| Author | Message | ||
     Morpheus78 |
I just bought a used 2004 Blast with 9000 miles on it. There is a horrid clacking and rumbling noise comming from the primary case. The man who sold me this bike said that its a single cyclinder and that is normal? Well it seems to be getting worse. I read up on the forums about primary adjusting. When I try to adjust the primary chain with the adjusting bolt, it goes right flat with the cover without any form of resistance whatsoever. I can acutally hand tighten it right in. Im thinking the boot is just gone and the chain is flopping around. Im hoping its not some other problem. Should I try to tackle this myself or just take it to a mechanic or something? Also, were two hoses just hanging randomly down by the front of the rear tire near the ground. I know one is routed to the nipple on the fuel cap and the other is routed to the bottom right side of the crank case. Are these supposed to be hanging there? Any advice helps. Thanx | ||
| Ezblast |
Yes - one hose is the engine oil drain hose - not the primary drain - which is the bolt under the case. Sounds as if your primary chain tensioning shoe is shot - need to replace, then adjust loosely - if not, your primary chain would probably need replacing - you'll have to open up the primary side to find out though. EZ | ||
| Morpheus78 |
I thought the engine oil drain hose was attached to the left side frame bracket with a plug in it? There are two hoses there with plugs in them. This hose is literally hanging off the back of the bike freely open with no plug in it. My oil levels are fine...strange...i have no idea where its supposed to go to. How much do you think the labor would be to take care of the primary issue if I took to a mechanic? | ||
| Ezblast |
Cost of a primary gasket around 25 to 35, inspection gasket - 10, o-ring for primary plug - 1 buck, shift shaft seal 5 bucks, shoe - 10 bucks, labor 3 hrs - ease of doing it - 8 yr old level - so they will at least charge you 500 dollars. That must be the primary breather house routed outside of the frame - lol EZ | ||
| Berkshire |
"That must be the primary breather house routed outside of the frame" Concur! Normally that hose runs up inside the frame on the left side under the seat. If you look on the left side, there's an opening between the top/rear of the primary cover and the bottom/rear of the airbox inlet & coil cover, just to the front of where the peg hanger bracket is bolted on. You will see two tubes running down there, which are the oil drain and breather/condensate drain that go to the rear peg hanger (with the plugs in them), and also some other tubes & wires. The fuel vent line should be there, routed down between the swingarm & tranny. Hidden behind the tubes & wires, at the very front of the rear section of the frame, there is an opening that leads up inside the frame going toward where the rear subframe is attached. The transmission vent should go into that opening and as far up as the hose will reach. | ||
| Morpheus78 |
OK great...I was afraid it was the oil return and my pump wasnt working. Ok so its ok that those hoses dont have plugs in them? Should i just stuff them back to where they go? Im going to remove the cover after work today...I have all my tools together. Where can I order all these seals and parts? Is there an online resource? I dont really have a local Buell or Harley dealer. Thanx everyone | ||
| Berkshire |
The labor charge would be MUCH higher than the price of a service manual! And since you bought a used Blast and not a new one, I'm guessing you're not just made of money, so my suggestion is that you fix the primary yourself. The dealership will most likely adjust the primary too tight anyway, so it's something every Blast owner should get familiar with. The service manual will give the basic procedure & pictures for changing the shoe (and everything else!), and check here in the Thumper forum for adjustment tips (8 to 12 flats, I think?). Check ebay for a service manual (any year model will do), also, you may be able to find a download somewhere. I think my primary cover gasket was a paper type the first time I opened it, but the replacement is a re-useable plastic-coated metal type. Same goes for the clutch inspection cover seal. I also replaced the shifter shaft seal, and have re-used all several times since then. The replacement gaskets are good stuff, worth switching over to. The shoe is basically the only moving part you have to deal with in there, aside from the clutch adjustment parts, so it's not too difficult a job in retrospect. Also, the clutch adjust probably needs to be done anyway, so you can do both and change the primary fluid in one go. (Message edited by berkshire on July 02, 2008) | ||
| Ezblast |
Concur! | ||
| Morpheus78 |
Does anyone know where i can get these seals and parts online? | ||
| Ezblast |
Our sponsors or Chicago HD. EZ | ||
| Morpheus78 |
OK..you guys ready! Me and my brother got the primary cover off. WOW...nothing plastic survived! Chain guide...GONE... Chain tensioner...GONE! Spring that holds tensioner... WORN IN HALF! The first thing we thought was OMG look at all the metal shavings...this thing is toast. But luckily upon closer inspection...it was all just mulched plastic. The chain was just starting to cut into the cover. Thus my second concern There was BARELY any oil whatsoever in the case. And it seemed thick, more like gear oil than the 20w50 recommended. Im guessing this had about half to a quarter quart of oil in it. Maybe the oil was absorbed by the plastic dust bunnies decorating the internals? I dont know...i just pray that there is no permanent damage to anything. The chain looks good, the gears look good...the clutch was strong before I did this, so I think im golden. I didnt see alot of metal shavings at all. I just think that the primary on this bike was TOTALLY neglected for the 9000 miles that are on this bike. Which makes me wonder...what else was neglected? What do you think guys...should i repair this and sell it, or take my chances? | ||
| Gearheaderiko |
I'd say repair it and keep it. See how it runs when you get it back together and there are things you can check to see how bad it is. They do take a beating well! But...what kind of shape is the bike in and take in account how much you paid for it. | ||
| Morpheus78 |
The bike is in rather good condition. I paid $1900 for it with 9000 miles on it. Brakes and tires are good....no body damage. | ||
| Gearheaderiko |
See our sponsors for parts: http://www.badweatherbikers.com/buell/messages/171 43/17143.html Dont forget to mention Badweb! Chicago HD (not a sponsor) may take awhile to get you your order. | ||
| Ezblast |
While your in there, chamfer the edges of your Stator wire protection plate, do the Pawl adjustment, check your clip and make sure all your drum pins are the same length, put some red locktight on the long one(s) and tap back in gently till the same length as the rest, do the clutch adjustment, then do the clutch cable adjustment, then the primary adjustment, then add oil and seal her on up, should shift better than new - which is a damn pity. EZ | ||
| Gearheaderiko |
Concur! If at all possible and since you have it apart (and hopefully a repair manual) try and do the above stated 'work'. Its not likely you'll ever take the cover off again and you'll be sure that everything is as perfect as can be and will shift as best a Blast can, increasing satisfaction and helping preserve a transmission that clearly has had a hard life. If its seems beyond your capabilities, your Blast could live without this work, but its well worth looking into. | ||
| Morpheus78 |
What should I use to chamfer the edge...a file? What is the clip? Do I need to put locktight on any of the other cover bolts? | ||
| Ezblast |
The clutch, chain and Rotor can come off as a unit - you just need to torque to speck when putting the bolts back on and one is reversed threaded - the special tool you can make in 10 minutes after a stop in a local hardware store - lol - a buck to 5 bucks spent depending on the store. EZ | ||
| Ezblast |
A fine file - create a nice curve where the angle used to be. The infamous E clip? I replaced mine just because I was there - preventive medicine - - I forgot - c clip - naw - holds the shift plate in place on the drum - If I ever split a case - a Baker drum kit would definitely go on with a bolt on shift plate - and smooth shifting! EZ | ||
| Morpheus78 |
Are you talking about retaining ring 11019 or part 8 from the shifter diagram in the parts manual? Is that the C-Clip in mention? | ||
| Ezblast |
part 8 - looks more like an e clip - pg 32 part #8 - #11019 | ||
| Morpheus78 |
So thats what im looking for to replace...correct? | ||
| Ezblast |
Yuppers - buy a new one - a buck, if the old one is tired, it will break and leave you stranded, since your there replace it and have better peace of mind. EZ | ||
| Morpheus78 |
Am I filing down the top edge or bottom edge of the Stator Wire Cover? Sorry if my questions are becoming redundant, I just like to be sure. | ||
| Ezblast |
The edges close to the wire - there have been a few cases where the wire protectors caused the damage - lol EZ | ||
| Morpheus78 |
Parts have been ordered! Ill let you all know how it goes. Thank you everyone! | ||
| Themagster |
Just my luck (I guess it could be considered in some ways, good luck) return from summer trip, go into withdrawal, head out again for long weekend and start hearing that "horrid clacking noise coming from the primary case". Was also hearing a noise with rear brake, rear caliper was a little loose. When took bolt off, the threads just fell right off. Working on getting replacement bolt. In the meantime, I guess it is time to open the primary and check to be sure I have any plastic left. At a total loss without my bike, but at least I have a navigator seat to keep warm this weekend. Hopefully it will not take long to diagnose, repair and get me back on road. Once again, I would be remiss if I did not thank EZ and Gearheaderiko for the knowledge and input that has helped me over the last few years. THANKS!!! Wish me luck. Morpheus78 how did your repairs go? | ||
| Ezblast |
Mag - it sounds like an opportunity to share a case of beer, basic tools and time - take the clutch/chain/rotor off as a unit and do the other things recommended above as well, heck as many miles as you have on yours - I'd replace the Stator as well, and the clutch cable - lol - its all real easy. Don't forget music to work by - ;0) EZ (Message edited by ezblast on July 10, 2008) | ||
| Gearheaderiko |
Thanks, its all for the love of the Blast. Happy to be of service. Good luck on the repairs, I'm sure you'll do fine as always. PS With the price of gas, bout the only thing you can keep warm up on the Navigator is the seat! | ||
| Themagster |
Appreciate your input  And I know it needed to be done, but...just hate to not be in motion. Clutch cable was recently replaced, good there. Will pass other info along to my mechanic/best friend/riding buddy/husband. I'm pretty lucky in that aspect. (Thanks Thumper). Music (southern rock, hillbilly, bluegrass) never leaves the garage, good there. Gas not a problem. The navigator seat, I guess ya'll refer to that as a pillion seat. Spent many years with map in hand pretty much directing the voyage, so I earned the name Navigator. Just need parts and patience. | ||
| Ezblast |
Good music!  | ||
| Morpheus78 |
Still waiting on parts. I had to order everything from out of state. No Harley dealer on the Island was willing to order the parts for me. So here I am...waiting for the parts to get to my house. I see other people riding their motorcycles and I get so jelous...i hope they come in this week. |
