I'm replacing a broken drive belt and having rouble removing the inner case. Should it come off without using some type pully? I've lightly hammered and pryed but it hasnt moved. I spoke with HD mechanic earlier today but he didnt mentioned that it would take special tool or would be that difficult to remove.

 

It should come loose with light tapping. Did you remove the starter bolts? They hold it in place also, and are pretty hidden to remove.

 

Yeah, make sure you loosen those starter bolts. The case itself is probably not gonna budge untill you give it a little tap with a rubber hammer. That thing is probably singed on there from all the heat, it's a simple job.

 

Going with these guys on the 2 starter bolts. Gotta get to them from the right side of the bike under the oil tank. You can leave them resting in the holes of the starter, just screw them out of the primary.

 

On my way to garage now. I half *** looked from right side but obviously not very well. Its hell being stupid! Thanks to all and Merry Christmas

 

On mine it's sort of a bear to get to the starter too and manual even says pull oil tank. With the line disconnect tools makes it a lot easier to get oil lines loose. It's a big job to replace the belt for a first timer and a lot of stuff has to be out of the way. Hope you have a Harley service manual. You have lot of different torques and settings to maintain for safety. Done wrong could get you or someone else seriously hurt or killed. Take pictures and post on here.

 

It can be done without removing the oil tank, but you can BARELY see the bolts. You need a long handled T allen wrench and almost do it by feel. Use a good wrench or the torque will bend or break a cheap one.

 

Good luck with the starter bolts. I used a ratchet with a long ball end allen. I did take the 4 bolts out of the oil tank so I could maneuver it around a bit. Definitely leave the rear starter bolt in the hole. I took it out and it was not too easy to get back in.

 

Also; replace the bolt and locking washer that mounts the starter drive gear with new parts, 9 times out of 10 that bolt (screw) will twist off when you try to torque it on.
Think about a chrome inner primary and chrome screws & washers while you have it apart!

 

Don't know about your TC, but on my EVO, there is a bolt from the backside underneath for the ground strap that goes into the IP housing. I used a 2X4 to "tap" the housing off from the back side with a 3lb hammer. Had I read the manual very carefully, I could have saved myself a lot of trouble. Now I get to call in a favor from my favorite welder friend.