Has anyone ever re-used the primary/derby cover gasket? I took my cover off and remembered that it is the one thing I forgot to buy.

 

I've reused that gasket at leas 6 times with o problem. Of course your HD dealer will tell you it will surely leak

 

As long as its not torn or stuck to either surface. Torque the screws properly in the recommended pattern. AND USE LOCKTITE!!!!

 

if you're talking about the quad ring (on your 2010), i've reused mine at least 7 times with no issue. would be more, but i ended up trading the bike in on a new one.

 

i changed the derby cover O ring and the primary cover gasket once in the 28 years i owned my 85.

 

Locktite on those little bolts in aluminum?? No thanks.

 

How far should clutch lever come out before clutch engages? About 1/4 to 1/2?

 

+1 on that, that's a good way to end up stripping those little bastards next time you have to remove it, totally not needed!

 

When the gasket is fine, I do not bother to change it.... and those torx screws really grip tight to the cover so I never even considered loctite. I had enough fun last time getting a couple of them out.

 

I changed my torx screws to allens, always reuse gasket.