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It's fairly easy. Remove footpegs, shifter lever and anything else in the way. Drain primary oil. Plug is underneath the cover.
Back off primary chain adjuster by loosening the locknut then cranking the adjuster counterclockwise at the bottom of the cover. It is located approximately the center of the cover at the bottom.
Remove the round cover (not the oval one) and remove the spring and lock. Unscrew the clutch adjusting nut.
If you are replacing the cover, the clutch cable can be popped out of the lever. Installation is the reverse of disassembly.
Remove cover bolts. If the cover does not come off easily, rap it with a SOFT hammer to break the seal. I do NOT recommend jamming a screwdriver between the case and cover to pry it loose. Should pop right off. If you got all the bolts out, and followed the above instructions, nothing holds it on.
Honestly, it would be FAR better if you bought a manual to do this. It will be the best $60 you ever spent when doing basic maintenance. You will need to re-adjust the clutch and primary chain after you replace the cover.
Make sure you use a new gasket sprayed with Copper-Kote or equivalent, and refill with the PROPER oil. Don't overtighten the cover bolts!!!!
There are a number of allen head bolts you have to remove, unless you are planning on working on your clutch or your primary chain needs replacing I would not bother going to all the trouble of removing it, as the primary chain adjuster can be accessed through the the small access plate in the primary cover. You will have to replace the gasket but you won't lose your primary oil this way. If you do remember you will have to replace the gasket and the primary oil when you reassemble as well as torquing the bolts back to their specifications.
You need to remove the derby cover from the primary that goes over the clutch adjuster. Remove the sping and the locking nut. Turn the adjuster screw clockwise while gently pulling the cover off. The cover should come off then.
To change the starter on your Sporty, first disconnect the battery. Remove the exhaust system and anything else that it is the way of the starter. Take the battery cable off the starter. Then go to the left side of the bike and remove the foot peg and shifter. Loosen the lock nut on the primary chain tensioner on the underside of the primary. Turn the adjuster screw out a few turns. Take the derby cover off and remove the spring and lock nut on the clutch adjuster. Then drain the oil out of the primary by removing the plug on the underside of the primary. Remove the bolts that hold the primary on. As you pull the primary cover away from the engine, turn the clutch adjuster screw in the center of where the derby cover came off in a clockwise direction. The primary should come off as you turn the screw. Once the cover is off, lay it aside. Remove the two bolts located directly above the clutch assembly. They are different lengths so make sure you remember which goes where. Once these two bolts are out, the starter will come off.
Hmmm, now that's a new one on me. Will only shift WITHOUT using the clutch. If you pull in the clutch, what happens? Does it make a noise or something? The only advice that I can give you is to go into the primary and see what the problem is. Unless there is some very obvious damage to the outer primary cover, I'm at a loss as to what it could be. I'm sorry but just being honest with you.
Disonnect the battery, drain the primary oil. Remove the shifter and anything else that may be in the way. Loosen the primary chain a couple of turns. Look under the bottom of the primary and there is a bolt with a lock nut on it. This is the primary chain adjuster. Loosen the nut and back the bolt out a couple of turns. Remove the bolts from the derby cover, remove the spring and the lock nut. Remove the bolts from around the outer primary. They are different lengths so keep trackof which bolt goes where. As you pull the outer primary off the engine, turn the clutch adjuster rod in the middle of where the derby cover was clockwise. This will allow the cover to come off. Once you have the cover off, check for the proper operation of the clutch release and the bearing. Inspect everything and see if you can find the problem. I honestly don't have a clue on this one.
First disconnect the battery and drain the primary. Then remove any shifters, footpegs, or anything else that might get it way of the removal process.
Look on the very bottom of the primary and you'll see the primary chain tensioner adjustment bolt. Loosen the locknut and back the bolt down as far as it will go.
Remove the clutch adjuster cover and remove the spring and the locknut. Remove all the bolts holding the cover on and while pulling on the cover gently, turn the clutch adjuster inwards and remove the cover.
To remove your primary cover, first, disconnect the battery and drain the oil from the primary. Then, remove any footpegs or shifter mechanisms that might be in the way.
Look on the bottom of the primary cover and you'll see a bolt and locknut. This is the primary chain tensioning device. Loosen the locknut and turn the screws out (downward) to loosen the chain.
Then take the derby cover off. Remove the spring and the locknut from the clutch adjusting mechanism. Remove the bolts that hold the outer primary on. Turn the clutch adjuster screw clockwise as you remove the cover.
When you replace the cover, turn the clutch adjuster screw counterclockwise until it stops. Put all the bolts back in the cover and tighten them. Turn the screw counterclockwise again until it stops and then back off 1/4 turn. Install the locknut, the spring, and the derby cover.
Remove the upper inspection cover and reach in with your finger and check the primary chain tension. Using the bolt on the bottom of the primary, turn it upward (inward) and tension the primary chain to between 1/2" and 5/8" up and down play. Reinstall anything else that was taken off and pour in one quart of primary lube. Reconnect battery.
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.
You add it to the primary case on the left side of the engine. The same oil lubricates the primary and the transmission.
Remove the clutch inspection cover. On the clutch, you will see a dark blue colored steel plate. This is the diaphragm clutch spring. With the bike standing straight up, the oil level should be just to the bottom of this plate. If you add too much oil, the clutch will drag causing a problem with getting the transmission into neutral whent he engine is running. Do not overfill.
You must remove the primary to reach 2 bolts holding in the starter. This is a pretty big job, first completely loosen the clutch cable, remove the derby cover, disconnect clutch cable, remove inspection cover, drain primary fluid, loosen primary chain tension er, remove shifter linkage, remove primary cover ( use a Styrofoam board to place bolts in order due to different lenghts), remove ramp and ball assembly ( need snap ring plyers), using a tool to lock the clutch basket and primary drive remove bolts( I don't remember which but one removes left hand), you now can reach the bolts holding in the starter. As I stated this is a pretty big job and you should have a manuel before starting, if you don't want to buy one you can check one out at most library's. Reverse to install and remember LOCK TITE everything.