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1. You don't need a hole in the bearing to provide adequate lubrication. The oil that makes it through the oiling hole has to go through bearing to get back into the primary case.
2. The process would not only require EDM a hole in bearing but an altered case hole.. Would be the same size as the original? If so you've just weakened the bearing..
3. IMO if the issue is oiling then the problem is the capture and not internal passage..
4. The truth is that the comp needs the heavier oil.
5. The root cause it 2 issues. Both have to do with HD swapping the position of the primary chain with the starter ring gear.
A. The first issue comes from moving the chain further out on the shaft. This increases load on the end of the shaft as power is transferred from one shaft to the other.
B. The clutch chained so that the ring gear covers the IPB limiting the amount of oil the bearing gets. That coupled with increased load required HD to add an oiling hole as band aid to help with bearing survival. Also HD added dowels in 07 to help with alignment.. The older 5 speeds did not need any of this.
As stated more oil seems to help but edm-ing a hole in the bearing is not the answer. I do think that increasing the capture of oil to the hole helps. Oil that splashes behind the ring gear hits an abutment and can slide past the hole.. This is an 07 EGC at about 30000 miles. The mod can be shown here and the bearing after 90000 miles.
You can see where the clutch rubs when bearing fails.
Some of the original failure in this case was I suspect to the bearing fit being too tight tho and not alignment. One thing to look at on the roller is which side of the roller fails. I suspect it's the outside on the 06s. If so it would likely help to push the primary lightly toward the back of the bike then torque the primary to tranny bolts first.
Number 5 100% I didn't look that closely at my 05 Road King when it was apart.. your right, what engineer would think moving the load outward and also putting the ring gear over the oiling location for the IPB was a good idea!!! I had seen a few older IP Cases and noticed no oiling hole, now I see why!!
In my case it had 90000 miles and the rollers were showing signs of wear. In the last 90000, I've had the primary off a few times for stator, crank seal and shift shaft seal replacement.
The clutch basket was rubbing slightly on the front inner part of the primary case . You can still see where the aluminum was rubbed off. I guess not enough to cause real damage since i caught it early. It was making some bad noises. I thought by putting in a Hayden adjuster I might save myself the trouble with the bearing but no such luck.
Other problem, some of the 2006 primary cases did not come with the IPB oil slung weep hole to begin with to allow fluid to the back side of bearing, to help push the old fluid out and back into the clutch side of the bearing. https://i.ebayimg.com/images/g/gT0AA...YX/s-l1600.jpg
So on a bearing like this that the input shaft sleeve just galled the hell out of the rollers on one end.
will bank that trashed side of the rollers was the trans back side, and only the front of bearing was getting fluid to at least keep that side of rollers lubed with cleaner fluid.
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