Inner primary cover removal
Thread Starter
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Elite HDF Member
Joined: Jul 2008
Posts: 4,762
Likes: 12
From: north jersey
Here is what you do. Take the 4 mounting bolts for the oil tank out. Two are in the rear of the oil tank, two in the battery box. Get a long wobbly extension and long ball end allen wrench socket. Once the bolts are out of the oil tank wiggle it a little so you can gain access to the rear mounting bolt for the starter. That is the one that is difficult to get to.
Once you get the allen in the head of the bolts loosen the bolt. DO NOT TAKE THE REAR STARTER MOUNTING BOLT OUT OF THE HOLE THAT IT IS IN OR IT WILL BE A LOT OF WORK TO GET IT BACK IN THE HOLE. The front bolt is accesible with the oil tank in place. Someone posted pics of how to do it in a primary thread a while back. I can't remember who. I'll see if I can find the thread for you. No need to let the dealer do this.
As far as the compensator is concerned, I usually use a piece of wood to lock the primary sprockets and a 36" ratchet. BFW. I step on the ratchet and it comes loose. Don't forget the threads are reversed from how they would normally be on the compensator bolt. If your weight is not enough, drink a few more beers until it is.
Once you get the allen in the head of the bolts loosen the bolt. DO NOT TAKE THE REAR STARTER MOUNTING BOLT OUT OF THE HOLE THAT IT IS IN OR IT WILL BE A LOT OF WORK TO GET IT BACK IN THE HOLE. The front bolt is accesible with the oil tank in place. Someone posted pics of how to do it in a primary thread a while back. I can't remember who. I'll see if I can find the thread for you. No need to let the dealer do this.
As far as the compensator is concerned, I usually use a piece of wood to lock the primary sprockets and a 36" ratchet. BFW. I step on the ratchet and it comes loose. Don't forget the threads are reversed from how they would normally be on the compensator bolt. If your weight is not enough, drink a few more beers until it is.
Thanks for the replys guys, I really appreciate it. HOGPRO, if you could find that thread it would be sweet. I'm so much better when I have pictures to look at.
Thread Starter
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Elite HDF Member
Joined: Jul 2008
Posts: 4,762
Likes: 12
From: north jersey
UPDATE UPDATE
Ok guys, i have good news and not so good. I WAS ABLE TO GET TO THE TWO STARTER BOLTS without removing the oil tank. All it takes is a long extension on a 1/4 inch ratchet. The size of the bolts is 1/4 allen heads.
just reach right underneath the oil tank and you can reach both without having to take the oil tank off.
the not so good news is that I'm still baffled as to how to get the compensator nut off without air tools. I'm trying to do it without having to buy an air compressor and an impact gun. Someone recommended an electric impact gun but i don't know that it'll be strong enough.
By the way, here are some pics of the chop job i did on my fender. I cut the fender right at the axel, gonna mount the rear lights low on the fender (right by the swing arm).
Sorry about the crappy pics guys, i used my iphone and there isn't much room in my garage to get a wide shot.
My buddy was so impressed with how simple it was to take the fender off and cut it that he decided to do the same thing to his rocker's fender. lol
Ok guys, i have good news and not so good. I WAS ABLE TO GET TO THE TWO STARTER BOLTS without removing the oil tank. All it takes is a long extension on a 1/4 inch ratchet. The size of the bolts is 1/4 allen heads.
just reach right underneath the oil tank and you can reach both without having to take the oil tank off.
the not so good news is that I'm still baffled as to how to get the compensator nut off without air tools. I'm trying to do it without having to buy an air compressor and an impact gun. Someone recommended an electric impact gun but i don't know that it'll be strong enough.
By the way, here are some pics of the chop job i did on my fender. I cut the fender right at the axel, gonna mount the rear lights low on the fender (right by the swing arm).
Sorry about the crappy pics guys, i used my iphone and there isn't much room in my garage to get a wide shot.
My buddy was so impressed with how simple it was to take the fender off and cut it that he decided to do the same thing to his rocker's fender. lol
Last edited by Alain; May 22, 2012 at 07:27 AM.
Outstanding HDF Member
Joined: Aug 2009
Posts: 2,729
Likes: 7
From: Republic of Texas
I have on an occasion or two used the weight of the bike to break bolts loose. Like the shock bolts. On the compensator nut I would use as long as possible 1/2" breaker bar. Jack the bike up, place the socket and breaker bar on the nut about half way between the 4 and 5 o'clock position so that the end of the bar is against the floor. Might even have to use a cheater pipe if the breaker bar is not long enough. Slowly lower the bike to the ground. It always worked for me until I invested in a large compressor and air tools.
Thread Starter
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Elite HDF Member
Joined: Jul 2008
Posts: 4,762
Likes: 12
From: north jersey
I have on an occasion or two used the weight of the bike to break bolts loose. Like the shock bolts. On the compensator nut I would use as long as possible 1/2" breaker bar. Jack the bike up, place the socket and breaker bar on the nut about half way between the 4 and 5 o'clock position so that the end of the bar is against the floor. Might even have to use a cheater pipe if the breaker bar is not long enough. Slowly lower the bike to the ground. It always worked for me until I invested in a large compressor and air tools.
If i can get an air compressor and an impact gun for under $200 i'll do the job myself. If i can't find those two items for under $200 then i'll take the bike to him and have him do it for me.
i'm stuck on this phase of the job. the inner primary is the only part i have to take off before i can send everything for powder coat.
Road Captain
Joined: Apr 2010
Posts: 520
Likes: 3
From: East Coast
Compressor
someone gave me a quote to do the job of taking the inner primary off. He wants $200 bucks to take it off and put it back on after I powder coat the primary covers.
If i can get an air compressor and an impact gun for under $200 i'll do the job myself. If i can't find those two items for under $200 then i'll take the bike to him and have him do it for me.
i'm stuck on this phase of the job. the inner primary is the only part i have to take off before i can send everything for powder coat.
If i can get an air compressor and an impact gun for under $200 i'll do the job myself. If i can't find those two items for under $200 then i'll take the bike to him and have him do it for me.
i'm stuck on this phase of the job. the inner primary is the only part i have to take off before i can send everything for powder coat.
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Thread Starter
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Elite HDF Member
Joined: Jul 2008
Posts: 4,762
Likes: 12
From: north jersey
*********UPDATE, UPDATE, UPDATE, UPDATE *************
You don't need air tools for the compensator nut boys !!!! I got it loos with a breaker bar and an impact socket !!!!!!!!!!!
Just got it loose a few minutes ago !!!!!! Wasn't able to get the entire primary assembly off cause it's getting dark here in jersey and i don't have a light in my garage. I'll finish the job tomorrow, i'll post then.
So glad I was able to get the ****er off myself without having to buy air tools!!!
You don't need air tools for the compensator nut boys !!!! I got it loos with a breaker bar and an impact socket !!!!!!!!!!!
Just got it loose a few minutes ago !!!!!! Wasn't able to get the entire primary assembly off cause it's getting dark here in jersey and i don't have a light in my garage. I'll finish the job tomorrow, i'll post then.
So glad I was able to get the ****er off myself without having to buy air tools!!!
