I posted this in Softails but realize now it was probably posted in the wrong area, so I am reposting here.

I have an '07 Deuce and my primary has developed a noise that only happens when having engaged a gear and then put into neutral. I thought it was a case of a loose chain or sorts.
I drained all oils (I had to do a change anyway), adjusted the primary by 2 notches. This gave me a tension of 3/4".
The cover had a wear mark from where the chain was hitting it - near the bottom front.
I dremmeled the wear just enough to smooth it out WITHOUT taking off any excess.
Cover back on, filled with oil, and still a noisy primary - not nearly as much but still there.
I didn't notice any wear on the automatic adjuster.
Is a new adjuster and/or chain needed? although (I would think) it's still early days to be replacing those - approx. 20,000 miles.

Thanks in advance for any help

 

Try this:

With the engine running, put the transmission into neutral, and let the clutch lever out, do you hear the noise?

Now pull in the clutch lever and drop the transmission into first gear, did the noise stop?

 

I have done exactly that while at a stop light or such and yes, while still in gear and with the clutch lever in, there is no noise.

When I start the bike to go riding - (in neutral while I get my act together) - no noise. Put it in gear, take it out of the garage, put it in neutral to close the garage door etc, noise appears.

 

I tried to attach a file from Harley explaining this condition but it is too large. Shoot me an e-mail and I'll send it to you. mark@bakerdrivetrain.com