Primary leak
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Joined: Aug 2011
Posts: 17
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From: Titusville, FL
Primary leak
Hey all, newbie here. Just bought my first harley a few months ago, its a 2004 sportster 1200 custom, been running fine then one day i came out to the garage and had a few spots under the bike, there was a drop of fluid on the primary drain plug, i could also see fluid on the whole left side. But i thought maybe it was the o-ring on the plug, so i replaced that and changed my fluid while doing it, took it out for a test came back, still fluid..this time it looked like it was leaking from the bottom of inspection cover, bought new gasket and screw o-rings. still leaking, cleaned up all spotless, took for another short ride, and it looks to me like its coming from where the shifter goes into the primary cover? i see a black seal, could this have gone bad? and is it a hard DIY?
thanks in advance
thanks in advance
They do go bad.You can get one for about 3 bucks.Just remove the shifter,Take the old seal out with a small screwdriver,Clean the seal seat out good with rag or something.Put new seal in,replace shifter.I done mine in about 10 mins.Some people say they use and o-ring but i went with the seal.Yea the seal comes out from the outside so you don't have to remove the cover again.
Grand HDF Member
Joined: Jul 2007
Posts: 4,007
Likes: 126
From: Manassas, VA
A dental pick works nicely to dig out the old seal after the shift lever has been removed. Set the new seal in with the appropriate size deep socket (might need a metric size, iirc) and a light tap with a dead blow hammer.
Last edited by HarleyScuba; Aug 10, 2011 at 07:01 PM. Reason: nunya
Yes.Just one nut and remove the bolt.You may have to pry the shifter apart a little with a screwdriver while working it off.Try to avoid prying against the primary cover if you can.A little shot of lube may make it easier to get off.
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