Question about 2000 Harley Davidson FLHR-FLHRI Road king

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Inner primary leak, base gasket leak.

How to repair

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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.

Posted on May 15, 2010

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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

Posted on Mar 24, 2010

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I have oil leaking from the primary cover beside the pulley that drives the belt What needs to be done to replace the gasket 1996 Harley fxdwg

The INNER primary cover has an oil seal where the transmission shaft goes through.
You'll need to tear down the entire primary drive to get the inner cover off.
Some notes:
The engine sprocket nut is 160-180 Ft/Lbs of torque, with RED LocTite!
This is going to take some power to break it loose (think impact wrench)
The central nut holding on the clutch pack is a LEFT HAND thread!

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1 Answer

My outer primary wont stop leaking on my 1974 shovelhead.

Hi Anonymous, check the mating surfaces for cracks, deep pry marks ect. use silicone to fill any serious imperfections and weld any cracks. The surfaces should be clean of all previous glued on gaskets. You can use Gasket Cinch if you want to hold the new thick silicone bead impregnated gasket in place. Make sure all mating surfaces are clean and dry and install primary cover. I would do the same with the inspection and derby cover, someone makes silicone beaded gaskets for them also. Then in a criss cross pattern starting in the middle and working your way out ward torque screws to 5 ft lbs. then repeat the sequence to a final torque value of 10 ft lbs. This procedure is imperative to insure proper clamp load on the primary cover. Fire up the bike and ckeck primary vacuum it should be 25 inches of water vacuum with the vent line pinched and the engine running at 1,500 RPM. If you get zero on the gauge you got problems. Usual suspects are: broken or cracked engine case lip, bad motor sproket, inner primary, or starter jackshaft seal. And my personal favorite cracked inner primary just below the starter jackshaft cause by a loose chain. Good luck

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I have a 2004 Duece FXSTD. Drops of oil was found on the floor under clutch area of the primary. After some inspection, I found that it was streaming from the inner primary. Got a seal set from Motor...

Harleys are notorious for this, better today, but still leakers, the machined surfaces of most production castings are not flat, square, blueprinted, etc I recently built a 400 Chevy small block
the block was align bored , paralell decked, and the heads were machined aftermaket i Dart iron heads, all perfectly machined, I got the Edelbrock cam , lifters, carb and intake manifold a Performer package all from Edelbrock matched to work together.
I got the intake installed torqued and using Fel Pro gaskets filled the engine to check for any tiny leaks etc, when a river of green flooded the intake and poured off the end of the engine! WTH??? HOW?? WHERE?? WHY??Luckily I had My builder with me and He got out the micrometer etc and said this stuffs garbage!! we went to Kragen and checked every one they had, alll as abad or worse than mine! we went to 3 storse to only keep my original intake yet it required macjining and port matching to fit right and not leak as it was production not

Dec 27, 2010 | 2004 Harley Davidson FXSTD - FXSTDI...

1 Answer

I have an oil leak from the primary chain case. What do I need to do/replace? Thanks. Eddie Fowler

There are 6 places that oil can weep/seep/leak from on a Softail primary chaincase. The drain plug, the inspection cover gasket, the cover's gasket, and 3 "interior" seals. I'd thoroughly clean the entire area (under the bike as well) and go for a good test ride. Park on a clean surface so I could properly identify the source(s) of leakage. Remember, oil can "travel" while riding at speed. Hopefully you'll be better able to see if your leak is coming from the cover area itself or from the "inner" primary to engine and transmission interface area.

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1 Answer

Piamary leaking oil vary bad but its tray oil

I assume that your primary is leaking oil and by "tray oil", I think you mean "Grey oil". Oil in the primary that has been in there for about 5000 miles will be gray. It contains clutch debris and metal shavings from the primary chain and sprockets.

Now, the oil is coming from behind the inner primary cover, the inner will have to be pulled off meaning you'll have to take the engine sprocket, clutch assembly, and starter off. To get the starter off, you'll probably have to pull the exhaust system as well. That's a pretty good job.

But, if the oil is simply leaking out from the seam of the inner and outer primary or the derby cover, simply replace the gaskets there. If your outer primary is designed to use an O-ring on the derby cover, use the O-ring and a solid gasket as well. This works well.

Good Luck

Aug 18, 2010 | 2002 Harley Davidson FLHR - FLHRCI Road...

1 Answer

Severe transmission oil leak on a 04 softail. Leaked out on left side

Two places could be leaking. Primary cover leak on either side. Outside gaskets are not very difficult to replace. There is a oil seal on the backside that requires the removal of the inner primary. This is a difficult job for the amateur hobbist mechanic but it can be done. You'll need a lot of tool including a torque wrench that will torque a left hand threaded nut and one that will torque to 150 foot pounds. You'll also need a primary locking bar.

So, as you can see, if it's anything other than an outer primary cover, inspection cover, or derby cover leak, it's probably best to take it to a shop. If you do this, have them pull and inspect the front belt drive pulley while they're in there. Also, replace the transmission main shaft seal (small one) the final drive gear seal (the big one) and the "quad seal" behind the spacer for the pulley (like an o-ring). And replace the oil seal on the backside of the inner primary cover. Good Luck

Sep 17, 2009 | 2004 Harley Davidson FLSTC - FLSTCI...

1 Answer

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...

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

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3 Answers

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well when you have water and oil both leaking it most of the time means a head gasket or in your case a jug gasket

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you need to rebuild your engine sounds like you have a gasket leaking or you warped your primary

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Most inner primary leaks come from the alternator o-ring the best thing to do is put on a new one and put clear silicone on the primary and the engine case.

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