Well I'm going ahead with tapping and using an oversized plug in the gearbox but think in order to do a good job that I should drop the shocks, (Softail/Night Train) is this a difficult job? Can you simply drop the front or rear without completely removing? Is there room if your bike is on a jack? Any tips would be appreciated.

 

Removing the shocks is not a difficult job.
If you have a standard type jack you will not be able to drop the shocks while the bike is on the jack.

It doesn't sound as if you've got a maintenance manual.
You should buy one it will detail this procedure and it's the best tool to have.

 

As above, plus strap the bike down or have someone steady the bike whilst loosening the nuts when it's on the lift.

 

Can you drop just the front or backs without removing completely?

 

I worked on mine over 6 years ago and can't remember to be honest as they had to come off completely anyway.
My gut feeling is that they won't drop from just one end.


If it were me I'd use an extended tap wrench and leave the shocks in situ.

 

That sounds like a good idea Gaz, where did you find that wrench?
EDIT: Nevermind, looks like Walmart has em for $23!
https://www.walmart.com/ip/Hanson-21...&wl13=&veh=sem

 

YES> You can remove the front bolts and let the shocks swing down on the back bolts. You might need a second jack under the rear wheel to help taking the weight off the suspension. Take your time. You'll get it sorted.

 

Just another thought for you,
Have you got the Taps?
Don't be tempted by the cheaper carbon steel sets that are out there, they're only fit for diy repairs such as cleaning up damaged threads and using one for this particular job could end in tears if it snaps or jams tight!

Buy or borrow an industrial grade set of HSS taps consisting of a taper, 2nd and plug tap.
Also aluminium needs a thin lubricant, don't google it, you'll be overwhelmed!
For this job, a very light oil or paraffin will work a treat.

Hope you don't mind this post but I don't know your background/experience and only want to help.

Gary

 

You should be able to, the rear should turn freely enough for you to get in to the drain plug. May have to use a jack on the back tire to manipulate the bolts enough to clear the frame.