Removing shifter shaft from mid controls : V-Twin Forum: Harley Davidson Forums

03fxdl100th · 05-14-2008, 05:14 PM

I just installed a set of extended forward controls on my lowrider. The setup came with a beauty cap to put over the shaft that goes through the primary. I just don't like the look of having the shaft still stick through the derby cover (I think that's what it's called). I asked my service guy if it could be removed so it could look like the wide glides and he said something about having to take off the inner primary.
So my question is how difficult would this be to do? I consider myself mechanically inclined, but the only experience I have working on motorcycles is installing my forward controls and removing my mids, so would this be something you guys think I could tackle on my own? I can enlist the help of some of my friends that are experienced on bike maintenance if I get stuck along the way.

Fourcats · 05-14-2008, 06:30 PM

...Live with the "beauty cap".

03fxdl100th · 05-14-2008, 07:43 PM

I just installed a set of extended forward controls on my lowrider. The setup came with a beauty cap to put over the shaft that goes through the primary. I just don't like the look of having the shaft still stick through the derby cover (I think that's what it's called). I asked my service guy if it could be removed so it could look like the wide glides and he said something about having to take off the inner primary.
So my question is how difficult would this be to do? I consider myself mechanically inclined, but the only experience I have working on motorcycles is installing my forward controls and removing my mids, so would this be something you guys think I could tackle on my own? I can enlist the help of some of my friends that are experienced on bike maintenance if I get stuck along the way.
P.S. I also posted this in the dyna discussions forum.

tguil · 05-14-2008, 10:06 PM

Quote:

Originally Posted by 03fxdl100th

... I consider myself mechanically inclined, but the only experience I have working on motorcycles is installing my forward controls and removing my mids, so would this be something you guys think I could tackle on my own? I can enlist the help of some of my friends that are experienced on bike maintenance if I get stuck along the way...

I'm mechanically inclined too, but I had a tech at the dealer do the job for me. IMO it's worth the bucks to get rid of the "beauty cap". I don't get a kick out of doing my own work any more.

Tom

Texan · 05-14-2008, 10:18 PM

My first question is do you have a service/AIM manual for the bike? You're going to pull the out and inner primaries. This means removing the clutch basket, the compensator sprocket and primary chain and the inner primary. Removing the starter is one of the first steps. I'd guess by you user name the bike is a 100th Anniv...so probably wouldn't need a new primary chain.

You're going to need a banjo gasket, inspection cover gasket and primary gasket.. Also going to need a stator O-ring gasket. I'd also, beings you going to be in there, I'd replace the out put seal on the transmission...little $3.00 part that cost $300 or so down the road. And a quart of Amsoil ATF Super Shifter fuild.

Also, inspect the transmission shifter lever and lock bolt. This little bugger gets loose and either falls out or ruins the spline on the shifter collar. Replace the whole lever and bolt.

You're going to need larger sockets for removing the primary drive train...

Taking your time it's a pretty straight forward 3 hour job...But you need a manual....got it ..... GO FOR IT!!!!

o~\o

WS6 Formula · 05-14-2008, 10:20 PM

Removing the original shift shaft lever
Get a hacksaw blade and tape each end with duct tape, leaving about two inches exposed in the middle. Also put some duct tape on the primary and cylinder cooling fins. Tape a wrench on one end to get a better grip (on the end of the blade so as you pull on the wrench you will be on the cutting stroke of the blade). Slip the blade between the primary and engine from the bottom of the bike with the wrench end on the bottom. Position the shaft so you can cut about a quarter inch from the lever (not in the welded area). Use your other hand to guide the top of the blade as you cut. After cutting through, the shaft will slide right out, and the lever will just fall to the floor.

Cover for the original shift shaft lever hole
I used a chrome carriage bolt http://www.chromebolt.com/51618-x-13...olt-p-845.html, and put a two inch piece of rubber hose on the threads then added some shrink sleeving on the hose to get a nice snug press fit into the empty shaft hole. If you have a black primary: paint a unplated carriage bolt. Aluminum cover: scotch brite a chrome carriage bolt.

03fxdl100th · 05-17-2008, 06:10 PM

WS6, if I use your suggestion would I be able to just get a new blank cover like there is on the wide glides? My bike has a cover where the old shift shaft went into that is held in by 4 screws.

WS6 Formula · 05-17-2008, 07:19 PM

I'm not familiar with the earlier primary's, but I think you would be able to use an inspection cover without the hole in it, you just need to plug the inner primary through hole. Maybe just cleaning out the inner primary through hole and filling it with high temp silicone.

03fxdl100th · 05-17-2008, 08:00 PM

Do you think that would be do-able without removing the primary?

jerry34208 · 05-17-2008, 08:54 PM

Quote:

Originally Posted by WS6 Formula

Removing the original shift shaft lever
Get a hacksaw blade and tape each end with duct tape, leaving about two inches exposed in the middle. Also put some duct tape on the primary and cylinder cooling fins. Tape a wrench on one end to get a better grip (on the end of the blade so as you pull on the wrench you will be on the cutting stroke of the blade). Slip the blade between the primary and engine from the bottom of the bike with the wrench end on the bottom. Position the shaft so you can cut about a quarter inch from the lever (not in the welded area). Use your other hand to guide the top of the blade as you cut. After cutting through, the shaft will slide right out, and the lever will just fall to the floor.

Cover for the original shift shaft lever hole
I used a chrome carriage bolt http://www.chromebolt.com/51618-x-13...olt-p-845.html, and put a two inch piece of rubber hose on the threads then added some shrink sleeving on the hose to get a nice snug press fit into the empty shaft hole. If you have a black primary: paint a unplated carriage bolt. Aluminum cover: scotch brite a chrome carriage bolt.

Hey, nice Dyna.

WS6 Formula · 05-18-2008, 09:24 PM

Quote:

Originally Posted by 03fxdl100th

Do you think that would be do-able without removing the primary?

Yes....Once you pull off the inspection cover, you should get an idea on what you need to do.

Quote:

Originally Posted by jerry34208

Hey, nice Dyna.

Thank You........

03fxdl100th · 05-20-2008, 08:35 PM

Excellent thank you very much ws6

footballhi · 04-22-2009, 12:45 PM

03fxdl200th: how did the saw job work for you ,i need to remove mine as well. i have the cover with no hole. but how do you plug the other side?

1M$man · 05-10-2009, 06:37 PM

Quote:

Originally Posted by footballhi

03fxdl200th: how did the saw job work for you ,i need to remove mine as well. i have the cover with no hole. but how do you plug the other side?

Dont try to do this. It will be a disaster since you can not understand WS6's explicit, simple directions. This leads me to believe this. I am usually right about these things Sorry. That's my take. I dont mean to be disrespectful. Just dont try it at home. It will be a mess. But not to worry...

Copy the instructions with a printer and show them to a good friend or shade tree mechanic. The time and labor involved are minimal.

WS6 Formula wrote explicit complete and very easy to follow instructions. His way works incredibly well. There is absolutely no reason to go to the great expense of removing everything.

We did it on my bike WS6 Formula's way.Our plug method was different (his way is just fine) but it lasted 8 years until i had the inner primary chromed. We welded the hole at that point.

spgtti · 05-10-2009, 09:59 PM

Quote:

Originally Posted by 1M$man

Dont try to do this. It will be a disaster since you can not understand WS6's explicit, simple directions. This leads me to believe this. I am usually right about these things Sorry. That's my take. I dont mean to be disrespectful. Just dont try it at home. It will be a mess.

You meant to be disrespectful,that was the point of your post. The later primarys don't have an inspection cover and the directions could've been about plugging the outside hole. Asking about the inner side was a valid question. You're a million $ Ahol IMO.