Motorcycle

Motorcycle questions? Ask a mechanic.

Ask an Expert,
Get an Answer ASAP!

Cant get the primary cover back on 883 sporster 1993

Customer Question
cant get the primary cover back on 883 sporster 1993
Submitted: 2 years ago.Category: Motorcycle
Ask Your Own Motorcycle Question
Answered in 4 hours by:
2/27/2016
Motorcycle Mechanic: Steve, Motorcycle Mechanic replied 2 years ago
Steve
Steve, Motorcycle Mechanic
Category: Motorcycle
Satisfied Customers: 7,278
Experience: 30+ yrs. experience, MMI, HD technician, HD early, engine rebuild/performance, bike builder, kit bike program manager, CCI 2001-2004
Verified

tell me what you have done so far so that I can figure out what you missed or where you need help.

tell me everything you can.

Steve

Ask Your Own Motorcycle Question
Customer reply replied 2 years ago
i need to talk to You ,do you work in the daytime?
Customer reply replied 2 years ago
this being sunday u may not be on right now ,ok.
Motorcycle Mechanic: Steve, Motorcycle Mechanic replied 2 years ago

sorry, I don't do phone calls.

if you answer my post, above, we can continue.

Steve

Ask Your Own Motorcycle Question
Customer reply replied 2 years ago
I do u not use the phone?
Motorcycle Mechanic: Steve, Motorcycle Mechanic replied 2 years ago

my choice.

do you wish to continue?

Ask Your Own Motorcycle Question
Customer reply replied 2 years ago
ok , i have a harley factory shop manuel and have a shop. I have this harley for sale. The starter was not working right so I took it off to test it didnt want to sell it with a bad starter. tested the starter and it was the starter relay now i have the starter back on but the primary cover likes about 1/2 inch bolting up. broke the piece with 3 ball bearings and have another ordered.what else can i tell you?
Customer reply replied 2 years ago
have the clutch loosened like the manuel says
Customer reply replied 2 years ago
thank u steve ,I appreciate You help.
Motorcycle Mechanic: Steve, Motorcycle Mechanic replied 2 years ago

- once you slack the primary chain adjuster, you may need to help the chain up on top of the adjuster shoe. if you don't, the cover may not fit up flush.

- you also need to ensure the shift shaft is aligned with the bushing and seal.

these are the most common hang ups.

let me know if you need more help.

Steve

Ask Your Own Motorcycle Question
Customer reply replied 2 years ago
I can get the chain up and and the shift shaft in in the hole, help
Customer reply replied 2 years ago
i wish to contune
Customer reply replied 2 years ago
I can reach under thecover and push the chain up and push the cover almost closed likes about 1/2 inch .
Customer reply replied 2 years ago
i get the cover almost on but cant pull the clutch lever in .
Motorcycle Mechanic: Steve, Motorcycle Mechanic replied 2 years ago

- check to see if the cover is hanging up on the alignment dowels.

- ensure the clutch cable is not in the way.

Steve

Ask Your Own Motorcycle Question
Customer reply replied 2 years ago
did thatit doesnt get far enough to tuch the aligment dowels,cabel is not in the way
Motorcycle Mechanic: Steve, Motorcycle Mechanic replied 2 years ago

sorry.

I am out of suggestions.

best of luck.

Steve

Ask Your Own Motorcycle Question
Customer reply replied 2 years ago
i need a harley mechanic that knows sporster 883,s
Motorcycle Mechanic: RSRBOB, Technician replied 2 years ago
RSRBOB
RSRBOB, Technician
Category: Motorcycle
Satisfied Customers: 1,078
Experience: Former Factory Service Rep, Dlr Line Tech, Service Manager, General Manager, Store Owner
Verified

Hi and thank you for your question.

I suspect the problem you are experiencing is because of the clutch release mechanism.

First, when you are trying to install the primary cover and it stops about 1/2" away from the cases, do you have any free play in the clutch lever? If not, you will want to collapse the cable adjuster all the way. That entails breaking the lock nut loose at the cable adjuster and screwing the externally threaded portion of the adjuster in as far as it will go into the internally threaded adjuster.

Here is a parts diagram of the cable and lever. If you will look just below the reference #8 you will see the adjuster I am talking about. You want to make it as short as possible which will give you maximum slack in the clutch cable. Just to make sure I am being clear on what I want you to do, after you screw it in, you should not be able to see any threads on the adjuster any more. Just trying to ensure you screw it in as if you were tightening a bolt as opposed to backing it off.

http://partsfinder.onlinemicrofiche.com/ronnies/showmodel.asp?Type=13&make=hdmc&a=79&b=16&c=0&d=1993%20SPORTSTER%AE%20XLH%20120%20%28CA%29%20CLUTCH%20ASSEMBLY

Once you have the adjuster bottomed out as described above, try installing your side cover again and see if it will now go.

Once you get the side cover on, you will want to back that adjuster out so you have about 1/8" free play at the lever perch between the perch and the cable ferrule.

If you have any more questions, feel free to ask.

Thanks,

RSRBOB

Ask Your Own Motorcycle Question
Customer reply replied 2 years ago
i cannot see any threads have the clutch cabel backed all the way off , broke the ramp inner and have another one coming cover goes to about 1/2 inch to side wont go farther.
Customer reply replied 2 years ago
went right by the harley factory shop manuel
Customer reply replied 2 years ago
I dont think U know what is going on here ,have you ever had the primary off a 883 sporster?
Motorcycle Mechanic: RSRBOB, Technician replied 2 years ago

Many.

Did you see the link of the parts fiche I sent you? The adjuster is in the middle of the cable. Backing it off is going the wrong direction. You want to turn the adjuster IN so you cannot see any of the threads on the adjuster any more.

RSRBOB

Ask Your Own Motorcycle Question
Was this answer helpful?

How JustAnswer works

step-image
Describe your issueThe assistant will guide you
step-image
Chat 1:1 with a motorcycle mechanicLicensed Experts are available 24/7
step-image
100% satisfaction guaranteeGet all the answers you need
Ask RSRBOB Your Own Question
RSRBOB
RSRBOB
RSRBOB, Technician
Category: Motorcycle
Satisfied Customers: 1,078
1,078 Satisfied Customers
Experience: Former Factory Service Rep, Dlr Line Tech, Service Manager, General Manager, Store Owner

RSRBOB is online now

A new question is answered every 9 seconds

How JustAnswer works:

  • Ask an ExpertExperts are full of valuable knowledge and are ready to help with any question. Credentials confirmed by a Fortune 500 verification firm.
  • Get a Professional AnswerVia email, text message, or notification as you wait on our site. Ask follow up questions if you need to.
  • 100% Satisfaction GuaranteeRate the answer you receive.

JustAnswer in the News:

Ask-a-doc Web sites: If you've got a quick question, you can try to get an answer from sites that say they have various specialists on hand to give quick answers... Justanswer.com.
JustAnswer.com...has seen a spike since October in legal questions from readers about layoffs, unemployment and severance.
Web sites like justanswer.com/legal
...leave nothing to chance.
Traffic on JustAnswer rose 14 percent...and had nearly 400,000 page views in 30 days...inquiries related to stress, high blood pressure, drinking and heart pain jumped 33 percent.
Tory Johnson, GMA Workplace Contributor, discusses work-from-home jobs, such as JustAnswer in which verified Experts answer people’s questions.
I will tell you that...the things you have to go through to be an Expert are quite rigorous.

What Customers are Saying:

I would (and have) recommend your site to others I was quite satisfied with the quality of the information received, the professional with whom I interacted, and the quick response time. Thanks, and be sure that I'll be back whenever I need a question answered in a hurry.

Stephanie PElm City, NC

used your service this weekend with "Trecers" help. thank you ,thank you, thank you. replaced an A/C fan motor. Local Auto Zone had part. $15.00 "tracer" fee and $40.00 for parts, I saved several hundreds of dollers at a shop. i will recommend you and use you in the future.

David L.Richmond, TX

9 dollars, 2 hours of my time, and I drove away. Your diagnosis was right on the mark. Thank you so much.

PhilMarysville, CA

Lurch. Thank you very much. I had real doubts about this website but your promptness of response, quick followup and to the point answer with picture was incredible.

CharlesWalnut Creek, CA

As a single woman, I really appreciate an excellent and affordable opinion.
Thank you Geordie, I will not hesitate to contact justanswer in the future!

SueCharleston, WV

Another great insight to what may be the problem. I will have my mechanic take a look at it tomorrow. Thanks again, Frank...you do indeed know your stuff.

JimCastleberry, FL

Wonderful service, prompt, efficient, and accurate. Couldn't have asked for more. I cannot thank you enough for your help.

Mary C.Freshfield, Liverpool, UK

< Previous | Next >

Meet the Experts:

Jeff Policky

Jeff Policky

Motorcycle Mechanic

2,425 satisfied customers

Yamaha Gold, Suzuki Gold, Honda Bronze, Polaris Bronze, BRP

Louie

Louie

Technician

1,451 satisfied customers

25+ yrs. experience

TIMOTO

TIMOTO

Motorcycle Mechanic

1,246 satisfied customers

Honda registered technician, silver level award, former Kawasaki/Suzuki tech, 40+ years exp.

Andre Pilon

Andre Pilon

Motorcycle Mechanic

1,032 satisfied customers

Over 25 years experience, ICS, MMI, Owned shop for 12 years, worked tech-support for Harley Davidson

Kenny O.

Kenny O.

Motorcycle, ATV, Mules, Side by Side's Product Specialist. All Brands

619 satisfied customers

Worked for Kawasaki Motors as a Product Support Specialist (Factory Support) for 24 years

asphaltcycles

asphaltcycles

Motorcycle Mechanic

468 satisfied customers

I operate a motorcycle dealership and CCS Ducati Race team.

Glenn Adams II

Glenn Adams II

Motorcycle/ATV Technician

393 satisfied customers

6 years Motorcycle/ATV/Water Craft; 4 years auto; 18 years carpenter

< Previous | Next >

Related Motorcycle Questions
I have a 1988 Harley 883 Sportster with a primary cover that
I have a 1988 Harley 883 Sportster with a primary cover that requires a primary plug wrench. I have not been able to find a “cross” plug wrench and the straight bar plug wrench I have is tearing up th… read more
Steve
Steve
Motorcycle Mechanic
7,278 satisfied customers
Have an issue have an issue with my 1986 harley sporster 883.
Have an issue have an issue with my 1986 harley sporster 883. It constantly drains the battery. I have changed the stator and the regulator as well as the battery. Problem still exists....im supposed … read more
Steve
Steve
Motorcycle Mechanic
7,278 satisfied customers
hi, how do you de activate alarm of a 2008 sporster 883 will
hi, how do you de activate alarm of a 2008 sporster 883 will you want to transport it on a trailer?… read more
Andre Pilon
Andre Pilon
Motorcycle Mechanic
Vocational, Technical or Trade Scho
1,032 satisfied customers
65 mph in 4th it coughs, chokes, and back fires..conversion
I have a 1988 Sporster 883/1200 it hates higher RPM (guessing over 5k but I have no tach) top speed is 80mph but usually around 65 mph in 4th it coughs, chokes, and back fires like a SOB. it has 21,80… read more
Brian
Brian
CARS SUCK! CUSTOMS & REP, OWNER
Vocational, Technical or Trade Scho
211 satisfied customers
Leaking oil..it was low.I replaced solonid housing gasket..seal
why is my 1975 sporster xlh leaking oil when i shut it off?I believe its the primary oil because it was low.I replaced solonid housing gasket because thats where it look like it was coming from on the… read more
Brian
Brian
CARS SUCK! CUSTOMS & REP, OWNER
Vocational, Technical or Trade Scho
211 satisfied customers
I get a step by step instructions on how to install forward controls
can I get a step by step instructions on how to install forward controls on my 2007 sporster 883 R? The controls are from Dennis Kirk… read more
Brian
Brian
CARS SUCK! CUSTOMS & REP, OWNER
Vocational, Technical or Trade Scho
211 satisfied customers
2003 883 boreout 1200 custom sporster I built..kit..shifting problem
Hello I have a 2003 883 boreout 1200 custom sporster I built. I have modified it with a suicide shift kit. Recently while riding, I started having a shifting problem. I was downshifting at the time, a… read more
Steve
Steve
Motorcycle Mechanic
7,278 satisfied customers
2004 883 sporster...straight through tail pipes (no baffles)
2004 883 Sporster. Do I need to rejet my carby when I have removed standard tail pipes and replaced with straight through tail pipes (no baffles)?… read more
Steve
Steve
Motorcycle Mechanic
7,278 satisfied customers
im changing a broken clutch cable on an 883 sportster.
I'm changing a broken clutch cable on an 883 sportster. I removed the cable from the handle and taken the clutch cover off. How do I remove the cable from the clutch?… read more
Steve
Steve
Motorcycle Mechanic
7,278 satisfied customers
Fuel mixture is lean very cold blooded now cleaned carb..air cleaner
883 stock sporster just added drag pipes seems fuel mixture is lean very cold blooded now cleaned carb and checked main jet it is a 175 any reccomendations bigger jet possibly or ?? also stock air cle… read more
GW DICKINSON
GW DICKINSON
Associate Degree
78 satisfied customers
factory speedo OFF AND PUTTING AN AFTER MARKET ONE..SCHEMATIC..oem
IVE GOT AN 04 SPORSTER 883 XL. TOOK THE FACTORY SPEEDO OFF AND PUTTING AN AFTER MARKET ONE ON AND NEED THE SCHEMATIC FOR THE OEM ONE… read more
Chuck
Chuck
Shop Foreman
Vocational, Technical or Trade Scho
42 satisfied customers
Bike..the pushrods i have fitted a compufire 20200 timing mec i..coil
my bike is oa 1981 ironhead 883 sporster i would like to know how to set the pushrods i have fitted a compufire 20200 timing mec i have spark at the plugs but it wont fire i have fitted a new single f… read more
Steve
Steve
Motorcycle Mechanic
7,278 satisfied customers
I dropped my 2006 883 sporster,now the tip light comes
I dropped my 2006 883 sporster,now the tip light comes on and it keeps dying Iv been told I can reset it myself can you tell me how to do this… read more
Motorcycle Tech
Motorcycle Tech
1,297 satisfied customers
Clutch cable..the transmission oil back in the bike
i changed the handle bars on my 883 xlc .and in doing so i was told that id have to change the clutch cable which wasnt nessasary. but now im not sure how to put the transmission oil back in the bike.… read more
chopper
chopper
Vocational, Technical or Trade Scho
50 satisfied customers
I have a 1999 Harley sporster 883 that i bought used..never owned
I have a 1999 Harley sporster 883 that i bought used. I have never owned a Harley before. What kind / weight of oil should i use??… read more
Motorcycle Tech
Motorcycle Tech
1,297 satisfied customers
About an 03 sportster 883..adjust..clutch..removing..cold start
this is about an 03 sportster 883 ! is it possible to adjust the clutch without completely removing the primary cover and draining all the lube ! i ask due to some cold start slippage or is it possibl… read more
Brian
Brian
CARS SUCK! CUSTOMS & REP, OWNER
Vocational, Technical or Trade Scho
211 satisfied customers
I have a 1996 harley xlh 883 hugger sporster i..clip
I have a 1996 harley xlh 883 hugger sporster i am having troubles taking off the gearcase cover is there a retaining clip on the inside that is holding it on… read more
Bill
Bill
Harley Tech
High School or GED
146 satisfied customers
I have a 2001 harley davidson 883 sportster and cant..bolts
i have a 2001 harley davidson 883 sportster and cant get the primary chaincase cover off all the allen bolts are out and it seems lose but it seems like something is holding it up any help… read more
Motorcycle Tech
Motorcycle Tech
1,297 satisfied customers
Disclaimer: Information in questions, answers, and other posts on this site ("Posts") comes from individual users, not JustAnswer; JustAnswer is not responsible for Posts. Posts are for general information, are not intended to substitute for informed professional advice (medical, legal, veterinary, financial, etc.), or to establish a professional-client relationship. The site and services are provided "as is" with no warranty or representations by JustAnswer regarding the qualifications of Experts. To see what credentials have been verified by a third-party service, please click on the "Verified" symbol in some Experts' profiles. JustAnswer is not intended or designed for EMERGENCY questions which should be directed immediately by telephone or in-person to qualified professionals.

Disclaimer: Information in questions, answers, and other posts on this site ("Posts") comes from individual users, not JustAnswer; JustAnswer is not responsible for Posts. Posts are for general information, are not intended to substitute for informed professional advice (medical, legal, veterinary, financial, etc.), or to establish a professional-client relationship. The site and services are provided "as is" with no warranty or representations by JustAnswer regarding the qualifications of Experts. To see what credentials have been verified by a third-party service, please click on the "Verified" symbol in some Experts' profiles. JustAnswer is not intended or designed for EMERGENCY questions which should be directed immediately by telephone or in-person to qualified professionals.

Show MoreShow Less

Ask Your Question

x