Unfixable noise
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Intermediate
Joined: Sep 2007
Posts: 47
Likes: 3
Unfixable noise
I have a 91' FLHTC. Purchased it about 4 years ago. While riding home aftering buying it I starting hearing a loud noise from inside the primary case. I removed the primary cover and found the compensator sprocket nut had loosened up and was banging against the primary cover. The bike came with a shop manual so after reading up on the compensator sprocket I tightened up the nut, closed everything up and went for a ride. Again, loud clacking noise that sounded like it was comming from inside the primary case. Before taking everything apart again I began reading every HD forum I could find. Needless to say, the discussions covered every possible mechanical possibility for what could be causing this clacking noise. To make a long story short I'll just list the things that I found that were
busted, worn, loose, or incorrect part.
Compensator sprocket worn.....replaced
Compensator sprocket spring........replaced
Drive pulley splines worn .....replaced
Main transmission shaft splines worn, .....replaced, along with all transmission bearings
Clutch hub splines worn.....replaced
Primary chain worn.....replaced
The clutch shell bearing has not been replaced. There is some very slight movement in the
shell and bearing.
Though not related to the noise I was trying to fix, I decided to send the motor to HD for a manufacture rebuild. It had 56k on it so I figured what the hell, send it in and have it done right.
Bottom line, I still have that noise, not as loud but still annoying.
busted, worn, loose, or incorrect part.
Compensator sprocket worn.....replaced
Compensator sprocket spring........replaced
Drive pulley splines worn .....replaced
Main transmission shaft splines worn, .....replaced, along with all transmission bearings
Clutch hub splines worn.....replaced
Primary chain worn.....replaced
The clutch shell bearing has not been replaced. There is some very slight movement in the
shell and bearing.
Though not related to the noise I was trying to fix, I decided to send the motor to HD for a manufacture rebuild. It had 56k on it so I figured what the hell, send it in and have it done right.
Bottom line, I still have that noise, not as loud but still annoying.
Outstanding HDF Member
Joined: Oct 2007
Posts: 2,398
Likes: 34
From: Newport news, Virginia
Is it there at idle only, under load only? Continuous?
Does the frequency increase/decrease with speed? It may be the transmission gears themselves.
How does clutch take up feel.
Can you feel a vibration thru the clutch handle?
When the bike is cold is the sound more prevalent?
Does it decrease when it gets warmer?
When the bike is cool start it up and feel around the tranny with your hand or use a long screwdriver as a stethoscope. Hold the plastic handle to your ear and touch the metal end to various places and you can hear inside what ever you are touching.
Does the frequency increase/decrease with speed? It may be the transmission gears themselves.
How does clutch take up feel.
Can you feel a vibration thru the clutch handle?
When the bike is cold is the sound more prevalent?
Does it decrease when it gets warmer?
When the bike is cool start it up and feel around the tranny with your hand or use a long screwdriver as a stethoscope. Hold the plastic handle to your ear and touch the metal end to various places and you can hear inside what ever you are touching.
Intermediate
Joined: Mar 2007
Posts: 45
Likes: 0
From: New York City
I encountered identical problem on a 2003 Fatboy I recently worked on.
I see you didn't mention the rotor. In the bike I worked on, had all the same problems, but the rotor splines were also shot, causing it to wobble, and possibly even slip. Next time you have that all apart pull off the rotor. (You probably know this already, but the magnets are real strong.. use a bent wire hanger through one of the holes to pull it off).
Oops. Just re-read your post. Said you had a manufacturer rebuild. Never mind.
How about a flopping shift lever? Sometimes those splines wear out a bit, and they clatter up and down when idling, and at highway speeds. Sounds silly, but hold your foot against the shifter lightly, see if the noise subsides.
I see you didn't mention the rotor. In the bike I worked on, had all the same problems, but the rotor splines were also shot, causing it to wobble, and possibly even slip. Next time you have that all apart pull off the rotor. (You probably know this already, but the magnets are real strong.. use a bent wire hanger through one of the holes to pull it off).
Oops. Just re-read your post. Said you had a manufacturer rebuild. Never mind.
How about a flopping shift lever? Sometimes those splines wear out a bit, and they clatter up and down when idling, and at highway speeds. Sounds silly, but hold your foot against the shifter lightly, see if the noise subsides.
Thread Starter
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Intermediate
Joined: Sep 2007
Posts: 47
Likes: 3
I put in a new 40amp compu-fire alternator, not for the noise but for additional amps.
The shift lever is not the problem.
The noise is more prevelent when under load shifting through the gears. 5th gear the noise seems to lessen substantially. Main drive gear was replaced along with all bearings including trap-door bearings. Noise does not seem to change as motor heats up. The clutch plates were replaced along with the hub. The only thing that has not been changed is the clutch shell bearing. Perhaps someone can tell me what the allowable runout is on the clutch shell. As a last resort I brought the bike to a dealer. Waste of time and money.
The shift lever is not the problem.
The noise is more prevelent when under load shifting through the gears. 5th gear the noise seems to lessen substantially. Main drive gear was replaced along with all bearings including trap-door bearings. Noise does not seem to change as motor heats up. The clutch plates were replaced along with the hub. The only thing that has not been changed is the clutch shell bearing. Perhaps someone can tell me what the allowable runout is on the clutch shell. As a last resort I brought the bike to a dealer. Waste of time and money.
Tourer
Joined: Sep 2007
Posts: 447
Likes: 1
From: New Bern NC
Check this
May seem silly, but I was installing by drivers backrest and dropeed a 1/4 20 screw, could not find it, so I moved on. When I cranked the bike it shook like a dog ****ting thumbtacks. I found the 1/4 20 screw lodged between the frame and the primary case.
Sometimes it is the simple things.
Sometimes it is the simple things.
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