Question about Harley Davidson XLH Sportster 883 Motorcycles

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How do i remove primary cover on a 89 sportster

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  • Master
  • 4,565 Answers

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.

Good Luck
Steve

Posted on Oct 13, 2010

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Posted on Jan 02, 2017

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wd4ity
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SOURCE: remove primary cover 1990 sportster

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.

Good Luck
Steve

Posted on Oct 03, 2010

wd4ity
  • 4565 Answers

SOURCE: a lower bolt on the

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

Posted on Jun 28, 2011

FirsLonewolf
  • 186 Answers

SOURCE: 1995 883 harley sportster i would like to know

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.

Posted on Oct 01, 2011

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1 Answer

1998 harley davidson 1200 sportster custom


The trans lube is the same as the primary lube. As long as the primary fluid is touching the bottom of the clutch basket with the bike sitting upright, you are good. You will have to remove the clutch (derby) cover on the primary cover to check the oil level.

Sep 20, 2012 | 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.

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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

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1 Answer

Removing primary cover on 04 1200c


To remove the primary cover from you Sporty, you'll have to remove the shifter and foot peg. Then loosen the locknut for the primary chain adjuster and turn the adjuster downwards to loosen the primary chain. Then remove the plug at the bottom rear of the plug to drain the oil from the primary. Remove the clutch release mechanism cover from the outer primary. Remove the spring and locknut. Turn the clutch adjuster screw as far clockwise as you can turn it. Then remove all the bolts around the outside of the cover. While pulling the outer cover gently away from the engine, turn the clutch adjuster screw clockwise until the cover comes off.

Good Luck
Steve

Dec 18, 2010 | 2004 Harley Davidson XL 1200 C Sportster...

1 Answer

Remove primary cover 1990 sportster


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.

Good Luck
Steve

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Disconnect the positive battery cable. Drain the primaary and remove the derby cover. Take the spirng and the locknut out. Go to the bottom of the primary cover and loosen the lock nut on the primary chain adjuster and back the adjust out a good little bit. Remove anything that's in the way of the primary cover and remove all the bolts in the outer cover. Turn the clutch adjuster clockwise as your remvove the cover.

On the other side of the bike, disconnect the positive battery cable from the starter and remove the exhaust from the bike.

Back on the left side of the bike, remove the two bolts just above the clutch assembly. They are different lengths so remember which goes where.

Reassembly is the reverse of the disassembly. When you put the outer primary back on, turn the screw counterclockwise until you can put the bolts back into the primary cover. Once all of them are in and tight, turn the screw counterclockwise as far as it will go and then go back clockwise 1/4 turn. Put the locknut, spring, and derby cover back on the primary. Adjust the primary chain by turning the screw inwards until you have 5/8" to 1/2" inch of up and down play on the chain. Feel of it throught the upper inspection hole. Once finished, add one quart of primary lube to the primary.

Good Luck
Steve

Oct 01, 2010 | 2005 Harley Davidson XL 1200 C Sportster...

1 Answer

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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.

good Luck
Steve

Sep 27, 2010 | 2003 Harley Davidson XLH Sportster 883...

1 Answer

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1997 HARLEY DAVIDSON SPORTSTER XLH 1200

STARTER REMOVAL
1. REMOVE LEFT SIDE COVER
2. REMOVE NEG. BATTERY CABLE FROM CRANKCASE TO PREVENT ACCIDENTAL STARTUP
3. REMOVE POSITIVE BATTERY CABLE
4. DRAIN TRANSMISSION FLUID (5/8" SOCKET)
5. REMOVE PRIMARY COVER (IF YOU'RE UNSURE OR IT'S BEEN AWHILE - PLEASE CONTACT - I CAN PROVIDE INFO)
6. REMOVE REAR EXHAUST
7. REMOVE 2 STARTER BOLTS (5/16" ALLEN)
8. REMOVE STARTER
9. REMOVE GASKET
10. SLIDE BOOT BACK AND DISCONNECT THE POSITIVE CABLE FROM BATTERY (12MM)
11. DISCONNECT STARTER SOLENOID POSITIVE LEAD TO STARTER
12. LOOSEN WIRE BAND NUTS 3/8" SOCKET

If anything you're unsure about or been awhile just comment below or reach out. The primary cover has a few quirks to get off - can go further with you if needed. All The Best, Justin Lee
17 South Industries, LLC

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1 Answer

89 harley 1200 sportster goes into gear and will take off properly when you release the clutch.but then you ca'nt shift it into any other gear?


you have a broken shifter pawl. It's behind the primary cover. I think you can get to it without removing the clutch but I may be wrong. At least on the newer models you don't have to pull the transmission out.

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1 Answer

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I assume that by the term "transfer case", you're talking about the primary drive and transmission on your Sportster. The lubricant that you pour into the primary case also lubes the transmission. Not so on a Big Twin as they each have their own lubricants.

On the Sporty, theres a drain plug on the bottom of the primary case near the rear end of it. I'm pretty sure it uses a Torx driver to remove it. Drain the oil and refill with H-D primary & trans lube for Sportsters. Remove the derby cover at the rear of the primary cover and fill the primary until the oil level is even with the clutch pressure spring with the bike standing straight up. Replace the derby cover.

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