Question about 1993 Harley Davidson FLSTF Fat boy

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Oil coming from behind the primary case cover

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There are several places that the oil could be coming from. And, it could be either engine oil, primary lube, or transmission lube.

First, check for a leak at the cylinder base on the rear cylinder. I've seen that area leak badly enough to make it look like the primary is leaking.

The primary could be leaking from the seal that mainsaft runs through or the starter jackshaft seal.

The transmission could be leaking from the large final drive gear, or the front belt pulley could have become worn allowing the quad seal behind the pulley spacer to leak.

To repair these leaks is not difficult but you need a few special tools. Especially if your going to remove the front belt pulley. You need a device to hold the pulley while you put the 150 foot pounds of torque on it with the special socket you'll need for the nut. You'll also need a torque wrench that will torque in the reverse direction since the threads are left handed.

If you wish to tackle this job yourself, please repost and I'll give you step by step instructions but I would suggest you purchase a service manual for a job of this size and nature. A picture is sometimes worth a thousand words.

Good Luck
Steve

Posted on Sep 14, 2010

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First off, determine if it's transmission fluid, or primary chain case fluid.
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This can be changed with the transmission still in the bike, but the entire primary needs to come apart, and the transmission sprocket/pulley removed to access it.

If it's primary fluid, it's probably the seal on the inner primary case that the transmission shaft runs through and that the clutch assembly bolts to.
Again, the entire primary needs to be torn down to access this.

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If it is indeed coming from the primary case, most likely it could be the primary cover gasket, or the oil seal for the transmission shaft that extends into the primary (the black seal around the rear shaft in the pic), that the clutch hub mounts to, or the gasket for the round plate (with the 6 screws) that the above mentioned seal presses into.

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First disconnect the battery cable. Then you'll have to pull the primary cover off the engine. Find the primary case drain plug underneath the rear of the primary case and remove it to drain the oil. Find the primary chain tensioner underneath the primary cover near the center and loosen the locknut. Turn the screw downwards to loosen the tension on the primary chain. Remove the left foot peg and take the "derby cover" off of the primary cover. Remove the spring and lock nut underneath the derby cover. Remove the bolts around the primary cover. As you gently pull the primary cover away from the engine, turn the clutch adjuster screw under the derby cover in a clockwise direction until the primary cover comes off. Remove the battery cable where it bolts onto the starter motor and the small single wire that plugs to the motor. Just above the clutch assembly there are two bolts. Remove these bolts and the starter will come off the engine. The bolts are different lengths. Make sure you mark which bolt goes where.

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I am changing the transfer case oil on my 02 fatboy for the first time and do not have the manual. 1) Where is the drain plug? 2) Do you refill through the derby cover? 3) The screws that hold the derby...


The case you're changing the oil in is called the primary drive case or "primary" for short. Yes, it does the same thing as a transfer case but in the future you may confuse someone using that terminology.

The drain is a small pipe plug that uses a Torx bit to remove. It's on the underside of the primary cover back directly below the derby cover. You do fill the case through the derby cover opening. With the bike standing straight up, fill the primary with oil until it comes just up to the bottom of the clutch basket, the shiny aluminum drum that holds the clutch plates. It holds about a quart of oil. Do not overfill or the clutch will drag causing you to be unable to find neutral with the engine running.

You say the bolts won't tighten up on the derby cover. Your model should have the five bolt cover and the screws screw into the tapped primary cover. If the threads are stripped out in the primary cover, you can have it repaired by a competent machinist by having them install threaded inserts in the original holes called Timeserts or Keenserts. If the screws will tighten but the cover still leaks, the bolt holes in the cover may be pulled through and standing high on the backside. This will not allowing the cover to seat against the full gasket. In this case, the purchase of a new derby cover would fix the problem.

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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.

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To change the oil, drain the tank, change the oil filter, refill with three quarts of oil in the tank. You also have oil in your primary that should be changed every 5000 miles or so, and the transmission serviced at the same interval as the primary.

To drain the oil on the primary, there is a drain plug under the primary case at the very rear of the case. Remove this to drain the case. Refill the primary through the derby cover. Fill with oil until the level is just to the bottom edge of the clutch spring. 38-42 ounces of oil. Do not overfill or the clutch will drag and make finding neutral with the engine running impossible to find.

To drain the transmission, there is a small plug on the bottom side of the chrome cover on the right side of the transmission. Remove the plug, drain the tranny, and refill through the large plug that takes a hex key in the chrome cover. 20-24 ounces of transmission lube.

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