Primary Cover Problems

Discussion in 'Sportster Models' started by The_Q, Oct 30, 2008.

  1. The_Q

    The_Q Member

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    Had problems with my primary cover chain inspection cover leaking since it was serviced. I could never find time to take it back and figured it was caused by the new Harley gasket and no inspection cover change. I ordered the new and improved cover and gasket kit for my '04 XL883. Got it yesterday and went to install it. When I removed the front bolt some of the threads in the primary case appear to have pulled from the case (stripped). When I installed the new gasket and cover the front bolt wont torque to the proper spec., it just spins. The rear bolt torqued fine. I rode the bike and have no more leak issues, but I want to fix the primary cover. Anyone have a recommendation other than replacing the primary cover? When I was in the military we used an item called a heli-coil, or something to that effect to fix similar problems. Is it possible to fix this without removing the cover? Thanks in advance for your advise and suggestions.
     
  2. The_Q

    The_Q Member

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    Thanks, I was really hoping that would be the case :D Do you guys happen to know the size of the screws (thread, size and pitch) for the inspection cover? I was looking at ebay and kits are listed and very inexpensive. The hole looks like it needs new threads and going a plus size seems like more work than a helicoil insert and it retains the stock look too.
     
  3. The_Q

    The_Q Member

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    Update :D Installed two 1/4-20 helicoils last night and all is fixed now. I didn't have to remove the primary cover. I dipped the drill bit in oil prior to drilling to catch shavings and I caught shavings in a shop towel on the backside. Did the same with the tap. I used a dab of red locktite on the helicoils and let them sit overnight. I buttoned it all up this morning and all looks good. Thanks for your help.

    Ride Safe
    Q.
     
  4. Romain

    Romain Active Member

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    I'd never heard of helicoils before this post. Sounds like the ticket. I will keep them in mind for future reference.
    Thanks for the tip.
     
  5. NEWHD74FAN

    NEWHD74FAN Experienced Member Retired Moderators

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    Helicoils are stainless steel inserts developed when the Air Force was tightening stainless steel hardware into aluminum aircraft parts and stripping them out early on...WWII I think. Been too long to remember where I read about it...try Google...:bigsmiley32: