I am putting the Clutch Inspection Cover (derby cover) back on after changing my primary fluid. The problem is the orange rubber O-ring type gasket is now too big for the grove in the cover. Its diameter is about 1/4” too big. I can not get it to stay in the groove even with four hands. It just wants to pop out. There is no way it will stay in place to get the cover back on.

When I removed the gasket I remember hearing a slight ripping sound like it was pulling free from glue. But after wiping the fluid off everything there was no glue residues.

Has anyone else had this problem? Is there some trick in getting the ring to stay in the slot? Is it possible that I have a ring or cover that is out of specification?

This is on a 2008 Road King Classic.

Thanks.

Barton

 

you can cut it....then install again with cut at top and a small bead of silicone

 

the replacement is a big circular gasket

 

On my 07 Softail the manual says to throw that gasket away, there is a replacement gasket you can get from the dealer. P/N 25416-99C

 

Yup the gasket is a throw away. You need to buy a new one and it will look like a big black disk that covers the entire derby hole. It kinda sucks you cant re-use the old one, but if we did, HD would make as much money.

Chris

 

The dealer installed one of the new ones on my '06 at the 1K service and although I bought a new Derby cover and Primary inspection cover gasket I decided to try and re-use the old ones when I did my own 5K service a week ago to see if they would work again. They work fine with no leaks so I will probably change them out at the 10K since I have them on hand.

 

I used my old one over again.... I had to stretch it a bit (it stays stretched for a minute or so) to get it to stay in the slot, but has worked fine ever since. It's about impossible to get it to stay in the groove if you don't do that. Even with 4 hands...

Sounds like there's a redesigned one out now, so I'll probably get that next time, but in a pinch, just pull it so it's a bit bigger and it'll stay in the slots....

 

Stretching it sounds like a good idea except mine is too big not too small. So that would make it worse.

Thanks for the post though. At least I am not the only one with this quality issue.

 

If it ain't stretchedreal bad,,, throw it in the freezer for awhile,, you can reuse them and Bryan TTM's ideal would do as well.

 

mine was a bit larger than the ring grovve,,,, I worked it back into place after I put dabs of grease in the
o-ring groove, it held it in place.

if you do cut it, as mentioned above, superglue it back together