1994 FXD Primary Inspeection Cover Stuck!
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Grand HDF Member
Joined: Apr 2007
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From: Brighton, MI
1994 FXD Primary Inspeection Cover Stuck!
So going on a long cruise Saturday am, decided to change primary fluid and adjust primary chain. New "print o seal gasket and factory manual in hand.
Remove shifter and the four t-27 inspection cover screws. Insp. cover plate moves around now that the screws are removed, so I know the gasket is not holding it in place, I can move the insp. cover all round.
It looks like the plastic bushing around the shifter shaft is stuck on the shaft and I am slowly getting the insp. cover to come off using a wire slipped in behind the screw holes of the plate, but the plastic bushing is staying on the shifter shaft.
Slow going getting the cover off. I did put some penetrating fluid on the shaft/plastic bushing and it is coming off slowly...
Is the round plastic shaft bushing supposed to come off with the insp. cover? Or is it supposed to stay on the shaft? Of course manual says nothing. Don't want to eff it up and have to take my cage on the trip...
Am sitting next to the bike right now staring....thanks, YD
Remove shifter and the four t-27 inspection cover screws. Insp. cover plate moves around now that the screws are removed, so I know the gasket is not holding it in place, I can move the insp. cover all round.
It looks like the plastic bushing around the shifter shaft is stuck on the shaft and I am slowly getting the insp. cover to come off using a wire slipped in behind the screw holes of the plate, but the plastic bushing is staying on the shifter shaft.
Slow going getting the cover off. I did put some penetrating fluid on the shaft/plastic bushing and it is coming off slowly...
Is the round plastic shaft bushing supposed to come off with the insp. cover? Or is it supposed to stay on the shaft? Of course manual says nothing. Don't want to eff it up and have to take my cage on the trip...
Am sitting next to the bike right now staring....thanks, YD
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Grand HDF Member
Joined: Apr 2007
Posts: 3,725
Likes: 3,070
From: Brighton, MI
OK, cover is off, just had to wiggle back and forth a little more and it came off. Looks to me like the plastic bush is supposed to stay on the shaft when the inspection cover is removed?
Now to adjust the chain...it looks like it needs adjustment big time... 5/8 to 7/8 cold free play. YD
Now to adjust the chain...it looks like it needs adjustment big time... 5/8 to 7/8 cold free play. YD
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
OK, cover is off, just had to wiggle back and forth a little more and it came off. Looks to me like the plastic bush is supposed to stay on the shaft when the inspection cover is removed?
Now to adjust the chain...it looks like it needs adjustment big time... 5/8 to 7/8 cold free play. YD
Now to adjust the chain...it looks like it needs adjustment big time... 5/8 to 7/8 cold free play. YD
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Grand HDF Member
Joined: Apr 2007
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Likes: 3,070
From: Brighton, MI
Man moving the adjuster is a trick in itself....I did not remove the nut and washer, just loosened it. Don't let the adjusting shoe assembly drop down or it will be a witch to get your hands or tools down to slide it back up.
I discovered the bracket that actually connects the shoe to the bolt has holes in the front and threaded holes in the rear. A couple of long 1/4 bolts thru the front hole and threaded into the rear hole gave me a good solid hold to slide the assembly up and pull things away from the notches or grooves at the same time so I could get the assembly in the proper spot (chain tension).
The original issue regarding the plastic bushing is the bushing stays in place and the inspection cover slides off the bushing. That bushing has a O-ring to seal things up from the primary fluid. Mine was just stuck and some penetrating oil and back and forth wiggling and pulling got it off. A little grease on that bush/O-ring prior to putting the inspection cover back on made a big difference, it slipped right on.
Now this is the first time I used the dealer supplied foam/aluminum inspection cover gasket. Used a little non hardening sealer (hylomar) on it as I am not familiar with this type of gasket and hylomar has never failed me.
Gonna go for a test ride in an hour or two. YD
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Grand HDF Member
Joined: Apr 2007
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From: Brighton, MI
Used rotella 15w-40 in the primary. Only took a short 10 mile test ride. Seems a little notchy but no leaks! Will know more after this weekends rides cuz it's EASY RIDER's WEEKEND HERE IN MICHIGAN WOO HOOO!!
Road Master
Joined: Oct 2011
Posts: 957
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From: Carlsbad Springs Ontario
Too tight ?
I hear you ... you want to ride this w/end and not wrench but if it " seems a little notchy " then its probably too tight right .?
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Grand HDF Member
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From: Brighton, MI
Well chain was definitely loose with lots of free play, and I only raised it one notch so not sure what else I can do? Maybe a fluid level thing, or my bike does not like rotella in there?
Heading out in about an hour for the rest of the weekend, so it is what it is for now...YD
Heading out in about an hour for the rest of the weekend, so it is what it is for now...YD
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Road Master
Joined: Oct 2011
Posts: 957
Likes: 2
From: Carlsbad Springs Ontario
Enjoy your scoot.
Well chain was definitely loose with lots of free play, and I only raised it one notch so not sure what else I can do? Maybe a fluid level thing, or my bike does not like rotella in there?
Heading out in about an hour for the rest of the weekend, so it is what it is for now...YD
Heading out in about an hour for the rest of the weekend, so it is what it is for now...YD
Let us know how it went .
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Thread Starter
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Grand HDF Member
Joined: Apr 2007
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From: Brighton, MI
Shifting improved after a few miles put on her. Little dribble of oil out of the shaft area, hope it's just some residual penetrating oil, couple streaks of the side cover for an inch or two.
Just noticed the oil streak this eve when I got home after a total of 400 miles this weekend. Might be the plastic shift lever sleeve, might be the O-ring. Oh well, will watch it.
Great weekend! Great rally, great times! Got there early Saturday am, and no kidding, smelled the beer way before I got the fairgrounds in sight!
Took my nephew, it was a first time for him, he has been pretty down due to some recent family events, so he really needed the break. Anyways, as freak luck would have it, ran into a few patched friends in the parking lot when we were pulling in, they got us in for free, fed us, we went to a few parties, and we hung out at the wont mention their name club tent/barn all weekend. My nephew was totally impressed! He now thinks his uncle is a bad ***! Ha Ha
Again, it was just dumb luck to run into these guys but they made the weekend very memorable for my nephew. He has ADHD (can be a little to allot annoying) and they treated (tolerated) him well! He is a good kid, works hard, financially supports his mom and dad, and will do anything for you, he just won't shut the hell up or sit still unless he is riding or sleeping!
He had a blast and really needed the get away. The kid is already planning for next year and he left with a smile on his face. Just seeing him let off some steam was worth it's weight in gold. YD
Just noticed the oil streak this eve when I got home after a total of 400 miles this weekend. Might be the plastic shift lever sleeve, might be the O-ring. Oh well, will watch it.
Great weekend! Great rally, great times! Got there early Saturday am, and no kidding, smelled the beer way before I got the fairgrounds in sight!
Took my nephew, it was a first time for him, he has been pretty down due to some recent family events, so he really needed the break. Anyways, as freak luck would have it, ran into a few patched friends in the parking lot when we were pulling in, they got us in for free, fed us, we went to a few parties, and we hung out at the wont mention their name club tent/barn all weekend. My nephew was totally impressed! He now thinks his uncle is a bad ***! Ha Ha
Again, it was just dumb luck to run into these guys but they made the weekend very memorable for my nephew. He has ADHD (can be a little to allot annoying) and they treated (tolerated) him well! He is a good kid, works hard, financially supports his mom and dad, and will do anything for you, he just won't shut the hell up or sit still unless he is riding or sleeping!
He had a blast and really needed the get away. The kid is already planning for next year and he left with a smile on his face. Just seeing him let off some steam was worth it's weight in gold. YD
Seasoned HDF Member
Joined: Dec 2010
Posts: 7,736
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From: Coromandel Peninsula New Zealand
My Nephew is ADHD and we manage his condition with diet, music and some herbal remedies....kid has a good job and is nowhere near as annoying now....do the research, it will change his life!
You used to be able to get a thing called an M-Pulse which retuned the kid's brainwaves.....worked really well when he was at school! Can't get them here anymore but I think the USA still does them.
You used to be able to get a thing called an M-Pulse which retuned the kid's brainwaves.....worked really well when he was at school! Can't get them here anymore but I think the USA still does them.
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