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[hogasm]

3 to 5 lbs is what we test lower units with.

Now back to reality.....if you hadn't of fu**ed with stock components

Course if you need some duct tape

[Twolanerider]

Well if I get any pan/case leak jobs in the shop,I'll call.You must have the remove/replace time down to a record.
Here's what I would do:
Warm bike up(5 mile ride).
Clean around the suspicious area with brake clean,or similar stuff.
Pressurize the trans.case with an air gun,and don't forget to plug the vent.You may need to use a goodly amount of pressure,as some air will escape through the mainshaft.
Soapy water spray the area,if you can't see oil.
Do the same thing to the engine.
You may need another set of eyes to help.
You should be able to find your problem. 
John

Too true John, practice makes it quicker.  First time I had to have spent close to four hours from beginning to end.  Last time was 45 minutes down and just slightly longer back together.  That's not practice I really wanted though .

Had wondered about pressurizing the tank but hadn't given it much thought.  The idea came more from the notion that the leak is worse after 10 minutes on the highway than it is after ten minutes putting around town.  All the vent lines are clear though (have checked) and the vent of the heads actually goes to atmosphere.  All open and clear.  And it's never puked out the dipstick. 

I'll take the other pan and see where the oil level is inside of it when 3 or a bit more quarts are poured in.  Then will look more at pressurizing looking for signs of some kind of passage.  Thanks for helping to clarify the idea.

[Twolanerider]

Now back to reality.....if you hadn't of fu**ed with stock components

Course if you need some duct tape

Duct tape holds oil ?


kewl.......

[hogasm]

Duct tape holds oil ?


kewl.......

Enough duct tape will hold almost everything

I remember fishing a tournament in Venice La a few years back when then tropical depression hit. Waves went from flat calm to over 12 foot in a matter of a few minutes. On the way back into South Pass I came off the back of a wave and stuffed the bow into the back of the wave in front of us and broke the Tee top legs on the front of the top. Used a gaff on one of the legs and the deck brush on the other with a roll of duct tape between the two. Held together to get the boat back to NC where I still believe it was stronger than the welders fix.

damn forgot the rest of the story.....we punctured a hole in the oil tank  in the bilge. Used duct tape to temp fix the hole so the tank would stay pressurized. It held so well that when we sold the boat we had forgotten about it and the new owner called and asked us why there was a ton of duct tape on the tank. It was dry when we put the tape on the tank but it still held oil a year later

[miker]

As long as you do not try to use duct tape to fix ducts, it works..

I guess welding the pan on is not an option...?

More goop, thicker soft gasket? 

[Twolanerider]

As long as you do not try to use duct tape to fix ducts, it works..

I guess welding the pan on is not an option...?

More goop, thicker soft gasket? 

In an early morning finish after the fourth leak I considered using two gaskets next time.  But the gasket is actually plenty thick.  Especially the metal lined version with fiber on each side.  Will mess with it again this weekend....

[miker]

Dammit...JB weld for gasket sealer?

[Twolanerider]

Dammit...JB weld for gasket sealer?

That's why this site is important.  An idea I'd totally not considered !

[Rooster]

How about GOOP. Used that once to hold my stator plug in place, the heat made it seal around it like it was made that way. Good luck and hope you figger it out soon.

[mattm]

It's a long shot, but any chance your drawing for a lot of bad gaskets?  Are you buying the from the same place at the same time?

[sadunbar]

It's a long shot, but any chance your drawing for a lot of bad gaskets?  Are you buying the from the same place at the same time?

"Have sprayed the surfaces with UV reflectant and shone light behind under a machinist's rule then ran the machinist's edge along the surface and the reflectant comes off evenly.  It's as flat as you'd hope it is.  Certainly nothing that a metal cored gasket with fiber base's on both sides wouldn't be expected to handle.  Other gaskets were a solid thick fiver gasket and a paper/fiber gasket with a sealing bond chemical ring made on to it (interestingly all three different gaskets supplied under HD part 26077-99A)."

Looks like Don has tried three different types of pan gaskets...   

[Twolanerider]

It's a long shot, but any chance your drawing for a lot of bad gaskets?  Are you buying the from the same place at the same time?

Thanks for any ideas guys.  I was totally hoping someone would offer an insight or epiphany that I was boneheadedly missing.  And no suggestion should be assumed to be dumber than I might have missed.  I'm desperate!

As Scott mentioned had used different types of gaskets that were also purchased at both different times and different places (ran the local shop out of stock).  Potential bad run of product is a perfectly reasonable idea though.  Just wish that had been it.

Saturday or Sunday will mess with it again.  If everyone notices hearing a rather loud sound and a small mushroom cloud emanating from nearly the geographic center of the continental US it wouldn't be unfair to think maybe it wasn't fixed and I'd gone on to other methods....

[hogasm]

Thanks for any ideas guys.  I was totally hoping someone would offer an insight or epiphany that I was boneheadedly missing.  And no suggestion should be assumed to be dumber than I might have missed.  I'm desperate!

As Scott mentioned had used different types of gaskets that were also purchased at both different times and different places (ran the local shop out of stock).  Potential bad run of product is a perfectly reasonable idea though.  Just wish that had been it.

Saturday or Sunday will mess with it again.  If everyone notices hearing a rather loud sound and a small mushroom cloud emanating from nearly the geographic center of the continental US it wouldn't be unfair to think maybe it wasn't fixed and I'd gone on to other methods....

Ah fusion.....hadn't thought of that

[murphy]

I had never heard of Permatex until today, I looked on the web and there are all kinds of products... what ones are you guys using and for what applications?

[johnsachs]

I will say,that most Harley gaskets are designed to be used WITHOUT sealer.Most times you will create more of a mess when you try it.
Diagnose the problem,and fix it properly.
John