Fix for the Primary Cover

[mmcn49]

I read somewhere that 07 and newer Lightning’s are much less prone to case failures. Does anybody know if this is true?

Eric – Would reducing spring force by 20 pounds have any real effect on reducing the case failure rate?

Any opinions about being pro-active, (grinding out the lip on a good case and adding the aluminum plate)?

 

[dflack001]

Mine broke and its an '08...
I have sent orders to customers with '04, '05, '09, and 2010.
I think it has more to do with the style riding and how many stops you have and how long you are holding your clutch.
How would you reduce the spring force?
As far as proactive...if you have it apart then what can it hurt to put the fix in! I don't recomend just breaking the lip off, use a grinder or sander.

 

[Restlessrustler]

I will help and say...mine wasnt broke yet....but I have 10k and it sounded good. bought it and installed. I sanded down my cover...(ouch) and followed the instructions to the T. all was well but it rubbed a tiny bit under clutch hold. after a few miles and a primary oil change its all good and the stuff feels safe. I will run this until it breaks or if i find a 12 motor to drop in, but all in all im looking for a bolt for the woman so i would buy a kit from him again in a heartbeat!

 

[dflack001]

Thanks Restlessrustler! I have modified the instructions a bit so that there should be absolutely no chance of rub since you notified me of such rubbing...

 

[dflack001]

Hey! So just wanted to give a shout out to the potential customers outside the USA...
I'm not making any money on shipping and its $23.50 for International USPS Priority Mail. If there were a bunch of orders going to the same address I can ship up to 4lbs at that price. Then the group of people ordering could split the cost of shipping making your kit a little cheaper...

Thanks a bunch everyone!
-Dave
https://docs.google.com/forms/d/16PZVxuprasCLpqpEYbq7XREvAl2HUpc0pardeENsd5A/viewform

 

[dflack001]

Wondering if there is actually a difference (besides color) in primary covers between the different models and years of the XB Lightning's and Firebolts?
Thanks in advance!
-Dave

 

[rah7777777]

Mines not broken yet, but think I might go ahead and get a kit soon to be safe.

 

[Cosworth]

There is a difference in the shift shaft between the 03-05 and 06-10 models.

 

[dflack001]

rah: You wouldn't be the first! It sucks when your bike breaks and you have to wait for parts!!

Cosworth: So the actual covers are essentially the same just different shift shafts? Or the shift shaft is in a different location on the cover?

On a different note:
-I am offering refurbished primary covers with the DFLACK Cover Fix and a fresh black paint job ("Tan" is extra $$) for $150.00 shipped.
-I ship USPS Priority Mail (ships in 3 Days or less!) the day after your order is placed.
-Working at getting things lined up so that I can ship the same day.
-Kits will soon be coming with Thread Locker and a #3 Phillips Drive.

Thanks a bunch!
-Dave

 

[Cosworth]

Same location different size.

 

[rah7777777]

I'm looking at this in further detail and I honestly think the aluminum will be just fine, its not a blunt force being applied. My concern would be the threads coming out. But, I honestly think it would be a while before you would have any issues, if at all.

For those folks who worry about this (basically the anal worry warts like me), it looks like you could easily tap some extra threads into the primary and drill the aluminum plate in those spots for a couple extra bolts to go in.
You'd just have to mimic the screw hole design already made for the 3 main holes so the bolt was not sticking out any. (Basically take a larger drill bit and make the cone for the angled bolt head to fit into)

And this is assuming you have access to tools and what not.

If I buy a kit, can you throw in a few extra screws?

With 5 screws/bolts in it and 3 being right by the ramp, I think this would be a rock solid setup.
(BUT, I do tend to go over board with things!!)

 

[dflack001]

Cosworth: Is the shift shaft a different diameter?

Rah: I would throw in a couple extra screws...just put it in the notes so I don't forget! Where would you tap and drill for more screws though? If you look on page one of this thread there's a picture of the inside of the primary cover...the only place I see you being able to add screws would be the vanes. They are too thin for a 1/4-20 screw...maybe a really thin machine screw would work.

 

[Cosworth]

I honestly dont know what the exact difference is, but it is different and listed that they will not work on non corresponding years.

 

[dflack001]

OK...I'm looking into it. Thanks again Cosworth!

 

[Cosworth]

My bikes an 06, ill take my dial caliper to it this afternoon and report back with the shaft measurement.

 

[dflack001]

Well after a quick search on eBay I'd doesn't look like there's a difference in primary covers between the models/years. Just color...

 

[Cosworth]

Ebay ads are often wrong for our bikes. Heres some solid evidence below.

http://americansportbike.com/newdir/Item/17528
http://americansportbike.com/newdir/Item/17531

 

[tomahawk1976]

I just bought a new primary cover.....damn

 

[dflack001]

What's the return policy? You can fix it with my kit
for way less! If you don't return it I may be interested in your old one...

 

[Dingo1]

Hey just wondering if possible to send to new zealand
I need this kit for 2004 xb12s
Cheers