I have a 2002 Sportster 1200 with just under 5000 miles on it. I have had a squealing noise while I ride. It doesn't squeal in neutral while rolling or when the clutch is pulled in. The squeal is noisiest in 3rd and 4th gear while accelerating. When I let off the throttle, no squeal. Oil and gear oil has been changed. The squeal seems to be coming from the front left area. Any thoughts on what this might be and how to get rid of it?

 

I'm not sure on this one but maybe check the primary chain tension?

Curious what others have to say.

 

+1 check the primary chain tension first

 

Tough to say without hearing it. Maybe clutches? Just a thought

 

I tightened the primary chain a few weeks ago. Just checked it and it seems to be loose again. I'll tighten it up and see if there is a difference in the noise

 

Report back on how it goes man, curious about it.

 

Took it out for about a 15 minute ride. Squealed the entire time. 3rd and 4th gear is still the worst with the noise

 

Depending on how alarmed/annoyed you are at this, you can pull the trans out and check the gears. See if you notice any unusual wear. Once you get the primary out of the way, the trans is held in by 5 bolts and comes out as an assembly.

 

Are there any other possibilities before having to open that up? With under 5000 miles I would really hope something wouldn't be wrong within the transmission

 

I don't think it's a trans issue but it's something to keep in mind and if you don't mind pulling **** apart, it would rule it out. Without having heard it, it might just be some stupid little thing that's loose or rubbing I just can't think of anything off the top of my head.

I wouldn't expect trans issues that early either, mine **** around the 40K mark.