Hey Gang,

I wrote before regarding my bike last year but did not get the replies I hoped for so I'll try again. I have an 04 Fat Boy bought new with the following mods done by the dealer before taking delivery: 95ci kit, 250 mid-range cam, SE Racing Module; heavy duty valve springs, HD endorsed Mikuni carb, SE airkit, V&H BigShot staggered pipes. Cost me over 22K.

The bike has been parked in my garage since about June-July of 08...I lost most of the 08 riding season. A problem started at about 15-16K which sounded like a preignition rattling noise coming from the vicinity of the front of the primary cover. This would happen intermittently. But by about 18K miles, the problem progressed to the point where after about 15 miles of driving, it would make a sickening, gut-wrenching noise like dry metal grinding that isn't getting oil/lube. The noise is so bad you are compelled to turn off the bike immediately.

Brought the bike to my "dealer" several times....they had it for a whole week and replaced the ICM (and supposedly tightened something in the primary case) after about 2 short rides the problem returned...they then recommended changing the intake manifold sensor...that didn't work....and then recommended replacing the crank position sensor...that didn't work...the last two fixes they recommended I did myself per the manual. The shop said their recommendations are based on the 'codes' they saw when they first had my bike for the problem.

I have lost all confidence in this dealership to fix this problem. They didn't even have the courtesy to offer to buy back the parts I bought as a result of their misdiagnosis.

I have since spoken with a certified car mechanic...he is also a long-time HD guy with a good reputation for HD bike repairs. Based on a phone call I had with him, he said the problem could be the bolt securing the primary drive front sproket (2-piece sprocket) may be coming loose. He said he encountered this problem with several HDs and recommended torquing the bolt to 200 ft/lbs. He said HD will not allow their mechanics to torque this bolt to 200 ft/lbs...this was confirmed by another dealer's mechanic I know who said torque to 165 and use alot of lock-tite. Unfortunately, the first guy is not available much to work on my bike.

Did/does anyone else have this problem? I live about an hour north of Philadelphia and would like a recommendation for a competent, non-dealer, Harley mechanic who can actually fix a bike and not just talk about "codes"....afterall the codes are only as good as the guy who programmed them! $22K for 18K miles...that's a shameful disgrace from such a proud, boastful company!!...pathetic dollar/mile value ratio from the big HD...and an equally pathetic dealership!!!!

So... I'm challenging forum members (and HD reps if they actually read this forum) to pony up with some advice....other than, "Gee isn't it time for a new bike??!!" Now we get to see if there's more to these bikes (and HD) than just cosmetic aftermarket add-ons, flames, chrome, your money, and a short hopper B-to-B scooter (LOL) to impress your bar mates. I would love to be able to go 1-2000 miles without some part defecting or some little nuisance repair. I would love to be able to count on my bike to take a real trip. My new dealer catch phase is "Oh, so you want to go the next 1,000 miles???.....that'll be another $500 please!!!! ....and this is a bike design that's over 100 years in development...that's not evolution...that's de-evolution!!!

This bike was great when it ran....I loved it...but right now my Schwinn is more reliable!! I'd like to get back to riding but I need a reliable bike I can count on...or a trailer to haul my Fat Boy's fat a$$ around!!

Totally frustrated and disappointed in the big, bad HD...!!