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14th March 2011
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Master Custom Bike Builder
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Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,331 Sportster/Buell Model: XL1250 Sportster/Buell Year: '02
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UFP - Unidentified Flying Pieces out of my primary, where do they go?
Ok well I'm swapping my primary cover out when this piece falls to the ground, didn't see where it came from. Then when I'm taking the belt tensioner/shoe thing out of the old cover to put into the new cover another one falls out???
I've looked at the diagrams in the FSM and I don't see them, please help
where do they go?
thanks
and for kicks, here's what I'm looking at

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Well of course, everything looks bad if you remember it.
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14th March 2011
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Turbo Mafia
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Join Date: Jul 2010
Location: North East PA and NJ
Posts: 1,616 Sportster/Buell Model: Turbo Nightster Sportster/Buell Year: 2010
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I'm far from an expert, but they look like alignment dowels....are there any holes that are bigger than the others?
this hole here looks like it might take one....

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14th March 2011
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Know It All
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Join Date: Jan 2011
Location: Thailand/Los Angeles
Posts: 158 Sportster/Buell Model: xl 883 Sportster/Buell Year: 2003
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Yep, check your side case. I can see where one goes from the picture (right).
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14th March 2011
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XL FORUM TEAM MEMBER
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Join Date: Feb 2011
Posts: 805 Sportster/Buell Model: XLCH Sportster/Buell Year: 1968 Sportster/Buell Model #2: XLH1200 Sportster/Buell Year #2: 1991 Other Motorcycle Model: Chopped Shovel Other Motorcycle Year: 1978
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Too slow, your answer has already arrived above.
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Disclaimer: I'm not the guru on this stuff, be sure to seek further opinion/knowledge.
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14th March 2011
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Master Custom Bike Builder
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Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,331 Sportster/Buell Model: XL1250 Sportster/Buell Year: '02
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THANK YOU!!! I was too focused on the guts to consider that area, there is another identical spot on the right hand side
You guys are life savers!
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14th March 2011
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I can break anything
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Join Date: Jan 2011
Posts: 126 Sportster/Buell Model: XL883 Sportster/Buell Year: 2005
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sometimes its right in front of our noses and we still cannot see. 
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'05 883XL. SE A/C, SE Slip ons. Smoked signals and L.E.D. Brake.
OIF 1/2/3 Combat Vet ('03-'05)
Member:
Veterans of Foreign Wars
VFW Riders Association 
DAV
United States Concealed Carry Association
NRA Life Member
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15th March 2011
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Master Custom Bike Builder
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Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,331 Sportster/Buell Model: XL1250 Sportster/Buell Year: '02
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BTW this is has been a PITA!!!!! I'm still struggling to get it on
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15th March 2011
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XL FORUM TEAM MEMBER
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Join Date: Oct 2007
Location: Perfidious Albion
Posts: 6,936 Sportster/Buell Model: XL1250S Sportster/Buell Year: 1998
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Slacken the chain adjuster all the way off, and push the chain up from the underside to clear the adjuster as you install the cover.
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15th March 2011
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Master Custom Bike Builder
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Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,331 Sportster/Buell Model: XL1250 Sportster/Buell Year: '02
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Quote:
Originally Posted by steelworker
Slacken the chain adjuster all the way off, and push the chain up from the underside to clear the adjuster as you install the cover.
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Thanks, I keep forgetting to lift the chain
The problem seems to be the gear shift linkage? that rod sticking out in the very center that connects to the shift lever, well there's 2 mountain ranges of ridges on the tip of it that I have to slide the new cover over and it seems the hole is a tad too small, guess it's to prevent leaks, and it's a new piece, and it's a V-twin part
at this point I have it half way over the 2nd mountain  but thats after a few hours on my back pushing and cursing... I'm throwing in the towel for now, and get it finished tomorrow.. it's beer time
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15th March 2011
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JESTER Mafia-Hooligan Div
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Join Date: Sep 2005
Location: West Central Indiana
Posts: 9,442 Sportster/Buell Model: 1200 R Sportster/Buell Year: 2005
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Quote:
Originally Posted by Phillober
Thanks, I keep forgetting to lift the chain
at this point I have it half way over the 2nd mountain  but thats after a few hours on my back pushing and cursing...
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Shouldn't be that hard. Use a little oil on that seal as well. Is this the same cover that you took Off? I believe there was a seal diameter change on some years.
The cover should pretty much slide right up!
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Stuff: YES
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