I have a strange noise coming from my primary case. I have an 04 FatBoy. When I first start the bike and it's very cold out....(below 45 degrees), there is a knocking sound within the primary case. Once it warms up, it completely stops. I saw in American Iron Magizine in the Hog Helpline page 140 (April 2011) that a guy with 2010 Ultra has the same problem and even Harley can't diagnose the problem. Any suggestions?
Thanks

 

If you have access to an old stethoscope, use it on the primary cover (inner and outer if necessary) when the bike is cold. There are 4 major assemblies in there:
1. compensator sprocket
2. balancer assembly (only on a "B" motor)
3. chain tensioner assembly
4. clutch assembly/output belt sprocket
Shouldn't be too difficult to find the area that noise is coming from.
If you don't want or can't do that, pull the outer primary cover entirely (after draining the oil of course), and let the machine idle from a cold start would be another way.

good luck.

 

I have the exact same problem. Mine is a stock 89 softail custom. This just started about 500 miles ago. Just hit 9000 miles on this rebuild.

 

My primary case knock was caused by worn Alternator... if knock is towards front of case, this could be the culprit. Happened on my 04 Heritage at around 40K mile.