The reason I asked about the sealant was because when I last changed the oil (previous service was the 1000 mile service at the dealer), I noticed a grey substance on the threads. Wasn't sure if it was thread sealant or maybe anti-seize. I'll check the bolts on the clutch release cover and see if that does the trick. If not, I need to take it in for the brake switch recall and I'll have the dealer check out the leak.

Thanks for the suggestions.

 

+1
I have double checked the manual, and there is no sealant recommended. Even tho on the first time open the oil plug screw, I have seen some light grayish stuff on thread, which appears as anti-seize.

 

I think they put some kinda Teflon dope on the threads at the factory, which wears off over time. I just clean it off & install a new O-ring every time. Never a problem.

 

You are probably right!
BTW. I have reused the O ring for 6 times (25K on my bike), and it appears still good. No leak!
I am lucky, I guess!

 

It's not your oil plug for goodness sake. It's the two bolts at the bottom of the transmission cover that hold the exhaust bracket. This is a common issue.

You can re-tighten with the end of a ball type allen, or when you remove your header, replace the bolts with some grade 8 black hex head bolts, use a lock washer, and use red locktite...blue if you are afraid of red. Torque to service manual specs. Then it's fixed for good.

 

Yup, u have a warranty so use it!!! I like wrenchin as much as the next guy but when it comes to any leak on a 20k+ vehicle thats under warranty they'd be hearin from me ASAP!!!

 

I just wanted to pop back in and say this answer hit the nail on the head! In my case, the bolt closest to the front was loose. I don't have any SAE ball-end allen wrenches, and I managed to get it somewhat tight with a small allen wrench, but I wouldn't say it's fixed. But I now know where the leak is coming from, and what needs to be done to fix it. Thanks!

 

I had the same problem with those two transmission bolts. There is an old thread a few months back that addresses this and provides a number for an HD service bulleton on new higher torque numbers for the 103s for these bolts. if you look back you will find it. i had those bolts and the ones around the oil pan retorqued under warranty and have had no problems since.

 

Here's my final follow up to this saga...

I finally had a day off, so I took the bike to my dealer yesterday to have the rear brake switch recall done and to properly fix the oil leak. The tech found 3 oil leaks:, the side door gasket (where the clutch release assembly attaches to the transmission), the stator, and the oil filter mount plate gasket.

They replaced all 3 gaskets, including my stator and all under warranty. Thanks to Chandler HD for a great job!

 

Wow, three leaks! Who would have thunk!