Am trying to remove the cam cover to get to my cams on my 2009 Ultra with 49000 miles. Removed the 10 screws, and it stayed put. I hit it with a rubber mallet, and it didn't budge. I took a crow bar and pried on a lip at the bottom and only scratched it when it didn't budge. How do you get it off?

 

Mine was stuck pretty good too. Got a super sharp knife with a somewhat narrow blade (the goal here is THIN) and I held it on the gasket line between the cover and the engine case, gave it a tap with my plastic hammer and it popped loose. Worked for me.

 

Do you mean one of those exacto knives?

 

I actually used a thin folding knife, but an exacto might work too. It didn't take much, you just wanna break that seal and not crack the cover. Hell, a one sided razer blade with a tap on the back of it might even do it too? WEAR SOME SAFETY GLASSES. Like I said, didn't take much of a tap on mine. Also, find a "corner" area of the cover when doing this, it's just a little easier.

 

Good tip razor blades are great for getting things to start separating covers!

 

Put 1 screw back in at the top loosely to hold it from flying and then whack the crap out of it with your rubber mallet. You won't hurt anything.

 

I got my exacto knife and started tapping it in, and although the tip broke off, it came off. good suggestion, and I got the broken piece out.

 

That's a good sign that the cover has probably never been off since new, especially if the gasket is fossilized...the guy I got my FLHX claimed that his mechanic...that he claimed was his friend...had that cover off just 6,000 miles before I got it, and that the 'friend' had intended to change out the cam follower shoes at the next 10K service. I don't think so, Tim...I had the same problem as the OP, solved it in the same way, if the cover had been off like the 'friend AKA mechanic' claimed, it wouldn't have been so difficult to get off, and the gasket would have been supple.


Just something to keep in mind when previous owners/mechanics make claims...

 

I bought this bike in 09 brand new, so am 100% sure this is first time off, and the gasket was brittle. But it is off. Proceeding now to remove that tensioner but can't get it to retract by hand. Hate to use pliars but may resort to that.

 

Sandcrab...I'm trying to figure out why you're thinking about removing the tensioner...it's a hydraulic system, I don't think pliers would be the way to handle the cam tensioner shoe... a little confused here...in another post, you referred to the primary side...which is another kettle of fish wherein a pair of channel locks or Vice Grips might be handy...