the tool i found to do the job is the kastar intake manifold wrench (kas5530) the sad part it's 30 bucks, but i do use it elsewhere on the bike, for those hard to get to allens, that kind of makes up for the price.

 

2011 Ultra classic. Same problem. Loosen the exhaust heat shield and you can get at the 2 bolts with a ball end allen wrench. Mine werent even finger tight. The front bolt was ready to fall out. Tightened the both up, hopefully that was the problem.

 

I had the same two bolts loosen this past week, however I blame Hales H-D for low quality work.

mikebaby

 

I'll be damned!

This Message board has helped me thru numerous DIY fixes, glad I kept researching today.

09 FLHTC,33.5 K miles.. been smelling that burning smell last week or so...couldn't see any leaks on floor because I park on black outdoor carpeting...

After reading a little at work I finally checked that exhaust bracket under the transmission side cover...yup, it's wet..tranny fluid is still on the mark and ok tho..

I called today and made an appointment for that and a burned out fuel gauge bulb, because I thought it was the actual side cover leaking, but I ran my finger around the edge and it's dry, and the bolts on the cover are all tight... but I think i'll climb underneath tonite and try tightening the exhaust bracket bolts and go from there...

Thanks guys...saved me $50 in co-pay if this fixes it....and I've read as well that the small $2 light bulb that lights up the fuel gauge isn't "really" covered under ESP as well.


I'll update tonite or tomorrow if this indeed is the exhaust bracket bolts...

How STUPID is that to have those bolts actually penetrating into the tranny where fluid is?

 

It WAS the 2 bolts holding the exhaust bracket..altered a 1/4 allen wrench and got in there and tightened them up, they both were loose...cleaned the bottom of the bike and let it sit overnite and then about 30 miles to work, no leaks!

Called my local Dealership to cancel the appt, the service manager (really cool guy i'm familiar with)...says oh, had you down for a leaking trans. cover? I said yea, I fixed it, it was the 2 exhaust bracket bolts...he says...


ohhhhhh yea...Been hearing alot of that and everytime they have conference calls or meetings
with upper management, he advises the engineers how stupid it is to have it mounted that way.....lol

 

I had the same issue last year on my 2010 Ultra at 23,000 miles. Fixed under extended warranty, $50 deductible. Shop told me that there are revised torque values for that. Had to have a leaky stator plug replaced at the same time. $900 worth of work for $50!

 

I had the same thing happen to my 2010 Street Glide. Stopped for fuel and smelled something burning. Checked bike and found leak on bottom of transmission bracket. I had one bolt completely missing and the other one was backed out 3/4 of the way. I went to the dealership and bought a new bolt and asked mechanic what they used to tighten bolts. He loaned me his Screaming Eagle Intake manifold Wrench. It worked like a charm and I didn't have to loosen up exhaust or anything else. The wrench has a long enough handle that you can get plenty of torque when tightening the bolts. I liked it so much I bought one for my tool box.



Screamin' EagleŽ Intake Manifold Wrench



This reversible ratcheting box wrench simplifies and speeds up the installation and removal of the intake manifold socket head cap screws used on Big Twin engines. The comfortable soft vinyl grip with Screamin' EagleŽ logo protects the engine from scratches.

94063-09


For use on all Big Twin engines.

DHDTAC online price: US $34.95.

QTY:

 

Yup, I got that leak too. (I think) after installing a new clutch cable I smelled the burning fluid and saw fluid collecting on bracket under trans cover. figured trans cover was leaking. Removed cover, cleaned things up and installed new gasket. still leaking. Next step was going to be removing cover and adding RTV until reading this thread. I'll check these exhaust bolts when I get home today.