has taken over the business. I may be confusing that but this website came up . Give it a try. https://www.karata.com/intimidatorbigdog.htm
Sorry! I just called the number at Karata and the message was that the owner had passed away and the drives were no longer available.
Click to expand...
It's a so disappointed,no one has made anymore for big dogs..Big dogs have a large number of people who enjoys in this gorgeous motorcycle and definitely deserve same parts to be fabricated
 
HMAN

HMAN

I just like my Freedom
Ivica88 said:
It's a so disappointed,no one has made anymore for big dogs..Big dogs have a large number of people who enjoys in this gorgeous motorcycle and definitely deserve same parts to be fabricated
Click to expand...
Its all about the Franklins. Takes a whole lotta $$$ to tool up for just 1 model of drives. Not many want to pony up a shit-ton of cash for maybe 50 sales a year? Nowdays who got the xtra 3-5k to order a new belt drive? BDL may have something for ya? For how much longer, anybodys guess?

 
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