Either different models are filled/checked different or I've been doing mine wrong on 3 Harley's since 2005. I have always filled on side stand per manual. I have had my best clutch feel and engagement with Dino oil and 32oz added after drain on side stand. I use Shell Rotella 15w40. Never replaced a clutch or comp. and no metal on drain plug.

 

Either different models are filled/checked different or I've been doing mine wrong on 3 Harley's since 2005. I have always filled on side stand per manual. I have had my best clutch feel and engagement with Dino oil and 32oz added after drain on side stand. I use Shell Rotella 15w40. Never replaced a clutch or comp.

 

Do you have any engine mods? When I changed my cams, even with a properly adjusted clutch, it'd slip when I got on it hard in 6th and when it did, the 6th gear light would go out. I went with the 2003 big twin clutch spring and the AIM VPC clutch plate. It was a little pricey but I now have a strong enough clutch to withstand future power adds and my clutch effort is still easy and smooth.

 

07 and up are 38oz.

 

Clutch adjustment wouldn't explain the 6th gear light going out. Only way light goes out is if outta gear.

 

the 6 gear light is computer controlled based on the speed and rpm that you're engine is running. if your clutch slips, then the rpms are gonna go up and you're computer is gonna think you downshifted into a lower gear. so yes, it will go out.

 

+1 on that. The ECM has a map and if the rpm and speed sensor signal is within those parameters, it illuminates the 6th gear light. There is no mechanical 6th gear switch that's engaged when you're in that gear like there is with neutral. Any one of you can test this by getting into 6th gear when your riding and pull the clutch in. You'll see the 6th gear light go out. 6th gear is still engaged and those gears are still turning. The engine is decoupled from the gearbox and drivetrain due to the clutch disengagement and the rpm is no longer in the range that's required to turn the light on.

 

With the recommended primary fluid level on my 03 Lorider, I never had it up to the bottom of the primary cover. With my 08 Roadking I never had it up to the bottom of the primary cover. Guess I too have been doing it all wrong.

 

Probably a Gremlin fell off and got under the rear tire. Have you checked your Gremlin Bell lately???? Or it could be a clutch adjustment.

 

you are correct...fluid should just come up to the clutch plates bolt ring.