Primary Leak Found Where, Need Help Why

[cj-in-kc]

Ok, I have an 04 chopper that's leaking primary fluid from the middle (front to rear) on the back side of the primary (lower section). The hole its leaking from appears to be right directly behind the plastic portion of the primary chain adjuster.

When the bike is on the kickstand, no leak. Lean to the right and it leaks out this hole. It appears to be a bolt hole (lt feels threaded). To get my ass home, I placed an extra primary cover bolt with some teflon tape (just happened to have one lying around) into the hole and tightened it. It doesn't feel like quite the right size, but it slowed the leak down and got me back 50 miles to the casa.

Any ideas on what should be in that hole. Should there be a bolt there that screws into the back side of the plastic adjuster? Does the plastic adjuster have a plastic piece that should be in that hole and has somehow broken off?

Any help would be appreciated.

 

[slowrower]

Could be the vent for the primary, it is small and is located right about where you put the bolt in. You can get one from Nelson.

Cheers

 

[dogvet]

On 04 and earlier models, there are two thru holes drilled and tapped for the two countersunk screws that hold the primary chain adjuster ratchet plate. Typically, the factory filled these screws with silicone RTV after the ratchet plate was installed.

Hard to tell from the picture what exactly your showing us.

 

[cj-in-kc]

The picture is looking through the frame from the right side of the bike, right behind the engine in front of the transmission, to the left (backside of the primary). THe black items at the bottom are the shocks. It feels as though the bolt won't seat (like if you kept tichtening it, it would just keep spinning), so it very well could be RTV i'm going into. I can't think of anything in the primary that a bolt would connect to, especially coming in from the backside.

 

[cj-in-kc]

here is another pic, shooting straight down on the primary. You can see the bolt i put in sticking out right by the arrow. Again, this is about an inch up on the back side bottom, in the middle (front to back). You can see the shift linkage in the photo.

 

[dogvet]

The picture is looking through the frame from the right side of the bike, right behind the engine in front of the transmission, to the left (backside of the primary). THe black items at the bottom are the shocks. It feels as though the bolt won't seat (like if you kept tichtening it, it would just keep spinning), so it very well could be RTV i'm going into. I can't think of anything in the primary that a bolt would connect to, especially coming in from the backside.

Now I see what your seeing! That would be one of the ratchet plate screw holes.

The Counter sunk screws inside the primary are typically Loctited with 271 loctite (Red). Maybe one of yours got missed, and backed out a bit. Might want to open the primary inspection cover and have a quick look. You'll probvably have to remove the primary cover to see the lower screw.

 

[dogvet]

Could be the vent for the primary, it is small and is located right about where you put the bolt in. You can get one from Nelson.

Cheers

Its's an 04...different primary (harley style!)

 

[cj-in-kc]

hmmm, the top counter sunk screw was very loose today when i took the inspection cover off (screw by arrow). I tightened it 2 weeks ago when I replaced the primary gasket too.

I Didn't know there was a lower screw. Maybe it fell out. Is the screw you're speaking of the one I am pointing to the pic. Is the lower one behind the plastic adjuster piece? Will i need to pull that, after pulling the primary cover, to get to it?

Just trying to determine how long this will take.

 

[cj-in-kc]

yea, 04. Primary is like a HD softtail.

 

[cj-in-kc]

and there is a threaded hole, with the end of a screw head in it, about 4 inches about the hole I am speaking of...sounds like its the lower adjuster screw.....wish i knew that was there 2 weeks ago

 

[dogvet]

and there is a threaded hole, with the end of a screw head in it, about 4 inches about the hole I am speaking of...sounds like its the lower adjuster screw.....wish i knew that was there 2 weeks ago

Well, at least you know it's not a big problem!

 

[dogvet]

hmmm, the top counter sunk screw was very loose today when i took the inspection cover off (screw by arrow). I tightened it 2 weeks ago when I replaced the primary gasket too.

I Didn't know there was a lower screw. Maybe it fell out. Is the screw you're speaking of the one I am pointing to the pic. Is the lower one behind the plastic adjuster piece? Will i need to pull that, after pulling the primary cover, to get to it?

Just trying to determine how long this will take.

That's them! You can remove the outer plate on the adjuster and remove the shoe itself and loosen up the adjuster nut and should be able to access the lower screw. Clean out the holes and red loctite em get the screws good and tight...I'll try to find the torque spec for you, it will be the same as a Harley softail.

 

[cj-in-kc]

thanks dogvet!!! i love this bike!!!!!!!!