On the 5 and 6 speeds I have done. Once the cutch and comp is out, it is quick to remove inner primary. Not sure worth grinding.

2009, I would probably replace tranny shifter shaft seal, primary bearing too. If they havn't been replaced.

But either way, its not that hard to pull inner primary. Atleast on my 01 and 07, once clutch and comp is out.

Myself, I like to do as much as I can when something is apart.

 

Do a search here on this forum, it has been done and people have posted the process with before/after pics.....

Personally, I don't believe it's that hard to remove the inner primary, just a couple more bolts, gaskets, and make sure you don't nick the trans main shaft seal on the inner primary....

 

If I was inclined, I would grind the inner primary off the bike, and test fit. rather than grind a bike and worry about shavings.

 

no, i cut a piece of 2x4

 

I have. I used a dremel from about the 6 o'clock to 10 o'clock position. Doesn't take much grinding. Leaves a lot of dust left behind. I sprayed down everything with PJ-1 to get it clean. That said, I found it just as easy to remove the inner primary. It's not hard at all

 

I ground down the lip on my primary case when I replaced my stator a few months ago. I used a die grinder and took my time. It turned out fine.

 

Thanks for the info!
Does grinding down that lip effect the thickness of the area of the case that the gasket sits on?

 

Thanks for the info! Yes, the shavings was a concern I had. I was going to cover everything with rags first. My other concern was the grinding would effect the gasket seal??? Does this thin out he contact area??
For 2009 heritage , I would have to un bolt the starter from the inner primary, and to do that the oil tank would have to come out to get at the bolts. I didn't want to get into all of that, if grinding down that lip would do the trick.

 

a simple Dremel grinds that down, I was surprised how quickly it went. take time

no issue pulling inner primary but then per manual you have to replace the screws, gaskets etc. $$$. I have had mine off, but only if I needed to be in there.

 

I have an '09 Fatboy and used a dremel to ever so carefully shave the part of the inner primary where it was catching. It did the trick. Ensure you give it a good clean before reassembly because it will leave shavings behind.