Question about 2000 Harley Davidson FLSTF Fat boy

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My primary chain /clutch cover has no o ring, but has a flat gasket.Do I need an o ring also?

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  • afroz1 May 11, 2010

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The flat gasket is the new "replacement" gasket for the O-ring. But, to tell the truth, I run both the O-ring and the flat gasket. Never a leak. Good Luck, Steve

Posted on May 05, 2010

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1 Answer

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

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 chain rattling & have to rock bike to engage starter. 2001 Electrica Glide Classic


If you're having to rock the bike to get the starter to engage, you have a problem in the primary. There is a starter ring gear around the outer clutch drum that is engaged by the starter jackshaft. If the jackshaft is not engageing and not turning the engine, you may have some damage to this ring gear. It could be that your starter clutch in the starter is bad but that would not be effected by rocking the bike but rather just repeated attempts to start the engine. Either way I'd go into the primary for a look around. Disconnect the battery and drain the oil out of the primary through the pipe plug on the bottom of the primary at the very back. Take the floor board off and if necessary, the shifter mechanism. Take all the bolts out around the outer primary cover as well as the inspection cover in the center of the primary cover. With the cover off, you can inspect the starter ring gear and check the clutch for excessive looseness. Also check the starter jackshaft for damage. If find nothing, you may have a starter clutch problem. The starter clutch is inside the starter and the starter must be removed and disassembled to replace it. Adjust the primary chain so that it has 3/4" to 7/8" up and down movement in the middle of the top run of the chain. Adjust by moving the adjuster shoe up or down as necessary.

Good Luck
Steve

Jul 30, 2011 | Harley Davidson FLHT Electra Glide...

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

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

Removal and installation of 1988 harley sportster clutch


In order to remove the clutch from your bike, you must have a special tool. You'll need H-D #34761 in order to remove the snap ring holding the clutch together.

Disconnect the battery, drain the primary, and remove the primary cover. Once you have the primary cover off, you can remove the nut from the compensator sprocket at the engine end of the primary chain.

Install the H-D 34761 or equivalent tool and compress the clutch spring. Remove the snap ring and then back off on the tool to release the pressure on the clutch spring. Once the pressure has been removed, remove the adjusting screw assembly, the outer clutch spring seats, the clutch spring, the inner clutch spring seat, and the pressure plate.

Then you can disassemble the rest of the clutch. Remove the remove the four friction plates and three drive plates. Then you can remove the spring plate and the remaining plates after that. Remove the snap ring that holds the clutch assembly onto the transmission clutch gear and remove the inner and outer clutch shells, the primary chain, and the engine sprocket as a group.

For this job, I would recommend that you purchase a service manual. It's has pictures that show you what you're dealing with and in this case, a picture is truly worth a thousand words.

Good Luck
Steve

Nov 05, 2010 | Harley Davidson XL Sportster 883...

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

HANGS BETWEEN GEARS, MANIPULATE THE SHIFTER UP AND


Sounds like you have some shifter pawl problems. If you remove your outer primary cover, you can see the shifter pawl just behind your clutch assembly. The problem could be the shifter pawls, the springs, or the carrier. You'll just have to go in there to find out exactly what it is.

To get the outer cover off, first loosen the primary chain tensioner beneath the primary cover. Then remove the large round cover from the outer primary cover. Beneath the cover is a spring with a locknut over the clutch adjuster. Drain the oil out of the primary and remove all the bolts around the primary including the left side foot rest and the nut at the front. Slide the outer primary cover off as you turn the clutch adjuster clockwise.

With cover off, you may can see the problem with the shifter pawl but I'm afraid that you're going to have to pull the engine drive sprocket and the clutch assembly off to repair it. To do this, you need an air wrench to remove the front sprocket nut and the clutch assembly nut. The clutch assembly nut is left handed threads. Take the snap ring out of the center of the clutch assembly and remove the clutch adjuster plate.

When reassembling the primary, torque the engine nut to 150-165 Foot pounds, the clutch nut torque is 70-80 foot pounds left handed, adjust the primary chain to 3/8 to 1/2" up and down with the engine cold. Check the primary chain adjustment thorough the upper inspection hole on the outer primary cover. I highly suggest you purchase a service manual to refer to if you decide to do this job. If you do it yourself, the book will pay for itself with this one job. Otherwise, this is a pretty advanced job and you might be better off taking to an experience mechanic.

Apr 01, 2010 | 2003 Harley Davidson XL 1200 S Sportster...

2 Answers

When pulling in the clutch there is a loud squalching noise.


Sounds like your clutch throwout bearing is either bad or going bad. This is due to improper clutch cable adjustment. Just like in a straight shift automobile, if you keep your foot on the clutch pedal, the throwout bearing runs continuously shortening the life of the bearing. On a motorcycle, if the clutch cable is not adjusted to have just a bit of freeplay in it, the bearing will run continously as well shortening the life of the bearing. But, then again it could have just been a faulty bearing.

To repair the problem, you must remove the outer primary cover. First, drain the primary/transmission oil. Then you must loosen the primary chain adjuster beneath the primary cover. Loosen the lock nut and turn the adjuster bolt outward to lower the adjuster shoe inside the primary.

Then remove the clutch inspection cover, the small spring, and the locknut on the clutch release mechansim. Remove the left hand foot peg. Remove all the bolts holding the outer primary cover on. As you remove the primary cover, you will have to turn the screw inside the release mechanism inwards to get it out of the release mechanism.

Once you get the primary cover off, you can see the clutch throwout or release bearing in the center of the clutch assembly. Remove the snap ring and pull the bearing out. Inspect and replace the bearing if found to be defective. Carefully drive the center bolt out and the bearing out of it's holder. Install in the reverse manner.

Reassembly is reverse of disassembly. Install a new gasket on the primary and slide the primary cover in place while turning the clutch release screw into the the release mechanism. Install the bolts that hold the primary cover on and tighten. Tighten small primary cover bolts to 80-110 Inch pounds and the left foot peg bolts to 16-28 Foot pounds.

Adjust the primary chain tensioner to obtain 3/8' to 1/2" up and down slack when checked through upper inspection cover on outer primary. To adjust the clutch cable, find the bellows looking cover over the cable adjuster. Loosen the lock nut and adjust the cable as short as possible. Back at that the adjuster on the primary cover, slowly turn the adjuster screw clockwise until it bottoms out and quits turning. Do not force the screw to turn, just until it bottoms out. Now, back it up 1/4 turn and install the locknut. You may have to turn it just a bit one way or the other to get the locknut in. Install the spring and the cover with the quad ring in place. ADD OIL TO THE PRIMARY, 32 OUNCES of H-D Sport Trans or equilivent. To adjust the cable, adjust cable adjuster in the middle of the cable out as far as it will go without forcing anything. Squeeze the clutch lever a few times and adjust the adjuster so that you have 1/16" to 1/8" freeplay at the lever, about the thickness of a nickle between the lever and lever stancion. Lock the locknut on the cable adjuster and reposition the bellows cover.

As you can see, this is not a very difficult job but it is not for the "faint of heart" since it involves removing the primary cover. I would rate the job difficulty as "moderate" due to this necessity. The only special tool required would be a set of snap ring pliers. Good Luck!

Feb 14, 2010 | 2003 Harley Davidson XLH Sportster 883...

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

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