I have a 85 FLHTC, and am looking at a Dyna when I get back from overseas next month. Question: What is involved after you install the forward controls, to pull the oldshift arm and "plug" the outer primary cover.Since the old shift lever goes through the outer primary cover, and through the intercover, as aFL guy I never have had the outer primary of a Dyna off to know what it takes. Please, IDO NOT want to just leave the old shift lever sticking out of the outer primary cover and just "tie it off" on the inside. Thanks for you insight! Also, if it is a big job, beyond what most wrenches may want todo the first time, what costs would HD charge?

Hogback

 

HogBack....

Not trying to hijack your thread, but, your question is where I am right now.

I have put forward controls on my 06 Lowrider, but, the mid shift linkage remains sticking out of the primary cover.

To get the remaining mid linkage off, the following must be removed, the primary cover, the starter, battery, battery tray, primary chain, clutch, compensatating sprocket, and finally, primary chaincase housing. While this sounds like a MAJOR undertaking, it isn't really that hard with the proper tools. If you have good wrench skills AND the HD SERVICE MANUAL you can do it in a day.

Back to my question for you guys........

Once the old linkage is removed, what are the best ways to block (and still look good on the primary cover side) the holes in the primary cover and motor side of the inner chaincase housing so lube doesn't leak out?

HogBack...tools needed:
good set of wrenches, ratchet, sockets, torque wrench (in/# and ft/#), HD-47977 (primary drive locking tool), snap ring pliers...interestingly...need metric wrench/socket for positive battery cable (or a crescent wrench)

Comp sprocket.......ft#'s, clutch and cover bolts in#'s

 

hogback

dead easy, make life simple for your self.
get a 12 inch hack saw blade, put electrical tapearound half the blade, and just cut the shaft between the pirmary case and the engine, the reason for the tape is just incase the blade scrapes the caseing, if your carefull it wont, it will take a bit of time, but works a treat, done mine already.
when you buy the forward control kit , it has a crome plug for the hole.
When i took my bob for its first service, the mechanic was impressed, he said he wished he could do it that way, but they aint aloud.

hope this helps

[IMG]local://upfiles/7198/0B5F868659DF44828D0ED2A61D5B61AE.jpg[/IMG]

 

Stewart....

Not quite sure I understand your technique.....

Did you take the primary cover off and saw off enough of the exposed shift shaft to place the plug on so it wouldn't protrude through the primary case cover?

Or did you saw the shaft between the chaincase housing and motor?

 

I'll jump in here with a quick comment regarding the HD 47977 lock tool.
I don't know what HD gets for this thing but I bet it ain't cheap. First time I had to pull my clutch assy off my 2003 Dyna I just went and bought me a foot of 1 1/4 inch diameter Delrin rod. Grind two flates on it and then 'step it' with a hacksaw. Cheaper than a dealer..........pg


[IMG]local://upfiles/8331/5BDC8DBF54C9458980606DD5686E1A0E.jpg[/IMG]

 

This has been dicussed many times here a link with details on installing forwards on an "06 Dyna with out removing the primary.

https://www.hdforums.com/m_514536/mpage_1/key_/tm.htm

 

Aneasy way would be to pull the stock cover off, cut the shift shaft, and then put on a Wideglide cover that doesn't have the hole in it.

I think if I ever decide to go with a chrome cover that's what I'll do.

Right now I have the 2005 kit and don't really think it looks back even with the chrome cap on the shift shaft. It was $250 from M&M Cycles.

Here is a pic of the chrome cover:
http://img.villagephotos.com/p/2002-...7/12020003.JPG

 

Thanks for the help guys... Roadrider your hijack was very helpful as your hijack may have said it better.Stewart1962 that was a great help... I knew if there was a short fix you would find it.Hogrida really helped as I knew this must have been discussed somewhere, but when your overseas and have to beg, borrow or steal a chance to use a computer, times is precious on extended searches.

Thanks again

 

Roadrider
i cut the shaft between the chain case and engine, didnt have to unbolt anything, very easy, just time consuming.

 

Gotcha Stewart...thanks for the response to the PM.....

Did you block the hole on the engine side of the inner primary housing after removing the mid shift linkage? If not, any problem with lube blowing out?

I haven't had the primary cover off a Dyna yet, so I don't know if the mid shift shaft runs through a shaft housing within the chaincase housing or is exposed to the lube within the chaincase housing.

If the shaft runs through a shaft housing, lube blowing out seems to be a non-issue.

06 HD Service Manual doesn't show a good picture.