"DIY MODS" and TRICKS to SAVE $$$$$$

I was changing the clutch release bearing on my 95 Electra Glide. Every thing was going very smoothly.
I drained the transmission.
Loosened the exhaust system.
Removed the dipstick.
Removed the Clutch release cover.
Replaced the release bearing.
Installed the clutch release cover.
Adjusted the clutch.
Tightened up the exhaust system.
Filled the tranny with oil.
I try to screw in the tranny dip stick and it won't go in.
The threads in the cover are buggered.[sm=headbang.gif]
I don't know how the last guy ever got the thing threaded in.
Anyways, it's Sunday morning. It's gonna be 70 degrees, and I want to ride. You just know the dealer won't have a new cover in stock. But they'll be happy to order one.
I find a 3/4" rubber freeze plug but it's a little to large and won't start in the hole.

I have an Ace Hardware store about about 100 feet from my front door. You don't know how nice that can be.

I go to Ace Hardware and find a cone shaped rubber plug with the small end less than 3/4" and the large end greater than 3/4".
I drill a hole through the center of the plug, a little smaller than a #12 machine screw. You want a good friction fit.
Put a washer on a #12 machine screw and shove it in through the small end up through the large end.
Place a 1/4" fender washer over the screw then place a #12 washer over that. Place a #12 nut on the screw and run it up finger tight.
Be sure that the nut is on the large side of the plug. The outside.
The tight fit will keep the screw from falling into the tranny if the nut ever comes off.
Push the plug into the tranny cover. Tighten it up with a wrench and you're done.

At some point I will replace the clutch release cover but probably not until it gets cold again.
I've put about a thousand miles on it so far and it has not loosened or leaked.

Cost: About 4 bucks.
Riding with a BSEG. Priceless.
 
Well done Lost1.
When you go to change the cover, you can save some money and time if you drive your wheels up onto the flat of a 2 x 4 or wider 2" such as a 2 x 8. With the bike parked on the wood, it will lean a lot further to the left when you put it on the jiffy stand. Now when you remove the transmission side cover you won't loose much if any of your oil. If you put it up and leave it for a while before you remove the cover, there won't even be a drop.
Good luck.
 
I didnt like the look of the howard horn design with the cowbell under the horns but I like the look of the horn. I went to my friends metal fab and made up a couple of different brackets and then had them painted to match the bike. I put the compressor under the front part of the seat. Below are some of the pictures...
 
chop police windshield - I have a 2004 FLHTPI with a monster for a windshield...it distorts my vision and looks like crap. 61/2 smoked from HD is over $100 so i am thinking of scribbing a line across the shield using the edge of the fairing as a guide and cutting it down....questions: do i need to tape the cut to stop rip-out, will the heat of the saw melt the plexi? saber saw, band saw, sawz-all??? also, i was going to then film the shield to smoke it but concerned about it lasting...smoke inside or outside, etc Anyone chop their shield?? Thanks
 
Or you could go to ebay and find lots of windshields from different places for around $30.
Ijust purchased 3 chrome ones from a company in California for $120.00 shipped to Canada.
 
Yep, you can cut your shield, although a replacement lower shield is fairly cheap. But, if you want to cut yours, there are a few posts that will help you. Try looking for them in the search section. But, just a quick how-to, from what I have read. Take some posterboard and trace out the angle of the stock shield. Cut the template out. Use maskingtape to tape up the front and back of the shield where you want the edge. Make taped area about 6 inches tall. Tape the template to the area taped off. Take a jigsaw, with a plexiglass blade, and cut the edge out. Take your time, and don't go to fast, or to slow and burn the shield. Once it is cut, you will take some sandpaper and hone the edge. Leave the masking tape on until you are done withe the edge. I have also heard that running your palm along the edge, leaving the oil fom your hand on the edge, will give it a nice finish. You can then use the tented film, as you mentioned, or, I have heard of guys spray painting the inner portion of the shield... up to you... and yes, buying a cheap aftermarket replacement from ebay would be easier...
 
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