Getting a headache....Oil Leak +...
Road Master
Joined: Jan 2011
Posts: 893
Likes: 0
From: Knob Noster, MO
I think the previous drop warped/cracked the cover or you have a failing gasket. Drain the fluid, pull the cover and make sure it is completly flush all the way around. Inspect the cover gasket and replace it with a new gasket. Low fluid could cause the issue you are having with finding neutral, so once you inspect the cover for damage, etc. If everything looks good with the cover and replacing the gasket. Put it back together and torque it down to spec. Remove the inspection cover and fill it to spec, replace cover (I would get the gasket for the inspection cover) and replace it as well. Bolt the cover to spec and take it out for another ride and check it for a couple days for leaking.
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Cruiser
Joined: Nov 2010
Posts: 159
Likes: 0
From: Tampa, FL
I think the previous drop warped/cracked the cover or you have a failing gasket. Drain the fluid, pull the cover and make sure it is completly flush all the way around. Inspect the cover gasket and replace it with a new gasket. Low fluid could cause the issue you are having with finding neutral, so once you inspect the cover for damage, etc. If everything looks good with the cover and replacing the gasket. Put it back together and torque it down to spec. Remove the inspection cover and fill it to spec, replace cover (I would get the gasket for the inspection cover) and replace it as well. Bolt the cover to spec and take it out for another ride and check it for a couple days for leaking.
Also I noticed. The bottom right bolt on the primary cover(the one where it is leaking) does not have nut or anything that I can see on the other side. shouldnt this be actually bolted into a nut or something? perhaps this is what started this?
Supporter
Joined: Jan 2007
Posts: 15,787
Likes: 5,612
From: along the shore of Mishigami
The outer primary cover on the 2002 FXD has 12 bolts/screws around the circumference of the cover. They all screw in to the inner primary cover and are tightened to 108-120 in-lbs. The pattern starts on the bottom screw between the inspection cover and derby cover. Alternately tighten the screws bottom then top in a counterclockwise pattern till all are tightened. Drain your primary oil, the 2002 will need 26 ozs. of oil in the primary. Using a mirror and flaslight look up between the primary and transmission, the little shaft going in the tranny might be the source of your leak.
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Cruiser
Joined: Nov 2010
Posts: 159
Likes: 0
From: Tampa, FL
The outer primary cover on the 2002 FXD has 12 bolts/screws around the circumference of the cover. They all screw in to the inner primary cover and are tightened to 108-120 in-lbs. The pattern starts on the bottom screw between the inspection cover and derby cover. Alternately tighten the screws bottom then top in a counterclockwise pattern till all are tightened. Drain your primary oil, the 2002 will need 26 ozs. of oil in the primary. Using a mirror and flaslight look up between the primary and transmission, the little shaft going in the tranny might be the source of your leak.
I dont know if I mentioned this but the leak only occurs once the bike has been running. Otherwise you would not know. I dont know if that makes any difference but I thought I would add that little bit of info.
Supporter
Joined: Jan 2007
Posts: 15,787
Likes: 5,612
From: along the shore of Mishigami
If you know how to change the trans oil, change it also and put 20-24 ozs. of oil back in. a bit of caution too much oil could vent and guess where the vent hose dumps to, between the trans case and primary. I always put in 22 ozs. To get these amounts measured I use plastic baby bottles, they are marked in ozs.
Road Warrior
Joined: Oct 2010
Posts: 1,554
Likes: 52
From: Ottawa Canada
i had a leak that i thought for sure was the primary gasket, amazing how oil can travel along parts.In my case it was the o ring that goes on the drain plug, replaced it and all was good no more leak.Also my bike is a 2002 FXD
Rob
Rob
Supporter
Joined: Jan 2007
Posts: 15,787
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From: along the shore of Mishigami
Clutch- put slack in the clutch cable using the adjustment nuts on the cable, till clutch lever is slack. After removing derby cover, put the bike in gear to hold the clutch basket while loosening the locknut, screw in the pushrod till it's lightly seated, back out the push rod screw 1/2 turn, while holding the push rod screw tighten down the locknut. Readjust the cable using the adjustment nuts to obtain 1/16-1/8" play at the lever. Put the trans back to neutral, pull in the lever a couple of times verify the clutch basket is working, put the derby on and start the bike. Check clutch operation while bike is running. Make sure the clutch is cold prior to adjustment. Does this sound familiar?
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Cruiser
Joined: Nov 2010
Posts: 159
Likes: 0
From: Tampa, FL
Thats interesting, i'll have to give that a look see. I'm going to change all the fluids tomorrow. Hell I checked the engine oil the other day and I didnt even have a dipstick. I had to order one and just got it this evening. I'd rather know all fluids are where they are supposed to be by doing it myself.
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Cruiser
Joined: Nov 2010
Posts: 159
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From: Tampa, FL
Very good idea. Thanks, I was thinking about getting carb cleaner but that stuff is harsh. lol