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Is there a trick to getting the Primary Cover back on correctly? I am not sure I am getting the shifter on correct and it will not go all the way on.
 

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'K
1st thing is buy a bunch (at least the equivalent amount of bolts as holes for the primary) long metric bolts ('bout 3" long) to match the primary cover's bolts. Then, cut the heads off. Screw these long "dowels" into the engine casing where the bolts go... then gently put the primary cover back on. Make sure to line-up the shifter shaft as ya go. Be careful toward end of assembly! As the stator's magnets are very powerful and may pinch yer fingers (if ya don't watch it).

After the cover's in place, remove the "dowel bolts" and replace 'em with the correct bolts--one by one. Remember to cross tighten and watch for that short bolt at the bottom by the shifter shaft. NEW gasket should be applied to cover before assembly (sticky side toward the cover--away from the engine).
 

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Install

Take a couple of your mounting screws down to the local hardware store. By some new mounting screws with the same size diameter and tread pitch. Make sure and get the bolts if you can a inch or so longer. Take those home, cut the heads off of the bolts and screw them into the holes for mounting the primary cover. Use those bolts as alignment dowels. Ok so if they do not have bolts that are longer you can also get some all-thread or ready rod and cut them to the length you want and use those as alignment dowels also. NOTE: If you use the all-thread be sure and clean up the threads so they screw into the holes of your casing good on your engine. This can be done by screwing nuts onto the all-thread then cut it and screw the nuts off and on to the all thread, it may also require a file or a thread file to straighten out the thread or a die. Good luck.
 

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I've had my primary cover off 4 times now. The things that will get you are:

- The gasket moves
- The stator wire grommet moving out of place
- The cover will get hung up on the shift shaft, especially if you use a new shift shaft seal (a good idea)

When I was sure everything was aligned properly, a couple of well-placed hits with a dead-blow hammer on the cover got it onto the shaft all the way. Whether or not this is a good idea, I don't know, but that's how I did mine.

And yea. That stator magnet loves to chomp on fingers.
 

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I use a fewer homemade dowels than DaveT, but that was a tip I saw that helped me a lot. The first time I misunderstood the directions and tried to install the shifter shaft with the cover - No Joy. I use a plastic stick (used in the auto glass business) at the front of the cover to try to limit finger pinch and apply some grease to the shifter shaft to ease its passage past the seal.


The first one is always the worst one.

Good luck with the project.
 

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'K
1st thing is buy a bunch (at least the equivalent amount of bolts as holes for the primary) long metric bolts ('bout 3" long) to match the primary cover's bolts. Then, cut the heads off. Screw these long "dowels" into the engine casing where the bolts go... then gently put the primary cover back on. Make sure to line-up the shifter shaft as ya go. Be careful toward end of assembly! As the stator's magnets are very powerful and may pinch yer fingers (if ya don't watch it).

After the cover's in place, remove the "dowel bolts" and replace 'em with the correct bolts--one by one. Remember to cross tighten and watch for that short bolt at the bottom by the shifter shaft. NEW gasket should be applied to cover before assembly (sticky side toward the cover--away from the engine).
This is a great technique.
 

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Agreed. The learning curve is steep, but not that high :)
and we have lots of fingertips, ..winged it with mine a few times and got away with it😉
 
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