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Gunut75
| | Posted on Tuesday, June 14, 2011 - 10:45 pm: | 
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Got some time in on my primary cover today. I drilled out the holes, and finished threading the 1/4-20 through. The new plate will be held on with screws that uses the holes from the inside. There is about .270 of thread that is left after the cover is screwed in place. The cover screws use .4+ of thread. I'm going to use .37+ of thread for the fix, and .27 (5 threads) for the cover screws. Some of the material IS removed in machining. It will look completely stock with the cover in place. The fix will be screwed in with epoxy used on the screws I put in place. I got a first mock-up plate made today. I will make one out of steel in the AM. Mine took about .145 to clean up.
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Whisperstealth
| | Posted on Tuesday, June 14, 2011 - 10:53 pm: |
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WHOO HOO! Awesome! Looking good, keep on, keeping on  |
Greg_e
| | Posted on Tuesday, June 14, 2011 - 11:06 pm: |
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Sucks that it takes a larger mill than I have, no way I can get the cover under my mill and get all the way around that feature. |
Gunut75
| | Posted on Wednesday, June 15, 2011 - 08:38 pm: |
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Here's the finished product. I have to take the in/lbs torque wrench to work tomorrow. I will also post a pic of the final product. I only need to take about .06 off of the stock cover screws. I'm also going to do some miles to make sure everything is kosher.
To work and back is 70-80 miles each day. I cant wait to see what a properly adjusted primary is going to feel like tomorrow. With the outer thrust washer missing, the whole clutch pack was able to rock. Explains why sometimes my bike shifted great, and sometimes (rarely) like crap. My shifter rides on roller bearings to try to help this. Tomorrow should be sweet. Cheers y'all. |
Gunut75
| | Posted on Wednesday, June 15, 2011 - 08:40 pm: |
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Stalker: Thanks!!!!!!! |
Greg_e
| | Posted on Wednesday, June 15, 2011 - 09:34 pm: |
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I would still like to see a way that the home mechanic could fix this if they had the parts created by someone else. It looks like this is possible with a grinder and a drill but it is hard to explain. On the inside there is the omega shape and a bunch of cast webs that are supposed to help hold the lips in place. What if a person went through and ground the entire lip area and webs down to the flat area where the gasket sits. Now machine a big block structure that will replace the lips and get screwed to the space just inside of where the gasket seals? |
Whisperstealth
| | Posted on Wednesday, June 15, 2011 - 10:06 pm: |
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Looks fantastic Gunut! Great job 
Look forward to hearing your ride report. Have a good feeling, you'll be having good vibrations! |
Gunut75
| | Posted on Wednesday, June 15, 2011 - 10:07 pm: |
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You mean sleeve it? The ball ramp takes up the whole round area of the omega. The bottom of the omega is so the cable hookup can swing fore and aft. The bore of the omega would have to be machined out and replaced with a sleeve with the new lip on it. The part of the lip on mine that broke is only .06-.07 thick.
Believe me, if there was a kit I could make to fix it at home; I would make it. I have not come up with anything............... yet. |
Greg_e
| | Posted on Wednesday, June 15, 2011 - 10:47 pm: |
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Got a picture of it from the backside before the repair?
It is still going to take someone with a milling machine to make the parts that I am thinking about, but after getting these parts a person at home with a drill and dremel could make the repair. |
Whisperstealth
| | Posted on Thursday, June 16, 2011 - 12:17 am: |
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If you were to check out the Obiewan link, you will find someone did use a drill and dremel to make the repair. The post is below Obiewan's fix and above B_I_B's.
I thought about trying to do this myself. If I had, had a plate already made, I might have given it a shot. But I do not have the drill bits or a dremel, or the ability to make a plate without spending a bunch of time with a hack saw and dulling my made for wood hole saws. I don't even have a grinder. In the end the lack of tools, transportation, and experience made it a good idea for me to seek outside help. I'm very happy to have Gunut make the repair and believe his work will speek for itself.
All this does have me seriously looking into learning some metal working skills. And increasing the tools I have on hand. Thinking a grinder, drill press, bits, and dremel set up would be very good investments! Would love a metal cutting band saw, but then your talking space and $$. |
Gunut75
| | Posted on Thursday, June 16, 2011 - 09:42 pm: |
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Okay......the missing thrust washer is a whole other deal!!!!! The clutch works great. I had to adjust it a touch when I got home, but it works great. Just like it should.
The missing thrust washer............Imagine never being able to properly adjust your primary. It's a whole different bike with the washer in there. Less noise, smoother shifts..........HOLY S41T!!!!! Smoother than it has EVER been. Wow......just.....wow! |
Whisperstealth
| | Posted on Friday, June 17, 2011 - 12:12 am: |
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Great to hear! Gotta be nice, you get to fall in-love all over again. You only found out it was missing after you took it apart right? No way to check otherwise?
And the lip repair was all silk, right on! |
Rwven
| | Posted on Friday, June 17, 2011 - 07:45 am: |
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I like it Ian! |
Joel9
| | Posted on Sunday, June 19, 2011 - 03:40 pm: |
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Gunut, your repair looks great! now your missing washer, how was it missing? not installed from the factory or recent work done on the bike? i gots to know, thanks. |
Gunut75
| | Posted on Sunday, June 19, 2011 - 09:40 pm: |
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I have all of the service records for the bike from the day it was sold brand new. I got the bike with somewhere close to 5k miles on it. The primary cover has never been off. Therefore, it was missing since day 1. I cant believe how much quieter everything is. I always thought it was a loud valvetrain. Nobody that has a Buell has ever ridden my bike, and I have never ridden any XB other than mine. There was nothing to compare it to. A friend of mine wanted to swap bikes for a ride, and we never got around to it. I told him that if we had, he would have asked me "What the he11 is wrong with your bike?!?!" It sings a whole new song now. I can hear all sorts of new sounds. |
Whisperstealth
| | Posted on Wednesday, June 22, 2011 - 01:48 am: |
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Update:
Gunut has finished my cover, and will be shipping it to me tomorrow. Can't wait to get it! So for those of you who need repairs, send him a PM, and get lined up! |
Whisperstealth
| | Posted on Saturday, June 25, 2011 - 06:17 pm: |
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It's here, it's HERE!  
I'll tell ya all how it goes! |
Whisperstealth
| | Posted on Monday, June 27, 2011 - 08:46 pm: |
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How well did it go? Well, I got it all back together around 8:00 Sat night, and went for a quick test ride. Came back adjusted clutch. Took a shower, packed a bag, - And split for two days!!
It's working GREAT. Had to re-adjust clutch next day, because I had not got it right, and still need to tweek the cable adjustment to my taste. That said, the repair is working flawlessly! It's kick-ass, the shifting is sharp and solid. The work looks clean and well done on the inside of the cover, and factory on the outside. Can not tell by looking at it sitting on the pavement that anything went wrong.
Riding home today, I thought this to myself:
Some days your the windshield, some days your the bug... Ripping through North Eastern Arkansas, today I am definitely the windshield! And the green look of envy on that truckers face, as I pulled around in third gear, as the bugs destroyed themselves on my windshield and body, brought a huge smile to my face. As I hit forth, and then fifth, I hoped he'd have a chance to do the same someday. But today was mine. God forgive me, I love this bike!
So, a big Thank You to Ian aka Gunut! Thanks again. You did a fantastic job, and I look forward to meeting you and working with you again!
CHEERS   |
Joel9
| | Posted on Monday, June 27, 2011 - 08:58 pm: |
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Hi Gunut! i sent you a pm. |
Doncasto
| | Posted on Tuesday, June 28, 2011 - 08:45 am: |
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PM sent yesterday . . . |
Rex_1_mn
| | Posted on Saturday, July 09, 2011 - 04:41 pm: |
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Im Thinking I may have the same problem will check on monday. About 1000 miles through a 2000 mile trip it was starting to shift like crap and the clutch wasnt completely releasing. Adjusted clutch and it got better but still not as it should be...
TBD |
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