HarleyTechTalk

Trying to fix my buddies 2011 Super Glide Custom's primary leak. He's got dealer installed forward control but they didn't replace the outer primary cover, now it's leaking(outer only). Thing we want to do the freeze plug trick Inner and outer but would like to know the size i need before I start.
So far I've read it's metric size on older HDs and then 9/16th for newer?

Your question is kind of vague. They didn't replace the outer primary cover?

Quote from: truck on March 07, 2014, 01:28:14 PMYour question is kind of vague. They didn't replace the outer primary cover?

I was looking at this just the other day. According to some parts pages, it appears that there is no Primary Inspection Cover on some cases to replace with a blanking plate or "no hole" version. To blank the hole off, it appears one has to replace the entire primary cover.

Now, I don't know if that is actually true - I am not upto speed on latest models - but it was certainly how it appears in the part fiche I was looking at.

Do you have one and which style?

As for removing the plastic shaft, and blanking the hole on the inner cover, Alloy Art do a nice shifter shaft blanking plug ... (and try saying that after a few drinks. "Simon shoved a shifter shaft blanking plug back" ...) with two o rings. A number of outlets do blank or etched Inspection Covers.

What do you have and which shape?

(BTW, if you are removing that pipe and inner retaining plate and bolt, I'm looking for one).

Numerous primary covers are swappable across numerous models.

More information please

   If its leaking around the shifter hole there a gasket that goes in between  the inner and outer primary, with out the shifter shaft it might of slip out of place. The part# is 63869-06. The other thing you have to watch for is if you use a aftermarket primary gasket their sometimes thicker then the harley gasket, then you have to make sure you get the same thickness center one other wise it will slide out over time. If you want to do away with to shifter hole you can use a softtail primary cover and make a plug for the inner primary hole.

Around 2007 they did away with the "primary inspection" covers on  all bikes, and went to model specific primary covers. With shift shaft holes and without.  So a complete forward control conversion would need a $350 primary cover instead of a low dollar cap or solid inspection plate.  I like that inner primary plug pictured above.

Not sure if we are talking the same thing, but I was at my local Indy one day after he had done some clutch work on a bike that had an aftermarket forward controls put on.  All was well until he went for a test ride, and then he had oil running out the chrome plug they added to the cover to fill the hole.  With the bike off the jiffy stand, sitting straight up. the bike also had oil leaking down the back of the inner primary.  Turns out part of the original change was the installation of a purely decorative chrome hole filler and a round gasket that mated with the inside of the outer primary and inner primary on the old shifter shaft holes.  Without it, primary oil could get into the pathway and run out either side.

Note: I could be wrong that the installation of the forward control kit made the seal on the boss necessary.  It had a hole that allowed the mid control shaft to pass through, so it may be needed all the time.

As poor as it is...never had a problem with leaks from that chrome push-in plug that HD supplys with their kits to put forwards on a later Dyna. Follow the instructions for cleaning and Loc-tite and you should be good. Or pay more $$ for the Wideglide primary cover....

Quote from: BUGLET on March 07, 2014, 02:19:11 PMIf its leaking around the shifter hole there a gasket that goes in between  the inner and outer primary, with out the shifter shaft it might of slip out of place. The part# is 63869-06.

This? Where does it go in relationship to the bush/tube? Some folks make a metal replacement for those plastic tubes that are meant to have better tolerances and be tighter.



Ah, I see the later Dynas are different from the old FXR/FLH inner cases and have a raised boss ...

Homeward Bound.  That is the exact setup and seal I was talking about.  Thanks for posting.  Without the seal, everything looks good buttoned up in the shop, but after a ride enough oil migrates to the boss and runs out the backside of the primary (the chrome hole filler on the front side stays dry at that point).  While you are looking for the cause of the inner primary leak, you suddenly see the oil trail starting around the chrome plug ( bike is on jiffy side now, remember).  That is about the time you remember that little seal on the boss you removed and didn't put back during reassembly.  The boss on the inner mates up with the boss on the outer primary with just enough clearance for that seal to fit. 

The hole on the inside is the right size to tap for a aluminum electrical plug, a little blue Loctite and snug it  you can punch your own full face gasket and never have a problem.  Bob




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Quote from: Rags722 on March 08, 2014, 07:19:54 AMThat is the exact setup and seal I was talking about.

P/N: 63869-06     GASKET, CHAIN CASE HOLDING perhaps - $1.31.

If you haven't got a parts book for your bike, buy one. Or if you are cheap like me, print off the pages from World of Powersports website (link).

(Please excuse the confusion between old FXR style cases and new style ones, the latter haven't filtered down the food chain far enough for me to have come across them.)

I think a couple freeze plugs will fix it for life. Guess I'll need to measure it and post the correct sizes of them.

I put forward controls in my 2007 Dyna Streetbob. I installed the chrome and black cap on the primary case to cover the mid-controlled shifter which now leaks. If the plug is supposed to be in there, why didn't it come with the kit? And then there's the problem of the front leaking. Has anyone else had this problem? Can anyone explain how the gasket secures to the shifter tower hole on the primary housing?

Quote from: Danny733 on May 03, 2015, 03:11:03 PM
I put forward controls in my 2007 Dyna Streetbob. I installed the chrome and black cap on the primary case to cover the mid-controlled shifter which now leaks. If the plug is supposed to be in there, why didn't it come with the kit? And then there's the problem of the front leaking. Has anyone else had this problem? Can anyone explain how the gasket secures to the shifter tower hole on the primary housing?

When you pulled the primary apart to remove the shift shaft there is supposed to be a gasket that goes between the inner and outer primary.. It still need to be installed unless the caps can seal the hole.. If the gasket fell out or was removed, you need to replace it.. They typically come on a pad with sticky stuff on one side.. Evo / early TC  dyna/stoftail primaries had sticky gaskets for 2 of the screws on the primary inspection cover.. Expect they did something similar for the shifter shaft on the 06 up dynas..  Parts book shows the gasket.

I finally understand, the primary housing and the primary cover have towers (tunnels) where the mid shifter went through, there is a space in between where they meet that the sticky gasket squishes. This seals the passageway (where the old shifter shaft was). I Didn't think the oil could work it way into such a small space in the middle of the primary! I have to pull the cover back off and install the gasket and make sure it stays centered.

So two 9/16 rubber stoppers from the home Depot job DONE, no leaks.