HELP! why won’t a primary cover come off on a 1996 harley sportster?
I am trying to take off a primary cover on a 1996 harley 1200 sportster. i removed all the correct bolts but it just wont fall off like it is suppose to. Any suggestions?
Why are you removing the primary cover?
FIRST….do you have a FACTORY SERVICE MANUAL????……If not, that is your first step and REQUIREMENT!!!
******* SECOND….MAJOR requirement….DISCONNECT THE BATTERY!!!!!!
You said you removed all the proper bolts…..that is just the beginning.
The clutch cable adjuster must be undone and cable given all available freeplay.
The clutch adjuster and ball and ramp assembly must be removed from the primary cover.
The primary chain adjuster must be fully backed off.
The shift lever must be removed…….
Then, pull the cover away from the case, reach up inside from the bottom and lift the primary chain off the adjuster shoe ad slide the cover back.
This is why you NEED a manual….I won’t give directions for reassembly, the clutch and cable must be readjsted (lube the cable while it’s apart), and PROPER adjustment is critical…..GET A MANUAL!!!
I will tell you that you WILL have to replace the shift seal it or WILL LEAK…remove the old seal with the cover off, install the cover, then install the seal, use a 9/16 deep socket as a driver….don’t rip the rubber seal lip on the shift shaft splines!!!!
What lies under the primary cover.
|
|
PRIMARY COVER GASKET FOR 1977-1990 HARLEY SPORTSTER XL 883/1200 $7.99 Primary Cover Gasket For Harley SportsterFits 1977-1990 XL 883/1200OEM# 34955-75SOLD EACH… |
|
|
Twin Power Primary Chain Inspection Cover Gasket (5pk) 170463190 $28.95 Improved sealing capabilityMinimal required load to sealHigh crush resistanceExceptional torque retentionOutstanding resistance to blowoutH-D#34986-04This Item Fits the Following Applications:2010 Harley Davidson XL883N Iron 8832010 Harley Davidson XL883L Sportster 883 Low2010 Harley Davidson XL1200N Sportster 1200 Nightster2010 Harley Davidson XL1200L Sportster 1200 Low2010 Harley Davidson XL1200… |
|
|
Bikers Choice Primary Cover 210304 $170.09 Chrome-platedCovers are of die cast construction, reinforced at critical areasH-D#25460-04This Item Fits the Following Applications:2005 Harley Davidson XL883R Sportster 883 Roadster2005 Harley Davidson XL883L Sportster 883 Low2005 Harley Davidson XL883C Sportster 883 Custom2005 Harley Davidson XL883 Sportster2005 Harley Davidson XL1200R Sportster 1200 Roadster2005 Harley Davidson XL1200C Sportste… |