| Author | Message | ||
     Starwolve |
I have a 2004 Firebolt, and am still searching for a primary cover for the bike. I have read that the 06+ primary covers are different, mainly due to a larger diameter shift shaft. If this is true, has anyone found a way to run a newer primary cover on an older style bike? I'm thinking it may be as simple as a thicker bushing on the cover, or swapping out the shifter shaft and shift clamp for the newer style. The real reason for asking is that I may have a 2007 primary cover that I can use on my bike, if I can make it work. Turning a bushing on the lathe wouldn't be a problem at all, if that's all that would be required. | ||
| Teeps |
Compare part numbers on the case to engine gasket, between '04 and '07. That will tell you if the newer case will mate with the engine. | ||
| Starwolve |
Good idea - if the gasket number is the same, then it should line up. American Sport Bike has this gasket listed for all XB models: http://www.americansportbike.com/shoponline/ccp0-p rodshow/17128.html So the never covers should line up. I'll have to tear into my parts and service manuals to see what is involved in replacing the shifter shaft, and I'll be taking my beat-up cover off today to see what type of bushing or seal is in there. It seems do-able, either way, and that will help if I don't need to limit my primary cover search to a specific range of years. | ||
| Teeps |
You could call Al and ask him if the shift shaft can be "upgraded", if anyone knows it's he. I'm thinking if the shaft OD is larger on the primary case, it's probably larger on the inside case too. Machining the main engine case, not good. | ||
| Ericz |
The newer shift shaft will install right into the older style engines. I put an 06+ primary cover and shift shaft on my 2005 XB12 and it fits and works great! | ||
| 1313 |
I may have a 2007 primary cover Good on the '07 - up part:  Can't say as I ever heard of this being a problem area - but it's definitely *better* than pre-'07, 1313 | ||
| Starwolve |
Some good info here. I'm headed to the garage now to take the primary off and "see what I can see"! More to follow. | ||
| Starwolve |
Ok - I pulled the primary, and discovered that I do have a hole. I also figured out that the shifter shaft should not be too difficult to replace, as long as the inner shaft diameter is the same. If not, the new shaft could be easily modified in the lathe. Since Ericz mentioned that he had done it, I'm confident this should not be a problem. So if I find a decent 06+ cover, I'll look for a new shaft to go with it. Here's some pictures of my cover:  The hole in the cover:  Hopefully I can close the deal on a replacement cover, and move on from here. I have a few new parts that need to be installed:  | ||
| Mtnmason |
what would it take for you to part with that seat cowl? | ||
| Fast1075 |
I would have the cover welded up if it was mine...then find a spare for inventory. | ||
| Starwolve |
I will probably have the cover welded, and use that one as a spare if I can find another. I really don't want to part with the seat cowl - I plan on mainly running this in a single seater configuration. | ||
| Dfishman |
Chris, If that hole is the only problem,it can be fixed with Belzona.It is an epoxy that is stronger than PC-7/JB-Weld etc.I punched a hole in my magnesium side cover on my honda & used it to make the repair.I'm not sure how to get it because it was given to me,but I'm sure it can be found on the web.It has been used to patch holes on engine blocks where a connecting rod tried to escape.It has also been used to build up SS boatshafts that were worn at the cutlass bearing.Great stuff.Check it out. | ||
| Jhallgren |
JB Weld would work just fine on that tiny hole. Just my 2 cents | ||
| Starwolve |
Donnie - thanks for the heads up on the Belzona. I'll try to find some around here. http://www.belzona.com/prod1k.aspx It looks like that stuff is machinable, so if I use it to fill the hole and build back up the shifter mount, I might be able to drill and tap it to put the shifter back in place. On the XB's - are the threaded holes in the primary cover just for mounting the shift lever in 2 different locations, high for stock pegs, and low for the 1" drop pegs? If so, I can just use the upper mount for the time being. I have drop pegs for it, but the shifter slightly out of place will be okay for getting it back on the road. | ||
| Dfishman |
Chris, Enjoy your short time home.Good luck on your deployment. We just spent a little time around Tuggles. Remember that Buell will love it there. | ||
| Greg_e |
Glue or weld that hole. Many years ago I had some aluminum parts repaired at a shop in Liverpool, they were right next to the tracks off Old Liverpool Rd, if still there I bet they fix that hole for about $20. Alternate to having it welded would be to buy a small MIG like a Hobart Handler 140, maybe down to the Handler 125 (not the EZ because it does not use gas and does not do aluminum), the 125 requires a gas upgrade so the 140 is probably the same price. | ||
| Starwolve |
Greg - I think I can get it welded up over at County Line Choppers - I'm friends with the owner. His brother is a welding inspector, and he can weld just about anything. The real challenge will be welding it up so that the shift pedal mount can be used again:  Also - I sent you a PM about the Exhaust - I have the Uly pipe, are you still up for trading? I can meet you somewhere this weekend to make the swap if you're around. Donnie - I'm jealous that you're so close to those roads, but I know I'll be back there again soon enough. Squirrel Spur was just the road to convince me that I need a bike like this, instead of trying to force my Harley through those turns. I hope you weathered the storms okay - I was in El Paso and haven't seen a drop of rain in weeks. | ||
| Brumbear |
cut a carbon shaft on a lathe and put it in the hole any machine shop should have carbon | ||
| Ducxl |
THis thread sounds startling  I once replaced my '05 cover with an OEM part for about $225.This thread leads me to believe the covers are no longer available??? Is that true? | ||
| Starwolve |
They are available - just not cheap or plentiful. I know I can replace it with a new one if needed, but I would rather repair the old one and/or find a used one. I'm trying to repair this bike without breaking the bank - the whole thread can be found here: http://www.badweatherbikers.com/buell/messages/327 77/643027.html?1315532586 | ||
| Ducxl |
Whew!! Thanks.Glad they're still out there. Yeah,i remember that thread.Good luck  | ||
| Froggy |
Duc, the covers are available, but the magnesium colored ones were on backorder last I heard. If you are willing to wait, you can get one for sure. | ||
| Greg_e |
Any decent welder should be able to build that mount back up, then drill and tap, if needed drill bigger and install a helicoil. I sent you a reply about the muffler, check your spam folder. Decided I better stick with what I have. | ||
| Richardbiker |
To Starwolve - PM sent. Re: Muffler swap. Rich | ||
| Starwolve |
Thanks Rich, and sorry Greg. I had the wrong person, it was rich I had discussed trading with. Sorry for the confusion. Rich - I'm traveling right now, but will be in touch tomorrow regarding the exhaust. | ||
| Paul_in_japan |
I replaced my 04 primary cover with a 06 one as the lip had snapped off the hole where the clutch housing pushed up against it.(a common problem). I was told at the time, that I'd have to also replace the gear shift mechanism as the shaft was bigger in diameter. As the primary cover was about $300 and the gear shifter $30 the cost didnt bother me. I would have thought that if you only upgraded the cover then oil would pour out of the rubber seal where the shifter enters. | ||
| No_rice |
the mount above your broken one(behind the black plug) is also threaded and will accept the shift lever bolt... |
