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Does the primary cover have to be removed to remove the starteron a 2001 110inch rev tech?

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Yes, It's built just like a Harley. You must remove the small bolt that holds the jackshaft to the starter. If you take the jackshaft out, make sure you notice and mark the direction the coupling comes out. It will only go one way.

Good Luck
Steve

Posted on May 21, 2011

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2005 ultraclassic primary cover removal


Hi Anonymous, for more information on your question please visit the websites below and good luck:
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Sep 02, 2012 | 2005 Harley Davidson FLHTCUI Electra Glide...

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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.

Good Luck
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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.

Good Luck
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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.

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

1 Answer

There is a loud metallic 'thunk' coming from the motor when i rev the engine. Not when I give it gas to go, but when I rev it at a stop light or something. 2002 Fuel Injected HD Heritage Springer. Very...


When is the last time you checked the tension on your primary chain? Remove the oval inspection cover and reach in with your finger and lift the top run of the chain up and down. It should have between 3/4" and 7/8" with the engine cold.

About the only other thing that I can think of is the compensator sprocket on the engine's output shaft. The springs my be weak or the nut might have backed off.

I'd just pull the primary cover off and check it all at the same time.

Good Luck
Steve

Oct 15, 2010 | 2002 Harley Davidson FLHR - FLHRCI Road...

1 Answer

How do i remove primary cover on a 89 sportster


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
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Oct 12, 2010 | Harley Davidson XLH Sportster 883...

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

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
Steve

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
Steve

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

1 Answer

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First secure the bike on a lift. disconnect battery.remove standard footpeg.Remove standard shifter. Remove all allen head bolts from outer primary cover. Some bolts are longer so keep track of where they go.Two bolts on the primary inspection cover also hold the outer to the inner primary case, so remove the cover.Now remove the outer primary case.The clutch,primary chain,adjuster, and compensating sprocket must be reoved as a single unit.Once you have done this take a rag and grasp the rotor and slide it off of the main engine shaft.Unplug the stator and remove the set screws holding it in place.Reverse procedure to install new stator.

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