Makin' metal...
Thread Starter
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Stage IV
Joined: May 2012
Posts: 4
Likes: 0
From: Thunder Bay, Ontario
Makin' metal...
Well, after a very long day in the shop I felt my first post would be good therapy for me.
I bought my 2001 Ultra Classic (103) last year. I only had time to put about 2,000 kms on it. Since day one I had an odd chirp coming from the engine. Needless to say there are endless posts online about Harley chirping noises. I spent last summer ruling out all obvious causes to no avail. Got to the point where I couldn't tell if it was getting worse or was just irritating me more. It's at the point now where I can duplicate the noise when its parked. It happens typically between 2,000 and 2,500 RPM... especially when there is little to no load on the engine. I've been convinced since the beginning that the noise was coming from the front cylinder.
Well, today I did my first oil change and the magnetic plug was covered in metal. I cut open the filter and flushed it out... again, lots of metal dust and shavings.
So this afternoon I started pulling the engine and its ready to be lifted out in the morning when my buddy comes over to help.
I'm convinced I'm going to find connecting rod bearing(s) packing it in, but I've read very little about any issues with them.
Any tips or suggestions going forward would be appreciated. But again... Not sure if I'm asking questions or just venting.
Cheers!
I bought my 2001 Ultra Classic (103) last year. I only had time to put about 2,000 kms on it. Since day one I had an odd chirp coming from the engine. Needless to say there are endless posts online about Harley chirping noises. I spent last summer ruling out all obvious causes to no avail. Got to the point where I couldn't tell if it was getting worse or was just irritating me more. It's at the point now where I can duplicate the noise when its parked. It happens typically between 2,000 and 2,500 RPM... especially when there is little to no load on the engine. I've been convinced since the beginning that the noise was coming from the front cylinder.
Well, today I did my first oil change and the magnetic plug was covered in metal. I cut open the filter and flushed it out... again, lots of metal dust and shavings.
So this afternoon I started pulling the engine and its ready to be lifted out in the morning when my buddy comes over to help.
I'm convinced I'm going to find connecting rod bearing(s) packing it in, but I've read very little about any issues with them.
Any tips or suggestions going forward would be appreciated. But again... Not sure if I'm asking questions or just venting.
Cheers!
Tourer
Joined: May 2013
Posts: 451
Likes: 0
From: Fort Mill, SC
Well, after a very long day in the shop I felt my first post would be good therapy for me.
I bought my 2001 Ultra Classic (103) last year. I only had time to put about 2,000 kms on it. Since day one I had an odd chirp coming from the engine. Needless to say there are endless posts online about Harley chirping noises. I spent last summer ruling out all obvious causes to no avail. Got to the point where I couldn't tell if it was getting worse or was just irritating me more. It's at the point now where I can duplicate the noise when its parked. It happens typically between 2,000 and 2,500 RPM... especially when there is little to no load on the engine. I've been convinced since the beginning that the noise was coming from the front cylinder.
Well, today I did my first oil change and the magnetic plug was covered in metal. I cut open the filter and flushed it out... again, lots of metal dust and shavings.
So this afternoon I started pulling the engine and its ready to be lifted out in the morning when my buddy comes over to help.
I'm convinced I'm going to find connecting rod bearing(s) packing it in, but I've read very little about any issues with them.
Any tips or suggestions going forward would be appreciated. But again... Not sure if I'm asking questions or just venting.
Cheers!
I bought my 2001 Ultra Classic (103) last year. I only had time to put about 2,000 kms on it. Since day one I had an odd chirp coming from the engine. Needless to say there are endless posts online about Harley chirping noises. I spent last summer ruling out all obvious causes to no avail. Got to the point where I couldn't tell if it was getting worse or was just irritating me more. It's at the point now where I can duplicate the noise when its parked. It happens typically between 2,000 and 2,500 RPM... especially when there is little to no load on the engine. I've been convinced since the beginning that the noise was coming from the front cylinder.
Well, today I did my first oil change and the magnetic plug was covered in metal. I cut open the filter and flushed it out... again, lots of metal dust and shavings.
So this afternoon I started pulling the engine and its ready to be lifted out in the morning when my buddy comes over to help.
I'm convinced I'm going to find connecting rod bearing(s) packing it in, but I've read very little about any issues with them.
Any tips or suggestions going forward would be appreciated. But again... Not sure if I'm asking questions or just venting.
Cheers!
Keep us up to date and more importantly send photos as you do this project!!
Thread Starter
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Stage IV
Joined: May 2012
Posts: 4
Likes: 0
From: Thunder Bay, Ontario
Well, the engine came out of the frame surprisingly easy. So before my second coffee I was into the tear down.
The engine looks great inside. The only part still assembled is the crankshaft and connecting rods. Everything else is spread across my work bench and I has found nothing that points to the metal loss and noise. It's been a bitter-sweet day. No smoking gun but I'm very pleased with the condition of the engine. Pistons and jugs are flawless.
All of the bearings look and feel fine. I even pulled the oil pump apart just in case it was failing. No issue there either.
So, with that all said, I believe I have very excessive side play on the inner connecting rod at the crankshaft. I don't feel any up and down play, but definitely has the potential to slop around side to side. And the fact that the noise is worse when there is little to no load on the engine but fairly high RPM, suggests to me that is when the connecting rod may be banging around in there. So tomorrow I'll take the crankshaft assembly to HD and see what they tell me.
Cheers
P.S. I would post some pictures of the carnage but its asking me for a URL for the photos. When i figure that out I'll post them.
The engine looks great inside. The only part still assembled is the crankshaft and connecting rods. Everything else is spread across my work bench and I has found nothing that points to the metal loss and noise. It's been a bitter-sweet day. No smoking gun but I'm very pleased with the condition of the engine. Pistons and jugs are flawless.
All of the bearings look and feel fine. I even pulled the oil pump apart just in case it was failing. No issue there either.
So, with that all said, I believe I have very excessive side play on the inner connecting rod at the crankshaft. I don't feel any up and down play, but definitely has the potential to slop around side to side. And the fact that the noise is worse when there is little to no load on the engine but fairly high RPM, suggests to me that is when the connecting rod may be banging around in there. So tomorrow I'll take the crankshaft assembly to HD and see what they tell me.
Cheers
P.S. I would post some pictures of the carnage but its asking me for a URL for the photos. When i figure that out I'll post them.
Thread Starter
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Stage IV
Joined: May 2012
Posts: 4
Likes: 0
From: Thunder Bay, Ontario
Well, it's been a while so here's an update.
I ended up sending m flywheel to Darkhorse. All I can say is they were fantastic. The price was right, they turned it around quick and I'm convinced it was a better choice than just buying a new HD flywheel. My theory was correct... The forward connecting rod was wearing badly at the crank bearing. The bearing wore about 0.030" into the bore. If I can figure out how to attach photos to this I'll post it.
I did a full overhaul on the bottom end and did the SE hydraulic cam chain tensioner/oil pump kit at the same time. The engine is all back together and ready to install tomorrow. Looking forward to running this bike with the new bottom end and balanced/tuned flywheel.
Cheers!
I ended up sending m flywheel to Darkhorse. All I can say is they were fantastic. The price was right, they turned it around quick and I'm convinced it was a better choice than just buying a new HD flywheel. My theory was correct... The forward connecting rod was wearing badly at the crank bearing. The bearing wore about 0.030" into the bore. If I can figure out how to attach photos to this I'll post it.
I did a full overhaul on the bottom end and did the SE hydraulic cam chain tensioner/oil pump kit at the same time. The engine is all back together and ready to install tomorrow. Looking forward to running this bike with the new bottom end and balanced/tuned flywheel.
Cheers!
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