Question about Harley Davidson XL 1200 C Sportster Custom Motorcycles

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I have a 2005 harley xl 1200 custom..i am leaking oil or i think it is transmission fluid..from the round side cover..the clutch cable enters the transmission just a little bit towards the inside of the motor..fluid is leaking from that do i replace the covers gasket..i guess its the clutch inspection is round..

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That's exactly what that is. We call it a "derby cover". It's held on by four screws. Take this cover off. There is a locknut and small spring that is behind the cover. This holds the clutch adjuster. Just put it back in the hole. The plate is sealed by a "quad ring". This is an O-ring made of square material. Just replace the quad ring and it should solve your leak. You can use some thick grease to hold the quad ring in place while you replace the cover. Don't forget to put the locknut and spring back in first.

Good Luck

Posted on Mar 14, 2011

Testimonial: "I thank you..your explanation was perfect, and thank you so very much for your advice about the lock nut and spring..i did not know it was in there."


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How do i replace a starter on a 2005 harley 1200 sportster

Disconnect the battery and then the wires on the charger. Drain the transmission (left cover). After that, you can remove the shift lever connection and the clutch cover. Disconnect the clutch cable from the clutch assembly. Now you can remove your complete primary cover. After all that you will want to remove the two screws that hold the starter to the engine. Then simply put everything back in the reverser order using all new gaskets and seals and fill the transmission back up w/the proper amount and weight of oil.

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Left side usually the primary case outer cover is a chrome or polished aluminum case cover that the jiffy stand will come up to or against when it is up in riding position. Clutch cable enters in front of clutch inspection cover (derby cover) which is secured with four T-27 Torx screws. You would add fluid here and only up to the bottom of the clutch diaphragm spring. There is another small cover plate in the more forward portion of the primary case cover and this is where you would inspect the primary chain tension.

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1 Answer

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You need a new cable. It points downward from the primary cover which contains oil, and some of it sits in the lower part of the cable. If it is frayed, it will leak.

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1 Answer

1998 harley davidson 1200 sportster custom

The trans lube is the same as the primary lube. As long as the primary fluid is touching the bottom of the clutch basket with the bike sitting upright, you are good. You will have to remove the clutch (derby) cover on the primary cover to check the oil level.

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Oil leaking out of clutch cable

Hi Anonymous, if the oil is leaking from the clutch cable point of entry into the cover then there is an o-ring OEM part number 11179 that can be replaced. If it is leaking from the clutch cable metal housing crimp boot then you will have to replace the cable and I'm sorry you can't find the very first and best tool you ever bought for your Harley Davidson. Despair not, for a mere $6.50 you may be able to download another one from the website below and good luck.
Harley Davidson Manuals Mark Workshop

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1 Answer

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Find the cable adjuster in the middle of the cable, loosen the lock nut, and turn the adjuster barrel inwards to get as much slack in the cable as possible. Take the E-clip off the bottom of the clutch lever pivot pin and remove the pin. Pull the lever out and disconnect the cable from the lever. Stand the bike straight up and drain the primary case. Down on the primary, take the round plate off to expose the clutch release mechanism. Disconnect the clutch cable from the link that connects to the release mechanism. Screw the end of the cable out of the primary case. Install in reverse order and readjust the cable. Add oil back to the primary case.

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1 Answer

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Take the round plate off of the primary cover back where the clutch is. A lock nut and small spring will come out. There is a threaded screw in the hole that is a clutch adjustment. Turn this screw clockwise to get your primary cover off.

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1 Answer

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1 Answer

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