'05 Road King Twin Cam 88 with 28,000, developed small engine oil leak - 1/2 qt in 4k miles. Drips down inside primary onto frame rail - its motor oil, not primary oil. Can see oil residue on drive belt sprocket area too. Any idea as to what all needs to be replaced? Anyone have a list of special tools needed and / or a step by step guide? Any guidance would be appreciated. Here's a photo looking down at drive belt between primary & tranny.

 

Welcome to the Forum from Colorado!
Pics of where it might be coming from would be helpful.

 

How do you know the oil is engine oil, not primary or gear oil? 1/2 quart in 4000 miles isn't much; well within acceptable limits for a TC. You are associating the oil consumption with the leak which may not be the case. Stop and think about; motor oil would have to be coming from the crank case or the top end and unless the crank main seal on the output is the source of the leak, those leaks are very easy to find.

Take the bike to the car wash and thoroughly clean the bottom; take her for a ride and then take a look.

When the bike sits after a ride; does it drip and then stop?

Drain the primary and see how much oil comes out. If the leak is from the main bearing seal on the output side of the crank, there will be too much oil in the primary.

Have you checked the transmission fluid level?

My money is on the primary or trans; maybe the inner primary bearing/seal, shift shaft seal or mainshaft/5th gear seal. It is unusual for an engine oil leak to show up in the area you have shown.

 

I'm with djl on that one. Leaks in that area are tough to pinpoint because there's so much going on there (all the seals djl mentioned) & because the belt and pulley carries and flings it all over the place. I would do (& have done) exactly as he suggested to diagnose the leak. Then, while the inner primary is off, replace ALL the seals in the area, since you're in there. The seals are cheap; it makes no sense to replace only one once you're in there.

 

Looks a lot like a shifter shaft leak, but I've been wrong before ...... clean the area and have another look, what are you using in tranny, if gear lube the smell will tell ya for sure!

 

Regardless of where the leak is coming from its behind the primary. Why not pull the inner primary and change all the seals. If one is leaking the others might not be far behind. Just my opinion.

 

Apologies to the OP for the hi-jack but was wondering how you are getting along with your repair?

 

Im still savin up so I can order my FM 107 jugs so I can send the pistons off with the crank for perfect balance at RP. Had a little set back with finding a cracked head and had to jump on a 2011 silver set from a member in hd tech for $250. Silver take off's are hard to come by. $600 more and I start ordering and shiping the crank out. In the mean time Im pullin chrome stuff to paint gloss black for free. Friends that paint are a good thing. Paintin fender struts, lights, stems and dash.

 

Okay, I had an inner seal leak a 5 years ago on my 05 RK when it was still under warranty, maybe longer. So it's back, and yes...

...when it sets the drip stops.

What does that point to?

There's a great youtube 5 vids of the seal replacement start to finish. Looks like a piece of cake with some walnut hulls in it. Hard part is the 2.5" 6.5" socket I think. I may have to fab one. Also the gear lock maybe. I'm low on oil, haven't checked gearbox fluid.

 

Tranny fluid and a mainshaft seal leak. Pull the primary and replace all the seals. Get a James or alike primary gasket/seal kit along with the correct mainshaft seal and get to replacing! We do this every couple of weeks at the shop as it is a common issue...