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Thread: Fix for the Primary Cover

  1. #161
    Senior Member outthere's Avatar
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    Outstanding. Need one just in case.

  2. #162
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    Funny to see this pop up today. I just ordered a kit today. My break is exactly the same as the other pictures posted here.

  3. #163
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    I'm looking at a '09 SB9SX with 11K miles... this thread has me thinking to check if the current owner has ever had to replace the primary cover and if not, this may be a PM thing when I get the bike.

    If the failure occurs... No clutch and the bike launches ahead w/o warning? Hopefully enough sense to apply the kill switch or brakes in time, but... is this what happens?

  4. #164
    Senior Member 34nineteen's Avatar
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    Usually most people just notice that the clutch goes soft. It doesnt happen a lot... never happened to me (or anyone I know)... but it does happen enough for someone to come up with a fix and decide to market it to others.

  5. #165
    Senior Member Cooter's Avatar
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    Ya, not very common. I put an eye on that part of the primary if I ever happen to have it off, but otherwise let it be. If it had a catastrophic failure (even more rare) completely cracks while sitting and running the bike would probably just stall.

    If you want to ease your brain, taking the primary off is super easy. Might as well look at the clutch and chain too.
    Buellmods.com

  6. #166
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    It happened to my wife's bike. We were in heavy stop and go traffic. She just slowly lost her ability to shift . Clutch became useless.

  7. #167
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    I did "the fix" on my primary cover and installed it last night.

    I had the usual break out on the flange
    IMG_1135.jpg

    I sent Dave Flack a few emails & he answered them promptly. One was how he held the cover while doing the machining. He told me he went off of the the "outer" surface of the clutch access opening in the primary cover. Since I'm somewhat lazy and have access to Solidworks and a waterjet cover I made up a spacer block using the dimensions of the cover.

    IMG_1155.jpg

    I drilled through the existing cover holes,

    IMG_1156.jpg

    and tapped thru using the existing 1/4-20 threaded holes as a tap guide.

    IMG_1157.jpg

    I mounted the fixture plate and spacer in the mill

    IMG_1158.jpg

  8. #168
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    and made it flat.

    IMG_1160.jpg

    I would consider this a very well thought out kit. I manage a small machine shop & could have figured out all of this on my own, but I think it's stupid to reinvent the wheel, especially when someone else has figured out a fix that is successful and the bugs have been worked out.

    The funny part was I spent more time than I should have figuring out what the orange and purple "seals" were.....

  9. #169
    Senior Member Cooter's Avatar
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    Very well done! Thanks for the insight

  10. #170
    Senior Member 34nineteen's Avatar
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    Quote Originally Posted by Boaski View Post
    and made it flat.

    IMG_1160.jpg

    I would consider this a very well thought out kit. I manage a small machine shop & could have figured out all of this on my own, but I think it's stupid to reinvent the wheel, especially when someone else has figured out a fix that is successful and the bugs have been worked out.

    The funny part was I spent more time than I should have figuring out what the orange and purple "seals" were.....
    Nicely done.

    Would you consider this kit as manageable for someone to install in their average garage with average tools? I know Dave offers a service to install the kit for you, which is probably the route I would go.



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