Primary Leaking

[cj-in-kc]

I just bought a 2004 Big Dog Chopper and have noticed a small leak near the drain plug. I've tightened all the primary bolts and have also checked the drain plug and it is tight as well. I pulled the inspection cover and added fluid as noted in other posts. After running it yesterday for 30 miles or so near 75-80 mph, I've noticed a more pronounced leak this morning. I'm thinking the Primary gasket needs replaced, or now after reading the forum, am thinking maybe the pinhole breather valve is clogged. Any ideas or suggestions?

 

[mcgroom]

I would start with the drain plug myself. It is the easiest in my opinion. I had a similar issue that some Teflon Tape on the plug itself took care of.

I am sure others will chime in as well.

Welcome to the site.

Tons of great people and info.

When you get a chance, go to the intro section and start a thread there.

Everyone will be asking for pics and for you to post a pin on the map as well.

 

[KnotSo]

First post should be an Introduction.

There are several threads on leaks, do a Search and see if any apply to your situation.

See Ya!

 

[dogvet]

I just bought a 2004 Big Dog Chopper and have noticed a small leak near the drain plug. I've tightened all the primary bolts and have also checked the drain plug and it is tight as well. I pulled the inspection cover and added fluid as noted in other posts. After running it yesterday for 30 miles or so near 75-80 mph, I've noticed a more pronounced leak this morning. I'm thinking the Primary gasket needs replaced, or now after reading the forum, am thinking maybe the pinhole breather valve is clogged. Any ideas or suggestions?

Is no pinhole breather on an 04 they vent throught the mainshaft around the pushrod, just like Harley.

If you need a good primary cover gasket, contact Innovative Sealing Solutions ask for Kim. they make the best gasket out there. the number is 602-944-4250.

The fluid capacity is dofferent on 04 and earlier models.

 

[cj-in-kc]

Great idea on the drain plug. I'll put some teflon tape on it tonight, while I put on the new gasket . I might have ended up not needing the gasket, but seeing I just bought the bike, I figure what the hell, I'll put one on, and have a look around in there. I'm picking up a gasket from the HD dealer here in town. According to a Big Dog dealer in Iowa, the left drive BDM chopper would use the same gasket as a 95 or older HD softail.

 

[mcgroom]

Keep us posted with the results.

 

[cj-in-kc]

well, the gasket from the HD softtail fit. Had to drill out a bolt, but other than that all is well. will post some pics in here of the job, later today. i do have a question on gear fluid. I've had someone tell me automatic transmission fluid, someone suggest 85w140 gear oil, and someone tell me castrol synthetic which they use in transmission, primary and oil (all the same type / weight). I haven't filled it back up yet. Any suggestions?

 

[woodbutcher]

well, the gasket from the HD softtail fit. Had to drill out a bolt, but other than that all is well. will post some pics in here of the job, later today. i do have a question on gear fluid. I've had someone tell me automatic transmission fluid, someone suggest 85w140 gear oil, and someone tell me castrol synthetic which they use in transmission, primary and oil (all the same type / weight). I haven't filled it back up yet. Any suggestions?

oh, you've stepped in it now!!!!!

 

[Gas Man]

Primary oil in the primary
Tranny oil in the tranny

Also, I'm not sure its a issue with the 2004 as they are HD LSD primaries. But is the starter gasket leaking? did you check to see how far up the oil leak is coming from?

 

[cj-in-kc]

well, i put the 85w140 in. I took it for a 10 mile ride last night, wiped the bottom of the primary and nothing took it for another 10 miler, tightened all the bolts and inspection plate cover etc and there's no dripping on the garage floor this morning..:up:

I did notice that the allen head screw at the top of the adjuster was VERY loose. Glad I was in there to tighten it up. Now it seems to shift smoother and have less of a "clunk" going into first from nuetral. All is well so far. Pics will be coming.