Hey there im new to the forum and hope maybe someone could give me any helpful advice.Ive got a 2003 deuce 1450cc with a five speed. The bike has 36 k miles on it and i have a chattering in the trans when the clutch lever is released. It only makes the noise when the clutch is engaged. Ive heard these bikes are notorious for the clutch springs breaking at around 30k. But have also had a couple friends who have had major trans issues Around the same mileage. Any input?

 

28,000 on mine and no trouble yet. What lube are you running in it? Straight cut gears are notoriously noisy. Have you had it since new? Is the clutch adjusted properly?

 

My 06 Deuce has no such problems, neither does my buddy's 01 Deuce.

This is the first that I've heard of them being 'notorious' for breaking clutch springs. Not saying it doesn't happen, I just haven't heard that.

 

80K on my 2002 no such noise and never had a clutch issue either.

 

Usually the only ones that have issues with the Tranny's are the one who don't take care of their bikes or run/race the chit out of them.

Burn outs are one the of the worst things U can do to a Softy motor.

Also U'd do better to quit listening to all the rumors from people that don't really know whats going on. More so if they've never owned a HD.




.

 

The Harley 5 speed is the most dependable and bulletproof transmission the MoCo has ever made. If they are notorious for something, it would be for lasting damn near forever...

No, they are not known for breaking clutch springs, in fact, I`v never heard of one breaking a clutch spring.

Check the easy stuff first, primary chain tension, also you could remove the clutch release cover on the right side of the transmission and have a look at the throwout bearing.

 

Hey, just thinking, what's in the trans for fluid? Mine runs quieter/smoother with severe gear lube. Try the easy stuff first...I think as someone else pointed out, I would have the clutch adjusted also FROM INSIDE THE PRIMARY. While your checking that, you can check the bottom of the primary for any pieces that may have come loose. Good luck.

 

Leaking any oil?

It could be a very common issue with the Inner Primary Bearing between the transmission and the primary, mounted to the inner primary. The clue is the noise happening with the clutch engaged and the noise going away with the clutch disengaged. Typically the seal there becomes damaged from the vibration and leaks.

There's a bearing race mounted to the transmission shaft that attaches to the clutch hub. The roller portion of the bearing is retained by a circlip to the back of the inner primary.

It's a DIY repair if you have an impact driver, torque wrenches, circlip pliers and the HD service manual. If the race is bad it's a press fit assembly and needs a special tool to remove the race and reseat a new one. You use a dremel tool to cut through and break off the race. With the two piece OEM setup you need to have the new race pressed back into position.

S&S makes a 1 piece bearing to replace it that is simpler to install and assemble.

Be sure to put all fresh seals and gaskets on the primary while it's apart.

About a 3 to 5 hour repair depending on the skill level. DIY about $100. I would suspect it's about a $400 to $700 shop repair.


I could be wrong about this, but ... be sure to come back and let us know here how you fixed it.

 

The first thing I thought of was the inner primary bearing. Does it kinda sound like a sowing machine?