| Author | Message | ||
     Jahwarrior007 |
Hey to all the buell family, am trying to take of my primary cover on our '99 X-1. We followed all the manual instructions, got down to the tensioner and loosed the screw as instructed, but noticed that the chain is still tight, we loosed up the nut, turned in the screw counter clock wise, all the way down to where it wouldn't turn with out messing things up...so not sure if I'm turning the screw the "right" way. Anyway, the cover won't come off...so not sure what's hanging up...did want to mention that when we took out the drain plug, not a lot of oil came out  ...so I had to take a break and ask for help or advice...thanks. | ||
| Gianni312 |
When you unscrew the primary chain tensioner screw with the alen key, it will make the screw stick out farther downward out of the bottom of the primary cover. Once done, the primary cover will pull off easily. I had to lift the primary chain over the tensioner with my hand when I was pulling off the cover. I hope this helps. | ||
| Malott442 |
Hm.... I'm assuming bike is in neutral? Using the allen screw, the screw should be sticking way out, which draws the tensioner to the casing, loosening the chain. | ||
| Ratbuell |
Shifter and clutch cable off? Chin spoiler? Sometimes yes...the cover can stick. | ||
| Akbuell |
If you have all of the fasteners out, shift lever, primary tensioner loose, ect. off and or out, you are ready. Depending which gasket is on there and how long it has been since that cover is off, it is now time for GENTLE raps about the cover with a rubber mallet. Putting fingers inside the chain insp cover and the derby cover holes and pulling can certainly help. Just don't get in a hurry. Hope this helps, Dave | ||
| Buellistic |
If whom ever put the cover on last put it on with gasket sealer(WHICH THEY SHOULD HAVE NOT !!!)it will make interesting to get it off ??? THE COVER IS THIN SO BE CAREFUL NOT TO BREAK IT !!! PRIMARY Class 101, just PM me for a copy ... | ||
| Akbuell |
And before I forget, application of heat, from a heat gun for example, probably won't hurt while tapping/pulling. Dave | ||
| Ceejay |
is it hung up by the shifter collar? sometimes those things can rust around the shifter shaft making it a b---h to get off. WD-40 can help...as well a bit of emery paper. If it's the cover to engine case interface then what the others are stating..the older gaskets are paper and can stick pretty good. Get the metal one when going back on. | ||
| Sportyeric |
Clutch mechanism? | ||
| Reepicheep |
It wasn't unusual for me to need a few taps with a rubber mallet. Like AKBuell said, pull on it, and tap with the mallet. Even with the bolts out, it has indexing collars in there, so don't expect it to "twist" off, it has to come straight back. | ||
| Screamer |
If you disassembled the clutch adjuster mechanism correctly.... the other thing I've seen (although fairly rare) Is a deeply worn chain tensioner which captures the chain and prevents the cover from being removed. Usually you can pull the cover enough to slip in through the bottom with something slender and push up on the chain and lift it out of the tensioner - then remove the cover. | ||
| Kalali |
At the risk of showing my ignorance, is it possible to maintain the clutch adjustment with the clutch cable removed? [Sorry, figured I'll ask the question here instead of starting a new thread]. Thanks. | ||
| Oldog |
Kal, to answer no not really BUT, you can remove the case and not move the adjuster on the cable. when you take the throw out mech off of the clutch you turn the screw out of the adjuster hut. | ||
| Jahwarrior007 |
I am glad to see all the responses...so the only one that really applies, (I think) is from Mr. Screamer, I took a flashlight and saw that the chain was actually worn into the tensioner...I did try and "pry" it off of it but nothing, plus the chain has not loosed after turning the tensioner screw all the way out...another bit of priceless info I forgot to mention is; the reason I had to remove the cover was; I had pulled over to fuel up, went to start the bike, all I heard was the starter spinning, looked and saw that it was actually coming out...soooo, I'm praying that the nut/bolt that was holding it, didn't get jammed in between the chain and primary sprocket and is has the chain all tighten up...been thinking of putting clutch back together and putting into gear and pushing backward to see if it helps. So. I'm in a bit of a "jam" right now... | ||
| Ratbuell |
If you have one of those flexible magnets on a stick, you may be able to feed it through the inspection hole, grab the bottom of the chain, and lift it enough to get the cover off... | ||
| Natexlh1000 |
Another approach would be to put the bike in gear and push the bike to get the slack out of the bottom of the chain. Magnet on a stick method is better. Why? Magnets.  | ||
| Akbuell |
OK, I'm guessing that the cover is loose from the mating surface with the crankcase. The original problem I thought needed solving. And to confirm, you have the primary chain adjuster turned so maximum threads are showing. No need to put the clutch stuff back. Put the arm back on the shift shaft and rock the bike back and forth and shift it by hand. Go to 5th gear. Now rock the bike back and forth and pull on the starter at the same time. Disconnect the battery negative cable before doing this. The bolts that hold the starter on should come loose, if that is the problem. You may want to consider taking the fuel tank off and setting it aside. Place a piece of scrap carpet or something similar on the floor and lay the bike over on the right, resting the throttle on a 5 gal bucket. Now you are not fighting gravity as much, and you can look (as best as possible)in both the top and bottom of the primary with what little clearance you have and maybe discover/solve the issue. Hope this helps, Dave |
