Hey guys,

Finally got around to changing up the derby (clutch) and inspection cover today on my Sporty. Pretty simple task to be honest, but one little bump in the removal which someone down the line might want to know. Anyways, here's the process I went through today to get them changed over to my newies.

 

As per usual, first up - the tools you'll need: Torque Spanner w/ long allen key bit, med/small allen key, small torx bit

 

Derby Cover Installation / Removal

1. One thing you need to do before you even think about changing that derby cover, is to get you bike straight/upright, or even better tilted to the other side. The clutch has a little load of clutch lubricant which is there for good reason and will fall out if leant the wrong way, and basically you don't want to loose any of this. You could probably deal with losing a couple drops, but best take the time to not loose any to save you alot of unessary effort. You can either throw the bike up on a lift, or you can just get a mate to help you out for 5 minutes and hold the bike for you.

 

2. First thing I realised I had to do was loosen the footpeg up. There are 6 screws in the derby cover, 5 which you can reach without anything getting in the way. However, no.6 has a nice big footpeg blocking you from screwing it out, so you'll need to loosen it up a bit in order to be able to access it properly. If you can get the bike high enough, you probably won't need anything special in regards to tools. But if you can't, you will most likely need to get hold of a relatively long (and large) allen key shaped piece. I think it's roughly like a 40 or 50 from memory?

 

3. Once the footpeg is loose, you're in the clear to get the derby cover off the bike. Just make sure that your bike is upright or leant over the other way at this stage.

 

4. Grab your new cover, and just screw it right back on (as long as none of that clutch fluid has poured out haha). Then tighten ur footpeg back up, and ur on your way. You should probably torque it, but I didn't.

 

 

Inspection Cover Installation / Removal

1. Even simpler than the derby, as nothing is in your way. You basically just need a med/small allen key, and ur good to go. I did however notice that the front screw is like a slight fraction smaller than the back screw. I think it was just a dodgy screw though to be honest.

 

2. Loosen up the screws. I noticed they had some loctite on them (blue liquid used to help lock the screws in place better). Once you've loosened the two screws, and free'd the cover, you'll notice there's still a little plastic cover thing in there. Remove this too if you have a new one, otherwise just leave it in there. I was supplied a fresh one along with my new cover I purchased, so I just popped the old one out, and put the new one in.

 

3. Grab some loctite (or any other tightning fluid), and squirt a bit of it onto the original screws. Give it a little rub in to cover the screw bit. Then just screw them straight back in. And you're done!

 

I personally think the black out look, looks great. Very happy.

Hope this helps someone one day

Looks good, Your o-ring on the derby cover stayed in place luckily.

When it doesn't, you can re-use it but use some grease to hold it in the groove.

Good stuff.

My only add on would be use a quality torx bit, and since sometimes those bolts don't come off easily (especially on older bikes) you may need an impact driver. One or two hits and they loosen right up.
I replaced my bolts with allen key head ones - much better.

I thought the manual said blue locktite btw (or locking compound). Might be hard to get them off next time.

Brash, cheers mate

Bonkerz, Yep, definitely agree with the quality torx bit as you wouldn't wanna' thread it. I also recommend a decent sized torque/socket wrench as well, like the one I used. Heaps of length in the handle to give you a lot of strength to work with for the older bikes like you said. Will come handy in a lot of different scenarios.

Regarding the blue compound, the HD manual recommends blue Loctite throughout the entire document, as it is the most commonly used motorbike locking compound, but I'm positive there's a bunch of different compounds that do the exact same thing.

Yeah I have a penchant for red loctiting everything and it brings you unstuck sometimes.

pro tip, let the bike idle and warm up and red loctite becomes easier to undo lol.