It sounds like you have your answers. Either try and manually adjust the wedge to see if that fixes your problem. If it does go to dealership and pick up the updated part number I gave you. I would rather the chain be a touch too tight than loose and grinding junk into your clutch. I am gonna use the updated tensioner when I install the Screamin Eagle compensator assy.
Dont forget to post your fix so that others may know the fix as well.

 

My new wide glide did the same thing. they did rachet my up,and it was quiet for a couple hundred miles.It did it one more time and quilt,I haven't heard it after that.

 

Good deal, Thanks Maxama

 

Well, I had enough of thinking about it last night and tore into the primary again. Although you can see most of the tensioner through the derby cover, I was unable to gain the right angle to advance the wedge. I was able to bend a thick coat hanger just right to get behind it but couldn't budge it.

I then took off the outer primary cover to inspect what was going on. There were no more points of contact with the cover, which confused me. I did notice that the links in the middle of the chain looked shinier than the rest, so maybe it was contacting the cover without making any marks. I then ground down just a little more of the last point of contact just to make sure. Looking at chain alightment on the compensator and clutch looked good, as well as the tensionser.

Checking the chain tension cold, I had about 5/8" of play in the chain. Just to see I tried to advance the wedge one notch to see how much it would take up. It wouldn't budge with just pushing with my finger. I did, however, notice that it had moved up one notch since the last time I had it apart (about 400 miles ago). So I'm guessing it's doing its job correctly.

I put everything back together with yet another fresh quart of Amsoil. Noise is still there. It's fairly faint when cold, but present. When it's mostly warm it is louder, but I'm guessing because the oil is thinned out and acting as less of a noise buffer. When completely hot, no noise. I'm getting frustrated trying to chase this noise. Running out of ideas and about to just live with the loud tapping at stop lights. Not real impressed with my first HD experience...

 

I would suggest using a screwdriver to advance the wedge on the tensioner,if contact was still evident.(which you confirmed is not)

The stock compensators or front sprocket assemblies are garbage and they make a bunch of racket when lugging up through midrange. Some are much louder than others as reported by other members. Mine sounds like crap and thats with earplugs,and drags with no baffles.

If you dont have any more contact issues I would call that issue corrected.

I had a buddy who rode jap bikes for years and switched to Harleys and he would bring his bike to me all the time for noises. I would always tell him,it is a Harley and they are going to have noises. The shear size and mass of the internals,and the HD specific way things are done with pushrods, rubber mounting, the primary design, is just going to have some noise to it.

 

Wanted to give an update for hope it might help someone else. After opening the primary one more time, I double checked everything to make sure no damage was occuring. I had put about 1,600 miles on the bike and the primary tap was the same as day one/two.

I did not find any contact with the primary case this time. Also, using a mechanic's stethiscope, I pinpointed the sound from coming somewhere around the tensioner. My best guess is that the chain slop combined with the pulsing engine as idle causes the tensioner to collapse and retract very quickly, allowing the chain to slap against the shoe going up and down.

I measured chian play to be about 3/4 of an inch at the tightest spot. I decided to ratchet the tensioner up one notch manually. I had to lift on the shoe and push the wedge up the ramp, but it did click to the next spot. This gave chain tension around 5/8 of an inch cold.

I slapped it all back together and threw in Amsoil 20w/50, started it up and all quiet! It does have a very slight whine now, but sounds more like the chain rolling over the tensioner shoe that bearing or tension whine. The difference in sound is very slight when hot or cold. I also rode new 2011 TC96s at a rally this weekend and all their primarys had a louder whine than mine.

If anyone runs into their primary making a ticking/tapping sound, I highly recommend checking your tensioner operation. Good thing I was able to fix my bike that Harley refused to admit to...

 

do you have pictures of the rubbing marks on the cover if so post them???


BigZ

 

They are attached to my first post.

 

Just keep an eye on that tensioner shoe with more pressure that ware out faster than normal. HD synthetic or Amsoils synthetic in the primary makes the bike a lot quieter and runs cooler. Good Luck with the new ride.

 

I have the same issue, after my stater taking a dump I took my bike to the dealership for warranty my 08 flhx came back with the same issue. Yes HD dealer said bike was ok but it sounds like crap, the tapping noise I hear it and bugs me. I thought it was the new stator but your issue you've talked about is exactly what my bike is doing and sounding. Thanks guys great help.