Sportster Models 883, 883 Custom, 1200 Custom, 883L, 1200L, 1200S, 1200 Roadster, XR1200, and the Nightster.
Sponsored by:
Sponsored by:

primary cover removal

Thread Tools
 
Search this Thread
 
Old Nov 17, 2005 | 05:14 AM
  #1  
angryfish's Avatar
angryfish
Thread Starter
|
3rd Gear
Joined: Sep 2005
Posts: 7
Likes: 0
From: Tampa, Fl
Default primary cover removal

the primary cover on my 98 sportster leaks a lot of oil. it started out as a couple of drops and then eventually turned into a steady leak. i picked up a gasket for it today cause i figured it would be a straight forward job to get it off and replace. i've taken all the bolts out that go around the edge, the bolts that hold the derby cover on and the bolts for the inspection cover. it still wont budge. what am i missing? is it necessary to undo the clutch cable? if so, whats the easiest/best way to do that? i'd appreciate any help you guys can offer on this.
 
Reply
Old Nov 17, 2005 | 08:31 AM
  #2  
Scout's Avatar
Scout
Seasoned HDF Member
20 Year Member
Liked
Loved
Community Favorite
Joined: Sep 2004
Posts: 6,197
Likes: 708
From: (Toronto) Canada
Default RE: primary cover removal

I've never worked on a Sporty, but on the Knuck and TC it was always tight and needed a good knock to get it loose. I hope a sporty guy answers soon.

 
Reply
Old Nov 17, 2005 | 11:50 AM
  #3  
schultz's Avatar
schultz
Tourer
Joined: Sep 2005
Posts: 299
Likes: 0
From:
Default RE: primary cover removal

Thats what I would do give it a few knocks with a rubber mallot if you got one sounds like it is just stuck.
 
Reply
Old Nov 17, 2005 | 12:32 PM
  #4  
brohrs's Avatar
brohrs
Road Captain
Joined: Aug 2005
Posts: 557
Likes: 0
From:
Default RE: primary cover removal

Just needs a little loving BANG!
 
Reply
Old Nov 17, 2005 | 02:31 PM
  #5  
angryfish's Avatar
angryfish
Thread Starter
|
3rd Gear
Joined: Sep 2005
Posts: 7
Likes: 0
From: Tampa, Fl
Default RE: primary cover removal

i've tried hitting it with the rubber mallet and it still hasnt budged a bit. any other suggestions or should i just keep beating it till it comes loose?
 
Reply
Old Nov 17, 2005 | 03:30 PM
  #6  
Thumper26's Avatar
Thumper26
Outstanding HDF Member
Joined: May 2005
Posts: 3,146
Likes: 50
From: A barrier island in NJ
Default RE: primary cover removal

angryfish,

My suggestion is to continue "tapping" with the rubber mallet on the cover next to the seam as you go around the case. Be patient and just keep tapping - nothing hard! The last guy to put it on may have used a gasket cement that's being a little stubborn and you don't want to crack that case cover. You might want to spray the joint with Liquid Wrench, WD-40, or some other penetrating oil before tapping it again - I'm not positive it would help, but it couldn't hurt. Above all, be patient!

Thumper26
 
Reply
Old Nov 18, 2005 | 02:47 PM
  #7  
Shovelhead77's Avatar
Shovelhead77
Cruiser
Joined: Nov 2005
Posts: 179
Likes: 0
From:
Default RE: primary cover removal

I had the same problem with my 77shovelhead and it took a while but it finnaly came loose, just be patient and it will loosen..
 
Reply
Old Nov 19, 2005 | 02:23 AM
  #8  
Wolhar's Avatar
Wolhar
Banned
Joined: Jul 2005
Posts: 14,082
Likes: 8
Default RE: primary cover removal

You need to take the cable loose from the clutch pack. That is not holding the cover on, but it needs to be "out of the way" when you get the cover loose. Contact pococj thru a PM. I guarantee he can solve your problem
 
Reply
HD Forum Stories

The Best of Harley-Davidson for Lifelong Riders

story-0

7 Times Harley-Davidson Chucked Tradition Out the Window

 Verdad Gallardo
story-1

7 Surprising Harley-Davidson Products that Are Not Motorcycles

 Verdad Gallardo
story-2

8 Best Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-3

10 Worst Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-4

Killer Custom's Jail Break Is The Breakout That Refused to Blend In

 Verdad Gallardo
story-5

Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

 Verdad Gallardo
story-6

Harley-Davidson Reveals Super Cool Cafe Racer Concept

 Verdad Gallardo
story-7

Engraved Rebellion: Inside Bundnerbike's Glam Rock II

 Verdad Gallardo
story-8

10 Motorcycles You Should Never Buy

 Joe Kucinski
story-9

10 Things Harley-Davidson Needs to Fix in 2026

 Verdad Gallardo
Old Nov 19, 2005 | 02:38 AM
  #9  
molsenice's Avatar
molsenice
Seasoned HDF Member
15 Year Member
Joined: Sep 2005
Posts: 8,882
Likes: 2
From: Glens Falls, NY
Default RE: primary cover removal

my .02 - treat it like a woman you love

- talk to it, tap it, talk more, give it a beer, talk more, look at it

somthing is holdin it, drink beer, talk to it, tap it and when you get sick of it, get help.

Be patient - Like my '67 Keikhaufer merc boat moter - just when you are about to LYFM - someone will give you a bit of advice that helps and you will pea youself with happyness - (my boat moter means alot to me - had it since I was 9 and POP just gave it to me this year) - I JUST TURNED 40 IN JUNE I love that motor - lots of childhood memories tied up with it - good luck keep us updated
 
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
AGAF
Dyna Glide Models
18
Oct 24, 2016 09:10 AM
Death.Proof
Touring Models
22
Feb 19, 2014 12:30 PM
slipvayne9278
Sportster Models
7
Aug 19, 2011 04:21 PM
HDKiz
Primary/Transmission/Driveline/Clutch
3
Oct 10, 2006 01:42 PM
rpoteau
Primary/Transmission/Driveline/Clutch
9
Sep 1, 2005 02:17 PM




All times are GMT -5. The time now is 06:22 AM.

story-0
7 Times Harley-Davidson Chucked Tradition Out the Window

Slideshow: Harley-Davidson built its reputation on nostalgia, but every so often, the company took a hard left turn into the future.

By Verdad Gallardo | 2026-05-20 11:18:19


VIEW MORE
story-1
7 Surprising Harley-Davidson Products that Are Not Motorcycles

Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.

By Verdad Gallardo | 2026-04-29 16:50:35


VIEW MORE
story-2
8 Best Harley-Davidson Motorcycles Ever

Slideshow: Not every Harley gets it right, but these are the ones that genuinely earned their reputation.

By Pouria Savadkouei | 2026-04-15 14:23:21


VIEW MORE
story-3
10 Worst Harley-Davidson Motorcycles Ever

Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.

By Pouria Savadkouei | 2026-04-01 20:01:09


VIEW MORE
story-4
Killer Custom's Jail Break Is The Breakout That Refused to Blend In

Slideshow: Killer Custom's "Jail Breaker" build focuses more on stance and visual aggression than mechanical overhaul.

By Verdad Gallardo | 2026-03-18 19:20:32


VIEW MORE
story-5
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.

By Verdad Gallardo | 2026-03-07 16:15:30


VIEW MORE
story-6
Harley-Davidson Reveals Super Cool Cafe Racer Concept

Slideshow: Harley-Davidson's new RMCR concept revives the café racer formula with modern hardware-and it may be exactly the reset the company needs.

By Verdad Gallardo | 2026-03-04 12:23:37


VIEW MORE
story-7
Engraved Rebellion: Inside Bundnerbike's Glam Rock II

Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.

By Verdad Gallardo | 2026-02-24 18:19:44


VIEW MORE
story-8
10 Motorcycles You Should Never Buy

Slideshow: There is no shortage of great motorcycles to buy, but we would avoid these ten.

By Joe Kucinski | 2026-02-19 14:50:51


VIEW MORE
story-9
10 Things Harley-Davidson Needs to Fix in 2026

Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.

By Verdad Gallardo | 2026-01-13 18:33:17


VIEW MORE