Noise in primary
Noise in primary
I just bought a used 2010 Iron with about 9,000 miles on it. I pick it up from the HD dealer and on my way home I notice that when I slow down to a slow roll then start to feather the clutch to keep it rolling I get a repetative clunking noise. It sounds pretty bad and quite loud. It only happens with the clutch halfway pulled in/out. So I went back to the dealer and the mechanic took it for a test ride and said that it is normal for that to happen with newer sportsters. And that it wouldn't happen if I wasn't half clutching it. He is right in the fact that if I wasn't half clutching it wouldn't happen because it doesn't happen with the clutch all the way in or all the way out. I tried not half clutching but seems impossible to do when in traffic. This is my 6th Harley and I have never had this happen before. I have a hard time believing that this is "normal" like the mechanic says. Im pretty sure they refuse to acknowledge that there is a problem because they don't want to fix it even though it is under a 90 day warranty.
So, has anyone experienced the kind of problem that I have described? Is this problem indeed "normal" for new sportys as the mechanic/dealer says? Im pretty upset about it. And being in Japan I am not sure what the local laws are about dealing with this kind of issue with the dealer.
Thanks in advance
So, has anyone experienced the kind of problem that I have described? Is this problem indeed "normal" for new sportys as the mechanic/dealer says? Im pretty upset about it. And being in Japan I am not sure what the local laws are about dealing with this kind of issue with the dealer.
Thanks in advance
Last edited by MichiganMikey; Mar 16, 2015 at 07:04 AM.
Seasoned HDF Member
Joined: Feb 2007
Posts: 5,067
Likes: 394
From: Edmonton Alberta Canada
I'd check the primary chain for proper tension as per the service manual.
If you haven't ridden a sportster before and are used to big twins or other manufacturers you will find that the Sportster is not very smooth at or near idle, it has pretty big pistons and a pretty small and light flywheel so you have to work with it and keep the revs up to smooth it out.
One thing that I found was the slow speed driveability was drastically better when I installed the PCV, I'm sure any tuner would do the same.
If you haven't ridden a sportster before and are used to big twins or other manufacturers you will find that the Sportster is not very smooth at or near idle, it has pretty big pistons and a pretty small and light flywheel so you have to work with it and keep the revs up to smooth it out.
One thing that I found was the slow speed driveability was drastically better when I installed the PCV, I'm sure any tuner would do the same.
Novice
Joined: Mar 2015
Posts: 16
Likes: 1
From: UK, Kent
I'd check the primary chain for proper tension as per the service manual.
If you haven't ridden a sportster before and are used to big twins or other manufacturers you will find that the Sportster is not very smooth at or near idle, it has pretty big pistons and a pretty small and light flywheel so you have to work with it and keep the revs up to smooth it out.
One thing that I found was the slow speed driveability was drastically better when I installed the PCV, I'm sure any tuner would do the same.
If you haven't ridden a sportster before and are used to big twins or other manufacturers you will find that the Sportster is not very smooth at or near idle, it has pretty big pistons and a pretty small and light flywheel so you have to work with it and keep the revs up to smooth it out.
One thing that I found was the slow speed driveability was drastically better when I installed the PCV, I'm sure any tuner would do the same.
Primary chain tension is important, and can cause a ringing/knocking noise if too loose or too tight. I set mine to 12mm approx of freeplay when cold, and that's fine. It's worth checking at least to rule it out. Probably worth checking you have enough primary oil in there whilst you're at it.
It may also be that your clutch is set up wrong. Mine mis-behaves if it's in need of adjustment.
Checked the primary chain tension. It is right in the middle of where it is supposed to be. Was really hoping to see it too loose or tight but that wasn't the case. 
Will check the clutch adjustment next. Its just that the noise it is making sounds really bad and has me paranoid. Its not just a normal clunk, its doing it with what seems to be every rotation of the engine. Im so pissed at the dealer for not acknowledging that there is a problem. I will ask them one more time to check it out, then I guess its time to lawyer up.
Will check the clutch adjustment next. Its just that the noise it is making sounds really bad and has me paranoid. Its not just a normal clunk, its doing it with what seems to be every rotation of the engine. Im so pissed at the dealer for not acknowledging that there is a problem. I will ask them one more time to check it out, then I guess its time to lawyer up.
Road Warrior
Joined: Jun 2012
Posts: 1,832
Likes: 67
From: Phoenix
Double-check your chain tension and clutch adjustment. I'd get a second opinion from another dealer or an indy. Sportsters are noisier overall, so there's a chance it sounds like there's a problem where there isn't one. I can't really give an opinion without hearing it myself. Hope it works out for you.
Could try changing the primary oil too. That way you can also check the drain plug, see if it has an unusual amount of metal shavings on it.
Could try changing the primary oil too. That way you can also check the drain plug, see if it has an unusual amount of metal shavings on it.
Road Captain
Joined: Oct 2014
Posts: 722
Likes: 9
From: Williamsport, MD
it doesn't sound normal to me, I'm not sure what you mean by "half clutching", usually you only have to pull the lever in about halfway to disengage the clutch completely and you should have no clunking noises if the clutch is disengaged. If the mechanic is saying that you have to pull the lever all the way back then that's just silly. obvisouly a clunk when you downshift is normal on a sportster, sportster definitely shift louder than a Big twin cam bike..
Tourer
Joined: Jun 2013
Posts: 321
Likes: 10
From: Oklahoma
I had a similar noise on mine when it was a few months old a few years ago. It was at idle or when the clutch was fully engaged. That was soon followed by a leak from the primary drain plug which was barely finger tight. It was in fact the primary chain that was loose. The tech at the local dealer adjusted the chain and re tightened the plug. When I asked how this could be on a new bike his remark was "it happens".
If you know your chain is tensioned properly I would definitely pull the plug and look for shavings as per a previous suggestion or possibly even pull the cover and inspect the whole area for damage.
If you know your chain is tensioned properly I would definitely pull the plug and look for shavings as per a previous suggestion or possibly even pull the cover and inspect the whole area for damage.
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Double-check your chain tension and clutch adjustment. I'd get a second opinion from another dealer or an indy. Sportsters are noisier overall, so there's a chance it sounds like there's a problem where there isn't one. I can't really give an opinion without hearing it myself. Hope it works out for you.
Could try changing the primary oil too. That way you can also check the drain plug, see if it has an unusual amount of metal shavings on it.
Could try changing the primary oil too. That way you can also check the drain plug, see if it has an unusual amount of metal shavings on it.
Chain tension is good to go. I am gonna dump the primary fluid this weekend to check for debris.
I know they are overall noisy bikes but this is definitely out of the ordinary and a big problem. It seems to be getting worse.
When I pull in the clutch and slow roll through a stop or a turn without coming to a complete stop, it starts cunking (2-4 clunks) as soon as I start to release the clutch. And its not just audible clunks, but I can feel it throughout the bike when it happens.
Im going back to the dealer tomorrow for another look after I had an indy check it out. As soon as I told him that I am going to consult an attorney his tune changed a bit. Hopefully this time he will know that I am not just gonna roll over on this.
I wish yall could hear what is going on with it. It sounds terrible, like nothing I have heard before on a bike.
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it doesn't sound normal to me, I'm not sure what you mean by "half clutching", usually you only have to pull the lever in about halfway to disengage the clutch completely and you should have no clunking noises if the clutch is disengaged. If the mechanic is saying that you have to pull the lever all the way back then that's just silly. obvisouly a clunk when you downshift is normal on a sportster, sportster definitely shift louder than a Big twin cam bike..
What I mean by half clutching is feathering the clutch between engaged and disengaged just to keep the bike rolling without lunging forward while moving through heavy slow moving traffic or parking lots. There is no clunking whatsoever when fully engaged or disengaged, its only happening right at that point between engaged or disengaged. And when I do get the clunking it clunks with every rotation of the motor until I release or squeeze the clutch fully. Hopefully the way I explained it makes sense. I think I actually just confused myself. LOL.
I greatly appreciate everyones input so far. Cheers!
Banned
Joined: Sep 2013
Posts: 1,127
Likes: 226
From: middle Tennessee
My 2014 superlow will do the same thing going about 5 to 10 mph with the clutch about half the way out. It does it when you continually pull the clutch in then let it about half the way out. The only time it does it is when I'm riding up a small hill in my back yard were I feather the clutch. I have not had it do it on the highway. They checked every thing at the 1000 mile service and all was alright.
I had a 2012 Honda Shadow Spirit that did the same thing and it does not have a primary chain. I think its nothing to worry about.
I had a 2012 Honda Shadow Spirit that did the same thing and it does not have a primary chain. I think its nothing to worry about.