Having to replace my bro's outer primary cover on his 2001 xl1200c. the clutch ramp race that is cast into the cover broke (looks like it has been slowly going over time) and we though it was just a snapped cable until I opened her up and saw the dang clutch ramp angled inward through the hole.

Got a new primary cover on the way for him, but my concern is the Bushing for the Shift shaft. Anyone have experience putting that in? I would heat the cover but don't want to screw up the chrome (not aluminum).I hate just pound stuff into a cast metal part. Any ideas and old wrench tricks would be helpful.

 

Maybe heat the cover area with a heat gun and freeze the bushing? Works well for bearings. Think it is a plastic bushing in the newer models.

 

Thanks for the tip. Unfortunately heat might screw up the chrome and it is a brass bushing, so it won't shrink quite as much. I may try it but 1500w heat gun may not be enough LOL. Good idea though!

 

Just think about how hot chrome rocker covers get...it will be plenty safe with a heat gun (not to be confused with a hair dryer).

 

I've tapped mine in using a small socket as a drift. Make sure it doesn't go in cockeyed, you'll be OK.

 

if your talking about the seal that goes around the shift shaft where it comes out of the primary cover and you mount the shift arm, you can either do it with the cover off or on the bike. i have done it both ways and always use a deep well socket to tap it in straight. i like to put a small amount of electric tape around the splines on the shifter shaft also to keep from damaging the seal.

 

Normally how i do it with other bushings. Ill stack a few wood blocks to keep from cracking the cover. I just don't wanna screw it up lol.

Iron, its not the seal, its a bushing chased into the opening that acts as a race or the shifter shaft.