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sportsterpaul · #1 30th September 2016

Riddle me this, after an all day rain ride clutch not releasing completely. Upon inspection we find "milky primary fluid". Change it out with formula plus do a sort one block ride after warm up and.......new fluid milky and noticeably greater volume than after the multiple hundreds of miles earlier today and symptoms still persist.

This time inspected the tranny vent tube and appears like slight seepage where it exits the top case but the top end of the vent is dry and dusty. No apparent leakage at either the inspection cover or derby cover.

. What are we missing here?

sportsterpaul · #2 30th September 2016

Primary off this morning, clutch pack seems fine. Puzzling that we have the " non-release " issue with the plates not welded together. Digging deeper.

sportsterpaul · #3 30th September 2016

Okay, clutch basket off, found basket support bearing very sloppy and thrust washer behind it caked with rust. Couple of parts should put us back in the "go" mode, however it doesn't resolve the infiltration issue. Come on people, is this the only bike out of thousands to have this problem? How many holes in the trans case cavity? Stator plug, starter motor, vent, derby cover, shifter shaft, inspection cover, clutch cable, speedo sensor, drain plug, and chain adjuster. Anyone want to chime in please do so, thanks.