Inspection cover leak : V-Twin Forum: Harley Davidson Forums

Gooms · 03-23-2005, 10:43 PM

I started having a slight oil leak at the top screw on the inspection cover. Dealer found cover to be warped and replaced it, but it still leaks. I am now thinking it could be the outer primary cover that is warped. Dealer recommended to apply sealant at the screw until they can see it again at the 1000 mile service. Anybody have a recommendation on a good sealant for the meantime, and any thoughts on this problem.
Thanks in advance.

Flyer · 03-24-2005, 12:09 AM

Pipe sealant with Teflon. Comes in a tube. Apply sparingly

Jeff S. · 03-24-2005, 02:21 AM

Most likely it is not a warped outer primary. The holes that the screws go into do not go all the way through. There is a possibility that someone stripped the hole, then attempted to helicoil it and drilled it through. That could cause it to leak. Pull it and check to see if its helicoiled, or if the hole is cracked. Also check to see if the tech had the common sense to install the seal correctly. People laugh, the new seals even have printed on them in orange, "towards clutch" But somehow, some techs still turn them around. The last part is they installed another warped cover. In any case, you can put some sealer on it temporarily, but you should have to leave it there, make them fix it.

Gooms · 03-24-2005, 01:19 PM

Thanks Jeff for the reply. I saw the original warped cover and the new one also placed on a flat surface. Afterward reinstall, it's still just a slight dribble out the top screw as before. One mechanic did suspect a stripped hole and possibly a crack too. At this point, I will remove and inspect for correct placement of the gasket. The gasket I purchased is concave versus flat, which would be straight forward on installing correctly, but like you said, they may have installed it backwards, again. Mine does not have any orange indications on correct placement. It is possible that the factory used a tapered tap and did not tap to correct depth. The screw could bottom out before actually tightening down enough.
Just when you think HD corrected their leak problems as in years past, I happen to be the lucky one to encounter this leak. Everyone I talk to just says, wow...unusual.

dzlfitr · 03-24-2005, 02:34 PM

Gooms....I had the same problem with my '00 Fatboy.
Mine started to leak after I did a chain adjustment, and
it drove me nuts. I went through all the hoops you are
going through. Save yourself the aggrivation, get a new gasket,
make sure everything is clean, clean, clean. Apply RTV
silicone to both sides of the gasket, and let it skin over.
Also, and this is key, apply a fairly liberal amount of
RTV to the underside of the screw heads, let it skin.
Tighten them up, and you should not have any more leaks.
On my sled, oil was wicking past the threads, and escaping
under the screws (no matter how tight I thought I had them).

Good luck........DZLFITR

Gooms · 03-25-2005, 01:54 AM

I purchased new washers for the inspection cover today. They were advertised on the HD parts website. The dealer seem to think these didn't exist, but after showing him on the website, they were in stock, and so I picked up a few.
If it works at stopping the leak, I'll just live with it, instead of having the dealer look into fixing under warranty. Applying sealant on a new gasket might not be a bad idea either.
I sure appreciate the different inputs and comments.

rickr01 · 04-04-2005, 01:34 PM

I think you guys are talking two different animals. The primary chain inspection cover gasket is concave not flat. There is not any writing on it indicating a specific direction. The Clutch or Derby cover gasket o-ring has been replaced by a gasket and it indicates toward clutch. The derby cover does have sealing washers that can be placed on the individual screws. The inspection cover (Primary chain) has two holes that go all the way into the inner primary. The top hole which is prone to leaks is one of them. There is a sealing washer that goes on the inner primary towers on these two through screws, before the outer primary is bolted on. Sometimes they slip during installation and sometimes just plain forgotten. ??? What are we refering to here, Primary chain Inspection cover, or Derby (clutch) cover?

berserker · 04-06-2005, 06:39 PM

Derby cover, clutch inspection cover has 5 screws. Inspection cover, for chain, has 4 screws. Unless they have changed or I am missing some kind of sarcasm.

Gooms · 04-07-2005, 03:52 PM

Installed the correct washer for this type of leak, and when tightening down just a little, it just compresses to the point of being useless. It is probably a soft nylon material or maybe rubber. So instead, replaced the gasket, and bingo. I guess when the dealer replaced the inspection (chain) cover, they neglected to change the gasket. Since the gasket isn't flat, had to guess on which way to install. Did I mention the original cover was warped.
Appreciate all the past feedback.