. 1998 FXDL. I pulled the whole assembly off last weekend. I rocked the clutch on the splines it wasn't loose. I could move it slightly a hair maybe felt normal no slop. I didn't physically remove the bearing to inspect. I assumed would be evident in rocking it. I did start and run it with the primary off. Rev to 2500, no visible play at all. The only thing moving that was visible was the comp spring cover because of the indents. Everything else looked very straight and steady. I was expecting to see wobble somewhere. I would love to start it with the comp and primary removed but I'm not aware or any way to fire it up without it all connected to start it.

 

Honestly, I think you need to find an Evo buddy near you.. Sounds like you've covered just about everything, except rotating assembly balance..

From my experience, my Dyna had a direct drive compensator sprocket in it at one time. It was much more direct and responsive than the spring and ramp style the bikes are born with. However, it was absoloutely horrible while lugging. Not saying this is your issue, but I can tell you that this bike would not ride below 60mph in 5th w/o bucking severely... What I learned from this was that particular RPM range was bad for the engine and caused a lug that the crank could not compensate for. HD engineers obviously knew this too, because they added the spring/ramp compensator nut to dampen it.. So, my story realy doesnt provide an answer or suggestion to your particular problem. But, before spending a ton more money chasing this down, I'd find a buddy that would be willing to swap bikes to verify that your not expecting too much from your bike..

 

On a side note did you ever get the timing straight?? That may be contributing to your issue.

 

I agree with Greg, you need independent advice. Any of us can chase around in circles trying to tie down a problem, but there comes a point in time when time passes, effort is expended and no gain is achieved. Sounds to me that you have reached that point. If you know another Evo owner reasonably well get him round to help you diagnose what you have. Failing that find yourself a local indy and get him to take a look. There is a limit to what we can do for you from in here!

 

Not all bikes like the same gear/rpm either. I'm not saying you can't ride or anything like that , but maybe try avoiding the tach. Shift by listening to the engine , and try not to short shift or lug the engine.

My wife's step dad swapped from carb to efi on his because he said there was no way he could lean it out enough for his riding style. When I rode his bike I never experienced the issue he did. I have a habit of stretching a gear out past mid range power , and he would be ready for fifth gear 30 yards off a stop sign.

 

The comp spring cover doesn't move. The slide cam is what moves. It should not move alot if free wheeling. I would look at replacing the cover/spring assembly as it's probably worn.

I speak from experience as far as this item can wear beyond servicable limits
I had to replace mine. The people I consulted all said that they never saw one go bad. Little did they know.

The spring pack had lost a good percentage of it's noncompressed height.

 

Regarding timing, no it's not dead on. I got it close but I posted two more questions on that thread as well. I'm going to need an extra set of hands to dial it in because I'm getting close but I can only get the TDC line using the dial and a hair of movement on the plate swings it from 34 to 40 on the timing light. I don't know anyone with an Evo. I reached out to some locally for sale and got one response the guy said his was silky smooth except at idle. Found a guy with a fat boy he said he didn't have the rubber mount and said it wasn't bad at all just idle. I found one local indie, still looking around, he said it's not right but again leave it for a week so he can go through everything I've gone through, It would get expensive fast rechecking things. I know there's only so much this forum can do, just looking for ideas, don't want to overlook anything. Also, the engine will go lower, I can take it below 2000 down to 1600 and it goes smooth after 1950 on the way down and stays smooth. It doesn't feel like a lugging jerk it honestly feels like a fast hard vibration like misfiring but it doesn't change with timing changes advanced or retarded

 

Check your coil and plug wires then... but again, you're lugging it below 2k RPM's and I wish you would take our word on that... I used to race motorcycles and got the trophies to prove it. We know what we're talking about.

 

. I checked the resistance, not sure how else to test without swapping another ignition on there to see if different. Plugs are new iridium, wires checked out with the right resistance unless my meter is shot. I posted on the timing thread I couldn't get a reading on the crank sensor but it's working or it wouldn't fire at all. Someone did mess with or replace the ignition at some point the plug wasn't in the harness locked down. I checked the grounds as specified to pin 7

 

I'm all out of ideas then... if I lived near you I'd ride it for you just to see, but other than that, I'm with these guys... either it's you, or you need to take it to someone with evo experience who can ride it. Not someone whose only ridden softails either... they're rigid mounted.

Did you ever think that maybe that fancy front motor mount you have could be the issue? Swap it out with an OEM motor mount and see what happens.