M1513

2023-02-01

M1513: DIAGNOSTICS AND REPAIR - LEAKS, WEEPS AND SEEPS
Residual Assembly Lubricant

Reason for Revision

See Figure 1, Figure 2 or Figure 3. Harley-Davidson uses P-80®
in assembly of the engine which is an emulsion lubricant to
help with installation of O-rings and seals. Though cleaned
post-assembly, residual lubricant can appear at joints, valleys
and during heat cycles. This lubricant can leave traces on
engine components that can be misdiagnosed as an oil leak.
Also, oil can drip and collect in a groove or gland in service.
This can likewise migrate out later in operation, so
understanding the source of the fluid is important. Such
observations should be cleaned and wiped away.

Refer to Table 1.
Table 1. Document History
Date

Revision Description
Verbal edits.
Updated: Diagnosing the Source, Seals,
* Residual Assembly Lubricant, Required
Dealer Action
2023-02-01
Removed sections.
Updated: Common Types of Leaks, Inside
*
Diameter, Outside Diameter
Sealant removal and typo issue
2020-03-26
Updated: Required Dealer Action,
*
Outside Diameter
2020-03-25 Initial release

Required Dealer Action
To efficiently diagnose an oil leak the technician needs to
confirm that the fluid is not residual from assembly or an earlier
service repair by following these steps:

Purpose for Service Bulletin
To inform dealers on how to diagnose leaking seals or gaskets.
This can sometimes be difficult, unless oil is obviously pouring
out of the seal. Usually, a seal will weep or leak at a very slow
rate.

Motorcycles Affected

NOTE
Do Not use PJ1™ Super Cleaner or any cleaner with
acetone in the contents.
1.

Using an aerosol cleaner, clean all the oil, dirt or other
debris around the suspected area.

2.

Start vehicle and run for a few minutes.

Any vehicle with seals or gaskets.

Markets Affected
All markets are affected.
3.

Diagnosing the Source

If a leak is not present, proceed to step 3.

b.

If a leak is present, repair as needed.

Add the fluorescent additive dye to the oil.
Special Tool:
(HD-28431-6A)

If a seal is leaking on a new or relatively new motorcycle,
chances are good that another issue caused the seal to fail.
Premature seal failure is usually due to damage to the seal lip
or an issue with the bore the seal is installed in.
Always examine the seals internal and external mating surfaces
carefully before replacing seals or gaskets to avoid
misdiagnosis.

a.

a.

FLUORESCENT

ADDITIVE

(OIL)

Use the HD-35457 I-Sheet.

4.

Warm engine up and take vehicle for normal test ride.

5.

Using a black light, check for fluorescent glow around the
suspected area.

Seals

Special Tool:
(HD-35457)

See Figure 2. By design all seals leak at a very low, controlled
level. Unless fluid is running or dripping, this is acceptable.
Only replace a seal if confirmed to be running or dripping fluid.

BLACK

LIGHT

LEAK

DETECTOR

a.

Dye is visible: Repair should be made.

b.

Dye is not visible: No leak present, do not repair.

NOTE
In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your dealership for either maintenance or service.
ROUTING

INITIAL HERE

SERVICE
MANAGER

SALES MANAGER PARTS MANAGER

WARRANTY
PROCESS
MANAGER

LEAD TECHNICIAN TECHNICIAN NO. 1 TECHNICIAN NO. 2 TECHNICIAN NO. 3 RETURN THIS TO

NOTE
Harley-Davidson recommends documenting these conditions
with before and after photos, in the event more information is
required around failures and repairs.

1439549

1439541

Figure 1.
1439545

Figure 3.

Figure 2.

2/2

M1513