Fix for the Primary Cover
- Thread starter dflack001
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Boaski
Well-known member
Funny to see this pop up today. I just ordered a kit today. My break is exactly the same as the other pictures posted here.
ZanderMan
New member
I'm looking at a '09 SB9SX with 11K miles... this thread has me thinking to check if the current owner has ever had to replace the primary cover and if not, this may be a PM thing when I get the bike.
If the failure occurs... No clutch and the bike launches ahead w/o warning? Hopefully enough sense to apply the kill switch or brakes in time, but... is this what happens?
If the failure occurs... No clutch and the bike launches ahead w/o warning? Hopefully enough sense to apply the kill switch or brakes in time, but... is this what happens?
Usually most people just notice that the clutch goes soft. It doesnt happen a lot... never happened to me (or anyone I know)... but it does happen enough for someone to come up with a fix and decide to market it to others.
Ya, not very common. I put an eye on that part of the primary if I ever happen to have it off, but otherwise let it be. If it had a catastrophic failure (even more rare) completely cracks while sitting and running the bike would probably just stall.
If you want to ease your brain, taking the primary off is super easy. Might as well look at the clutch and chain too.
Buellmods.com
If you want to ease your brain, taking the primary off is super easy. Might as well look at the clutch and chain too.
Buellmods.com
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It happened to my wife's bike. We were in heavy stop and go traffic. She just slowly lost her ability to shift . Clutch became useless.
Boaski
Well-known member
I did "the fix" on my primary cover and installed it last night.
I had the usual break out on the flange
I sent Dave Flack a few emails & he answered them promptly. One was how he held the cover while doing the machining. He told me he went off of the the "outer" surface of the clutch access opening in the primary cover. Since I'm somewhat lazy and have access to Solidworks and a waterjet cover I made up a spacer block using the dimensions of the cover.
I drilled through the existing cover holes,
and tapped thru using the existing 1/4-20 threaded holes as a tap guide.
I mounted the fixture plate and spacer in the mill
I had the usual break out on the flange
I sent Dave Flack a few emails & he answered them promptly. One was how he held the cover while doing the machining. He told me he went off of the the "outer" surface of the clutch access opening in the primary cover. Since I'm somewhat lazy and have access to Solidworks and a waterjet cover I made up a spacer block using the dimensions of the cover.
I drilled through the existing cover holes,
and tapped thru using the existing 1/4-20 threaded holes as a tap guide.
I mounted the fixture plate and spacer in the mill
Boaski
Well-known member
and made it flat.
I would consider this a very well thought out kit. I manage a small machine shop & could have figured out all of this on my own, but I think it's stupid to reinvent the wheel, especially when someone else has figured out a fix that is successful and the bugs have been worked out.
The funny part was I spent more time than I should have figuring out what the orange and purple "seals" were.....
I would consider this a very well thought out kit. I manage a small machine shop & could have figured out all of this on my own, but I think it's stupid to reinvent the wheel, especially when someone else has figured out a fix that is successful and the bugs have been worked out.
The funny part was I spent more time than I should have figuring out what the orange and purple "seals" were.....
Very well done! Thanks for the insight:eagerness:
Nicely done.
Would you consider this kit as manageable for someone to install in their average garage with average tools? I know Dave offers a service to install the kit for you, which is probably the route I would go.
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I found it a 3 beer repair from start to finish.
As long as it doesnt look like a 6 beer repair. LOL
Boaski
Well-known member
I wouldn't myself, but I've spent too many years as a machinist and look at stuff through that lens. I tend to get too tied up in the details. I also have a low skill level with a hand grinder and files.
I will say that I wouldn't do the machine work on someone else's bike for what Dave charges, especially considering the risk of damaging a primary cover.
Boaski
Well-known member
I just happened to reread my response. The last line wasn't meant as a dig, my intention is to say you're getting a good deal if you have him do the work.
I was picking up what you were putting down. :up:
I'm catching what you're throwing.
I'm reading what you're writing.
I'm smelling what you're cooking.
I'm hitting what you're pitching.
I'm cashing what you're checking.
I'm rocking what you're rolling.
I'm itching what you're scratching.
ok, I'll stop.
I do agree, its not cheap, but a small price for a job done right.
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If you have basic mech skills, a good angle die grinder and a dial caliper you should be fine. If you struggle with basic maintenance then you should pass on the repair.
After 43000 mi. my '04 XB12S primary cover gave up. Neutral was becoming more and more difficult to find, and when I started having to hold the brake at stops, I knew exactly what was going on. I messaged Dave Flack at DMF Machining, and also of course, of this forum.
I sent him my cover, he got it on a Friday, had it fixed Saturday morning and shipped it back, postage paid. The quality of his work and attention to detail, from the beautiful engraving and machine-tooled finish of the plate itself, to the careful packing for return shipment are truly impressive. I'm extremely pleased, and my Buell is shifting better than it has for a while. The cost, at $160 is about half that of a new cover - and the possibility of another failure down the road.
I sent him my cover, he got it on a Friday, had it fixed Saturday morning and shipped it back, postage paid. The quality of his work and attention to detail, from the beautiful engraving and machine-tooled finish of the plate itself, to the careful packing for return shipment are truly impressive. I'm extremely pleased, and my Buell is shifting better than it has for a while. The cost, at $160 is about half that of a new cover - and the possibility of another failure down the road.
Thats awesome! Glad to hear he is still TCOB:angel:
Bought the kit and did the replacement several years ago after similar problems. One of the best, most professionally made, and well laid out instructions of any repair, mod, or upgrade I have done to my 04 XB12S. Great to see Dave is still doing this and helping keep our beloved OG Buells on the road.
