Good morning group,
The inspection cover on my bike after 300 miles post changing my primary fluid is seeping oil. I have (according to manual) torquedbolts #3 & 4 properly (100 inch lbs) and did the same to bolts # 1& 2 although there was no torque spec for bolts # 1 & 2. I don't want to torque more for fear of stripping bolts.
New HD gasket.There is a convex and concave side to the gasket--Does it matter whether the concave side or the convex side of the gasket faces the primary housing??
Any suggestions?

 

'04 FXST Service Manual I have shows four bolts, labelled 3 and 4, 3 is short and left and bottom bolt, 4 is long and right and top bolt. Diagram does not show bolts labeled as 1, 2, 3, and 4. Spec on torque is 84-108 in lbs. Also, gasket should be new. Hope this helps.

 

Sure you have but make sure there wasn't some fluid on cover lip b4 you torqued it down. If there was it may seep out for a day or so then stop. Do not remove to see just watch. Didn't over fill primary? I had one do it my self one time. Never did know why. Put a new gasket on and all was well.

 

There is a convex and concave side to the gasket--Does it matter whether the concave side or the convex side of the gasket faces the primary housing??

 

I have a RK and the derby cover never leaked with the old o'ring gasket. But when they gave me a regular gasket instead of a new o'ring I started having seepage. I finally noticed that the derby cover was made out of very soft metal (like butter) and the screws, eventhough not over tightened, caused the back side of the cover to bulge out. That new style gasket is compressable. I continue to use my old o'ring after filing the back side of the cover flat. No leaks. Check the back side of your inspection cover for flatness.

 

The best gasket to use on the inspection cover is James Gaskets. I've used every type and these are the best.
part # JGI-60567-90-DL.

 

Hint: When you take the cover off make a mark on the inside of the cover with a sharpie marker where the top bolt hole is so you can put the cover on exactly the way it came off. Some of the primary cases are not perfectly shaped and once torqued the cover will take that shape. There is e thread (who knows where probably in the DIY) that shows how to take a block of wood and flatter the cover a bit to prevent leaks. But the easy way is to mark it when it comes off and keep it that way. FWIW, the ONE (last) oil change I had done at the dealer the tech put it on upside down...it was dripping when I got home.

 

the black lock-tite liquid gasket will solve that problem .
you could also place nylon washers just under the bolts , because the rubber "o" seal is located on the outher side of the bolts .....
Silly construction ,...but's not else.....