Question about Harley Davidson XL 1200 S Sportster Sport Motorcycles

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I tried to remove the entire primary housing cover not just the inspection plates and it wont come off. i made sure that all the bolts were out and the shifter linkage was off along with the rubber seal around shifter rod and it just wont come loose.i did remove small inspection plate but not the big one..but am thinking that should not matter.maybe im wrong but

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  • Harley Davidson Master
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Dont take chances go n buy a repair manual at bookstore -they r detailed in every step-become a pro

Posted on Sep 11, 2009

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1994 chev. diesel 4x4 clutch replacement how to


First lift truck high enough so when transmission comes down you can get it out from under truck disconnect both negative cables remove rear and front drive shafts disconnect linkage to transfer case there are 6 bolts around transfer case adapter plate that come out to remove transfer case some models the lower bolt is blocked by the mount if so support transmission and remove cross member once transfer case is out of the way. celebrate with a quick beer. Now comes the hard part lower down and remove shifter tower usually four bolts if part of top cover then remove floor cover and boot press down on center cap and turn CCW to remove spring cover shifter will come out. remove bolts that hold rock cover on front of bell housing remove slave cylinder then remove the 6 bolts that hold bell housing to engine. slowly pull transmission back to separate form engine. once out high five your helper. remove the 6 bolts or 8 bolts that hold pressure plate to flywheel and now both plate and disc are off. Inspect flywheel for burnt spots any have flywheel resurfaced . replace pilot bearing ( needle) bearing type requires a blind hole puller. bronze bushing types thread a tap into back off crankshaft as it cuts threads and bottoms out it will remove the bushing. Most clutches come with a alignment tool. Install new pilot bearing apply a small amount of grease. Using the alignment tool to hold disc then install pressure plate THIS PART IS IMPORTANT slowly cinch down the bolts with a 1/4 inch nut driver by hand by cross tightening cover if you dont do this clutch will chatter because you bent the cover once close enough use a ratchet and 1/4 quarter turn until tight TAKE YOUR TIME DO THIS ONCE. Now tighten bolts to a torque of 30-35 ft lbs. I forgot dont let the alignment tool sag as you tighten up cover make sure this tools slides in and out easily once done replace release bearing and inspecting transmission front collar for wear if bad replace collar release bearing has a groove inside of it make sure that it is full of grease. apply a thin coat very thin to shaft. remove the beer cans from under truck and install in reverse order . good luck if this is your first clutch it will take a weekend.

Apr 19, 2014 | 1998 Volkswagen Passat

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Yamaha banshee gear problem


Instructions
  1. Changing the clutch on your Honda dirt bike
    • 1 Drain the oil. Its best to have the bike slightly lower in the front on a jack or stand so the oil will drain out completely. Removing the filler cap will allow the oil to drain quickly.
    • 2 Remove the crankcase cover to access the clutch. Inspect the gasket and replace if needed.
    • 3 Remove the clutch housing cover with a ratchet and socket.
    • 4 Loosen the bolts on the pressure plate in a criss-cross pattern. Be careful when removing them as they have springs behind them. Slide the pressure plate out and be careful to catch the lifter behind the plate.
    • 5 Remove the friction plates and the judder springs from the clutch housing. Take a picture with a camera or make a drawing detailing how they are positioned so you won't get confused when you reinstall them.
    • 6 Replace the worn parts and reverse the steps above to reinstall. Consult your service manual for the proper torque when tightening the bolts on the pressure and friction plate.
    • 7 fix-clutch-honda-dirt-bike-1.7-800x800.jpg Check and make sure there is 2 mm to 4 mm of free play in the clutch lever to avoid wear on the clutch plates. Replace the oil, clean up your area, fire up your bike and hit the trails.

Jan 16, 2013 | Yamaha RD 350 Motorcycles

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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

Is there a bolt patern while removing the primary housing on a 07 dyna superglide


Well, some say that you always torque the bolt starting from the center and working out but I've done a lot of them and always just started at the top and went around clockwise. There are two bolts that hold the inspection cover on that also hold the outer primary on as well. I think they are the one at 12 o'clock and 3 o'clock position. There is also a small gasket between the inner and outer primary covers on these two bolts.

Good Luck
Steve

Aug 13, 2011 | Harley Davidson FXD Dyna Super Glide...

1 Answer

2007 1200 sportser sounds like the gear chain is lose how do i fix it...


If you're talking about the primary drive chain on the left side of the bike, with the engine cold and engine OFF, remove the inspection plate at the top center of the primary cover. Stick your finger in the hole and lift the chain. You should have 3/8" to 1/2" up and down movement. If you need to adjust the tension on the chain, loosen the lock nut on the adjuster bolt on the bottom of the primary case. Turning the bolt upwards tightens the chain. Once you get the tension set correctly, tighten the locknut. Make sure the oil level in the primary case is correct because this same oil lubricates your transmission. You don't want to run your transmission low on oil. If you're in doubt, drain the primary and refill with one quart of oil. There may be a lubricant level plug in the backside of your primary cover.

Good Luck
Steve

Aug 06, 2011 | 2006 Harley Davidson XL 1200 C Sportster...

1 Answer

I need to know how to set thte timing chain


Discoverd this indepth expalaination of process steps involved in the installation of the timing chain from an ASE certified technician. I hope this helps. See the repair manual on the link below.<br /> <br /> Link: <a href="http://www.2carpros.com/forum/2002-jaguar-xj8--gearbox-default-appear-on-dashboard/2000-jaguar-xj8-timing-chain-replacement-vt218070.html">http://www.2carpros.com/forum/2002-jaguar-xj8--gearbox-default-appear-on-dashboard/2000-jaguar-xj8-timing-chain-replacement-vt218070.html</a><br /> <table id="table14" style="BORDER-RIGHT: #000000 1px dashed; BORDER-TOP: #000000 1px dashed; BORDER-LEFT: #000000 1px dashed; BORDER-BOTTOM: #000000 1px dashed" bordercolordark="#000000" width="100%" bordercolorlight="#000000" border="0"> <tbody> <tr> <td style="BORDER-TOP-WIDTH: 1px" width="700"></td></tr> <tr> <td style="BORDER-TOP-WIDTH: 1px" width="700"><span class="name" roundtrip="0" lastvisited="3">By <a name="755408"></a><b roundtrip="0" lastvisited="0">Dave H</b>,<b> </b></span><span class="postdetails" roundtrip="0" lastvisited="0">Certified ASE Technician</span></td></tr> <tr> <td style="BORDER-TOP-WIDTH: 1px" width="100%" roundtrip="0" lastvisited="6"></td></tr> <tr> <td style="BORDER-TOP-WIDTH: 1px" width="700"></td></tr> <tr> <td style="BORDER-LEFT-WIDTH: 1px; BORDER-BOTTOM-WIDTH: 1px; BORDER-RIGHT-WIDTH: 1px"> </td> </tr> <tr> <td colspan="2"> <span class="postbody" roundtrip="0" lastvisited="77">PRIMARY TIMING CHAINS (NON-SUPERCHARGED) <br />NOTE:The 4.0L V8 has no engine timing alignment marks on the crankshaft or camshafts. Engine timing is achieved by installing the Crankshaft Setting Peg (303-531) and Camshaft Locking Tool (303-530). With the crankshaft setting peg in position, ensure the timing flat on each camshaft is in the uppermost position before installing camshaft locking tool. Variable camshaft timing unit may also be referred to as Variable Valve Timing (VVT) unit. <br /><br />NOTE:Special Tools Required: Crankshaft Setting Peg (303-531), Camshaft Locking Tool (303-530), Chain Tensioning Tool (303-532), Primary Chain Wedge (303-533) and Variable Camshaft Timing Oil Control Unit Setting Tool (303-654). See Fig. 232-Fig. 236 . <br /><br />NOTE:"A" bank refers to the right/passenger side of the vehicle and "B" bank refers to left/driver side of the vehicle. <br /><br />NOTE:Each door glass automatically drops 12 mm when the door is opened or when the convertible top is raised or lowered. It is important that windows are lowered before battery is disconnected to allow doors to shut properly. <br /><br />Removal ("A" Bank) <br />Tips Click a link to view tip <br />Tech1Tip: special tool <br /><br /><br />Remove timing cover. See TIMING CHAIN COVER (NON-SUPERCHARGED). <br />Remove the variable camshaft timing oil control solenoid. </span><br /> <span class="postbody" roundtrip="0" lastvisited="77">Remove the variable camshaft timing oil control unit housing retaining bolts and remove the variable camshaft timing oil control unit housing. </span><br /> <span class="postbody" roundtrip="0" lastvisited="77">Remove and discard the variable camshaft timing oil control unit housing "O" rings. <br />Raise and support vehicle. Remove the bolt which secures the Crankshaft Position (CKP) sensor to the flywheel housing. Remove the CKP sensor and allow it to hang free under the engine. Remove the torque converter bolts access grommet from the flywheel housing. </span><br /> <span class="postbody" roundtrip="0" lastvisited="77">Install the crankshaft damper bolt (old one) to the crankshaft, hand-tight only. Rotate crankshaft until the triangular arrow indent on the flywheel is visible through the access hole. See Fig. 144. Confirm that the timing flat on each camshaft is uppermost position. <br />Position the crankshaft so that the Crankshaft Setting Peg (303-531) engages fully into the timing slot. Install and tighten the bolt to secure the crankshaft setting peg. See Fig. 145. Remove the crankshaft damper bolt from the crankshaft and lower the vehicle. <br />Install the Camshaft Locking Tool (303-530) to the "A" bank camshafts, aligning the shafts slightly as necessary. Loosen the bolt that secures the exhaust camshaft sprocket and the bolt that secures the variable camshaft timing oil control unit. See Fig. 146. Remove camshaft locking tool. <br />Remove the primary chain tensioner bolts, primary chain tensioner and tensioner backing plate. See Fig. 147. <br />Remove the primary timing chain tensioner pivot bolt and remove the primary timing chain tensioner blade. See Fig. 148. <br />Remove the bolt which secures the primary timing chain guide. Noting the position of the primary timing chain guide, remove the primary timing chain guide from the upper retaining pin. See Fig. 149. <br />Remove the primary timing chain from the variable camshaft timing oil control unit and from the crankshaft sprocket. Clean and inspect all components. <br />Installation <br />If "B" bank timing chain was removed, see INSTALLATION. If not, go to next step. <br />If previously removed, install the timing chain sprocket to the crankshaft. The teeth of the "A" bank and the "B" bank timing chain sprockets on the crankshaft must be out of phase with each other. If they are in phase after installing, remove the sprocket, turn it on its vertical axis and reinstall sprocket. See Fig. 150. <br />Install the chain tensioning tool to the exhaust camshaft sprocket. Reposition the sprocket (and the variable camshaft timing oil control unit) for the most advantageous position for use of the tool. See Fig. 151. Remove the tool. <br />Install the primary timing chain into position over the crankshaft sprocket and the variable camshaft timing oil control unit. There must be no slack on the drive side of the primary timing chain and the sprockets must not be rotated on the camshafts, or the tensioning tool may not fit. See Fig. 152. <br />Install the primary timing chain tensioner blade to the cylinder block. See Fig. 148. Install the pivot bolt and tighten specification. See TORQUE SPECIFICATIONS. <br />Push the primary timing chain tensioner piston into the tensioner body to provide clearance for installing the primary timing chain. Insert a thin rigid wire through the hole in the end of the tensioner piston to displace the ball from the non-return valve seat. See Fig. 153. With the wire in position, press the piston fully into the tensioner body. Remove the wire. <br />Install the 2 primary timing chain tensioner bolts to the primary timing chain tensioner and locate the tensioner backing-plate on to the 2 bolts. Align and install the primary timing chain tensioner to the cylinder block and to the mating slot on the rear face of the primary timing chain tensioner blade. See Fig. 147. Tighten the primary timing chain tensioner bolts to specification. See TORQUE SPECIFICATIONS. <br />Use a Primary Chain Wedge (303-533), or 2 if needed, between the primary timing chain tensioner and primary timing chain tensioner blade, to take up the slack in the chain for tightening of the variable camshaft timing control unit and exhaust camshaft sprocket. See Fig. 154. <br />Using the chain tensioning tool, apply force to the tool in an counterclockwise direction to tension the chain on its drive side. See Fig. 151. While applying opposing force to the sprocket and chain, tighten the exhaust camshaft sprocket bolt to specification. See TORQUE SPECIFICATIONS. <br />Using the Variable Camshaft Timing Oil Control Unit Setting Tool (303-654), rotate the variable camshaft timing oil control unit fully counterclockwise to the fully retarded position. See Fig. 155. <br />Check that the primary chain wedges are still in place. While applying opposing force to the sprocket and chain using the chain tensioning tool, tighten the variable camshaft timing oil control unit bolt to specification. See TORQUE SPECIFICATIONS. Remove the chain tensioning tool and the primary chain wedges and camshaft locking tool. <br />Raise and support vehicle. Remove crankshaft setting peg. Install the CKP sensor and bolt to the flywheel housing. See Fig. 143. Tighten the CKP sensor bolt to specification. See TORQUE SPECIFICATIONS. Install the access grommet to the housing and lower the vehicle. <br />WARNING:Check that the ring dowels are engaged squarely. Fully locate the assembly as much as possible by hand. Failure to follow this procedure may result in damage to the vehicle. <br /><br />Install NEW "O" rings to the variable camshaft timing oil control unit housing. Lubricate the "O" rings and the bushing. Install the variable camshaft timing oil control unit housing. See Fig. 142. Install the variable camshaft timing oil control unit housing bolts. Tighten to specification. See TORQUE SPECIFICATIONS. <br />Install the variable camshaft timing oil control solenoid. See Fig. 141. Install and tighten the variable camshaft timing oil control solenoid bolt to specification. See TORQUE SPECIFICATIONS. <br />Install the timing chain cover. See TIMING CHAIN COVER (NON-SUPERCHARGED). </span><br /></td></tr></tbody></table>

Aug 26, 2010 | 2001 Jaguar XJ8

1 Answer

Removing starter


Since you haven't answered my question, I'm going to assume that you own a Softail. The reason I asked the question is that so often the heading under which the question falls is wrong and the person has a different model.

To remove the starter from a Softail, first disconnect the battery. Then drain the primary and remove the outer cover. With the outer primary cover off, you can remove the small bolt from the center of the jackshaft and remove it from the starter.

Now, from the right side of the bike, disconnect the small wire coming from the starter relay and the large battery cable. You'll have to remove the exhaust system to get to the starter as well. There are two large 3/8" bolts that hold the starter in. Remove these two bolts and the starter will come loose from the inner primary housing. Work the starter out.

To reinstall the starter is the reverse of the removal. Make sure you use a new lock plate on the jackshaft bolt along with Locktite #242 blue medium strength thread locker.

Good Luck
Steve

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

1 Answer

Its an 02 how do i check the torque convertor or flex plate bolts to see if that is were my noise is coming from


The inspection cover is usually plastic, it is bolted to the under-side of the bell-housing and it is held in place usually by 4 small bolts, and once you remove them the inspection cover should come out. (you might also have to remove the starter on some applications)

After you have removed the inspection cover most of the flex-plate and the torque converter will be exposed. Turn the engine over and use a good light to inspect for damage to the flex-plate, and also check to see if the torque converter to flex-plate bolts are tight when they revolve into a position where you can attach a good ratchet.

Jun 07, 2010 | 2004 Dodge Ram 1500

3 Answers

Need to remove and install inner primary cover


You really need a manual for this job if you have never done it before. readers digest version is as follows. Drain Primary Fluid, remove outter primary cover, Remove compensating Nut its the one on the front, use a snap ring plyer on the clutch, remove the clutch adjuster nut rod plate . will come out in one piece, Remove the Chutch Hub Nut it turns opposit ( in other words tightening is loosening it) remove bolt on the chain tensioner, whole system will now pull out.
Leave the stator magnet on dont have to remove thats the silver plate up front. Remove the jack shaft bolt on the starter pull it out. Go to other side of bike remove two starter bolts you will need LONG allen..then remove all the bolts on the inner primary and remove it. If you dont understand any of this you need a manual for your bike. or any Harley FL its all the same.

Jun 15, 2009 | 2001 Harley Davidson FXDWG Dyna Wide Glide

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