I have primary fluid leaking from the starter

Remove the negative battery terminal or the ground cable to case connection and then remove the primary cover and then remove the two starter mounting bolts and washers with a ball hex driver. THEN remove rear exhaust pipe, remove the positive battery lead and solenoid wire from the starter. Remove the starter and gasket from the right side of the motorcycle.

INSTALLATION procedures:

Install starter and starter gasket from the right side of the motorcycle, then attach the positive battery cable and solenoid wire to the solenoid and from the left side install the two starter mounting bolts and washers and tighten them to 13-20 ft-lbs which is 18-27 Nm. Then reinstall the primary cover, fill it to the proper level with primary chaincase/transmission fluid/oil and then reconnect the battery ground and re-install the rear exhaust pipe.

Remove the negative battery terminal or the ground cable to case connection and then remove the primary cover and then remove the two starter mounting bolts and washers with a ball hex driver. THEN remove rear exhaust pipe, remove the positive battery lead and solenoid wire from the starter. Remove the starter and gasket from the right side of the motorcycle.

INSTALLATION procedures:

Install starter and starter gasket from the right side of the motorcycle, then attach the positive battery cable and solenoid wire to the solenoid and from the left side install the two starter mounting bolts and washers and tighten them to 13-20 ft-lbs which is 18-27 Nm. Then reinstall the primary cover, fill it to the proper level with primary chaincase/transmission fluid/oil and then reconnect the battery ground and re-install the rear exhaust pipe.

Bottom rear, at the lowest point.

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.

Sportster Starter

Removal Procedures:

Remove the negative battery terminal or the ground cable to case connection and then remove the primary cover and then remove the two starter mounting bolts and washers with a ball hex driver. THEN remove rear exhaust pipe, remove the positive battery lead and solenoid wire from the starter. Remove the starter and gasket from the right side of the motorcycle.

INSTALLATION procedures:

Install starter and starter gasket from the right side of the motorcycle, then attach the positive battery cable and solenoid wire to the solenoid and from the left side install the two starter mounting bolts and washers and tighten them to 13-20 ft-lbs which is 18-27 Nm. Then reinstall the primary cover, fill it to the proper level with primary chaincase/transmission fluid/oil and then reconnect the battery ground and re-install the rear exhaust pipe.

The primary case is not marked. The book says that between 32 and 40 ounces of oil is to be used in the primary/transmission case. This oil lubricates both the primary chain and sprockets as well as all the gears in the transmission. The oil will not be visible inside the case. If it were, there would be too much oil and it would make the clutch "drag" making it impossible to find neutral with the engine running. The sprockets and chain are lubricated by a mist of oil generated by the starter ring gear on the outer clutch drum slinging the oil all in the primary case when the engine is running.

Some of the older Sportsters had a threaded hole with a screw in it towards the bottom of the forward end of the case. One would remove the screw and fill the primary until it started to run out of the hole.

Good Luck
Steve

yes, the jackshaft in the primary. Drain the primary case. Remove the outer primary cover. Just above the clutch assembly, you'll see the jackshaft. There is a small bolt with a bend tab lockplate under it. Remove this bolt and your starter will come off.

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

Trans plug is under the Primary cover ( Left side ) and the Oil line is under the frame on the left side. Look for a oil line with a plug attatched to it. Run the bike up to operating temp. Primary and trans are the same thing ( Sport Trans fluid ) 1Qt in the primary ( fill throught the little cover on the side of the primary, and fill the oil through the oil tank. Put a little oil in the filter too, before installing, this will give the motor a little bit of oil until the rest of it makes it way through. You'll also need 1 p/n 11105 for the drain plug on the primary.

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