| Author | Message | ||
     Redshiftquasars |
Turns out I've had 17k trouble free miles. Love the Bike and its utility. I rode the bike to work on Monday and noticed that the clutch was dragging and was hard to find neutral. I figured it was time for an adjustment so Monday eve I pulled it into the garage so I can start on the adjustment. I pulled off the clutch inspection cover so that I can start with the adjustment and started with the counter clockwise turns on the adjustment screw. The turns felt as if the threads were being bound up. I wanted to make sure that all was well so removed the nut, the outer and inner ramp and viewed what seemed to be a broken ring. I drained the primary fluid and pulled off the primary cover hoping to find the rest of the broken pieces but was unable to. I mocked up the broken piece back behind the spring diaphragm the way I had seen it when I pulled off the clutch inspection cover, inner and outer ramps.(more pics below)  On the rear side of the ramp I can see some wear marks that match up pretty close to the broken piece  Here's a closer look at the broken piece. You can see that the right side of the part is smooth and the left side of the piece is jagged and looks to be broken. I've looked through the service manual and on page 6-9 have attempted to identify the broken piece but have no clue what piece it may be. Any help would be appreciated.  I may pull off the diaphragm spring tomorrow to see if I can find the other half of the broken piece. (Message edited by redshiftquasars on May 07, 2009) | ||
| Redshiftquasars |
Well it turns out that after I posted this I did a search on badweb with the following: clutch broken pieces Turns out that someone else has already experienced my problem. Looks like I'm gonna have to shell out $220 for a new cover. http://www.badweatherbikers.com/buell/messages/384 2/282980.html  | ||
| Baydog |
Well that surely is disappointing. You'd think that for a motor that's been around this long they'd have figured out that's a weak point in the design. | ||
| Hughlysses |
Redshift- Isn't your bike still under warranty? | ||
| Tginnh |
Sorry to hear that. I hope your warranty is still in effect. Are you going to attempt a repair per the link you found? Seems doable except for the access to a milling machine - not a common thing. Good luck. | ||
| Natexlh1000 |
Isn't this type of thing what the warranty is for? | ||
| Redshiftquasars |
I'm reviewing what I had done and on Monday when I got to work I had loosened the locking nut(mid cable) and attempted to adjust there. My guess is that this allowed the ramp to put load on the weak part of the primary cover, the lip that broke. Yes the bike is still under warranty, but I just called my local HD/Buell here in Glendale Ca and they've got a black one in stock. We all know that the black ones are faster so I'm gonna go a grab me a black primary cover. I'll post some pics if I can get it all put back together tonight. | ||
| Court |
Sure looks like a warranty case. Interesting that two have done this. Thanks for the good write up. | ||
| Florida_lime |
For a 2008 Uly, I'd expect so.  | ||
| Court |
These are some of the ones that really get interesting. Two, apparently, identical occurrances out of well over a hundred thousand motors made. Something CAUSED that and I'm trying to decipher, at least in my mind, what it was. Two bad castings? Someone pried on the surface? I've no clue but am glad you found it and at least it looks like a quick and easy fix. | ||
| Panhead_dan |
Court, One possibility to consider; improper adjustment of clutch actuation resulting in undue stress on the snap ring landing. Proof; when adjusted correctly they don't do that. (should I press post or not?) it's just an opinion, don't nobody get mad please. | ||
| Redshiftquasars |
I'm gonna have to agree with Panhead. If I would of started the adjustment down at the clutch inspection cover things may have turned out different. But to let you all know, I went and picked up the black primary cover. The guy behind the counter said it would fit my 08 so I was pretty happy thinking I was gonna ride off into the sunset sometime this weekend. I got home and started removing all the covers and grommets from the original cover and started putting them on the faster black cover. They all fit but the rubber grommet that goes into the hole where the engine shift lever comes out didn't fit(thats the one below the chain inspection cover). I got worried real fast, if the rubber grommet doesn't fit than the engine shift lever may not fit. I proceeded to put the cover on and my suspicions were correct. The engine shift lever's diameter is larger than that of the primary cover. couple of questions. my bike is under warranty. Its very possible that since I started the adjustment mid cable(only so that I can get the bike home and do it correctly) that the lip gave. The cover is off so the bike is not mobile, should i take the broken one in, along with the new faster black one, and try to get it replaced via warranty? I hope that they refund my $220 for the faster black cover?  Here's the part number for the 09 primary black cover.  (Message edited by redshiftquasars on May 07, 2009) | ||
| Natexlh1000 |
If the part doesn't fit, there's no reason that you should pay money for it. The warranty issue is kinda hazy since I can't think of a way that the clutch release stuff could put that much force on the casting to make it break. It would be an open and shut case if you let the servicemonkeys play with your bike first instead of figuring out the problem yourself. If it had a flaw in the casting, I would thing the guys in the lab coats at BMC would like to see it. You should probably just call customer service and ask them what your next step would be. Perhaps they will like the tone of your voice and give you another case! | ||
| Redshiftquasars |
I somewhat agree. That lip is supposed to handle some load, enough load so that the ramp can pull on the adjustment screw enough for you to change a gears. Doesn't matter anymore, it turns out that I returned the Black primary cover that you see above and they were able to find me a black primary cover that has a large enough hole for the engine shift lever. In anycase(pun intended)as soon as I've got i all put together I'll post a pic of the completed job. Thanks for the input everyone. | ||
| Ourdee |
Can I have the old broken cover? |
