Just recently I have noticed a small (drop or two) leak coming from the outer primary, either at the drain plug or at the outer primary bolt right beside the plug. I needed to change primary fluid anyway, so when I did I wrapped some teflon tape around the drain plug. I also noticed that the inside of the head of the bolt was a little boogered, like someone tried to wrench it too much and rounded the corners.
Two questions. 1 - has anyone had any problems with drippage from the drain plug, and 2 - if I go to change out the primary bolt can I just take the old one out and put in the new without loosing too much fluid (keeping all the other bolts on the primary tight)??

Thanks,

JA

 

You should be able to replace a bolt without losing any fluid, but I would suspect that it is coming from the drain plug. You are fine using teflon tape, I use pipe dope myself but the tape is fine. The drain plug gets torqued to 100 INCH lbs. (around 8 FT. Lbs. and the primary cover bolts get torqued to 120 INCH lbs. (10 Ft. Lbs.)

 

agreed! check the torque on all the bolts... the shifter shafts are known to go bad at the seals as well... check it out by looking at the back of the primary to see where th drip is coming from... could just be a bad o ring on the drain plug as well... how can you pull the drain plug and not loose fluids!?

 

You are going to loose fluid when you take the drain plug out unless the bike is upside down. Why not just go ahead and drain the primary and get a good look at the drain plug hole threads ? I run Harley Formula in the primary and it just isn't that expensive to change plus you can see what is going on with the drain. I would also order/purchase a new plug. If you take the outer primary off you can chase the threads with a tap to clean them up.

 

Put a new O-ring on the drain plug, you want to have a few around when you do your services. If you tighten them too much it tears it up which is odvious when you pull the plug next time and it's chewed up.

 

The drain plug on the 03's get screwed in till about 4.5 mms are sticking out. I'm guessing about 1/8" to 3/8" in US terms. that plug is a pipe plug, tapered going into a drain hole of a constant size. If you tighten to tight you could crack the primary case by the drain hole, that could be the case now. Teflon tape could work at this point.

 

I have the same problem on an `01 wideglide. Leaks from the drain plug, not a constant leak and only a few drops. Also noticed the drain plug will back out at times. Did not know that overtighening the drain plug might crack the case and this may be the cause of the plug coming loose. Have to look at that a little closer.

 

The newer bikes have a plug with an "o" ring and the plug has a head and shoulder to hold the o ring. I suppose owners of 99's-05's could find the next size plug and tap out the existing drain hole to the new size plug. That cast aluminum is not forgiving. Just got to be careful.

 

sneaky little thing, if the tranny shaft seal on the inner primary is leaking, that's where the oil will tend to accumulate. Rub your fingers behind the drain plug on the inner primary to see if an oil line has formed. If your hands come out with oily dirt, you got some work ahead of you. Good luck.