Should I replace the inner and outer primary covers on my 2005 softail fxsti; or should it be done by a dealer? The part number for the outer primary cover is OEM #60543-99

not sure if this link will help you out but have a look... Torque specifications for Harley Davidson softail 2005 Inner and outer...

If you mean the shifter arm that is attached to the shifter shaft that exits the transmission behind the primary case then if you cannot loosen and remove the allen socket screw in the shifter arm and work the arm off of the shaft and another arm back onto the shaft etc then you will have to remove the primary inner case and outer cover etc.

Primary does not have an inner cover. DO you mean the primary case???? Is it a 2005 or a 2004???

The transmission of your Softail holds 20-24 ounces of oil. Stand the bike straight up and remove the large plug on the clutch release mechanism cover on the right hand side of the transmission. There's a dipstick on the plug. The oil level should be between the lines. To fill the primary, remove the derby cover and stand the bike straight up. Fill the primary through the derby cover until the oil comes up to the bottom of the clutch outer drum assembly, approximately 36-44 ounces. Both came filled with H-D Syn 3 20W50 synthetic engine oil.

Good Luck
Steve

First, disconnect the negative battery cable from the battery. Then, drain the oil from your primary. Remove the floor boards, shifter or anything else you need to remove in to remove the outer primary cover. Remove the outer primary cover. Remove the small bolt holding the starter jackshaft in and remove the jackshaft. There is a coupler that connects the jackshaft to the starter motor. If it comes out with the jackshaft, mark it so that you know which way it goes back in.

Now, on the right side of the bike, remove the exhaust system or whatever might be in the way of getting the starter off. Remove the bolts holding the oil tank but don't remove the tank. All you need is a little room that you get by lifting the tank up a bit. There are two large bolts holding the start onto the inner primary. Remove these two bolts and unplug the single wire going to the solenoid and the battery cable from the starter. Now, you can work the starter out from under the oil tank and off of the bike.

Good Luck
Steve

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

Remove the outer primary cover on left side. Don't forget to drain the oil first. Using a large pair of snap ring pliers, remove the clutch adjuster plate from center of clutch assembly. Remove compensator sprocket nut (very tight) and the clutch hub nut (left handed threads) and remove nut from bolt on primary chain adjuster. Grab the compensator sprocket and clutch assembly and lift out of inner primary.

This is your filter info it may help. Amsoil 1450 FXST Softail Standard 2000-05 SMF134 Black 1450 FXST Softail Standard 2000-05 SMF134C Chrome 1450 FXSTI Softail Standard F/I 2003-05 SMF134 Black 1450 FXSTI Softail Standard F/I 2003-05 SMF134C Chrome Filter Diameter 3” Filter Length 3.56” Filter Thread 3/4-16 Filter O.D. / Gasket I.D. 2.81 / 2.48 Wix Part Number: 51348 All Applications Style: Spin-On Lube Filter Service: Lube Type: Full Flow Media: Paper Height: 3.404 Outer Diameter Top: 2.921 Outer Diameter Bottom: Closed Thread Size: 3/4-16 By-Pass Valve Setting-PSI: 8-11 Anti-Drain Back Valve: Yes Beta Ratio: 2/20=21/37 Burst Pressure-PSI: 275 Max Flow Rate: 7-9 GPM Nominal Micro Rating: 19 Gasket Diameters Number | O.D...| I.D.....| Thk. Attach. | 2.734 | 2.430 | 0.226