Cometic Complete Primary Rebuild Kit For Harley Sportster 1991-2003

High-Performance Cometic Complete Primary Rebuild Kit for Harley-Davidson Sportster (1991–2003)

When it comes to sealing your V-Twin engine, Cometic Gasket is the name trusted by professional racers and top-tier builders worldwide. The Cometic Complete Primary Rebuild Kit for 1991–2003 Harley-Davidson Sportster models is the definitive choice for riders who demand more than just a standard replacement. Designed for the 5-speed Evolution Sportster era, this kit addresses the common sealing challenges of the XL platform, providing a modern, high-tech solution to prevent oil leaks and weeping.

The Cometic ACM Advantage: Advanced Material Science

The centerpiece of this Sportster primary gasket kit is the outer primary gasket, manufactured from Cometic’s proprietary ACM (Aluminum Core Material). This advanced gasket features a solid aluminum core chemically bonded to a thin layer of nitrile rubber on both sides. Unlike traditional paper or fiber gaskets that can saturate with oil and fail over time, the ACM design provides the structural rigidity of metal with the sealing flexibility of rubber. It is highly resistant to the chemical properties of modern primary fluids and can withstand the intense heat cycles of an air-cooled 883cc or 1200cc engine without shrinking or losing torque.

Total Sealing Solution: What’s in the Kit?

This is a comprehensive C9258 series (or equivalent) rebuild kit, specifically curated to provide every seal needed during a primary cover removal. Whether you are replacing a stator, servicing the clutch, or upgrading your primary chain, this kit has you covered. It includes:

• Outer Primary Gasket: Premium ACM construction for a leak-proof, high-pressure seal.
• Derby Cover Gasket: High-performance seal for the clutch inspection cover to prevent oil seepage.
• Inspection Cover Gasket: Precision-cut for the primary chain adjustment window.
• Shifter Shaft Seal: Durable, high-temperature rubber to stop leaks at the selector shaft exit.
• Starter Oil Seal: Engineered to maintain a tight seal around the starter drive interface.
• Drain Plug O-Ring: A fresh viton or nitrile seal to ensure every oil change is drip-free.

Compatibility & Fitment

This kit is precisely engineered for the Evolution Sportster 5-speed drivetrain. It is a direct fit for all models produced between 1991 and 2003, including:

• XL883 Series: Standard, Deluxe, Hugger, and Custom.
• XL1200 Series: 1200 Sport, 1200 Custom, and standard XLH 1200 models.
• Note: Specifically designed for the frame-mounted engine era (pre-rubber mount).

Why Choose Cometic Gaskets?

Proudly Made in the USA, Cometic Gaskets are synonymous with precision and performance. Their Harley-Davidson primary seals are developed using the same technology found in NASCAR and NHRA engines. By choosing a Cometic kit, you are investing in a product that eliminates the need for messy liquid sealants and provides a “one-and-done” installation. The rigid aluminum core makes the gasket incredibly easy to handle and align, significantly reducing the risk of a pinched or misaligned seal during assembly.

Installation Pro-Tips

For maximum performance, ensure that the primary cover and engine case mating surfaces are perfectly clean and free of old gasket material. This Cometic Primary Kit is designed for a dry installation. There is no need for RTV or gasket tack—the ACM material is engineered to seal perfectly on its own. Always follow the factory torque specifications and tightening sequence to ensure even compression across the entire primary face.

Upgrade your Sportster with the world’s best sealing technology. Order your Cometic Complete Primary Rebuild Kit today and keep your ride clean and oil-free!