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How to change inner clutch cover gasket(primary gasket)

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How to replace the starter on a 2002 harley


Pretty entailed job. Not like a car.
You will need to remove the primary and possibly the clutch basket/ starter ring gear to access an internal fastener holding the starter to the inside of the inner primary.
Will probably need a primary cover gasket and a quart of synthetic (klotz 80-90) primary chain case lube.
While you're in there you should probably check & adjust primary chain tension and the Delrin shoe the chain rides on.
Completely drain the old primary lube, don't mix old with new, the thing only takes 18-22 ozs (so okay, maybe you need 1.3 qts).
Consider the different kW starters available and get the one that best suits your needs (is the motor built? high use? etc...) Terry components makes great components with WARRANTIES!!
Gasket $20-$25, klotz fluid $16-$20.
Starter drive clutch $35 to $100+.
Starter $380- $490 and up
Also jack-shaft assemblies, ring-gears, etc...$50, $80, $$$$$
Finally; if you have a large displacement or built motor you should have compression releases. Use them religiously.

Oct 08, 2014 | Motorcycles

1 Answer

I have oil leaking from the primary cover beside the pulley that drives the belt What needs to be done to replace the gasket 1996 Harley fxdwg


The INNER primary cover has an oil seal where the transmission shaft goes through.
You'll need to tear down the entire primary drive to get the inner cover off.
Some notes:
The engine sprocket nut is 160-180 Ft/Lbs of torque, with RED LocTite!
This is going to take some power to break it loose (think impact wrench)
The central nut holding on the clutch pack is a LEFT HAND thread!

Apr 19, 2014 | Harley Davidson FXDWG Dyna Wide Glide...

1 Answer

Need to know how to change 85 lowrider alternator. Fxr. And help would begreat


Instructions
  1. Replacing the Alternator
    • 1 Remove the drain plug located under the clutch area of the primary chaincase and drain the chaincase lubricant into a catch pan. Remove all mounting bolts from the primary cover and slide the cover from its locating studs. Loosen the primary chain tensioner and inspect it for wear (this is a logical time to replace the tensioner shoe, since you are in the case).
    • 2 Lock the primary chain where it enters the bottom of the clutch drum. Remove the engine sprocket nut and slide the compensator/sprocket assembly from the engine sprocket shaft. Slide the reluctor bowl off the engine sprocket shaft. Push the stator plug through the hole into the inner primary case. Remove the stator mounting bolts and slide the stator from its support boss. Remove the stator from the case.
    • 3 Slide the new stator onto the support boss and orient it so that the stator wires are closest to the stator plug hole in the case. Install and torque the new stator bolts to factory specification (refer to manufacturer's torque sheet). Do not re-use the old bolts. The bolts come pre-treated with Loctite and are designed for one-time use. Insert the stator plug into the plug hole and snap it into place.
    • 4 Slide the reluctor bowl onto the sprocket shaft and bottom it onto the shaft shoulder. Align the splines on the shaft and the compensator/sprocket assembly and slide the assembly into position. Install the engine sprocket nut and torque to factory specification for your model of Harley. Adjust the primary chain tensioner to factory specification.
    • 5 Scrape the old primary gasket from the case. Harley Davidson gaskets are produced with a print-o-seal feature that melts and '"cooks" onto the case surface. Insure that all of the old gasket is removed from the machined surfaces. Use caution when scraping the gasket, as the cast-aluminum cases are easily gouged, leading to poor sealing and leaks. Install the fresh gasket onto the locating studs, followed by the primary chaincase cover. Torque the primary cover to the proper torque and in the recommended pattern according to the specification sheet for your model of Harley. Remove the inspection plate and add new chaincase lubricant. Replace the inspection cover gasket and re-install the inspection plate.

Apr 24, 2012 | 2000 Harley Davidson FXDL Dyna Low Rider

1 Answer

Change a drive belt


to change the final drive belt on your Road King, you must pull the entire primary off. The outer primary cover, the clutch and primary chain, the inner primary, and the starter must come off. Then, you have to remove the rear wheel, remove the shocks, and pull the swing arm out as well. It's a major job.

Good Luck
Steve

Feb 19, 2011 | 2000 Harley Davidson FLHR-FLHRI Road king

1 Answer

Removal of inner primary cover


For the cover you may have to loosen your shifter linkage to be able to remove it from the bike depending on what model you have
As for the inner primary you'll have to take off the clutch the front & rear primary sprockets and chain. You can loosen the bolts to both sprockets,then loosen the chain tensioner.
Slide the front & rear sprocket & chain off with the clutch still attached. leave them together and set it aside as one big unit.
The inner primary has bolts with bent washer tabs. Bend the tabs flat so you can remove the bolts.
Thre is a lock ring around the transmission shaft that holds the inner primary on too. Remove that with lock-ring plier.
Depending on your model, you may have to remove the rotor/flywheel first before the inner primary comes off.
Don't for get to put a new engine o-ring back on the front hole of the inner primary when re-installing.

Dec 03, 2010 | Harley Davidson FXST Softail Standard...

1 Answer

Piamary leaking oil vary bad but its tray oil


I assume that your primary is leaking oil and by "tray oil", I think you mean "Grey oil". Oil in the primary that has been in there for about 5000 miles will be gray. It contains clutch debris and metal shavings from the primary chain and sprockets.

Now, the oil is coming from behind the inner primary cover, the inner will have to be pulled off meaning you'll have to take the engine sprocket, clutch assembly, and starter off. To get the starter off, you'll probably have to pull the exhaust system as well. That's a pretty good job.

But, if the oil is simply leaking out from the seam of the inner and outer primary or the derby cover, simply replace the gaskets there. If your outer primary is designed to use an O-ring on the derby cover, use the O-ring and a solid gasket as well. This works well.

Good Luck
Steve

Aug 18, 2010 | 2002 Harley Davidson FLHR - FLHRCI Road...

1 Answer

Inner primary leak, base gasket leak.


Simply, the rocker box and cylinder will have to come off to replace the cylinder base gasket. And the out and inner primary will have to come off to replace the gasket. Of course all the stuff attached to the cylinder and the primaries will have to come off too. Not to mention the primary chain, clutch assembly and compensator sproket inside the primart case. It's a minor/major job in a shop.

May 15, 2010 | 2000 Harley Davidson FLHR-FLHRI Road king

1 Answer

Want to no what all has to come out to change trans 2003 deuce


To change the transmission you will have to disconnect the battery then remove the outer primary cover, starter, clutch, primary chain tensioner, stator, (clutch, stator and primary chain come out as a set) inner primary cover, exhaust, clutch cable and then transmission. Sounds like a big job but if you are mechanically inclined, have the tools and have a weekend to yourself it is reasonably easy.

Nov 19, 2009 | 2003 Harley Davidson FXSTDI Softail Deuce

1 Answer

Clutch cable broke at handle lever on 1979 harley davidson sporst


To change the clutch cable on you '79 Sporty, you'll have to take the outer primary cover off. To do this, you'll have to drain the oil from the primary, take the left side foot peg off, and loosen the primary chain adjuster on the bottom side of the primary. Loosen the locknut and use an allen wrench or hex key to screw the adjuster bolt downward.

If you need to know anything else, drop me a line at wd4ity@bellsouth.net

Then, remove the large "plug" towards the rear of the cover. Inside, you'll see something that looks like a nut but with no threads in it held in by a small spring. This the the lock nut, remove it. Below it is what looks like another nut with a slotted adjuster bolt sticking out. Remover the bolts from around the primary cover and break it loose from the engine. While turning the adjuster screw at the rear of the cover inward, remove the cover.

The cable connects to the cluch release mechanism. By turning the "link" downwards, you can disconnect it from the mechanism. Notice which way the "link" in attached to the release mechanism. Take the "link" off the end of the clutch cable.

Break the lock nut loose at the threaded cable adjuster on the outside of the case and screw the adjuster all the way out of the primary cover. Disconnect the cable at the handlebar lever and your cable is out.

Reinstall the new cable in the reverse order. When replacing the outer primary cover, make sure you use a new gasket on the cover as well as on the foot peg boss. The "foot peg boss gasket" is very important. You'll see an aluminum boss with a threaded rod sticking out of it that holds your left foot peg on. There is a round gasket that goes over this threaded rod and seals against the boss. If you leave this off, your bike will leak oil around this threaded rod when your foot peg goes on. Make sure you specifically ask for the "foot peg boss gasket" when you buy the new primary gasket. It's just a round gasket a bit larger than a quarter.

As you put the primary cover back on, there is a spring on the primary chain adjuster. Part of the spring is in the primary cover and the other part is in the engine. You'll see how it goes in. There is a large stud in that area that the outer primary cover slides up on. Adjust the tension on the primary chain by removing the "plug" at the top of the primary cover. You want 3/4" to 7/8" up and down play in the chain with the engine cold.

On the adjuster, as you're installing the outer cover, turn the ajuster screw back into the clutch release mechanism by turning the screw backwards. Once you have the outer primary cover completely installed, you must adjust the release mechanism. Adjust the screw inwards until you feel a resistance, then back the screw off about a 1/4 to 1/2 turn, insert the "lock nut" and spring, and install the "plug". Then, using the cable adjuster on the outside of the cover, adjust the cable. Add oil.

Oct 26, 2009 | 1979 Harley Davidson XLH 1000 Sportster

1 Answer

Have devolped a small leak on 2005 road king. drips from bottom of primary cover at drain bolt. running down from above. back of primary cover has slight oil dampness around transmission and starter shaft...


Spray it off at the car wash to remove all the oil , then spray Right Guard (Yes, that Right Guard) on the area of the leak. It will show up, but you may not be able to see exactly where. There are a couple spots where it can leak. The jackshaft oil seal, as you said, transmission output shaft (clutch shaft) on the trans itself, the inner primary seal where the trans shaft runs thru, the engine sprocket shaft oil seal, inner primary O-ring, the bolts that hold the inner primary to the engine/trans, the primary chaincase gasket and the drain plug. Hopefully when you get it apart, you will see which seal is leaking. If not, replace them all. Still want to fix the leak? LOL

Jun 30, 2009 | 2005 Harley Davidson FLHR - FLHRI Road...

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