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How do you get the primary cover off what is the trick?

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As both a Harley and a Buell owner, slacken off the primary chain adjuster and drain the oil.
Release the clutch, unscrew the outer screws and carefully use a plastic mallet to aid removal if needed.

Posted on Dec 31, 2010


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Is there a drain plug for the primary on a 2009 fatboy, 96 ci

Of course there is an inspection cover on the primary. It is called the clutch inspection cover or derby cover. The primary drain plug is right below the center of this cover and it is a 5/8 inch hex head with a 1/4 inch Allen socket in the middle of the plug head also. You fill the primary through this cover opening also and ONLY up to the bottom of the clutch diaphragm spring.

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this is covered in the FSM. factory service manual.
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How do I replace starter on 2002 sportster

First disconnect the battery cable. Then you'll have to pull the primary cover off the engine. Find the primary case drain plug underneath the rear of the primary case and remove it to drain the oil. Find the primary chain tensioner underneath the primary cover near the center and loosen the locknut. Turn the screw downwards to loosen the tension on the primary chain. Remove the left foot peg and take the "derby cover" off of the primary cover. Remove the spring and lock nut underneath the derby cover. Remove the bolts around the primary cover. As you gently pull the primary cover away from the engine, turn the clutch adjuster screw under the derby cover in a clockwise direction until the primary cover comes off. Remove the battery cable where it bolts onto the starter motor and the small single wire that plugs to the motor. Just above the clutch assembly there are two bolts. Remove these bolts and the starter will come off the engine. The bolts are different lengths. Make sure you mark which bolt goes where.

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Sep 05, 2011 | Harley Davidson XL 883 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.

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Jun 28, 2011 | 2007 Harley Davidson XL 883 Sportster

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.

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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.

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Oct 03, 2010 | 2005 Harley Davidson XL 883L Sportster

1 Answer

How to remove starter from a 2005 sportster custom

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

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

1 Answer

Clutch cable wont work. came loose on inside of cover

Are you sure it just came loose? More than likely, it broke. To find out, drain the primary oil and loosen the locknut at the cable adjuster on the outer primary cover. Turn the adjuster inwards as far as it will go. Remove the four screws on the derby cover. and lift it away from the primary cover. Remove the spring and the locknut.

Now, remove any footpegs or anything else that may be in the way of the removal of the outer primary. Loosen the locknut on turn the primary chain tensioner out on the bottom of the primary cover. Remove all the bolts from the primary.

Now, turn the clutch adjuster screw back at the derby cover in a clockwise direction and remove the outer primary cover. With the primary cover off, you can replace the cable if necessary or simply hook it back up.

Reassemble in reverse order. To adjust the primary chain, turn the adjuster bolt upwards until you have 1/2" to 5/8" up and down slack in the top run of the primary chain. To adjust the clutch, turn the screw counterclockwise until it stops. Then, go back clockwise 1/4 turn and install the locknut, spring and the derby cover. Then adjust the cable adjuster out until you have 1/8" freeplay in the cable.

Good Luck

Oct 01, 2010 | 2001 Harley Davidson XL 1200 C Sportster...

1 Answer

Is it hard to change the primary gasket on my sportster

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

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