Please Help! Primary Cover

[Goiter24]

So I have been working on replacing my primary cover ans some other parts on my 2008 XB12Ss. I went to put on the new cover yesterday and for some reason it wont fit over the engine shift shaft. The part numbers are the same on the two covers. There is a difference in the hole though. The stock one has some plastic and rubber fittings in side it, and the new one has like a copper looking piece and seems to be a smaller diameter, because its getting caught up after the teeth on the shaft and not sliding through. The stock one goes on and of easily, and not too snug at all.

I'm not too sure what to do. Also, I need to know if I need to get a new oil seal for the new cover. It didn't come with one, and I'm guessing I need it. I tried to take the rubber deal out of the stock one, but it messed it up, and a little spring came out. Does any know whats up with that?

Can some one please help me? I really need to get this back together. Thanks! I tried to upload some photos on this post, but I'm not sure how to. If someone could tell me, maybe it'll be easier to see what I'm talking about.

 

[chrispudd]

Just above where it says " welcome Goiter24!" You'll see some headings. click the one that says "my pics"
Upload photos to there.
Then when you message, click the "add your photo" box and choose the pic from the ones you uploaded to the site.
Never experienced your problem, but just a guess... maybe there's a copper sleeve inside the cover that you have to tap out?" When i purchased a gasket set from harley for my xb9s, it came with 2 different size shift shaft seals. Best of luck. Chris

 

[Goiter24]

 

[Goiter24]

Well user travis, says in this post (link below) that there are different diameter sizes of shift shafts depending on years of the bike. But the two primary covers I have are both the same part number (HD 25543-02). But the new one definitely has a smaller hole. Is there anyway I can find out the exact diameter of the shift shaft and bore out the new cover with a drill or something?

http://www.buellxb.com/Buell-XB-For...yX-XB12Scg/Primary-cover-oil-seal-HELP-PLEASE

 

[dave_xb12r]

That sounds like HDs problem. Regardless of where you bought it, take them to a dealership and see what they say. That's BS

 

[Buellysses]

I ran into the same issue replacing my primary. There is a shoulder on the inboard side of the shifter shaft hole that needs to go away.

I went down to ACE and picked up a 3/4" drill bit and some emery cloth. Drill the shoulder out, drill from the outside of the cover. Make sure you use plenty of oil, go slow, and CLAMP THE COVER DOWN TO SOMETHING! If it binds on the drill bit you are going to get hurt. Use the emery cloth to clean up the inside of the hole.

This part kind of sucks, but it's necessary. Use a die grinder, or whatever you have handy, to take off a small amount of material from where the cover contacts the shifter shaft. Once again, go slow, and only remove a small amount of material at a time. You will need to use the inboard bushing from the original cover.

 

[Goiter24]

Thanks guys, that sound like what I'm gonna have to do. Bullysses, how do I get the bushing out of the old cover? It seems stuck in there pretty good. I already ordered new seals from American Sport Bike. With the grinder, you mean like bevel off the edge on the inside of the hole a bit?

 

[Buellysses]

As far as beveling, yes, you are correct. Try to get it to look like what your stock one looks like. You are just going to need to add some clearance so when you bolt the cover tight it isn't pushing in to hard on the shoulder of the shifter shaft. If you don't get enough clearance in there the shifter won't move (learned that one the hard way)

As for getting the bushing out, if I remember correctly I just put a deep-well socket in the hole (from the outside) and gave the socket a few whacks with a hammer.

 

[Goiter24]

Ok, so I got everything put back together, and everything was going great, until I got it running. It now is having a hard time shifting. It will go down into 1st just fine, but hard to get back into neutral and won't go up above 1st. Any clues about what could be causing this?

 

[ztied]

Make sure you did put a gasket in there.Without a gasket it will bind the shifter up.

 

[Goiter24]

Put a gasket in where? I put in a gasket on the primary cover and an oil seal around the shifter on the outside of the cover like the manual said to do. Where are you referring to?

 

[ztied]

Sorry I was talking about the primary gasket.Without one, the primary cover will act like a clamp when it is tightened,and keep the shifter from shifting.Sounds like you got it covered.

 

[Buellysses]

If your shifter is binding you may just have to take some more metal off the primary cover. It took me about 3 or 4 attempts to finally get it loose enough to function correctly.