i have a 2000 nighttrain with 8000 miles. changed all of the fluids before the riding season and after about 300 miles there is oil leaking out of the back side of the primary case. i cant see exactly were the leak is coming from, but its got to be either the mainshaft or startershaft right? if so how easy is it to remove the clutch, primary chain, rear primary case to replace the seals.

 

You will need a service manual to perform that repair correctly. That will outline the correct procedure & tools needed.

 

yeah i have the owners manual and it looks pretty straight forward so im going to buy all of the seals and switch them out this weekend. the dealership wants $250 bucks to do it and i can't get it in there for another week. i needs to ride

 

It's actually pretty straight forward.Your going to need a special deep well socket to get the mainshaft nut loose and an Impact wrench. While you in there change the shifter shaft seal as well,your already there and it's cheap insurance.

 

Well i got it all taken apart the other night finding out it wasn't as easy as just the main shaft seal. after taking off the inner primary it looked like something had been chewing at the aluminum around the bearing.turns out the nut that holds on the sprocket for the drive belt has a locking plate that is held in with two 1/4 inch shcs. well the two shcs snaped off and have been rattling around in there for awhile and have been eating at the inner primary. and they actually ate a 1/4 inch hole in the case and thats were my oil leak was coming from. good thing the local dealership had a used one on hand so it wasn't to expensive.

i'm trying to post some pictures below of the old and new inner primary case.

[IMG]local://upfiles/59508/A6D69AD2EC5445C8ABCB12EB43B0D1E9.jpg[/IMG]

[IMG]local://upfiles/59508/47F1169FF36D4BF49E53D1270A65186D.jpg[/IMG]

 

Wow there is some damage there. Any idea what caused them to snap off?

 

i believe they backed themselves out then began eating at the inner primary and eventually broke off.
after this happening for the second time i figured there has to be something serious wrong. the pulley on the transmission seems to be a little loose on the shaft and the spline on the pulley looks to be wore. this may have caused the pulley to vibrate and the bolts to loosen, intern hitting the inner primary.
has any seen the transmission pulley wear and cause problems?

 

replace the nut with Jims mega nut........