I have an 06 1200 R. I had the gear cover powder coated because of stains from chicken **** ( Long story). I cleaned the inside of the cover and masked off the back part with the bushings. I spoke with my Harley dealer about the heat curing the powder coat and they said no problem that they had done a few. The problem was that after implicit instructions not to touch the back of the case cover the powder coater, not the dealer, media blasted the back of the damn thing. After I explained in great detail not to touch it. Well needless to say the bushings are now pitted and useless. My attempts at finding out if I can replace the bushings has turned up three different solutions. #1. involves splitting the case and a bunch of stuff that seems totally unnecessary to me. #2 buy a replacement side cover from the dealer @ about $400.00 #3. buy a removal tool and new bushings and do it myself. I can't get a consistent answer. Any help will be greatly appreciated.

 

#1 is the proper way to do so. New bushings need line reamed to match the right side case bushings. If you do not do this the cams will bind and overheat in the bushings. It doesn't take a lot of misalignment for this to happen.

In order to do this you need to split the case (or find a spare right case half) so you can run the reamer through the inner bushings as a guide.

I know people have done it other ways and been okay, however it's hit or miss whether the bushings are lined up and properly clearanced.