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[mrmagloo]

HarleyRider2004,

I got your PM and have read the entire thread.

Firstly, the dealer is a retard. As the others suggested, the 'fill cover cap' can be easily removed with the right sized hex. If your exhaust pipe is in the way, try one with a balled end, or 3/8 socket. Suggesting you have to remove the cover would really make me question that dealer, unless you heard them wrong. Are you sure they weren't talking about the primary?

Anyway, I have actually removed mine and swapped to the Trans Speed-Check Dipstick, which is much easier to deal with. I've attached a pic, but cannot find the correct PN for the SED with the hydraulic clutch right off the bat. If the dealer can't help, let me know and I'll try to sort it out for you.

Regarding the rest, here's a quick run down...

I run the following:

20w50 Mobil 1 in the crank. I buy 4 qts, fill with 3 and adjust up from there.
10w40 Mobil 1 4T in the Primary approx 22 oz.
70W90 Mobil 1 Gear Lube in the Tranny approx 28 oz.

The drain plug for the oil is on the right side frame. The trans is in between the rear shocks. And the primary is on the outer (or inner) cover toward the rear. Make sure you replace the O-Rings every time. I also use a very little bit of plumbers dope on the threads for added seal and to ensure the threads don't seize.

From there, you need a filter - I run the Definitive 5 system, so I use the factory push on, the 3 O-rings, and the primary cover gasket. You might also want to hit the plugs at the same time. I go through this whole routine every fall before I store it.

If you have anymore questions, shoot me a PM.

[HarleyRider2004]

MrMagoo-  I am sure I did not hear the dealer wrong...I even questioned the guy and asked "so to check the trans fluid I have to remove the cover"  he replied "that is why I don't have one on my bike" so anyway he went and got another guy who said yes it has to come off and I could go see the sevice writer who may be able to help more.  Service writer said it also needs to be removed.  Retards!  Ocean City Harley Davidson...just a FYI.  Thanks.

I will have to find a hex that will fit to remove it.  Anybody know where I can pick one up.  Pepboys sure doesn't have one.  I have bought the socket, and a regular allen and they do not fit.  If I can find something as suggested like a dremel with a blade I will cut mine.  Maybe my neigbor has one...

Thanks guys!

[mrmagloo]

The local Sears has a variety of hex sizes on both socket and T-handles that go up that far. If you don't have a set of Metric and Standard T-Handles, might be a worthwhile investment.  If I can find my stocker, I will measure it and give you the size you need.

[HarleyRider2004]

Just to let everyone know. My neighbor has a SED 2003 trans plug is easy as can be to get too. We cut down my hex to fit but guess what as I thought it would not come out as it screwed into the trans cover. I will attach a pic later. Now my neighbor is an expert working on cars and such and he said I can't imagine how you can get that out with out removing the cover. Well I had already scratched the chrome by screwing the plug into it a little so I decided that the trans cover just needed to be bent in a little so with the help of a hammer and a few whacks it bent in enough for the trans dip stick to come out. Well I have scratched my chrome a little but it is out.

Guys thanks for your help was not trying to be a PIA but I knew this wasn't right. By the way if I have to drill out the 2 screws that are stripped in the derby cover what size bit should I use?  I don't think that I am going to get the
out any other way.

[REGGAB]

Just to let everyone know. My neighbor has a SED 2003 trans plug is easy as can be to get too. We cut down my hex to fit but guess what as I thought it would not come out as it screwed into the trans cover. I will attach a pic later. Now my neighbor is an expert working on cars and such and he said I can't imagine how you can get that out with out removing the cover. Well I had already scratched the chrome by screwing the plug into it a little so I decided that the trans cover just needed to be bent in a little so with the help of a hammer and a few whacks it bent in enough for the trans dip stick to come out. Well I have scratched my chrome a little but it is out.

Guys thanks for your help was not trying to be a PIA but I knew this wasn't right. By the way if I have to drill out the 2 screws that are stripped in the derby cover what size bit should I use?  I don't think that I am going to get the
out any other way.

Can you drill a small hole into the center of the screws and use an EZ Out to get the stripped screws out?  Try drilling a 7/64" diameter hole 3/16" deep into each screw and use an 1/8" EZ Out.  Should come out easily.

[LarryB]

First of all, do you know how to use an EZ out and do you know the drill bit to use is backwards, counter clockwise.
you say they are stripped, I would try anything else before the EZ out thing, like a different size Torx, or hex head, or even a flat head screw driver, and beat it in and turn with vise grips. if you F#@k it up, huge fix.
there is another tool that acts like a EZ out but without the drilling needed. may its called a NOT SO EZ out.

[Twolanerider]

If there's anything left of the head try the "screw out" tool from Craftsman.

http://www.craftsman.com/shc/s/p_10155_12602_00952156000P?vName=Tools+%26+Equipment&keyword=remover

There is no "best" or absolute answer as they always get damaged slightly differently.  Drilling and use of EZ-Outs would be my last option before any other tool option that might still grab the damaged head of the screw.

[REGGAB]

First of all, do you know how to use an EZ out and do you know the drill bit to use is backwards, counter clockwise.
you say they are stripped, I would try anything else before the EZ out thing, like a different size Torx, or hex head, or even a flat head screw driver, and beat it in and turn with vise grips. if you F#@k it up, huge fix.
there is another tool that acts like a EZ out but without the drilling needed. may its called a NOT SO EZ out.

Thanks, Mr. LarryB.  Sounds like sound, technical advice.  I'll give it a try the next time I find myself faced with a stripped screw.
You certainly know your stuff.  

[HarleyRider2004]

Larry, TwoLaneRider, HML, Mrmagoo and everyone else...I really appreciate the help.  I bought a T30, figured I will try to bang that in to see if it will bite.  If it wont then I will go to SEARS.  Gives me an reason to buy some more tools!    

OK but just to show you guys what I was talking about here is the pic as promised.  There is no way this was coming out.  I took a screw driver an bent the bottom of the trans cover in and finally was able to remove it.  But it was still a tight fit. 

Hey MrMagoo.  I read the trans speed check is not supposed to be used with the hydro clutch.  Will it be OK to replace it I think that you said you did it anyway.  Reason I ask is if it sticks out just a little it will hid all of the scratches.  If you get a chance will you post a pic of yours.  Thanks.

[LarryB]

take the trans cover off. It's bling anyway

[mrmagloo]

I'm just sitting here scratching my head wondering what the heck the problem is? The only thing I can possibly imagine is that the stock exhaust is in the way. Fortunately for me, I removed mine before the second day, and I have very easy access even with the 2 into 2 Big Radius.

On the Trans-Speed version, I did look it up this morning and noticed the new warning. I'll try to look up the PN I used, but I can assure you that wasn't there when I got mine 4 or 5 years ago. They might be referencing newer transmissions, or something? I don't know, but mine works perfect.

[HarleyRider2004]

I dont have stock exhaust.  Have V & H pipes on her.  It wasn't the exahust it is the trans cover that caused the problem.  Bent it a little and now can get it out.  So I am OK on getting it out but would like to put the trans speed cap on to cover the scratches that I made.

Tried using the T30 head to get the stripped heads out with no luck.  So will attempt to use flat head and pray that works. 

[mrmagloo]

Dude,

I just wish you lived closer, becuase I would sure like to have a close look at what the heck is going on.

In this pic on this post, that shows this should be wide open for you to access, so with the right hex, you should never been forced to remove the side cover. Seriously, this is normally a 5 second job!

http://www.cvoharley.com/smf/index.php?topic=38084.msg607059#msg607059

Sounds like something is terribly wrong. Bring it up here and I'll get you sorted out.

[HarleyRider2004]

Well yours looks easy to get to.  Take a look at mine.  But I have gotten this part taken care of.  I can now get the trans fill plug out had to bend the cover.  Now trying to get the stripped heads out of the derby cover!!!   

[Twolanerider]

Well yours looks easy to get to.  Take a look at mine.  But I have gotten this part taken care of.  I can now get the trans fill plug out had to bend the cover.  Now trying to get the stripped heads out of the derby cover!!!   

A thought.  Since others who have or had side covers have been able to access the service hole might it be that the cover you're using has been bent out at some time in its life?  You might have never had reason to notice it until you found it in the way.