Okay, we have a big problem. Sean was putting new Cams in the Ultra. When he went to re-install the oil pump there was a loud pop and the little gear things (the ones that fit inside each other and go around the crankshaft) broke. So we picked up a new oil pump and when putting that one on same pop. He had some trouble getting the oil pump back off this time as it was stuck! He got it off and this time it didn't break though. He installed it properly but upon further inspection Sean says the crankshaft has a nick in it and now he cannot get the oil pump back on at all.

Are we f&cked? We have the extended service plan but Sean says they won't cover it since he was doing a mod when it happened. Should we try to get it covered? Should we just cash in the service plan and use that money to fix it? How much will this end up costing us? Right now I have a bike we can't ride and it makes me sick to my stomach thinking how much this is going to cost. HELP!

 

It all depends on where the nick is and how bad. Can you post a picture of the damage?

 

I'm at work now. I will see if Sean can swing home and get a picture. It is preventing him from seating the oil pump back on the bike.

 

Shadetree mechanic

 

I have no idea what you mean by that.

 

For the record, Sean's no stranger to working on the bike. He's always done his own work. This should have been no problem. He knew what he was doing. It's just a fluke. I think there was probably something already wrong. I'm just looking for advise on where to go from here with the service plan. If there is no chance of them covering anything I'll just cash it in. I guess I'll run over to Harley on my lunch hour and talk to them.

 

Service plan will not cover it as they will claim that it was caused by you. Unless you have a great relationship with your dealer.

 

The nick could possibly be gently stoned smooth.

 

Sean just talked to someone and that what they said to do....gently file it and smooth with an emery cloth. I guess the gears weren't lined up correctly and it snapped. So a new gear for the oil pump and it should be okay. Thank god!

 

Most likely will not have to take off a lot of material to get it to fit fine. Good luck. I know exaclty how it feels when severything is going smooth then something breaks.