Water in the clutch case
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Joined: Mar 2015
Posts: 89
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From: Alabama
Just a short update on my progress in locating and correcting my major oil leak. I am certain the source of the leak is the transmission since neither the chain case or engine have lost a drop while the transmission dip stick shows no oil on it and I had about 1/3 qt in the pan under the bike. The only place I observed oil was at the lowest point on the chain case and apparently running down the back of the inner chain case.
I removed the outer chain case, the clutch, compensator, primary chain etc. and removed the inner primary case. Had to remove the oil bag to access the two starter bolts, a PIA. After removing the inner primary there was evidence of oil leaking on the back of the case from the area of the clutch shaft seal in the inner primary. Not sure what that means, if oil was leaking from there wouldn’t it have to be chain case oil, not transmission?
At this point I await the monster socket I ordered for removing the final drive pulley nut. But feeling around on the back side of the final drive pulley it appears to be dry, as is the front side of the pulley. This of course has me doubting I’m chasing the real culprit. Could transmission oil leak past the primary pulley without soaking the pulley?? Maybe my first sentence of this update should have been “I suspect the source of the leak is the transmission”. Has me wondering if I should replace the inner primary seal and put the whole thing back together and see if I still have a leak. Wonder if I’m overthinking this…a bad habit I have.
I removed the outer chain case, the clutch, compensator, primary chain etc. and removed the inner primary case. Had to remove the oil bag to access the two starter bolts, a PIA. After removing the inner primary there was evidence of oil leaking on the back of the case from the area of the clutch shaft seal in the inner primary. Not sure what that means, if oil was leaking from there wouldn’t it have to be chain case oil, not transmission?
At this point I await the monster socket I ordered for removing the final drive pulley nut. But feeling around on the back side of the final drive pulley it appears to be dry, as is the front side of the pulley. This of course has me doubting I’m chasing the real culprit. Could transmission oil leak past the primary pulley without soaking the pulley?? Maybe my first sentence of this update should have been “I suspect the source of the leak is the transmission”. Has me wondering if I should replace the inner primary seal and put the whole thing back together and see if I still have a leak. Wonder if I’m overthinking this…a bad habit I have.
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Joined: Mar 2015
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From: Alabama
Turned out the culprit was the inner bearing race on the main shaft. It had migrated over 0.125" into the seal between the 6th gear and the main shaft. It was in so deep I could not get a puller on it. Several members suggested grinding a slot in the race which I did. A smack with a hammer and cold chisel split the race and it slipped off. New seals and inner race and it is all back together and, so far, no leaks.
On another note, it seems my compensator had loosened some and was causing a "bang" on start-up. Torqued to spec the bike now starts without the loud bang.
On another note, it seems my compensator had loosened some and was causing a "bang" on start-up. Torqued to spec the bike now starts without the loud bang.
Intermediate
Joined: Jul 2021
Posts: 35
Likes: 15
From: Torrington CT
Damn. Wish i knew ya had comp noise. 07 to approx 11 can have faulty compensators. The spring fails and ya get a clunk on start up and shut down. The fix is to install an SE or quality AM unit. Woulda been a good time to get it done. Glad the trans is fixed. Good job
Tourer
Joined: Aug 2014
Posts: 337
Likes: 30
From: SLC, UT
Turned out the culprit was the inner bearing race on the main shaft. It had migrated over 0.125" into the seal between the 6th gear and the main shaft. It was in so deep I could not get a puller on it. Several members suggested grinding a slot in the race which I did. A smack with a hammer and cold chisel split the race and it slipped off. New seals and inner race and it is all back together and, so far, no leaks.
On another note, it seems my compensator had loosened some and was causing a "bang" on start-up. Torqued to spec the bike now starts without the loud bang.
On another note, it seems my compensator had loosened some and was causing a "bang" on start-up. Torqued to spec the bike now starts without the loud bang.
Seasoned HDF Member
Joined: Feb 2012
Posts: 13,456
Likes: 10,452
From: Sunshine State
First off, fiber washer on that primary.
Second, every Harley owner knows you get caught in the rain you water in the fluidds.
Harley got around it so they didnt have to cover it. Scooter should be washed with a mist spray.
Second, every Harley owner knows you get caught in the rain you water in the fluidds.
Harley got around it so they didnt have to cover it. Scooter should be washed with a mist spray.
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Joined: Mar 2015
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From: Alabama
Been riding Harlys for quite some time, never experienced water ingestion like this. And yeah, I've made good use of my rain suit many times.
While working on it I found that someone had been inside it previously finding socket head cap screws rounded out such I had to drill the heads off and double nut them after removing the primary. Could they have re-used the original gaskets?
While working on it I found that someone had been inside it previously finding socket head cap screws rounded out such I had to drill the heads off and double nut them after removing the primary. Could they have re-used the original gaskets?
Seasoned HDF Member
Joined: Sep 2008
Posts: 14,161
Likes: 11,252
From: San Diego, CA
Been riding Harlys for quite some time, never experienced water ingestion like this. And yeah, I've made good use of my rain suit many times.
While working on it I found that someone had been inside it previously finding socket head cap screws rounded out such I had to drill the heads off and double nut them after removing the primary. Could they have re-used the original gaskets?
While working on it I found that someone had been inside it previously finding socket head cap screws rounded out such I had to drill the heads off and double nut them after removing the primary. Could they have re-used the original gaskets?
Anything is possible, and after reading what some people do to their bikes, I am sure reusing critical gaskets is done many times...
But I will add, that I have reused the outer primary cover gasket up to 4 times with no leaks... I always check it to make sure it's in good shape before reusing it.
It's not that I'm cheap, I have a couple new gaskets in my shop supplies waiting to be used, but when they look really pristine... I figure I'll try them again, it's not a big job if it should leak and I need to then swap it out...
Along the same lines, I have reused pushrod tube o-rings (even though I have a drawer full of them), and rocker cover gaskets (I have 4 on the same shelf as the outer primary cover gaskets)... but only after very close inspection...
I all cases, they were finally replaced during a service/repair/mod, because I thought I'd be pushing my luck to use them again or I saw something I didn't like on/with the gasket.... never because a reused gasket started leaking... go figure...
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