Unstoppable primary leak.

[kpchief]

Hey guys,

The primary on my 04 bulldog has had a leak for awhile now. I have replaced the main cover gasket, I have added RTV to the gasket. I even drilled a hole and put in a barbed hose fitting in the back of the primary to try and prevent any pressure build up. And as a last resort I put RTV on the cover in place of the main gasket, and now my primary cover is stuck on.

Any ideas on what I can try next to prevent the leak? Could the cover be worped? Also, anyone have an idea of how to get a primary cover off that is stuck on with RTV?

Thanks!

 

[Bobby Schulz]

Sounds like something is warped or is out of alignment. Due to the RTV you added you may need a heat gun and have to pry it off.
1) Get a inside/outside primary gasket kit, and some shims for the trans.
2) Take off the inside/outside primary.
3) Make sure that the engine is mounted tight,and square in the frame.
4) Loosen the transmission, and check to see if it needs any shims to sit flat(check with feeler guage.
5) Install inner primary, and bolt it to the engine first.
6) Bolt the inner primary to the trans.
7) Bolt the trans down to the frame, this time checking again to see if it needs any shims so that when you bolt the trans down it does not tweek the inner primary.
8) Check the vent tube again, and blow it out with compressed air.
9) Install outside primary, and install fluid etc.
10) Ride it like the devil is after you and check for leaks

This has always worked for me on a cycle that just wont stop leaking

 

[kpchief]

Sounds like something is warped or is out of alignment. Due to the RTV you added you may need a heat gun and have to pry it off.
1) Get a inside/outside primary gasket kit, and some shims for the trans.
2) Take off the inside/outside primary.
3) Make sure that the engine is mounted tight,and square in the frame.
4) Loosen the transmission, and check to see if it needs any shims to sit flat(check with feeler guage.
5) Install inner primary, and bolt it to the engine first.
6) Bolt the inner primary to the trans.
7) Bolt the trans down to the frame, this time checking again to see if it needs any shims so that when you bolt the trans down it does not tweek the inner primary.
8) Check the vent tube again, and blow it out with compressed air.
9) Install outside primary, and install fluid etc.
10) Ride it like the devil is after you and check for leaks

This has always worked for me on a cycle that just wont stop leaking

Thanks Bobby, I will look into that. Much appreciated.

 

[BadBrad]

I was just going to agree with Bobby, that if you've sealed the outer primary with all that, it may be the inner primary that is causing the leak. If I'm not mistaken, you'll have to pull the clutch to remove the inner primary, but someone may chime in on how to replace the inner primary gasket without removing the clutch.

 

[KaptinAmerika]

Could you tell us exactly what kind of leak?
Heavy, light
Exactly where is the leak coming from?
Underneath at a specific gasket, front, back, from a bolt

You see where I am going here?

 

[BadBrad]

Curtis makes a good point. It could be as simple as a loose drain plug on the primary or the front main bolts that hold your inner primary to the motor may have come loose. Mine have before and it leaked bad.

 

[kpchief]

Could you tell us exactly what kind of leak?
Heavy, light
Exactly where is the leak coming from?
Underneath at a specific gasket, front, back, from a bolt

You see where I am going here?

Gotcha, this may help.

The leak appears to be coming from the bottom of the primary cover along the main gasket towards the back, a couple inches before the drain plug and ends at the plug.It is a light leak only after it has heated up. It will not leak just sitting. I did notice some oil a little farther up the back of the primary where the bottom tensioner bolt would be. I will try to add some RTV around that bolt and see if that helps. Seems like a weird spot for the oil to end up if that is it. Thanks again!

 

[Th3InfamousI]

Gotcha, this may help.

The leak appears to be coming from the bottom of the primary cover along the main gasket towards the back, a couple inches before the drain plug and ends at the plug.It is a light leak only after it has heated up. It will not leak just sitting. I did notice some oil a little farther up the back of the primary where the bottom tensioner bolt would be. I will try to add some RTV around that bolt and see if that helps. Seems like a weird spot for the oil to end up if that is it. Thanks again!

light leak a few inches north of the primary drain plug after shutting hot engine down??

Sounds like business as usual for Harley engines to me....

 

[Raywood]

Don't remember the exact configuration of your starter on the 04 but could be the starter like all the 05's and newer. Worth a check

 

[liferider]

Ok, I had the same problem. I replaced 12-14 primary gaskets. It would not leak until I romped on it. The torque of the 107 engine with the 1 7/16 offset is a problem. I finally said ,"screw it" and went with a BDL open primary. I have never been so happy!

 

[HMAN]

I put on a brand new primary cover. At several bolt holes the mating surface curled upwards forming a lip. I filed these down and put on a new gasket...no leaks. Just my two cents.

 

[KaptinAmerika]

HMAN is likely to have hit it.
I would put a straight edge on both surfaces and correct any flaws. Unless you find some serious warpage then its a whole different game.

 

[minermark]

HMAN is likely to have hit it.
I would put a straight edge on both surfaces and correct any flaws. Unless you find some serious warpage then its a whole different game.

X2 on the warpage issue......

 

[kpchief]

I got my cover off last night by tapping a couple utility blades in the seam along the top, then I was able to pull it off. I then checked my tensioner carriage bolts and they were loose. I put some RTV on them and tightened them up. I should know tomorrow when my new gasket arrives, if that was it. Thanks for all the replies!

 

[HMAN]

.....I then checked my tensioner carriage bolts and they were loose. I put some RTV on them and tightened them up. I should know tomorrow when my new gasket arrives, if that was it. Thanks for all the replies!

Instead of rtv, try some Loctite threadlocker. It does a much better job. Just my two cents

 

[kpchief]

Instead of rtv, try some Loctite threadlocker. It does a much better job. Just my two cents

Hman, thanks for the input, I was kinda looking to seal them too. Not sure how well loctite will seal.

Thanks

 

[kpchief]

Looks like I finally found the issue. The bolts for the tensioner carriage were loose enough to leak through the back, I seemed to have checked everything else except that. Thanks for all the help!

 

[Bobby Schulz]

That is great! Sometimes it is a easy fix.

 

[Tomtang aka Reptilejim]

Thanks Bobby for the info. I found a a leak between my inner primary and the motor. I ordered gaskets and seals from Bikers Dreams. Am about to start replacing things. My leak is at the lower front of the primary. I've removed the inner and outter primary covers. Do you think that I need to loosen the trans. bolts? Can the trans. shift without prior repair? I had the counter-shaft replaced last year in April.

 

[HMAN]

You shouldn't have to loosen the motor or trans. Pull the covers clean and replace gaskets and o rings and you should b good.