I noticed some oil on the lower portion of my outer primary casing on my 2002 FLHTC (11K miles). I changed the fluid and resealed the threaded drain plug hoping that was the source of the leak. Noticed a small spot of oil yesterday after a 200 mile ride when parked for 20 minutes. Again, a number of the protruding "dimples" on the bottom of the casing had fresh oil. Retorqued the bolts in the appropriate sequence to 10 Nm. All had a slight bit of movement, but the spec range is 9-12 Nm, so they may have been at 9 posssibly or do they need occasional tightening with the rubber mounting??. Could this small amount of torque solve the issue, or should I just get a new gasket and put that on assuming that will solve the problem. Is this common?

 

New gasket will most likely fix you up.

 

If a re-torque don't fix it, a new gasket should do the trick.

 

All,

Found out that the real issue was a leak at the inner primary seal. Can be seen by looking under the bike with a mirror to identify the source of the leak. Unfortunately this was not the overflow located above, which could have caused similar appearance from overfilling. Hopefully the new fix just done yesterday will provide me with miles of leak free riding.

 

I have a 07 Ultra and sprung a leak at the primary. Almost beside the drain plug. I thought it was the drain plug but later realized it wasn't. Took it to the dealer, it is covered under the warranty. Picked the bike up and the mech. said it was not the primary gasket. It was a seal that had gone bad. He also noted he had no idea what happened but it was good to go now.

Now that I have said this I have ran across a few others with the same problem. So if it is under warranty let them fix it.
Jim