I have a 2002 Softail Standard, recently whilst out riding I heard a grating noise coming from the the primary cover, I can only hear this when riding, it stops when operating clutch and when the bike is in nuetral (stationary).

We do not have a dealer here in Gibraltar, does anyone possibly know wot it might be? So I can order parts.

Graham

 

Have you tightened the chain? or is the tensioner boot worn?

 

The tensioner is at max, chain still has play, not sure if this normal,dont want to get into the bother of buying things I dont need.

Thanks anyway, if you think of anything else let me know.

Regards Gibraltar

 

Your best investment at this point would be a shop manual. That IS something that you need, especially without a close by dealer.

You should have some play in the chain, the amount of which is in the shop manual. I don't know what it is supposed to be for your model... but it's probably 5/8" or so.

The chain tensioner at 'max' would mean that the tensioner is all the way UP from the bottom of the primary case, correct?

C#

 

CW SHARP, Thats correct, do you think I need both the tensioner and chain, any idea of cost from dealer over there? (USA)

 

You should take off the primary cover and get a good look at what you are dealing with. You can post pictures here for help.

Since the tensioner is all the way up, then that sounds like your chain has too much stretch in it... or your tensioner shoe is completely worn through... or both. This would mean that the oil used in the primary case is improper, something was defective from the factory, the tension adjustment has been too tight all along, or your bike has very high mileage.

If your chain tensioner shoe is worn clear through I personally would recommend that you get the newer design from Harley which keeps the tensioner continuously adjusted. It is part number 40063-05A
and is US$ 110. You will have to look on e-bay or elsewhere on the internet... you cannot buy it directly from HD online... only at a dealer. You can easily find one on ebay. You won't have to worry as much about the proper tension adjustment once you get one of these and the intervals between adjustment is much longer. You will need a new primary case gasket, some oil, a new drain plug o-ring, and possibly a chain

The slack in the chain should be measured at the weakest point.

To see if the chain is bad you will need to remove it from the bike and see how much axial bend there is in the chain or if there are 'kinks' in the rollers around the chain. You will most likely need to remove the clutch shell and the primary drive sprocket to get the chain off. You need to have a sprocket locking tool or you can insert a piece of wood between the chain and sprocket and try that. There is a special alignment requirement between the two sprockets when you put it back together. The chain part number is 40007-36A and you should be able to find one on e-bay.

I would recommend buying the shop manual first and then starting in on this project.

C#

 

Take care of it before it gets worse. My tensioner broke and I ended up having to get the engine rebuilt. Hard and expensive enough here in the US - can't imagine the challenge you'd face without a dealer nearby.

 

Can't seem to get a reply from any US dealers about supply and cost of primary chain and kit, anyone have any GOOD contacts, road trip approaching end of june