How do you adjust primary chain on a harley Davidson 2002 1200c sportster?

Answer 1

Drain the primary/transmission oil. Remove the primary chain inspection plate (the plate that is just above the shifter that has two fasteners, not the big dome shaped one). Grasp the primary chain inside, and move it up and down, measuring the amount of "play". Turn the rear wheel with the engine in gear, and repeat measurements. Checking your service manual for the correct values (which I _believe_ is 5/16"), if it is too loose, loosen the jam nut on the adjuster (on the bottom of the primary, in line with the inspection hole) and using an Allen wrench, turn the adjuster to screw it into the primary to lift the tension adjuster. After adjusting, if you can not get the freeplay within specs, the adjuster will have to be replaced. Since you will be taking the primary cover off, it would be an excellent opportunity to install Balance Masters on the crank pulley and the clutch, and replace the manual tensioner with an automatic one. If you don't have to replace it, retighten the jam nut, refill the primary with one quart of sport-trans, and replace the inspection cover, taking care not to damage the gasket.