Just checking, since I am replacing the outer primary cover I refill with 45 oz vs 38 oz on my 09 FLHT?

 

I think the primaries are all the same across all 07+ big twins.

At the least, the user manuals I've got for 08 Softail, 09 Dyna, 10 Softail and 10 Touring all say the same thing for primary.

 

Owners manual says.Primary chaincase (approximate) 1.40 US qt. 1.32 Liters

 

My manual says 45 oz. if you have removed the primary cover, 38 oz. if just changing the fluid.

 

Correct.

 

Look through the derby cover and verify by shining a flashlight down inside that while in the upright position the fluid just covers the bottom of the clutch basket by about 1/4" I don't measure out exact amounts. Just know that you will need to purchase 2 bottles of your favorite fluid and that you will have some left over.

 

I look for the fluid to be just barely cutting the edge of the clutch spring.

I'd pour in 40 then look with a flashlight. Bike sitting level.

 

Well...I cheated.

Since it was all coming off I drained the fluid and pull the primary off with the derby still attached. Since I usually dont think ahead I didnt realize that I needed the derby bolts for the new one anyway....duh.

I put 45oz in.

I wanted to reuse that primary gasket soooo bad. It only had about 2k on it and still looked new. But, I used the new one and saved the old one. I did reuse the derby gasket, I have a new one if I need it.

The dealer did the 10k service when they took the bike in on trade. The primary fluid was still clean after about 2k of use. The derby bolts on the other hand. 1 bolt I could turn with my fingers, 3 of them were about right, 1 of them was tough to get off. What, did they have 3 different guys working on the bike?

I did learn today that I need better tools. After 35 years of metrics most of my sae tools are HF or an off brand. Those are ok for alot of jobs but when working on threaded aluminum or next to a $200 chrome piece you dont want a cheap tool to break or slip.

Did HD plan on useing a different size fastner on every single part on my motorcycle or was that just an accident.

Are those grade 8 bolts strong enough to hold the outer primary and derby covers on or do I need to beef them up?

 

seriously? Grade 8 is right up there!

Honestly grade 5 would probably work.

 

Same same.