Primary chain alignment...
 

2003 Dyna, S&S stroked motor.

ok, I've got some issues. The chain is clearly out of alignment. But I don't know why. See the top view here.

http://i727.photobucket.com/albums/w...322_144732.jpg

It appears the clutch is further in than the compensator sprocket. Is there a spacer that should go between the clutch basket hub and the primary case? I'm not missing anything on the compensator end, am I? Here's the order of assembly as I have it:

http://i727.photobucket.com/albums/w...322_143307.jpg
http://i727.photobucket.com/albums/w...322_143355.jpg
http://i727.photobucket.com/albums/w...322_143413.jpg
http://i727.photobucket.com/albums/w...322_143707.jpg

then the spacer and nut (shown below without the chain in place)
Also, with this spacer under my compensator sprocket nut, the primary cover doesn't fit.

http://i727.photobucket.com/albums/w...322_143501.jpg

The book shows it in the exploded view:

http://i727.photobucket.com/albums/w...322_144206.jpg

but it doesn't appear to be there in the picture:

http://i727.photobucket.com/albums/w...322_144219.jpg

If I remove the spacer, the cover fits.

I need help ASAP on both issues if anyone can offer it. I'm kinda losing faith in online tech here, so hopefully someone knows what's going on.

That spacer goes under the shaft extension, at least that's the way I've always remembered it (which would also change your chain alignment). There is no spacer that I remember under the comp nut like that. Is your rotor a 38amp or 45amp as that makes a difference whether or not there's a spacer there. Stupid question, but what did it look like when you took it apart?

Mine didn't have the spacer. The shaft extension kind of has one built in as seen in the third picture in the original post.

If I had anything else in there it would only push the compensator out further, making alignment even worse. at this point it looks like the clutch basket needs to be shimmed out to line things up.

I just had my '03 FXDL apart to replace a grounded out stator. I thought I was going to get away with only removing the compensator, but ended up pulling the clutch pack as well. I was a bit concerned when I couldn't find the 0.070 hex spacer on the compensator as I reinstalled it and am now a bit more at ease reading your post. Thanks. There was no spacer behind the clutch pack, and it sounds like your primary cover would never fit if you pushed out that side too. I did run into some issues getting the sliding cam to fit well, but in the end I was able to put the sprocket nut spacer on without any clearance issues. It doesn't look like it, but is there any way the rotor is not fully seated? Have you fully torqued the nut down? It might be obvious, but I wouldn't run the bike with that kind of chain offset. Best of luck with it.

I think we may have figured it out. With the new crank (and Timken bearing conversion) apparently there's a different length spacer needed behind the rotor. I'll pull it all back apart today (sigh). What sucks is I have to pull the inner primary cover off too or else the rotor won't come off :(

I found the length for the spacer I need (I think). I will take mine to work tomorrow and machine it down. I'll post my findings later today

http://i727.photobucket.com/albums/w...323_133048.jpg

supposed to be .888 after the timken conversion