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2005 Harley-Davidson® Sportster® XL 1200...Expand / Collapse
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Posted 1/5/2008 7:06:36 PM
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Today I have changed my primary transmission fluid for the first time (at about 1800 miles), following the steps provided in the owner's manual.

Take note:

Knowing what I do now I will not open the clutch inspection cover (the large round cover on the left side of the transmission) to add tranny fluid again, but rather add the fluid through the Primary Chain Inspection Cover (the smaller cover on the top left portion of the left side of transmission). I even called the dealer to ask if this is an option as it appeared that it is all the same compartment, which was verified. The reasons are: 1. I now know that the tranny will hold ~ 3/4 of a quart (to the lubricant fill level specified in the manual) of fluid; 2. it is very hard to fill the fluid through the clutch inspection cover, as it is a tight opening; 3. in order to open the clutch inspection cover you must first take off the left side foot peg bracket; 4. the O-ring under the clutch inspection cover is easily twisted or off track when replacing the cover, therefore, causing a possible leak; 5. there is no reason to now that I know exactly how much fluid it will take to fill the tranny case.

I hope this will save you all some time and grief when completing this task. It took me several trips to the store to get the right tools, and a couple of tries to figure out that the o-ring in the clutch inspection cover was loose/twisted, and therefore leaking.
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