Primary cover (Clutch ramp lip cracked)

[DonOfPensacola]

So I was riding to work when my clutch wouldn't disengage. Was able to find neutral and stop. Pushed it to a safe place and trailered it home after work. I checked the clutch adjustment and cable. I found the clutch ramp was not moving correctly. Removed it to inspect it and found the primary cover where it sits was cracked on the lip. Luckily the chunk didn't break off and fall in. So is this a common failure at 22k on the 04 XB12R's? I'm going to have to order a new one I guess (+seals). I just purchased the bike 1 month ago. Here's a pic of the cracked primary cover.
http://www.buellxb.com/buell_images/9267_20110411151420_L.jpg

[stellio78]

They can be repaired if you are the DIY type

http://www.badweatherbikers.com/buell/messages/3842/282980.html

[DonOfPensacola]

Thanks, I planned to get it welded even if I replace it. I have a friend who works at a welding/machine shop. Think I will show him the link you posted. See if he could do the second one shown.

[gbalias]

its hard to get a good weld on it. the alum is impregnated with all kinds of contaminants from the oil.....i tried to weld it 1st, was unhappy with it, then decided on the other method:

http://www.buelletinboard.com/forums/showthread.php?15873-Primary-Cover-Fixed&highlight=primary+cover

[DonOfPensacola]

Looking at my pic I noticed the other side was no good. Think the old one will become wall art in the garage. I found a cover from a dealer for $219 shipped. My dealer has all the gaskets in stock. Now I'll be playing the waiting game. Said up to 2 weeks before I get it.Thanks for all the help everyone.

[DonOfPensacola]

Primary cover will be in Thursday. Just in time for a three day weekend. Guess I'll start buttering up the wife now. That way I can ride all weekend for sure. LoL, that's if my bike doesn't get pissy. My Buell is like the wife, always so needy. I got to put the wrench on her to make her happy :)

[DonOfPensacola]

I installed my new cover and gaskets last night. Sure was nice to hear the bike come back to life. Everything went smooth thanks to all the info here on Buellxb.com

[Gazsi]

Hi all!

I repaired clutch cover

(Hungary)

http://www.buellxb.com/buell_images/8972_20120330080226_L.jpghttp://www.buellxb.com/buell_images/8972_20120330080212_L.jpghttp://www.buellxb.com/buell_images/8972_20120330080144_L.jpghttp://www.buellxb.com/buell_images/8972_20120330080129_L.jpghttp://www.buellxb.com/buell_images/8972_20120330080113_L.jpghttp://www.buellxb.com/buell_images/8972_20120330080055_L.jpghttp://www.buellxb.com/buell_images/8972_20120330080041_L.jpghttp://www.buellxb.com/buell_images/8972_20120330080027_L.jpghttp://www.buellxb.com/buell_images/8972_20120330080013_L.jpghttp://www.buellxb.com/buell_images/8972_20120330075959_L.jpghttp://www.buellxb.com/buell_images/8972_20120330075943_L.jpghttp://www.buellxb.com/buell_images/8972_20120330075924_L.jpghttp://www.buellxb.com/buell_images/8972_20120330075855_L.jpg

[Gazsi]

2004 Xb 12s Lightning :)

I love Buell :)

[motoqueiro]

So what is the most probable cause for this to happen?

[JOEL9]

i think it's just a flawed design, too weak of material for what it's supposed to do, or the clutch not being adjusted correctly, i don't know. here is another recient thread about this:

http://www.buellxb.com/Buell-XB-Forum/Buell-Firebolt-XB12-XB9/My-clutch-just-gave-up-on-me

[Theycallmecrash]

Wrong thread edit

[user_deleted]

he posted this 2 years ago. would think it's repaired by now.[confused]

[ich]

http://shop.strato.de/epages/63112045.sf/de_DE/?ObjectPath=/Shops/63112045/Products/PF-Bue-0018

[xbtiger]

hi.................the reason why this breaks is because of a manufacturing fault. There is a little readious missung at the lip and this is why it breaks. Another reason is when the bike had an accident and the cover had Ground contact and the geometrie of the cover is slightly altered resluting in eccess Stress on the lip, this is why one should take the primary cover off when one has gone down.
A friend of mine has developed a repair kit with a steel insert that is bonded into the cover. The only problem is that you would need to send the part to Germany and that would not be cost effective. Having said this.................it all depends on the spare parts prices.................the cover in Germany is arround 400 USD

Shris