Gear cover removal on 93 sportster

[richardl]

I am trying to remove the gear cover to gain access to gears on my 93 sporster as an ongoing problem with slipping drive...not the clutch plates apperently. However having taking off all holding bolts it only wants to slide off about 4 to 5mm. Am I missing something I should have undone?
Richardl

[girlyglide]

At a guess I'd say your missing a workshop manual

If you are trying to take off the primary cover you will need to remove the clutch inspection cover, disconnect the clutch cable end from the adjuster and then take off the clutch adjuster mechanism as it's held onto the clutch basket by the adjuster screw. This is by no means a "how to" just from what I can remember on a Sunday afternoon (and my memory isn't always reliable after lunch).

Do yourself a favour and invest in a Moco manual and parts catalogue if you intend to go this far (or further) into the engine.

[richardl]

Its the casing on the left side of the engine not the right side which houses the clutch. It has 11 allen key bolts holding it on. All have been removed but still no joy in pulling it away to expose inside. Richardl

[girlyglide]

Yes, the primary cover, as it's commonly known.

Have you tried doing what I posted?

[girlyglide]

Have you also removed the gear change lever?

[Limey_Dave]

Originally Posted by richardl

I am trying to remove the gear cover to gain access to gears on my 93 sporster as an ongoing problem with slipping drive...not the clutch plates apperently. However having taking off all holding bolts it only wants to slide off about 4 to 5mm. Am I missing something I should have undone?
Richardl

You asked if someone with basic mechanical knowledge could replace the clutch disc,and you were told yes,with a factory manual.
Phil said to check the front pulley,did you?
You seem to have decided to have a go without the manual,and have discounted the clutch disc as being the problem,before you've even seen it.Why?
As Phil said,you need to disconnect the clutch cable,remove the gear lever,and also I think,slacken the primary chain adjuster.
Before you do anything else,the best advice you'll get is

Disconnect the battery,we give tips,but not finger tips.

[girlyglide]

Originally Posted by Limey_Dave

Before you do anything else,the best advice you'll get is

Disconnect the battery,we give tips,but not finger tips.

Always the first job when working on the engine/trans/clutch!

This highlights one of the problems of giving advice on a forum, you can easily assume a level of mechanical competence and then the accidents start.

Richard, go buy a factory manual, follow this instructions, don't rush anything and you should be fine. If you subsequently think the job is beyond you then stop and employ someone who does it for a living. A badly maintained/repaired bike is a hazard to yourself and other road users.

[richardl]

I have now got a manual...but due to a touring holiday with the bike looming, have loaded it onto my pickup and taken it to a "Professional".
My enthusiasm for my Sportster sometimes overtakes my abilities with it. I really appreciate all the advise given and am desperate to learn more. Someone in Berkshire/Hampshire/Surrey please start a Basic, Intermediate and advanced Harley Davidson Maintenance class. I will be first in line!!!!!!!!!!
Richardl(still got all my fingers)

[Limey_Dave]

Fair play to you Richard,but don't just put that manual on the shelf.If it's a HD factory manual,you can learn alot by just reading it.
Good luck with the repair,and have a good trip.