Question about 2005 Harley Davidson FLHR - FLHRI Road King

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Have devolped a small leak on 2005 road king. drips from bottom of primary cover at drain bolt. running down from above. back of primary cover has slight oil dampness around transmission and starter shaft area. monitoring fluids doesnt indicate loss of any of the three. suspect starter jackshaft tranny seal.

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Spray it off at the car wash to remove all the oil , then spray Right Guard (Yes, that Right Guard) on the area of the leak. It will show up, but you may not be able to see exactly where. There are a couple spots where it can leak. The jackshaft oil seal, as you said, transmission output shaft (clutch shaft) on the trans itself, the inner primary seal where the trans shaft runs thru, the engine sprocket shaft oil seal, inner primary O-ring, the bolts that hold the inner primary to the engine/trans, the primary chaincase gasket and the drain plug. Hopefully when you get it apart, you will see which seal is leaking. If not, replace them all. Still want to fix the leak? LOL

Posted on Jun 30, 2009


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1 Answer

How to change the oil on a 2004 flhrs primary trans. oil change

Drain from the drain plug on the bottom of the primary case and refill only up to the bottom of the clutch diaphragm spring through the clutch inspection (derby) cover.

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Oil leaking from crank case

Hi Anonymous, I would take it over to your local dealer or reputable shop and let them evaluate the leak. Good luck

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Hi Anonymous, it's a small 1/8th inch pipe plug located on the bottom of the primary cover in the rear. Good luck.

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Bummer on the oil leak. Typically the oil is not from the crankcase, but from some connection, somewhere and leaking down to the bottom of the crank case. Pressure wash completely, run the bike and inspect carefully. Much more common issue is a primary to crankcase seal.

Jul 14, 2011 | 2002 Harley Davidson FLHR - FLHRCI Road...

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Very load chain sounds coming from left side of engine, could hear this when new, brought back to dealer several times they said it was normal since then i have 25,000 miles on it and the noise is much...

Now, I'll address the primary chain but the warranty is between you and your dealer. From my experiences with the dealers, don't get your hopes up though. Now, find the drain plug on the bottom side of the primary back near the derby cover. Drain the primary. If you have to take the shifter and the floorboard off to get the primary cover off, do so. Then take the bolts out of the primary and take the cover off. You'll have to take the bolts out of the oval inspection cover to get the primary off. Remove the bottom bolt and the rear bolt of the inspection cover. Once you get the cover off, look for anything obviously wrong in there. If the primary has a conventional chain tensioner, check the up and down movement in the top run of the chain. It should have 3/4 to 7/8 inch up and down play with the engine cold. If the chain has an automatic adjuster in it, the chain will be tight. Look to see if you see anything that the chain might be rubbing. Look at the underside of the inner primary at the top just above the engine sprocket for signs of rubbing. See if the chain is running in the middle of the tension shoe at the bottom of the primary.

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1 Answer

Need assistance on changing oil and primary. Warrenty is out and doing it myself.

The oil drain plug is on the bottom of the transmission as the oil tank is located there. Usually the drain plug is the one closest to the left front of the pan. Drain the oil, change the filter, and add fresh oil. To change the primary, locate the small pipe plug on the bottom of the primary directly below the derby cover and remove it. Drain the oil, remove the derby cover, and stand the bike straight up. Fill the primary with oil just until it comes up the bottom of the outer clutch drum. Do not overfill. To change the transmission lubricant, locate the pipe plug on the front of the oil pan on the bottom of the transmission. Drain the oil and refill though the plug and dipstick in the chrome release cover on the right side of the transmission. Add 20-24 ounces of oil.

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1 Answer

How to remove starter from a 2005 sportster custom

Disconnect the positive battery cable. Drain the primaary and remove the derby cover. Take the spirng and the locknut out. Go to the bottom of the primary cover and loosen the lock nut on the primary chain adjuster and back the adjust out a good little bit. Remove anything that's in the way of the primary cover and remove all the bolts in the outer cover. Turn the clutch adjuster clockwise as your remvove the cover.

On the other side of the bike, disconnect the positive battery cable from the starter and remove the exhaust from the bike.

Back on the left side of the bike, remove the two bolts just above the clutch assembly. They are different lengths so remember which goes where.

Reassembly is the reverse of the disassembly. When you put the outer primary back on, turn the screw counterclockwise until you can put the bolts back into the primary cover. Once all of them are in and tight, turn the screw counterclockwise as far as it will go and then go back clockwise 1/4 turn. Put the locknut, spring, and derby cover back on the primary. Adjust the primary chain by turning the screw inwards until you have 5/8" to 1/2" inch of up and down play on the chain. Feel of it throught the upper inspection hole. Once finished, add one quart of primary lube to the primary.

Good Luck

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Leaking oil from primary cover, I road my bike to work is it safe to ride it home . I checked the engine oil it's still full . and how hard is it to change this cover?

All old harleys leaked oil, so its no big deal. First try tightening all bolts to primary cover, they should be allen head, so you will need a allen wrench of correct size. To change gasket you will first need to remove floorboard to primary bolts, then all the allen bolts. Put a pan under to catch oil. scrape old gasket off and install new gasket with a small bit of rtv to hold it in place. Put everything back together.

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