I have a 2001 fxsti that is leaking from the derby cover and inspection plate after putting on a new outer primary cover. Does anyone know how much oil goes into the primary and do you fill it level or on the jiffy. I know harley's don't leak oil, they just mark their spot, but this is the first time I've had problems with leaking from the derby and inspection.

 

When the derby cover is off, you want to fill it until you can see the fluid just covering the bottom of the clutch basket, it takes 32oz. You fill it level and not on the jiffy stand. Also, could be a possibility that some oil was on the lip where the cover sits and that you simply squeezed it out, making it look like it was leaking.

 

Your derby and inspection cover may have warped to the shape of the old primary case cover. Remove both and lay them on a glass table top and see if they are deformed. If so they most likely need to be replaced.

I am assuming you are using new gaskets and torquing the derby cover screws in a star pattern (starting at the top hole) to spec. ( my derby screws take 100 INCH lbs to seal)

If you do get a new derby cover be certain to mark (index) which hole is the top on by scribing an arrow on the inside of the cover pointing to the top hole. This will insure you return the cover to it's original position each time you remove it.