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Buell Forum » Old School Buell » Archive through May 23, 2016 » Removing/Replacing primary cover shifter shaft rubber seal « Previous Next »

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Two_seasons
Posted on Tuesday, May 17, 2016 - 06:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Does the primary cover have to come off to replace the seal? What tool(s) are needed?

If primary cover is off, new seal, then when installing I need to put a plastic baggie over the spine area to protect, right?

TIA
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Buellrobot
Posted on Tuesday, May 17, 2016 - 08:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You'll need to pull the cover off (allen wrenches), pull out the seal (I used needle nose pliers I think), and replace with the new one. Baggie or tape over shaft to protect seal.

I had an old school seal with a metal body – the whole thing has to come out (don't worry about damaging it – you'll be tossing the metal sleeve).

See here: http://www.badweatherbikers.com/buell/messages/384 2/669258.html?1450720540#POST2521071

I'm assuming you've taken off primary before, but in case not, it's recommended to replace the seal under the primary cover. Use the manual to tighten everything in order, to spec, etc etc etc.
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Jim2
Posted on Tuesday, May 17, 2016 - 09:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You may be able to pull out the old seal with the cover on. I'm not sure. Might be really hard to do with an old hardened seal. Might be doable if the seal is still pliable. You would probably destroy it trying so would have to be prepared to take the cover off just in case. You might need a pick to pull out the seal spring after destroying the rubber that was around it.

To take the cover off:
-drain the primary (means you may or may not have to take muffler off), loosen clutch cable adjuster. remove clutch adjuster cover.

-loosen the primary chain adjuster. The adjuster is attached to the primary cover and if you try to remove the cover without loosening the adjuster it will just hold tight onto the primary chain.

-Remove shifter lever. Loosen pinch bolt (might need a cut-down allen wrench to do this. I use the same one I use on the valve covers). Then I use a hardware store two-claw faucet handle puller to remove the stick on lever. Works great. Clean off crud from the lever spines (stiff metal brush and PB Blaster or brake clean).

-loosen all primary cover bolts (two different allen bolt sizes. Draw picture of primary shape on cardboard or a used plastic cardboard election sign. Poke holes in proper location for each bolt you remove and stuff bolt into hole to store the bolt on the cardboard. You need to put the same bolt back into the same place so this is a tool to help you do that.

-Cover should pull off, might have to reach under and help lift the primary chain off of the adjuster block. Don't lose the alignment pins on the front and rear of the cover.

-If you already have the updated non-paper gasket you should be able to re-use the gasket. If not you want to have a new updated gasket on hand before you start the job.

-With cover off you should be able to find a socket the correct size to push out the old shift-shaft seal from the back side. Coat new one in seal-glide or O-ring lube to make it last longer. Cover shift shaft with corner of plastic baggie or wrap with teflon pipe tape. I've even used plain electric tape.

-don't forget the alignment pins when you put cover back on. Clean out old thread locker and gunk before starting the reassembly. When pushing cover on you have to have four hands. Two to hold the cover, one to catch the alignment pins as they fall, one to help lift the primary chain as you push cover on and two to hold the gasket in place. I use an appropriate sized socket that fits over the shifter shaft and is sized to press evenly on the shift shaft seal as I'm pushing on the cover.

-dont' forget to use a torque wrench, re-install drain plug, re-adjust primary chain, and re-fill primary with fluid, re-adjust clutch, re-install adjuster cover and shifter, etc.


You probably know most of this already. I hope it helped.

Great time to ensure you have an updated primary adjuster plate. It's thicker metal. Great time to ensure that the shifter detent plate hasn't popped loose and that the shifter detent pins aren't working their way out. Great time to replace a starter gasket if it is leaking. Great time to apply high-temp gasket seal or silicone high-temp RTV to stator plug that hold the stator wires as they exit the primary.

I'm sure I forgot something.
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651lance
Posted on Tuesday, May 17, 2016 - 09:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The seal can be done without pulling the cover.

Drill a small hole in the face of the seal insert a small sheet metal screw and pull on the screw to remove the seal. Done it a couple time and it works.

To install, use a piece of shrink wrap on the spline end of the shifter shaft and heat it up the tighten it up. Put a little grease on the shrink wrap and slide the seal over the top and tap the seal in with a deep well 1/2" socket.
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Two_seasons
Posted on Tuesday, May 17, 2016 - 10:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks guys, you are always quick to respond.

I've had the primary cover off already a couple of years ago. Put another new shoe in while I was in there, but did not replace the seal and it's leaking a little bit. I stuffed some grease around the shaft/seal for now.

Adjusted the primary chain as per the Lafayette. Man I sure miss that guy.

We'll see how much I lose (Formula+)on my trip tomorrow...going to Philly for my oldest cousin's funeral Saturday. My youngest brother just passed away too, so it's been a sad couple of weeks for our family.

You guys are awesome. Thank you very much.
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Ebutch
Posted on Tuesday, May 17, 2016 - 11:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Try adding some Lucas stop-leak to trans oil.
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