How Do I Remove the Primary Cover on a Harley Road King Motorcycle?

Written by jim murkot sr.
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How Do I Remove the Primary Cover on a Harley Road King Motorcycle?
The Harley-Davidson Road King motorcycle utilises a wet clutch system. (trittbrett einer Harley image by Thomas Duchauffour from Fotolia.com)

The Harley-Davidson Road King motorcycle utilises a wet clutch system as part of its primary drive. This clutch is bathed in lubricant and contained within the engine primary chain case located on the lower, left side of Harley's signature V-twin engine. In general, it is not necessary to remove the primary cover to perform routine clutch maintenance. However, should a more detailed or intensive procedure need to be performed, then removal of the cover is mandated. The time necessary to remove the primary chaincase cover will vary upon skill level, but should generally take between 30 to 60 minutes.

Skill level:
Moderate

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Things you need

  • Cross-tip screwdriver
  • 10mm open-ended wrench
  • Drain pan
  • T40 Torx drive
  • SAE socket set
  • Hex wrench set

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Instructions

  1. 1

    Remove the seat using a cross-tip screwdriver on the rear seat fastener. Disconnect the positive and negative battery cables utilising a 10mm open-ended wrench.

  2. 2

    Place a suitable-sized drain pan underneath the rear of the primary chaincase. Loosen and remove the primary's drain plug using a T40 Torx drive. Allow all of the primary fluid to drain. Reinstall the drain plug.

  3. 3

    Remove the Road King's left-side passenger footboard with an SAE socket. Loosen and remove the three hex bolts holding the front footboard to the frame with a hex wrench.

  4. 4

    Disconnect the shifter rod from the shifter lever with an SAE socket. Take out the 10 hex-head fasteners from around the perimeter of the primary. Drop the primary cover.

Tips and warnings

  • If the primary cover will not come free once all of the fasteners have been removed, then gently tap the cover with a rubber mallet to help loosen it.

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