Question about 2007 Harley Davidson XL 883 Sportster

1 Answer

Derby cover change

Does the gasket need to be replaced when I put on skull derby cover?

Posted by on

Ad

1 Answer

  • Level 3:

    An expert who has achieved level 3 by getting 1000 points

    All-Star:

    An expert that got 10 achievements.

    MVP:

    An expert that got 5 achievements.

    Vice President:

    An expert whose answer got voted for 100 times.

  • Harley Davidson Master
  • 448 Answers

Yes, you should replace the o-ring every time you remove the cover.

Posted on Jul 21, 2013

Ad

4 Suggested Answers

6ya6ya
  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

Hi,
a 6ya expert can help you resolve that issue over the phone in a minute or two.
Best thing about this new service is that you are never placed on hold and get to talk to real repairmen in the US.
New users get 2 Free calls (no credit card required) and instant help on almost anything you can think of (from cars to computers, appliances, handyman, and even pets).
click here to download the app (for users in the US for now) and get all the help you need.
Goodluck!

Posted on Jan 02, 2017

Ad
  • 420 Answers

SOURCE: replaced the clutch in my xlh1200 1995 with a kevlar clutch kit. when I put it back together I couldnt squeeze the clutch. I took off the derby cover and figured out that the adjustment screw was hitt

I would go back to scratch. Disassemble the clutch basket and reassemble it making sure you have it set in proper order. Then reassemble every thing. Also double check the clutches you bought are the proper ones for your bike.

Posted on Apr 27, 2009

  • 196 Answers

SOURCE: I want to change the primary oil in my 03 Hugger

I never pull the derby cover unless I have to fix something. I do exactly what you described and have for 20 years. Never had a problem.

Posted on Jun 03, 2010

wd4ity
  • 4565 Answers

SOURCE: I am changing the transfer

The case you're changing the oil in is called the primary drive case or "primary" for short. Yes, it does the same thing as a transfer case but in the future you may confuse someone using that terminology.

The drain is a small pipe plug that uses a Torx bit to remove. It's on the underside of the primary cover back directly below the derby cover. You do fill the case through the derby cover opening. With the bike standing straight up, fill the primary with oil until it comes just up to the bottom of the clutch basket, the shiny aluminum drum that holds the clutch plates. It holds about a quart of oil. Do not overfill or the clutch will drag causing you to be unable to find neutral with the engine running.

You say the bolts won't tighten up on the derby cover. Your model should have the five bolt cover and the screws screw into the tapped primary cover. If the threads are stripped out in the primary cover, you can have it repaired by a competent machinist by having them install threaded inserts in the original holes called Timeserts or Keenserts. If the screws will tighten but the cover still leaks, the bolt holes in the cover may be pulled through and standing high on the backside. This will not allowing the cover to seat against the full gasket. In this case, the purchase of a new derby cover would fix the problem.

Good Luck
Steve

Posted on May 20, 2011

Add Your Answer

Uploading: 0%

my-video-file.mp4

Complete. Click "Add" to insert your video. Add

×

Loading...
Loading...

Related Questions:

1 Answer

My 2012 883 superlow 5 speed gearbox is leaking around gasket, is gasket bad or something else


Over filled with with transmission oil or "O" ring in cover is out of position. If it was just seeping a little after the transmission oil change it could be residual oil from the derby cover. There is a specific torque to those screws on the derby cover. Also very easy to over fill the transmission by not draining long enough and/or when oil is not warm. If you aren't talking about the derby cover as the point of leakage please repost the question. If the gasket to the derby cover is broken or nicked the part number is 25463-94A. The torque for the derby cover screws is 90-120 inch pounds. Inch pounds, not foot pounds that we usually associate touque with.

Sep 26, 2013 | Harley Davidson XL 883 Sportster...

1 Answer

I have an oil leak on the primary cover on my bike. How hard is it to replace the gasket. I am a small engine mechanic but have never worked on a Harley.


If you can work on small engines, you can work on a Harley. A Harley is just another machine just like anything else out there. It's not rocket science. On your wide glide, simply find the primary oil drain plug on the underside of the primary back by the derby cover and drain the oil. Remove the screws including the ones for the oval inspection cover and the primary cover comes off. Remember to replace the two small gaskets on the two screws in the inspection cover. Once you have the primary cover back on, refill with oil through the derby cover opening. Stand the bike straight up and fill until the oil level is even with the bottom of the outer clutch shell. Do not overfill or your clutch will drag.

Good Luck
Steve

Jun 05, 2011 | 2001 Harley Davidson FXDWG Dyna Wide Glide

1 Answer

I am changing the transfer case oil on my 02 fatboy for the first time and do not have the manual. 1) Where is the drain plug? 2) Do you refill through the derby cover? 3) The screws that hold the derby...


The case you're changing the oil in is called the primary drive case or "primary" for short. Yes, it does the same thing as a transfer case but in the future you may confuse someone using that terminology.

The drain is a small pipe plug that uses a Torx bit to remove. It's on the underside of the primary cover back directly below the derby cover. You do fill the case through the derby cover opening. With the bike standing straight up, fill the primary with oil until it comes just up to the bottom of the clutch basket, the shiny aluminum drum that holds the clutch plates. It holds about a quart of oil. Do not overfill or the clutch will drag causing you to be unable to find neutral with the engine running.

You say the bolts won't tighten up on the derby cover. Your model should have the five bolt cover and the screws screw into the tapped primary cover. If the threads are stripped out in the primary cover, you can have it repaired by a competent machinist by having them install threaded inserts in the original holes called Timeserts or Keenserts. If the screws will tighten but the cover still leaks, the bolt holes in the cover may be pulled through and standing high on the backside. This will not allowing the cover to seat against the full gasket. In this case, the purchase of a new derby cover would fix the problem.

Good Luck
Steve

May 20, 2011 | Harley Davidson FLSTF - FLSTFI Fat Boy...

1 Answer

Is it a big deal to replace a primary gasket on a 1996 sportster,any thing i need to know before the change out


No, as long as you understand how to adjust the primary chain and disconnect the clutch mechanism. Remove the derby cover, spring, and locking nut. As you take the primary cover off, you have to turn the screw clockwise to so that it will come off. Turn the screw counterclockwise to get the primary cover back on.

GoodLuck
Steve

Oct 24, 2010 | Harley Davidson XL 1200 C Sportster Custom...

1 Answer

I have a 1996 fxdl I changed the primary cover changing both primary gasket and inspection cover gasket. I now leaks around the inspection cover bolts . What are my options


If you'll remove your inspection cover and the derby cover as well, look on the backside, you'll probably see that the bolt holes have been "pulled" through on each bolt hole. The raised backside of the bolt holes holds your covers up just slightly allowing oil to creep underneath the gasket.

Now, you can do three things. Replace the covers with new ones or use a large smooth file, lay it flat on the backside of the covers and file the "pulled" through areas down level with the rest of the cover, or apply a generous amount of RTV to both sides of the gasket. On the Derby cover, Harley now offers a solid disc type gasket for this application. I use both the solid disc and the original O-ring on the derby cover.

Good Luck
Steve

Oct 08, 2010 | Harley Davidson FXDL Dyna Low Rider...

1 Answer

Is it hard to change the primary gasket on my sportster


No, just drain the primary. You'll have to take anything like shifters, foot pegs, and other stuff that might be in the way off the bike. Then, go underneath the primary cover and loosen the locknut of the primary chain tensioner and turn the screw downwards to remove the tension for the tensioner. Now, take the derby cover off and remove the spring and the locknut. Take the bolts out of the cover and then turn the clutch ajuster inwards as you pull the cover off. The cover will come off.

Then to install the cover, hold it up to the clutch adjuster and turnt the screw counterclock wise as you put the cover back on. Put all the bolts in the cover and tighten them. Then back at the clutch adjuster, turn the screw outwards until it stops. Then turn it back inwards 1/4 turn, put the locknut and the spring in and replace the derby cover. Remove the top plug of the primary cover. Stick you finger in and feel the up and down play of the primary chain. Adjust the bolt at the bottom of the primary upwards to reduce the play to about 1/2" to 5/8" and lock the lock nut. Refill the primary with one quart of primary-transmision lube. Replace anything else you have taken off the bike.

good Luck
Steve

Sep 27, 2010 | 2003 Harley Davidson XLH Sportster 883...

2 Answers

2005 Harley Davidson FLHTCUI Electra Glide Ultra Classic clutch adjustment ?


To adjust the clutch, first find the clutch cable adjuster. It should be somewhere along the downtube of the frame in front of the engine. Slide the rubber bellows cover either up or down to expose the adjuster. Loosen the lock nut and turn the adjuster inwards shortening the cable as much as possible.

Remove the Derby cover from the primary cover. In the middle of the clutch assembly is an adjuster bolt and a lock nut. Loosen the lock nut and turn the adjust inwards until you feel a resistance. Don't not force the adjuster, go inwards until you feel the resistance of the throwout bearing on the other side. Try it a couple of times until you get the feel of it. Go inwards until you feel the resistance and then come back out 1/2 to 1 full turn. Lock the lock nut down and replace the derby cover.

Then go back to the cable aduster and and adjust the cable adjuster out until you have about an 1/8" freeplay at the lever. Lock that lock nut down and reposition the bellows cover.

Good Luck
Steve

Jul 21, 2010 | 2005 Harley Davidson FLHTCUI Electra Glide...

1 Answer

I am trying to get the OEM part number for a 2002 Softail Duece FXSTD primary chain, primary gasket and Derby cover gasket. Being overseas and no dealer for Harley here, I am limited to online orders and...


According to the Harley shop here, your numbers are as follow:
Primary chain - 40007-36B
Primary cover gasket - 60539-94B
Derby Cover gasket - 25416-99X or C

Hope this helps

Good Luck
Steve

Jun 23, 2010 | 2002 Harley Davidson FXST Softail Standard

1 Answer

How do you adjust the clutch. Mine doesn't completely disengage when I shift gears. Too much play in the clutch handle.


You need to adjust the clutch cable adjustment for the clutch handle, THEN adjust the clutch itself.

1.First go to the clutch cable. Halfway down the cable is a rubber boot. Pull the rubber boot up the cable, (Or down. Pull it. Do NOT push), until it clears the adjustment. (The adjustment is a hex shaped piece, that is made of two parts. It's called a Barrel)
Use a 9/16 inch open end wrench, and a 1/2 inch open end wrench. Loosen the lock nut until you have around 1/16th to 1/8th of an inch clearance, of slack in the handle.
(Where the clutch lever, touches the clutch lever mount on the handlebars)

2.Now open the derby cover.
(The round cover on the back of your primary cover. Not to insult your intelligence. This -> https://www.denniskirk.com/jsp/product_catalog/Product.jsp?skuId=02649&store=&catId=&productId=p02649&leafCatId=&mmyId=
<-shows a custom primary inner, and outer cover. The derby cover is the round cover all the way to the right, on this custom primary cover. You can click on the photo to enlarge)

You will then see a single threaded stud, (Adjuster screw), in the middle of the clutch pressure plate.
This adjuster screw has a nut on it, to lock the screw from turning. (Jam nut)
Hold the stud end,(adjuster screw). from turning with a large flat tip screwdriver,
(May have changed to a small square end, that you use an open end wrench on), loosen the jam nut with an open end wrench.

Turn the adjuster screw in, until there is 1/8th inch slack of the clutch lever, to the clutch lever mount.
(The clutch lever mount is the part that attaches to the handlebars. The clutch lever is the part you squeeze in with your hand. The slack is the small space in-between the clutch lever, where it touches the clutch lever mount)

Now turn the adjuster screw out 1/2 turn. Tighten the jam nut. (Make sure you hold the adjuster screw in that place you set, as you tighten the jam nut. DON'T let the adjuster screw turn as you tighten the jam nut!)

3.Now tighten the lock nut, (Jam nut), on the adjustment barrel for the clutch cable. You should grease the threads of this adjustment barrel to prevent corrosion in the future. Pull the rubber boot back into place.

4.Replace the derby cover gasket as these will leak like a sieve. Replacing this gasket is cheap insurance. Install the derby cover, tighten the derby cover screws evenly. (Go to one screw, tighten until it touches. Then go to another screw, and do the same. After all three are touching, snug them down one turn at a time, going from screw to screw)

This is a thin cover. If you don't tighten the screws evenly, you can cause this thin cover to warp, and be the cause of a constant annoying oil drip.

Jul 13, 2009 | 2002 Harley Davidson FXD Dyna Super Glide

Not finding what you are looking for?
2007 Harley Davidson XL 883 Sportster Logo

Related Topics:

142 people viewed this question

Ask a Question

Usually answered in minutes!

Top Harley Davidson Experts

Arnie Burke
Arnie Burke

Level 3 Expert

4535 Answers

Mike

Level 3 Expert

4340 Answers

yadayada
yadayada

Level 3 Expert

76630 Answers

Are you a Harley Davidson Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides

Loading...