General
Refer to Maintenance Scheduling → Regular Service Intervals → Regular Service Intervals: 2011 Sportster Models. Primary (front) chain adjustment should be checked at proper intervals and serviced as necessary. If the chain is allowed to run loose, it will cause the motorcycle to jerk when running at low speed, and chain and sprockets will wear excessively. If this happens, see a Harley-Davidson dealer or service manual for adjustment procedure.
Table 1. Primary Chain Freeplay Specifications
ENGINE
in
mm
Cold
3/8-1/2
9.5-12.7
Hot
1/4-3/8
6.3-9.5
1Measurement point between sprockets
2Free play measurement
Figure 1. Primary Chain Vertical Free Play: Sportster Models
Primary Chain Inspection
The primary chain can be inspected and if required, adjusted without removing the primary cover.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Remove main fuse. See Maintenance and Lubrication → Fuses and Relays.
  2. See Maintenance and Lubrication → Transmission Lubrication → Primary Cover: XL Model. Remove the two hex socket screws which secure primary chain inspection cover (3).
  3. See Figure 1. Check primary chain tension by measuring vertical free play.
    1. Measure vertical free play through chain inspection cover opening.
    2. Rotate engine to move primary chain to a different position on sprockets.
    3. Measure vertical free play several times, each time with primary chain moved so that the measurement is taken with sprockets rotated to the tightest chain position.
  4. The tightest measurement in previous step must be within the specifications listed in Table 1. If necessary, see PRIMARY CHAIN ADJUSTMENT to adjust chain tension.
Primary Chain Adjustment
NOTICE
Do not adjust the primary chain tighter than specified. Running chain too tight will result in excessive wear. (00202a)
1. See Figure 2. Loosen locknut (1).
2. Turn chain adjuster screw (2) clockwise (inward) to reduce free play or counterclockwise (outward) to increase free play. Vertical free play must fall within the limits specified. Refer to Table 1.
NOTE
If vertical free play cannot be set within the limits specified, then primary chain and/or chain adjuster are worn beyond adjustment limits. Replace parts as necessary.
3. When tension is set correctly, hold chain adjusting screw and tighten locknut to 27–34 N·m (20–25 ft-lbs).
4. Install primary chain inspection cover and new gasket. Tighten hex socket screws to 10.2–13.6 N·m (90–120 in-lbs).
5. Install main fuse.
1Locknut
2Chain adjuster screw
3Transmission chaincase drain plug
Figure 2. Primary Chain Adjuster: Sportster Models