A lower bolt on the primary cover broke,so i removed the shifter and foot peg bracket,then removed all of the bolts from primary cover after draining primary fluid. The primary cover still doesnt seem to want to come off, i need to get the cover off to remove the broken bolt so that i can replace it. Inspection cover and cover by the clutch cable were also removed, what is holding this cover in place? (Sportster 883xl)

On a Sportster, the engine and transmission are what we call "unitized". This is a term that us old guys use to describe an engine/transmission setup in a bike. It comes from the early British bikes. Prior to 1972 or so, the British bikes had a seperate engine and transmission connected by a primary drive case like the Big Twin Harleys do even to this day. Later, they went to an engine/ transmission design that was all one piece or "unitized" like most of the *** bikes. The Sportster has always been like this since their introduction in 1957. The point I'm trying to make is that I don't understand your statement of ",i can see where the tranny meets the mtr. a bead of caulk" The tranny does not meet the motor on a Sportster. The engine cases are two halves put together with the split being lenghtwise or down the middle of the engine cases. Go to this site and look at how your engine is put together. http://www.bikebandit.com . If you can, please take a picture and send it to me at [email protected]. Make sure that the view is wide enough so that I can get a reference of exactly where this bead of caulk is. There should not be a bead of caulk visible either inside or outside of the engine cases. To keep the bolts tight, use Loctite 242 med. strength blue on the bolts. Some places you can use the high strength red but I don't advise it unless the bolt is threaded into steel instead of aluminum. On a Sportster, the engine and transmission are what we call "unitized". This is a term that us old guys use to describe an engine/transmission setup in a bike. It comes from the early British bikes. Prior to 1972 or so, the British bikes had a seperate engine and transmission connected by a primary drive case like the Big Twin Harleys do even to this day. Later, they went to an engine/ transmission design that was all one piece or "unitized" like most of the *** bikes. The Sportster has always been like this since their introduction in 1957. The point I'm trying to make is that I don't understand your statement of ",i can see where the tranny meets the mtr. a bead of caulk" The tranny does not meet the motor on a Sportster. The engine cases are two halves put together with the split being lenghtwise or down the middle of the engine cases. Go to this site and look at how your engine is put together. http://www.bikebandit.com . If you can, please take a picture and send it to me at [email protected]. Make sure that the view is wide enough so that I can get a reference of exactly where this bead of caulk is. There should not be a bead of caulk visible either inside or outside of the engine cases. To keep the bolts tight, use Loctite 242 med. strength blue on the bolts. Some places you can use the high strength red but I don't advise it unless the bolt is threaded into steel instead of aluminum.

Harley does use a sealant on the cases when they put them together but most of the time that get any excess that squeezes out off before the engine goes into the frame. Maybe someone got a little sloppy that day or it was almost time to go home. At any rate, the Sportster engines usually do not leak in this area. Most of the time when you see oil in that area it has run down to that area from somewhere else. You're on the right track. Clean the bottom of the engine off as best as you can and go for a short ride. When you get back. look for the oil. If you see it. you can use some talcum or foot powder to "dust" the bottom of the engine case. The powder will stick to the case anywhere there is oil and you can see where the oil came from and once you've finished, the powder comes off easily. If you had a broken bolt on the primary cover, this could have been the source of the leak. When riding, the wind blows the oil around on the bottom of the engine as well. Good Luck. Steve Harley does use a sealant on the cases when they put them together but most of the time that get any excess that squeezes out off before the engine goes into the frame. Maybe someone got a little sloppy that day or it was almost time to go home. At any rate, the Sportster engines usually do not leak in this area. Most of the time when you see oil in that area it has run down to that area from somewhere else. You're on the right track. Clean the bottom of the engine off as best as you can and go for a short ride. When you get back. look for the oil. If you see it. you can use some talcum or foot powder to "dust" the bottom of the engine case. The powder will stick to the case anywhere there is oil and you can see where the oil came from and once you've finished, the powder comes off easily. If you had a broken bolt on the primary cover, this could have been the source of the leak. When riding, the wind blows the oil around on the bottom of the engine as well. Good Luck. Steve