SHORT VERSION OF LONG POST: Inner Primary Case appears to be leaking at bolt to tranny. Will applying silicone to the bolt and torquing the bolt to spec stop the primary oil leak? Long version: I’ve checked the archives and didn’t find any post on this problem (but that doesn’t mean there’s none there). My 2002 FXDL Low Rider has a leak behind the inner primary case. It’s not crankcase engine oil: the leaking fluid is clear, clean, and with almost no odor (whereas on the oil dip stick, the crankcase engine oil is not clear and is dark). I raised the bike on a 2-arm m/c jack and sprayed brake cleaner around the area to the rear of the primary case and to the inside between the case and the oil pan where I saw the leak. I cranked (but not started) the engine several times to get the oil to leak (turns out it will leak by itself now without the engine running). Oil drops are accumulating on a protruding post at the back of the inner primary case where the case bolts to a threaded transmission tab. I can see the flush end of a threaded bolt that appears to come from inside the inner primary case through the case post that threads into the transmission tab. The end of the bolt points toward the oil pan on the other side of the transmission tab. The oil pan is clean. There’s no oil on the upper portion of the transmission tab that implies the oil is not coming from anywhere above the bolt (like from the tranny). The FXDL factory manual shows the inside of the inner primary case (but not the back of the case that faces the tranny). The inner case drawings show three (3) Primary-to-Transmission locktab bolts located on the right-half of the case (behind the clutch). One of the bolts looks to be in the right spot (the lower-right bolt) where I see the leak. So I'm assuming the bolt is loose, and/or any sealer applied between the inner case and the transmission has broken down. If I have isolated the leak correctly, I think there are a couple options, but I don't know which is best (or correct): Per the manual all my options would require removing the primary chaincase cover then removing the primary chain, clutch, and compensating sprocket to gain access to all three P-to-T bolts, then … A. Torque down all three bolts to spec and see if that stops the leak. B. Apply silicone sealer to all three bolts then torque them down and see if the leak stops. This was done in an archived post to fix a different primary leak. C. Completely remove inner primary case, clean off the contact points for all three P-to-T mounting bolts AND P-to-Engine bolts, add silicone at the mounting points, then bolt the case back up to the engine and transmission. Are there other options?? The C. option sounds like a lot of work, but it would give me access to the Jackshaft oil seal for a visual check. There's also mention of a "crankcase lip O-ring" that's discarded and replaced when removing the entire inner primary case. Am I on the right track here? If so, any thoughts on which is the best option (or is there a better option)?? TIA for any tips, suggestions, comments. Manjo 2002 FXDL
