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My biggest problem has been sealing the primary. I used the o-rings that came with the primary kit, bought others from Harley and even added gasket sealer to the o-rings but the damn thing still leaks. My tranny is offset for the rear tire so I have a 3/4 spacer between the engine and inner primary case. There are two o-rings. When the o-rings get put on, the spacer to engine fits metal to metal and I can not feel the o-ring, same with the spacer to inner primary - so its no wonder it leaks.
I have ordered fatter o-rings in hopes to cure this problem. It seems to leak a lot but when I check the primary, oil tank, and tranny, they are full.
It ended up being the 3/4 inch chrome spacer between the engine and inner primary case. The o-ring seats were way off.
I got a new aluminum spacer and used the stock o-rings - now no leaks.
I'm glad you fot that repaired. I know how frustrated I get if I have something that just want act right it get to throwing things at it then end up buy a new one.
I've always been told that you could use silicone sealer on the gasket area to eliminate the leaks. Since you are supposed to replace the gasket every time you pull the primary cover, using silicone should not be a problem.
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