Question about 2000 Harley Davidson XL 1200 C Sportster Custom

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How do I disconnect the clutch cable on my 2000 sportster. I need to replace the gasket for the primary cover

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  • Anonymous Mar 26, 2014

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Relieve the pressure on it by loosening the nut below the handle on the cable, (use a back up wrench) that will allow the cable to be removed from the keeper on the engine side

Posted on Jul 12, 2009

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How do i replace a starter on a 2005 harley 1200 sportster


Disconnect the battery and then the wires on the charger. Drain the transmission (left cover). After that, you can remove the shift lever connection and the clutch cover. Disconnect the clutch cable from the clutch assembly. Now you can remove your complete primary cover. After all that you will want to remove the two screws that hold the starter to the engine. Then simply put everything back in the reverser order using all new gaskets and seals and fill the transmission back up w/the proper amount and weight of oil.

Mar 07, 2015 | 2005 Harley Davidson XL 1200 C Sportster...

1 Answer

1995 883 harley sportster i would like to know what is involved in removing primary cover?.........please


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.

Sep 30, 2011 | 1993 Harley Davidson XLH Sportster 883

1 Answer

Primary gasket leaks oil is there something keeping me from getting the cover off inside. could not get the cover off to replace the gasket


Take the round plate off of the primary cover back where the clutch is. A lock nut and small spring will come out. There is a threaded screw in the hole that is a clutch adjustment. Turn this screw clockwise to get your primary cover off.

Good Luck
Steve

Aug 03, 2011 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

I have a 1979 the primaryharley sportster I removed cover to replace the gasket now I have no clutch when i put itto gatrher is there a secret to putting primary case on


When you took the primary cover off, you had to turn a screw back by the clutch to get the cover off. Now, you have to readjust that mechanism. This is the clutch release mechanism. First, up towards the front of the primary cover, there is a long threaded cable adjuster threaded into the cover. Loosen the lock nut and turn the adjuster barrel inward a good bit, at least a half inch or so. Now, take the round plug out at the back of the primary cover and remove the locking nut. This is not actually a nut but looks like one with no threads in it. Now, turn the screw counterclockwise until it stops. Then turn it back about a quarter turn. Put the lock nut back in and the round cap. Go back to the cable adjuster at the front of the cover and turn it out until you have about an 1/8" of freeplay in the cable. Tighten the locknut. If you still don't have a clutch, you have something wrong in the primary cover.

Good Luck
Steve

Jul 02, 2011 | 1979 Harley Davidson XLH 1000 Sportster

1 Answer

A lower bolt on the primary cover broke,so i removed the shifter and foot peg bracket,then removed all of the bolts from primary cover after draining primary fluid. The primary cover still doesnt seem to...


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.

Good Luck
Steve

Jun 28, 2011 | 2007 Harley Davidson XL 883 Sportster

1 Answer

I am reassembling the clutch cable, is there an online manuel for this job or bike


I'm afraid there is no online manual available. Harley is very protective of their copyrighted material.

If you've already gotten the outer primary off the bike and the old cable out. Insert the primary end of the cable into the primary cover and screw the adjuster with the lock nut on it all the way into the outer primary. Reconnect the cable to the release mechanism with the link.

Replace the outer primary but starting the screw for the clutch release into the nut in the release mechanism. Turn the screw counterclockwise while you put the cover back on. Do not forget the gasket. Once you get the cover in position, replace all the bolts in the cover an tighten them. Adjust the primary chain by removing the top plug and checking the slack with your finger. Adjust the primary chain adjuster on the underside of the primary until you 1/2" to 5/8" up and down play in the chain. Finish the assembly of anything at the primary, shifter, foot pegs, etc. Refill the primary with one quart of oil.

Connect the cable at the clutch lever. Back down at the clutch release mechanism, make sure you have the screw turned all the way counterclockwise until it stops. Then turn the screw back 1/4 turn. Adjust the cable adjuster at the front of the primary cover out until you have about 1/8 inch of freeplay at the lever. Lock the lock nut and replace the cover over the clutch release mechanism.

If you need a drawing, contact me directly at wd4ity@bellsouth.net I'll send you one directly.

Good Luck
Steve

Feb 10, 2011 | 1979 Harley Davidson XLH 1000 Sportster

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

Oil is coming out the clutch cable at adjusting threads what would cause this


Right where the threaded adjuster goes into the outer primary case, there's a locknut. There should be an O-ring on this treaded piece to seal in the oil. To replace the o-ring, you must go through the procedure to replace the clutch cable by removing the primary outer cover, disassembling the clutch release mechanism, and turning the cable out.

Good Luck
Steve

Aug 30, 2010 | 2000 Harley Davidson XL 1200 C Sportster...

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

How do I replace starter on 2000 sportster


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.

Jun 07, 2009 | 2001 Harley Davidson FXSTD - FXSTDI Deuce

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