Typical auto/bike maker. When has a car maker released anything that wasnt tested first? Alll the time.

 

I have been running Syn3 in all three holes with no problem so far...knock on wood.... I am approaching the 15K mark as well. I have a buddy with 35K on a 06 Dyna, running syn 3 in all three, with no IPB problems either. BTW,both these bikes where bought late 05. Not sure why some are having issues and some are not, but I hope my luck holds up. Glad to hear your problem got taken care of though.

 

It comes down to alignment issues on the '06 models. The '07 models have an additional 2 dowels in the inner primary that go into the transmission case. Inner primary and transmission case part numbers on '07 models are different (60800-06A and 34747-06A) .

The only reason I can think of why some Dynas have the problem and some don't is that if the primary ends up being aligned properly despite the missing 2 dowels when it rolls off the assembly line then it will be ok as long as you don't touch the inner primary.

I have images that show the difference but I just noticed that I can't post images here. I don't have an external site I could point to. I'll be happy to post if someone sorts this out for me, admin?

Andreas

 

Interesting. So I wonder if there is a way to align the primary and put to alignment pins/dowels in it, the same as the 07's?

What is the fix they are doing for the 06's with problems? Putting an 07 tranny/primary in it? Pinning the 06? Alighning it and putting it together w/out pins? If its the latter, is that sufficient, assuming it was alighned properly? This is above my knowledge base as a shade tree mechanic/parts changer, so I dont know if I am making sense or not. I know I dont have any noises on mine.....and I dont want any either! I have about 15K on the clock so far. Really love the bike, and plan on keeping it for quite some time.

 

The fix IMO is to swap out transmission case and inner primary. I recommend you ask for that should you get the same problem with your bike but it sounds like you're ok for now. Just don't touch that primary..... You might be ok with just a bearing and race change - depending on whether or not the primary gets aligned properly.

I do not know if the dowels could be retro-fitted without a drilling template. I suppose you could make one if you had an inner primary and a transmission case off an '07 Dyna. Not sure if the casting is different though on the '06's. Patrick is getting his bike fixed up with new parts - there might be an opportunity to find out. Pat, maybe your friends in the service department will let you take a look at both model year parts so you could compare?

Andreas

 

I think these are the images Andreas wanted to include in his post.





The two additional alignment dowels are circled in red on the '07+ image.

 

so how long will it actually go before its trashed? reason i ask i have the same noise symptoms ran it by 2 differnt shops last fall and was told its just the clutch pack coming together. pull lever in noise goes away.i am guessing i have put on 3 or 4k miles since then and the noise is no better or worse far as that goes.
also has anyone had hard time to get it replaced when outta warranty but have the papers where hd basically admitting fault there was a prob seeing they first said every 15k miles to have replaced.bike currently has 50k on it now

 

My first one went around 4K; went from no-noise to no-mistaking in about 40-miles of freeway riding. I rode another 70-miles home with no real increase in the noise/feel. They replaced the bearing & race (still under factory warranty) and I was good from last June 'til now (now at 12.5K). Some guys are getting tens-of-thousands of miles, and others of us are getting just a few thousand. Ive heard of a "high" of 4 failures in the same bike!
I've read posts here of guys getting HD to fix theirs for free well outside their 2-yr warranty period, but that seems to be at the discretion/good will of individual dealers, and NOT an official HD policy. If you have the "Amendment To Owner's Manual" letter you got when you bought your bike, it's strong evidence there was a known issue with the '06's (even though they sent a rescission letter some months later).
If you've got a noticeable noise that you can demonstrate using the steps described in my first post of this thread, then there's likely shaft runout, bearing breakdown, etc., like they found when they tore into mine. I had the extended warranty to fall back on IF HD wasn't gonna do the right thing by me. Maybe you need to shop around for a more accommodating dealer who's dealt with this issue before. Both of the ones closest to me were clueless about the '06 IPB issue before mine.
Ask your nearby shops to demonstrate the same noise with any Dyna on their floor...any HD, for that matter. I knew my bike, and the noises that were normal and abnormal. I was very riled when a HD Tech said my noise was normal. I had enough confidence they'd find a problem, that I gave permission to tear it down for closer inspection, knowing that I'd be out $400+ if they did and found all within spec. If I can be of any help, PM me or email this userID at Yahoo. Good luck.

 

I just had my inner primary off yesterday in my '09 and there were only 2 guide dowels on the inner plus the two alignment dowels for the starter, if that helps

 

awesome!!!