Primary leaking - Harley Davidson Forums: Harley Davidson Motorcycle Forum

Autotec · 08-05-2009, 06:51 PM

I searched for any information on this, but I only came up with pieces of the info I need. The bike in question is a 97 Fatboy.

To make a long story short, I have a leak coming from (I think) the seal between the primary and the engine. I'm not 100% sure of anything except it's primary fluid. The stator plug has been sealed so it's not coming from there. It was a small leak that I was hoping would be ok until the end of the season, but it got really bad in the last few days.

I have a manual, plus I figured this can't be more difficult than head gaskets on a Caddy Northstar, so I'm going to attempt to fix the leak. My only question is, does anybody have any tips, tricks or advice to any part of removing the inner primary cover? Or any parts that should be replaced with updated/better pieces?

Any advice would be great.

Justin

Blackdog 15 · 08-05-2009, 06:59 PM

Quote:

Originally Posted by Autotec

I searched for any information on this, but I only came up with pieces of the info I need. The bike in question is a 97 Fatboy.

To make a long story short, I have a leak coming from (I think) the seal between the primary and the engine. I'm not 100% sure of anything except it's primary fluid. The stator plug has been sealed so it's not coming from there. It was a small leak that I was hoping would be ok until the end of the season, but it got really bad in the last few days.

I have a manual, plus I figured this can't be more difficult than head gaskets on a Caddy Northstar, so I'm going to attempt to fix the leak. My only question is, does anybody have any tips, tricks or advice to any part of removing the inner primary cover? Or any parts that should be replaced with updated/better pieces?

Any advice would be great.

Justin

Is it coming from between the primary cover and the inner primary ?

Autotec · 08-05-2009, 07:03 PM

No, it looks like it's coming from in between the engine and the inner primary. I put some die in it, and it looks like that's where most of it is coming from.

All of this started after there was a starter installed last Fall.

**Dave63** · 08-05-2009, 07:04 PM

The seal between the inner primary and the engine is an O-ring, about 5.5" in diameter.

You need to remember that the clutch hub nut is REVERSE thread.

You'll need to remove the primary chain, clutch hub abd compensating sprocket.

The torque specs have changed on the compensating sprocket from 150-165 ft/lbs to 75 ft lbs and then another 45-50* clockwise.

Don;t forget to add silicone to your bolts that go through your inner primary innto the engine block.

It's a good time to replace your inner primary seal as well as your starter jackshaft seal and if your drive belt (to the rear wheel) is in question AT ALL, nows the time to replace it, cause all this stuff has to come off to get at it.

This is some of what you'll see..... http://www.harley-davidsonforums.com...r-install.html

Blackdog 15 · 08-05-2009, 07:06 PM

Lot more work...outer primary is just a gasket change...inner primary....pull the clutch, front engine sprocket, starter...stator...everything,,best have someone who knows the teardown do it....cause if you do it wrong..it'll leak again...soon...my bud & I did a 93 FXSTC and it was a bunch of work....

Blackdog 15 · 08-05-2009, 07:08 PM

There are some special tools made for loosening and tightening the left & right threads as Dave just mentioned....they jam the chain against the sprocket so you can loosten them and re torque them...

Autotec · 08-05-2009, 07:09 PM

Great information. I'm going to plan on installing a new primary chain,(almost at the end of adjustment) tensioner (auto adjusting) and belt now. (close to 40K on it, plus it's full of oil now)

This is why I always ask questions before I start on something. I HATE taking something apart more than I have to.

Justin

**Dave63** · 08-05-2009, 07:09 PM

Quote:

Originally Posted by Blackdog 15

..pull the clutch, front engine sprocket, starter...stator...everything,,.

Stator stays, however, I forgot about having to unbolt the starter.....

It's not hard to do, however, if you do it wrong, or forget something, you'll be spending more time and money to correct it.

You can get an antire inner primary gasket/seal set, including an inner primary bearing, from JPCycle, (James Gaskets) for $67.

Like I said....it's not hard to do, but there's a few things that can trip you up in a hurry.

Autotec · 08-05-2009, 07:11 PM

Quote:

Originally Posted by Blackdog 15

There are some special tools made for loosening and tightening the left & right threads as Dave just mentioned....they jam the chain against the sprocket so you can loosten them and re torque them...

I have all of the tools. About 8 years ago, my Snap-On dealer was going out of buisness and had a Harley Master kit. It was a great deal, so I picked it up. I'm glad I did now.

**Dave63** · 08-05-2009, 07:12 PM

The only "special" tool is the clutch hub holder. I use air tools to take it apart.

CLutch hub comes off in one shot. No clutch diaphram tool needed.

Unless you're going to replace the trans output shaft seals, no need for the inner race puller or sprocket nut.

Although.......you might want to make sure both retaining bolts are in the lock plate for the front sprocket. They commonly break, and if they do, the nut comes loose and trans fluid will leak out, and the only way to repair it.....is to take the inner primary off again.

Plan on it being a 3-4 hour job.

Compensating sprocket is normal thread. Put 2-3 drops of locktite red on the threads on reassembly. No more. Use it sparingly on this part. Do not loose any compensating sprocket shims on removal. They're important.

Clutch hub nut....I use a dab of Loctite as well. Sparingly.