1990 sportster 883 crank case cover help!
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2nd Gear
Joined: Oct 2017
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From: Atlantic city, nj
1990 sportster 883 crank case cover help!
Im new to thos forum. So i replaced the ignition sensor. Some guys said you dont have to remove the cover but some said you do. I chose to remove the cover. Why wont my crank case cover go back in? I did have to use some persuasion when i removed the cover so i figured tapping it back in would work but no luck. Please help, im really new to harleys as far as mechanical.
HDF Community Team
Joined: Dec 2011
Posts: 8,512
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From: San Diego, CA
Do you mean the camcase cover? That's where the ignition sensor is located. If you took off that cover, you may have pulled a cam gear out and it's hung up on another geartooth trying to go back in. You must make sure you have the cams positioned correctly before you put that cover on. If the cams moved out of alignment, you could do serious engine damage if you try to start it with camshafts misaligned. Each cam must be in the correct position or big trouble.
I think you could have changed the sensor without removing the camcase cover, but you would need to remove the sprocket cover to be able to fish the wire to the sensor area. I have a 1991 which has the same ignition system.
John
I think you could have changed the sensor without removing the camcase cover, but you would need to remove the sprocket cover to be able to fish the wire to the sensor area. I have a 1991 which has the same ignition system.
John
Last edited by John Harper; Oct 1, 2017 at 07:27 AM.
Road Captain
Joined: Mar 2009
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Im new to thos forum. So i replaced the ignition sensor. Some guys said you dont have to remove the cover but some said you do. I chose to remove the cover. Why wont my crank case cover go back in? I did have to use some persuasion when i removed the cover so i figured tapping it back in would work but no luck. Please help, im really new to harleys as far as mechanical.
But you should never remove the cover without removing the rocker boxes first. So long as the rocker boxes are on, you have downward pressure on the cams from the valve springs, and without the cover in place, the cams are only supported on one side.
I've literally seen someone crack their right case half doing it the way you're doing it. He pulled the cover with the rocker boxes in place, and then tried to rotate his motor.
If I were you, I'd take the rocker boxes off right away, then put the cam box back together (be sure to align the cams properly per their marks if any came out), and then put the rocker boxes back on.
The motor needs to be positioned properly before each rocker box is reinstalled.
You really should have a service manual handy, preferably the factory service manual.
Tourer
Joined: Jun 2011
Posts: 486
Likes: 35
From: St. Louis Mo.
Im new to thos forum. So i replaced the ignition sensor. Some guys said you dont have to remove the cover but some said you do. I chose to remove the cover. Why wont my crank case cover go back in? I did have to use some persuasion when i removed the cover so i figured tapping it back in would work but no luck. Please help, im really new to harleys as far as mechanical.
PS: If you replace the cam cover gasket make sure the new one is exactly the same as the old one, in other words don't trust the numbers, otherwise you will have a bunch more problems, ask me how I know
Thread Starter
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2nd Gear
Joined: Oct 2017
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From: Atlantic city, nj
Can i just remove spark plugs to release pressure? And the bike hasnt moved since the cam cover was removed. I guess when pulling the cover one of the gears got pulled out causing a miss aligbment witb another gear?
HDF Community Team
Joined: Dec 2011
Posts: 8,512
Likes: 3,924
From: San Diego, CA
It the valves/rockers/pushrods/lifters that's putting pressure on your camshafts. It has nothing to do with engine compression so pulling the spark plugs accomplishes nothing. The cams themselves may have moved and the teeth are not properly aligned with adjacent cam gears. Very critical to get this right.
John
John
Last edited by John Harper; Oct 3, 2017 at 12:16 PM.
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Road Warrior
Joined: Mar 2016
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From: SC
Looks like a mess just beginning to happen.
Before you do another thing, get the factory service manual and be sure of what you are doing.
You don't want to half-*** this any more than you have already.
No judgement from me brother, just concern for your scoot.
Take your time, listen to the advice; get a manual, remove the rocker boxes, check cam gear alignment, install new (and proper) gaskets, etc...
Read the FSM and get this thing back together correctly. Taking an extra week or two to get a manual, the proper tools and the proper information will be worth it in the long run.
Before you do another thing, get the factory service manual and be sure of what you are doing.
You don't want to half-*** this any more than you have already.
No judgement from me brother, just concern for your scoot.
Take your time, listen to the advice; get a manual, remove the rocker boxes, check cam gear alignment, install new (and proper) gaskets, etc...
Read the FSM and get this thing back together correctly. Taking an extra week or two to get a manual, the proper tools and the proper information will be worth it in the long run.
Thread Starter
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2nd Gear
Joined: Oct 2017
Posts: 6
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From: Atlantic city, nj
Thanks guys. I completely understand. I may just put it in the truck and have a guy do it. Just found out there is a local mechanic (not a dealer) who works on harleys. I just want this to be ridable before the season is over��.