Tips for removing/replacing primary cover

vve are the end · May 12, 2014

I'm replacing my broken primary cover (tonight hopefully) and was wondering if anybody had any tips or things I should look out for. I have a new shift shaft seal, clutch cable o-ring and gasket set. I believe I have to remove the clutch cable completely from the handlebars, correct? I know I have to also lower the chain tensioner.

I'm a visual person so photos or links to videos are extremely helpful for me in understanding even the simplest of repairs. I believe the manual explains this but for some reason I haven't been able to find that section. Also looking for the torqing pattern and torque specs if anybody has those.

user_deleted · May 13, 2014

I believe I have to remove the clutch cable completely from the handlebars, correct? I know I have to also lower the chain tensioner.

yes....on relieving pressure on the chain tensioner shoe.
no....on removing clutch cable. slide rubber boot up on cable at barrel adjuster. loosen barrel jam nut with 9/16th open end wrench then spin barrel clockwise a few turns with 1/2 inch open end wrench. go up to clutch lever....it will be very sloppy, pull cable end out of lever perch, rotate, and remove cable end barrel from lever and let cable hang.

cover removal and install straight forward. i strongly recommend replacing gasket. torque allen screws to feel and start center top then opposite bottom...go to 3 o'clock bolt then 9 o'clock bolt. snug up then work around in clockwise pattern. snug all bolts several times. just go by feel.

chief_of_smoke · May 13, 2014

its very simple to do. if the shift shaft is tweeked, due lay over or something like that, the shift shift will bind a bit. there is a brass bushing that my need honed a smidge.

vve are the end · May 16, 2014

Thanks guys. Got it all wrapped up with the exception of one bolt on the clutch inspection cover which I found out had been completely stripped out. Will be repaiting with a heli coil tonight and hopefully back on the road by tomorrow.

doberdann1019 · Dec 3, 2014

I just replaced the primary fluid last night and found the 3o'clock screw hole stripped out. Thank you Harley, they were the last ones to touch it. How did the heli-coil go? What size did you use?

Tips for removing/replacing primary cover

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