I bought a 2006 Sportster 1200 a few months ago, with 7900 miles on it. The clutch lever had to be pulled almost all the way back to the grip before it would disengage. I decided to do a clutch adjustment. When I removed the derby cover, the gasket, or quad ring as H-D calls it, partially came off. I have a new one, and was planning on replacing it anyway. But I can't find any way to make it stay in place. It's wide on 2 sides and narrow on 2 sides. It appears that the wider sides are what go against the primary cover, and face outward, against the derby cover. I can't get it to stay on the primary cover. I tried grease in the groove to hold it, but it popped right out. The way it came, the narrow edge faces out, and when I try to install it with the wider side facing out, it just twists back. Does it have to be glued on (there was some kind of white stuff on the old one that could have been some kind of adhesive) It is not an oem H-D part, I got it from J&P. I also noticed that of the 2 wider sides, one seems to be wider than the other, and there is a ridge around the narrow sides. The one that was on there is the same way.

 

I struggled with this the first time I removed the cover also. I think at one time I embarrassed the dog with bad words LOL. I used some (very little) ATV silicone dabbed here and there at 12,3,6,9,12 oclock to hold it in place. It barely worked and now if it ain't worn I leave it in place. Never had a leak there so it must be ok. I have also stripped the heads of three screws while torqueing them down. I now just tighten them hand + a tweak. I also have a spare set available if needed (about $12 at dealer).
An oil change can get expensive the first couple of times if not prepared or experienced. Hate when that happens.

 

Exactly what is a "quad ring?" Since that's what Harley calls it, how about a part number, OR a photo.

 

It's the circular rubber seal between the derby cover and the primary cover. It goes in sort of a groove around that opening, and fits against the back of the derby cover when it is installed. This is the new one I have https://www.jpcycles.com/product/601...or-derby-cover The OEM H-D part number is OEM 25463-94A, and they call it a quad ring. It is also referred to as a quad ring in my service manual. The problem is that the new part is shaped wrong. It is difficult to explain. It has to be twisted around to fit, and it won't stay that way while the derby cover is reinstalled. You can only flatten out about 2 inches of it at the time, and when you try to go further, the part that you flattened out pops back into its original shape. The one that came out was probably the original, factory installed one, that had been pressed flat for 16 years. After it came off, it is trying to return to the shape of the new one I have. There were spots of something white at the 12, 3, 6, and 9 o'clock positions on the old one, which I assume is some kind of adhesive. I don't see silicone being strong enough to hold it, but it might. The thing is, if it isn't really on there good, it could pop loose while installing the derby cover, and you wouldn't know it until it started leaking primary/transmission oil later.

And yes, I know not to use a torque wrench on those derby cover screws. They shouldn't be nearly as tight as the manual says. I was a car/truck/equipment mechanic for 40 years, and have developed a pretty good sense of feel for small screws like that. I'm just using an L shaped #27 Torx wrench on them, not a bit and larger ratchet. The manual says 90-120 inch pounds. Pretty much everybody says 40, and that sounds about right to me.

I need to replace the stock clutch with an extra plate kit. I was going to put that off a little longer. But if I can't get that seal on right, I'll go ahead and do it now, and while I have the primary cover off, I will take it to a local independent Harley shop and let them deal with it. I'm glad to hear it really is a PITA to deal with. Having been a mechanic for 40 years, I've seen just about everything. But this really had me puzzled. I thought maybe I had the wrong part or a defective part. Thanks for the information. Bob.

 

Part of the issue is the grove is wet with oil and when you try to put the seal in it becomes wet with oil. Everything becomes a slick mess and nothing will hold while wet. It doesn't take much to hold it long enough while you put the cover up to it and tighten it down.
Start with everything as dry as possible. I used plain grease the 2nd time. It just needs to be sticky enough for a second to hold the seal while you put the cover up to it. Just don't try to peek a boo to see if it worked. Every time I got the cover up to it I just tightened it down without further care. I never had a leak in this area once the cover was on. It shouldn't take a pro to perform this.

Just don't make your next job replacing the front springs. Those frickin caps will drive you insane and make your whole upper torso sore for weeks!
Good luck

 

Firstly , it sounds as if your new Quad Ring is twisted . It should be flat or else you have no chance . You will notice that the groove into which it fits has four equally spaced " Pinch points " for want of a better description . You need to get the ring to sit in all four of these at once and to lay flat in the groove . My preferred method was to use Red Rubber Grease which is extremely sticky but this is still a frustratingly tricky job . Once you do get it all in place , do NOT go anywhere near a Torque Wrench ! Just snug the thing up so that it don't fall off . When you've got it all buttoned up , this is usually the point at which you discover the Jam Nut and spring lying in the dirt next to your knees ! Oh what fun . Mind you , I shouldn't laugh . I haven't even read the manual on my Dyna yet . Heaven knows what pranks those funsters at HD will have devised to frighten me into a Dealership .

 

Oh yeah , it greatly helps is the bike is upright and not on the side ( Jiffy ) stand .

 

It's called a "quad ring" because it's cross section has four sides. Like my X ring chain where the rings cross section looks like an X. It's the seal for the derby cover on 1994 and up.

Anyone using a torque wrench on 1/4" or smaller bolts is begging for trouble.

John

 

YES, I took this as a given. Everything you said is spot on.

 

Quad ring . . . DUHHH Derby Cover O Ring. Clean the cover groove and apply some grease in the groove. Push in O ring, put on bike.