How to fix oil leak inner primary - 2005 Harley Davidson FLHRS - FLHRSI Road King Custom

SOURCE: leak on the inner primary for harley davidson

Replace gasket (fairly big job) at least 2.0 hours at your dealership.

SOURCE: oil leak at inner primary

06 Road king inner primary leak where shift lever comes out, seal was leaking...Under warranty fixed no charge, no further issues!

I have heard of this same leak on the V-twin Harleys due to normal motor vibration "unbalanced" which is normal on the older models the 2008's and newer baggers have a differant mounting system that eliminates the vibration/ jumping/ loping/ which again is a normal Harley engine

SOURCE: oil leaking from the back of primary case

There are several things behind the inner primary case that could be leaking. There is a seal behind the inner primary where the transmission mainshaft goes into the primary. This seal sometimes starts to leak. Also, there are seals in the transmission in that area. The final drive gear seal is the big seal right behind the front final drive belt pulley. Somethimes this pulley wears on the splines of the final drive gear and it loses tension on the "quad seal" on the final drive gearshaft.

You'll nee some special tools to get to this area. You'll need sockets to fit the compensator sprocket nut and the clucth nut. You'll need an airwrench, a primary locking bar, and a torque wrench that will pull 150-165 ft. lbs. torque in forward direction, 68-80 ft. lbs. LEFT-HANDED on the clutch nut, a primary locking bar, a final drive sprocket locking device, a mainshaft nut removal tool, and some seal pullers and installers. Good Luck.

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SOURCE: Inner primary leak, base gasket leak.

Simply, the rocker box and cylinder will have to come off to replace the cylinder base gasket. And the out and inner primary will have to come off to replace the gasket. Of course all the stuff attached to the cylinder and the primaries will have to come off too. Not to mention the primary chain, clutch assembly and compensator sproket inside the primart case. It's a minor/major job in a shop.

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SOURCE: oil leak -between inner primary and transmission

There are several seals that can leak in this area. You say you replaced the mainshaft seal in the back of the primary. I've seen a lot of people replace this seal only to have it start leaking immediately. The reason was that they didn't know you must lubricate the seal before you reinstall the primary cover. When you put the primary cover on with the seal dry, when the engine starts up, the mainshaft immediately goes to 1000 RPM or higher with no lubrication on the seal. The friction burns the lip of the seal up before the lubrication in the primary can get there. It only take a second, literally.

Other seals that can cause leaks in this area are the large final drive gear seal in the face of the transmission behind the front belt pulley and the "Quad" seal that is inside the transmission. The Quad seal is almost like an O-ring. It's purpose is to prevent transmission lubricant from seeping out through the splines of the final drive gear. If the front sprocket splines wear and the sprocket gets the slightest bit loose, the compression on the Quad seal will be lost and the tranny will leak. The tale tell sign on this leak is that the transmission will leak a spot of oil about the size of a quarter or a bit bigger when you park the bike. If you wipe up the spot, it won't leak anymore until you either ride the bike or simply start the engine. Then it'll leak that quarter sized spot and stop. Check your lube level in your transmission.

Whenever I pull the inner primary and the belt on a Big Twin, I replace ALL the seals. Make sure you lubricate the lips on the seals so they don't cook before lubrication can get to the seal.

Good Luck
Steve