Removal of Primary Cover ???
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Road Warrior
Joined: Oct 2006
Posts: 1,497
Likes: 35
Removal of Primary Cover ???
Ok, can you guys help me out please? I want to swap out a new clutch cable on a 1993 883 that I am rehabing for a friend. How the heck do you get the outer primary cover off? I took both inspection covers off, the shifter arm, all the allen bolts and the drain plug. The damn thing will rock abit but will not come completely off. The only other bolt even near the thing is a large bolt on the bottom that has the nut showing. Cannot imagine that needs to come off. Looks like the cover goes around it anyhow. So, please give me some insight to all your wisdom! Thanks Bryan
Road Master
Joined: Dec 2007
Posts: 1,125
Likes: 22
From: Phoenix, AZ
RE: Removal of Primary Cover ???
The only other bolt even near the thing is a large bolt on the bottom that has the nut showing. Cannot imagine that needs to come off. Looks like the cover goes around it anyhow.
That big a$$ nut needs to be backed off. It is the locknut for the primary chain adjusting shoe. Even with it backed off there may be grooves in the shoe that grab the chain. Try wiggling the chain in the hole. The cover may need some TAPS (not blows) with a rubber hammer. There are two alignment tabs, oneat either end of the cover.
Be carefulunscrewing the clutch cable. It can break. You will want to back everything off the adjusting threads. (This is not in the manual) Barnett cables have designed their cables arround this.
The manual will help with adjusting the new cable, unless somebody else wants to type that procedure.
This cable broke with 100,000 miles on it.
[IMG]local://upfiles/48626/7EE27106EB0B4919AC635B3BFC6869C3.jpg[/IMG]
Outstanding HDF Member
Joined: May 2007
Posts: 2,154
Likes: 5
From: Phoenix, AZ
RE: Removal of Primary Cover ???
Adjusting the cable.....
1. Make sure the slack adjuster on the CABLE is completely loose (no tension).
2.Screw inthe retainer nut after assembling everything with the new cable installed,
Turn the screw it until it is SNUG!!! Back it off 1/2 turn and install the spring andderby cover.
YES, it will be loose, but that's how it's supposed to be.
3.Adjust the slack in the cable until you have a 1/8"gap where the ferrule goes into the lever
bracket. A good way to check is to use a 1/8" allen wrench if you have one...pump the clutch
lever while holding the cable with your other hand...after about 3 or 4, release the lever QUICKLY
(snap it) and pull the cable. Check the gap. If it's 1/8", you're good.
4.Remove the inspection cover on the primary and adjust your chain slack using an allen and
Ibelieve a 7/8" wrench on the nut. You want about 1/2 an inch or so of play in it, too tight or
too loose andit'll be a pain in the *** or impossible toshift.
And you'll live happily ever after....THE END.
P.S. Harleys and Hammers DON'T MIX...you should never need a hammer for anything on your bike. EVER.
1. Make sure the slack adjuster on the CABLE is completely loose (no tension).
2.Screw inthe retainer nut after assembling everything with the new cable installed,
Turn the screw it until it is SNUG!!! Back it off 1/2 turn and install the spring andderby cover.
YES, it will be loose, but that's how it's supposed to be.
3.Adjust the slack in the cable until you have a 1/8"gap where the ferrule goes into the lever
bracket. A good way to check is to use a 1/8" allen wrench if you have one...pump the clutch
lever while holding the cable with your other hand...after about 3 or 4, release the lever QUICKLY
(snap it) and pull the cable. Check the gap. If it's 1/8", you're good.
4.Remove the inspection cover on the primary and adjust your chain slack using an allen and
Ibelieve a 7/8" wrench on the nut. You want about 1/2 an inch or so of play in it, too tight or
too loose andit'll be a pain in the *** or impossible toshift.
And you'll live happily ever after....THE END.
P.S. Harleys and Hammers DON'T MIX...you should never need a hammer for anything on your bike. EVER.
Road Captain
Joined: Jul 2006
Posts: 656
Likes: 2
From:
RE: Removal of Primary Cover ???
I don't know why your trying to take off the whole cover if your just changing a cable. But anyhow if you want to remove the entire primary cover you need to take off the clutch ramp assembly, the primary cover has a little lip that reaches behind it........hard to notice from the outside, but completely obvious once you see that's what hangin up. So take the clutch ramp peice off and the cover will come right off. The clutch ramp has to come off anyways to hook the new cable.
Road Captain
Joined: Jul 2006
Posts: 656
Likes: 2
From:
RE: Removal of Primary Cover ???
And yeah, you'll want to loosen the big adjuster screw on the bottom with the big nut on it, that's your primary chain tensioner, and make sure you adjust it properly when you put it back on. Also simply put, if you just want to put on the new cable only, all you had to do is take the inspection cover off, take the clutch ramp assembly off, hook new cable, and put back together and adjust cable and clutch then put cover back on and your done, no need to take the entire primary cover off. But if you do pull the entire cover, it'll be a good idea to take some measurements on the primary chain, make sure it's still within spec, and not stretched, also take a look at the chain adjuster shoe, and if it has deep grooves warn into it, you'll want to replace that, it's only a few bucks for a new adjuster shoe.
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