Sportster gear case cover

Hi, I have a 1998 1200 sportster sport. I'm replacing the gear case with a chrome one. The manual says to relieve the tension on the push rods. I've been told that I can just pull the cover off and replace it with no problems. I would greatly appreciate some advise, thanks. John

You probably have to loosen the top covers on the cylinders to relieve the tension on the cams..then carefully slowly pull the cover off making sure not to pull the cams out with the cover..might have to have the bushings miked to the cams..they can be reamed to HD tolerances..

thanks, I'm doing the right side camshaft cover. john

Thanks, thats what I was thinking was hoping to to just replace the cover. John

Here's a "how to" from NHRS...you can't just pull the cover off...The cover is part of the cam support

Disassembly: Before you can remove the gearcase cover and remove the cams, you need to relieve the pressure from the cams. Anytime a valve is open you've got some pretty substantial pressure on that camshaft, and there's always at least one valve open somewhere on an HD twin.



If you've got adjustable pushrods and collapsible covers, you can probably accomplish this without pulling the rocker boxes. Simply shorten each pushrod to close the valve and relieve the pressure. However, if you've got the stock setup, the rocker boxes need to come off. Pull a rocker box top and then position the engine (a swingarm stand works well) such that both valves are fully closed. You want the motor sitting about halfway between the point where the intake valve closed and the exhaust valve starts to open while turning the engine forward. Be careful not to position it in between the exhaust close point and the intake open point; that's overlap and there's no spot there where both are fully closed. Now remove the lower rocker box. Repeat the process for the other cylinder.



Now go downstairs to the gearcase. You may have to remove the exhaust system and footpeg and/or brake pedal assembly to get enough access, depending on your bike. For an '03 or earlier, you'll want to remove the timing cover, remove the timing plate, and the rotor cup. Now remove all the cover screws and gently work the cover off. I generally push on the #2 cam, through the timing hole, to make it stay in the engine as I do this. Once you get the cover to pull free from the engine, you'll notice that it's still attached by the timing pickup plate wires (03 and older only) as well as a vent hose coming off the back of it.

I didnt want to get into all the detail of the actual replacement of the gear cover..just covered problems he might have..actually every time I buy a HD I go buy the service manual..didnt want to type 2 or 3 pages of detailed instructions..

Me either...copy and paste... and said where the info came from...
Wouldn't want to see the guy just loosen the rocker box covers then try to remove the cover.... I suppose "follow the manual"would have been enough ....

if you have to ask the question,your probebly better off taking to a shop and having it done

thank you very much for the info. have a happy thanksgiving. John