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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Bodywork, Paint, Polishing and Cleaning » Kick Ash Airbox Cover keeps cracking! « Previous Next »

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Whatever
Posted on Saturday, March 24, 2012 - 12:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ok.

I have rarely had a problem that can't get resolved through the HD MoCo.

I am at a loss for what to do.

My 2010 City X was purchased in April 2010, however, it was a factory test model built in March 2009, or so the warranty says.

The front of my Kick Ash transluscent airbox cover cracked by Fall of 2010. It was replaced under warranty by Hal's HD in Milwaukee.

The replacement cracked again within two weeks. I ordered a new one under warranty, around November of 2010 again... used my backup for my cross country trip because it took over six months to get another replacement that I picked up at Hals in June 2011. I now live in NC.

My second replacement airbox cracked in July 2011. I got it replaced this time at Ray Price in Raleigh, NC.

They put in larger rubber o-rings on it... now it was ok for a few months, they thought this might be the issue.

The front of the airbox has cracked a fourth time now and I am sick and tired of replacing it. I am also sick of waiting for it to be replaced and I am frustrated with the fact that this seeems like a factory product supplier must have been changed in the last year of production, because I have not heard of other people having to deal with this.

I ride a lot (35K+ in 1.5 years) but I do not abuse my bike. It seems I could replace it under warranty a fourth time, but if the result is the same, why bother.

(Message edited by Whatever on March 24, 2012)
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Sticks
Posted on Saturday, March 24, 2012 - 12:39 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

My 06 hero blue cover will crack if you so much as fart near it.

I had toyed with the idea of getting a purdy new one, thinking that it would be more durable than my old one. Maybe not. Too bad. I always liked the translucent boxes.
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Froggy
Posted on Saturday, March 24, 2012 - 01:10 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The translucent covers are delicate and will crack if over tightened. I have over 20k abusive miles on my cover and fly screen without cracks. Hell I've even hit a car.
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Reepicheep
Posted on Saturday, March 24, 2012 - 02:47 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

My blue one on the 9sx would crack as well. You had to use the right bolts (shoulder bolts that snug down against the frame and only lightly load the plastic), and even then you had to be careful.

The solid color ones seem tougher, so if you don't mind giving up translucent, that would solve it.
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Schwara
Posted on Saturday, March 24, 2012 - 03:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

From a former life, I seem to recall that it is not uncommon that when clarifiers are added to some plastics they become more brittle and can crack under lower sustained strains. In those cases where we were forced to use a material like this we had to adjust the design to make certain that the parts of concern had very very little sustained strain. I have a feeling that the design in this case and material don't get along. I've heard many similar complaints about those parts. That's honestly the only reason I didn't go with a Kick Ash, because I think they look pretty cool. I would say to always make sure to use the plastic washers, the correct bolts Reep mentioned, and maybe not torque as high ... checking them often to make sure they don't get loose.
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Whatever
Posted on Saturday, March 24, 2012 - 06:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

They have not been over stressed. Both Hals and Ray Price are top notch as far as Buell service. In other words, they know how to use a torque wrench and in one of the cases I personally know the mechanic that set it up.

I think they probably switched something when they changed the logos on the airbox cover to the flat cheapos... they may have switched where they got the airbox covers from. I have always used the stock bolts that came with the airbox.

However, the last one they put in these mamoth rubber ones and even that didn't help. It pisses me off because it is not going to be available at all soon... like the HD MoFo really give a rat's ass...

Eventually I am going to get custom paint on the opaque airbox any way, but if I want to re-sell it, it will definitely be an issue.
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