Primary inspection caps stuck in primary cover

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Samuel Whittle

Samuel Whittle

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Apr 15, 2020
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Hi team,

I had ordered a brand new primary cover with three new inspection screws. A "friend" of mine thought he would help with my project and screwed the covers into the primary bone dry. I would have assumed these needed to be greased prior to being screwed in. As a result, they are completely seized in there. I will try heat and some lubricant but I think it may have been a $200 mistake. How SHOULD these be put in? Knowing that they are aluminum on aluminum, I am assuming dry was the problem more so than cross threading. They didn't appear to be cross threaded. Thanks in advance!
 
I think it's more likely the inspection caps have become 'stuck' to the O-rings.
 
Yes they need lubricant on the threads and O-ring, oil is as good as anything.

At the minimum, soak both sides of the plugs (one side at a time) with WD40 or even a acetone/light oil mix overnight.
Heat after that might do the job.

I know one thing from experience, if and when alloy on alloy galls backing something out it is pretty much game over so play the safety card for sure.
I have a new set of plugs for my original primary cover and am in not doubt if I screwed them home dry (no O-ring) there would be a drama.

Just a lubricant soak might do it but any sign of resistance, stop.
 
L.A.B. said:
I think it's more likely the inspection caps have become 'stuck' to the O-rings.
Click to expand...
I thought that but it was a very dry feeling. stuck in both directions. I am positive they were not cross threaded but after heating them up I got them out. I feel some lubricant preparations needed before hand for both the o ring and the caps. When looking into one of the untouched holes, there were quite a few burs and material so those probably got hung up as well and needed a wire brush before hand. DARN. Looks like my buddy is buying beers tonight.
 
Soak caps in a penetrant oil , from behind, then try to unscrew them of course using the proper tool for the job. I've seen a lot of these plugs chewed up by large screwdrivers. No luck ? Throw it in the oven ,open all the windows, as soon as the wife goes to her Yoga class then try at it again with oven mitts , on the bench, well before she gets back home. Have wine and dinner ready too.
 
If the internal and external threads are not dressed to remove the galling burrs trouble shall arise again down the road.... Don't ask how this was discovered by someone on a fork slider seal replacement job.... wink wink.
 
Never let anyone else work on your bike unless you know they are better at it than you, and even then maybe not. Also, never let anyone with a beer in one hand secure your boat to the dock. I learned that the hard way and it involved swimming.
 
Samuel Whittle said:
Hi team,

I had ordered a brand new primary cover with three new inspection screws. A "friend" of mine thought he would help with my project and screwed the covers into the primary bone dry. I would have assumed these needed to be greased prior to being screwed in. As a result, they are completely seized in there. I will try heat and some lubricant but I think it may have been a $200 mistake. How SHOULD these be put in? Knowing that they are aluminum on aluminum, I am assuming dry was the problem more so than cross threading. They didn't appear to be cross threaded. Thanks in advance!
Click to expand...
hey, where did you manage to buy a new primary cover? I was wondering about doing some work to mine to correct all the dents and gouges and paint it black, or powder coat it. I might want to buy an new one and keep it polished aluminum.
 
Starvingphotog said:
hey, where did you manage to buy a new primary cover? I was wondering about doing some work to mine to correct all the dents and gouges and paint it black, or powder coat it. I might want to buy an new one and keep it polished aluminum.
Click to expand...

www.rgmnorton.co.uk

PRIMARY CHAINCASE OUTER, UPTO 1975

061025 060370 OUTER PRIMARY CHAINCASE RGM NORTON 062585
www.rgmnorton.co.uk
"We currently have 1 in stock."
 
L.A.B. said:
062585, yes.
Click to expand...
I'm actually trying to order it now, but it keeps denying my address and I can't get past the personal information page. Can you hold it for me and I will call tomorrow when you guys are at the desk, and it's normal business hours in the UK?
 
Starvingphotog said:
I'm actually trying to order it now, but it keeps denying my address and I can't get past the personal information page. Can you hold it for me and I will call tomorrow when you guys are at the desk, and it's normal business hours in the UK?
Click to expand...

There's no way to reserve it as far as I can tell?
Did you select USD and United States?
 
L.A.B. said:
There's no way to reserve it as far as I can tell?
Did you select USD and United States?
Click to expand...
Aha! That was it! It's ordered!
Just so you know, to clean up and paint my current Combat primary cover shiny black would have cost me US$350. This new one cost me US$260...I'm no mathematician, but I think this is the right move. Although, I might want to still clean up and powder coat the old one black. I kinda like that look.Or at least would like to try it out.
 
Samuel Whittle said:
Hi team,

I had ordered a brand new primary cover with three new inspection screws. A "friend" of mine thought he would help with my project and screwed the covers into the primary bone dry. I would have assumed these needed to be greased prior to being screwed in. As a result, they are completely seized in there. I will try heat and some lubricant but I think it may have been a $200 mistake. How SHOULD these be put in? Knowing that they are aluminum on aluminum, I am assuming dry was the problem more so than cross threading. They didn't appear to be cross threaded. Thanks in advance!
Click to expand...
Hey, so back to this initial thread. What should we learn from this adventure that Sam went through? Are we to lube any bolt going into aluminum? I'm wondering because of whether I should redo the bolts for the headsteady with anti-seize into the head, and any other parts where bolts are entering aluminum. I wonder what other metals should be treated the same - stainless steel bolts, original Norton replacement bolts, etc.
 
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