Hello all. I got a great deal on a 2013 Sportster last summer. It had been laid down but only needed a few cosmetic items replaced. The Derby cover was also cracked. I replaced with an ebay derby cover. I couldn't get it to stop leaking even after multiple new gaskets. I ordered a different ebay derby cover. Again, I cannot get it to stop leaking after multiple new gaskets.

I'm not a mechanic. But I'm not a total idiot.

Over the years I typically haven't needed to use any sort of gasket sealant on rubber gaskets. Do these require something?

It's interesting. When I install a new gasket I will run the bike up to 20+ minutes with no leaks. Then after the bike cools back off it's leaks nonstop. And then doesn't stop leaking.

The primary cover looks in great shape. No road rash and everything lines up perfectly. But that may be my next replacement. Unless the community here has any suggestions?

I appreciate any opinions you guys might have. What would you all try next?

 

Are you torquing the fasteners in the proper order, and torquing per the service manual spec? If not, that will warp the cover.

 

Thanks for bringing that up. Yes I am. In fact the last couple times I torqued it down, I started at 40in lbs (from memory) and did it in 5 steps. Went all the way around in star pattern. Increased a bit... went around again. Increased a bit... went around again. 5 times. Up to book spec which (from memory) is 90-120in lbs. I was overly cautious of warping the derby cover. Thank you.

 

Is that an "O" ring or that full gasket? Some claim the "O" ring is being replaced by the full gasket. They tried that with me and the full gasket always leaked / seeped. Found an "O" ring, put it on an no leak.

 

What is the level of the primary/transmission fluid?

With the bike upright and level the fluid should come to the bottom of the clutch spring.

 

Is the Ebay cover you purchased an OEM cover or a Chinese knock-off?

Recommend getting an OEM cover and go from there as the other ones are probably not as thick and prone to warping.

 

I wonder is it possible the knock has distorted the casing somewhat which in turn is causing the derby cover to leak.???

 

My thoughts also.

 

Reread your post. If your derby cover had enough impact to crack it you need to look closely around the screw holes to see if there is a hairline crack. Clean the area up good with brake clean and make sure all the oil is off the outside area. Inspect closely with a good light and a magnifying glass. Could be small enough that when cold it will not leak but after it gets hot, the small hairline crack expands enough to let oil get out through capillary action.

Other than that I have nothing. Good luck and let us know what you find.

 

If you're sure it's the derby cover leaking you can try to double up on the gaskets.