Removal of stripped primary screws - 2008 Harley Davidson FLHX Street Glide

Duplicate question already answered

By stripped, do you mean the head is stripped, or are the threads stripped.
Head stripped = Damaged Screw Extractor Drill Bits 4 in 1 Bolt Extractor Set Easy Out...
Stripped threads = You need to "drill off" the head of the stripped screw. Get a sharp drill bit that is at least twice the size of the threads. Drill into the screw head until the entire head is gone or can be removed..Once the entire head is gone, you should be able to remove the cover..once the cover is off, you should be able to remove the screw with vise grips or other suitable tools.

First disconnect the battery cable. Then you'll have to pull the primary cover off the engine. Find the primary case drain plug underneath the rear of the primary case and remove it to drain the oil. Find the primary chain tensioner underneath the primary cover near the center and loosen the locknut. Turn the screw downwards to loosen the tension on the primary chain. Remove the left foot peg and take the "derby cover" off of the primary cover. Remove the spring and lock nut underneath the derby cover. Remove the bolts around the primary cover. As you gently pull the primary cover away from the engine, turn the clutch adjuster screw under the derby cover in a clockwise direction until the primary cover comes off. Remove the battery cable where it bolts onto the starter motor and the small single wire that plugs to the motor. Just above the clutch assembly there are two bolts. Remove these bolts and the starter will come off the engine. The bolts are different lengths. Make sure you mark which bolt goes where.

Good Luck
Steve

It's a little tricky.

There is a drain hose with a plug in the end on the left side clipped up toward the rear tire. The transmission/primary oil should be changed when you change the engine oil and filter.

I really recommend you get a Blast service manual - they are still available.

Getting to the cover for the primary requires removing the left foot peg and getting that off and on can be a real exercise in frustration.

Be VERY CAREFUL NOT TO OVERTORQUE the screws, they strip very easy.

To change the starter on your Sporty, first disconnect the battery. Remove the exhaust system and anything else that it is the way of the starter. Take the battery cable off the starter. Then go to the left side of the bike and remove the foot peg and shifter. Loosen the lock nut on the primary chain tensioner on the underside of the primary. Turn the adjuster screw out a few turns. Take the derby cover off and remove the spring and lock nut on the clutch adjuster. Then drain the oil out of the primary by removing the plug on the underside of the primary. Remove the bolts that hold the primary on. As you pull the primary cover away from the engine, turn the clutch adjuster screw in the center of where the derby cover came off in a clockwise direction. The primary should come off as you turn the screw. Once the cover is off, lay it aside. Remove the two bolts located directly above the clutch assembly. They are different lengths so make sure you remember which goes where. Once these two bolts are out, the starter will come off.

Good Luck
Steve

The case you're changing the oil in is called the primary drive case or "primary" for short. Yes, it does the same thing as a transfer case but in the future you may confuse someone using that terminology.

The drain is a small pipe plug that uses a Torx bit to remove. It's on the underside of the primary cover back directly below the derby cover. You do fill the case through the derby cover opening. With the bike standing straight up, fill the primary with oil until it comes just up to the bottom of the clutch basket, the shiny aluminum drum that holds the clutch plates. It holds about a quart of oil. Do not overfill or the clutch will drag causing you to be unable to find neutral with the engine running.

You say the bolts won't tighten up on the derby cover. Your model should have the five bolt cover and the screws screw into the tapped primary cover. If the threads are stripped out in the primary cover, you can have it repaired by a competent machinist by having them install threaded inserts in the original holes called Timeserts or Keenserts. If the screws will tighten but the cover still leaks, the bolt holes in the cover may be pulled through and standing high on the backside. This will not allowing the cover to seat against the full gasket. In this case, the purchase of a new derby cover would fix the problem.

Good Luck
Steve

To remove the primary cover from you Sporty, you'll have to remove the shifter and foot peg. Then loosen the locknut for the primary chain adjuster and turn the adjuster downwards to loosen the primary chain. Then remove the plug at the bottom rear of the plug to drain the oil from the primary. Remove the clutch release mechanism cover from the outer primary. Remove the spring and locknut. Turn the clutch adjuster screw as far clockwise as you can turn it. Then remove all the bolts around the outside of the cover. While pulling the outer cover gently away from the engine, turn the clutch adjuster screw clockwise until the cover comes off.

Good Luck
Steve

To remove your primary cover, first, disconnect the battery and drain the oil from the primary. Then, remove any footpegs or shifter mechanisms that might be in the way.

Look on the bottom of the primary cover and you'll see a bolt and locknut. This is the primary chain tensioning device. Loosen the locknut and turn the screws out (downward) to loosen the chain.

Then take the derby cover off. Remove the spring and the locknut from the clutch adjusting mechanism. Remove the bolts that hold the outer primary on. Turn the clutch adjuster screw clockwise as you remove the cover.

When you replace the cover, turn the clutch adjuster screw counterclockwise until it stops. Put all the bolts back in the cover and tighten them. Turn the screw counterclockwise again until it stops and then back off 1/4 turn. Install the locknut, the spring, and the derby cover.

Remove the upper inspection cover and reach in with your finger and check the primary chain tension. Using the bolt on the bottom of the primary, turn it upward (inward) and tension the primary chain to between 1/2" and 5/8" up and down play. Reinstall anything else that was taken off and pour in one quart of primary lube. Reconnect battery.

Good Luck
Steve

Are you sure it just came loose? More than likely, it broke. To find out, drain the primary oil and loosen the locknut at the cable adjuster on the outer primary cover. Turn the adjuster inwards as far as it will go. Remove the four screws on the derby cover. and lift it away from the primary cover. Remove the spring and the locknut.

Now, remove any footpegs or anything else that may be in the way of the removal of the outer primary. Loosen the locknut on turn the primary chain tensioner out on the bottom of the primary cover. Remove all the bolts from the primary.

Now, turn the clutch adjuster screw back at the derby cover in a clockwise direction and remove the outer primary cover. With the primary cover off, you can replace the cable if necessary or simply hook it back up.

Reassemble in reverse order. To adjust the primary chain, turn the adjuster bolt upwards until you have 1/2" to 5/8" up and down slack in the top run of the primary chain. To adjust the clutch, turn the screw counterclockwise until it stops. Then, go back clockwise 1/4 turn and install the locknut, spring and the derby cover. Then adjust the cable adjuster out until you have 1/8" freeplay in the cable.

Good Luck
Steve