You are not the first and won't be the last to encounter this problem. Some have had success with JB Weld on cases cracked at the case drain plug. That plug drains the crankcase. In either model the oil reservoir is either the oil tank (softail) or the oil pan (touring/dyna). There should never be more than 6 ounce of oil in the crankcase. If a softail sits for a long time, gravity will win out and the oil will get by the stop valve and drain into the crankcase.

The guys that have had success with JB weld replaced the case drain plug using a Permatex or Loctite thread sealer; do not use a thread locker. Once the plug has been reinstalled, take dremel tool and create a groove over the crack, clean it well and fill the crack with JB Weld. Do this with the bike on the jiffy stand so any oil in the crankcase will not be standing over the crack. Let the JB Weld cure then, cross your fingers and take the bike for a ride. If this works, leave the case drain plug alone.

 

Harley also makes a case sealent in a 3oz tube thats about $45.00 that's very good.

 

yea man, sucks I know but why put a bandaid on a wound that's always gonna be there. fix it right man. find someone that can weld aluminum if need be but I wouldnt suggest goin with a Mississippi patch job

 

I doubt thats gonna work on this particular crack man

 

Thanks for the input!

We are going to try and groove it out and weld (JB?) Thursday. I’ll post my results in about a week in case someone else has the same problem. Hopefully this thread will help someone prevent this same bonehead move.

It does seem like a very poor engineering flaw that could easily be prevented by the manufacturer but I’m not blaming them for me being a dumb ***.

 

It’s been fixed for awhile now and no leaks, not even a drop. A grinder and two part metal epoxy I guess can fix stupid! I hope it holds a LOOOOOOOONG time!