I believe I am going to need my second IPB in 20,000 miles. I am getting the same vibration I had last time it went out. I changed the oil in the primary tonight, less than 500 miles on it, and the magnet in the primary plug had a lot of metal shavings on it. I am not a happy camper. I think I still have a little bit left on the ESP. But, my question is, will this be a 10,000 mile replacement item? No hard starts, no burn outs, have no idea what the problem is here, but, as i said earlier, this is BS. 2010 FLHTUC. Really enjoy riding it, but, WTF?

 

Your not the only one with that problem, it seems to be a common problems with the inner primary bearings and six speeds, check these posts over in HTT

http://harleytechtalk.org/htt/index....html#msg632089

http://harleytechtalk.org/htt/index....html#msg636196

 

You can change to a sealed bearing but with time the shavings will destroy something else.
Do you know where they come from? I also found many when I did the first oil change in the primary.

 

I had the inner primary bearing fail at about 40000 miles but still had a bad vibration so they opened it up again and found the clutch hub inner teeth disintegrating. Why they didn't see that in the first place I don't know since it is a common problem. I'm pretty sure the output shaft has too much runout and that's why I'm still getting a vibration at 24-2600 rpm and will probably need a new bearing again soon.

Still have ESP till 2016. What I did discover is ESP will not pay for diagnoses like the HD factory warranty will so the piece pretty much has to fail to get it fixed. They only went back into the primary in my case because the stator wire seal was seeping and they replaced that whole unit as well.

 

If I read you correctly, its because a law forbids to let oil contaminate public soil / ground that your primary was fixed. You live in an environment 2 centuries ahead of the EU my friend!

After giving it a thought I remember the shavings I found were all alike, long-"ish" and parallel shaped like a machined profile would be. You may have given an explanation to the mechanical disintegration of the IPB cage.

 

The ESP covers almost everything the HD warranty does except for diagnoses. Even a small oil leak is covered. I was fortunate insofar as they replaced the entire stator unit since at the time, it was all one unit (gasket, stator and connector) now I understand they have a retro fit gasket instead of having to replace the entire stator.

The hub has been an ongoing issue with the later 6 speeds. So instead of a recall they're just waiting for either it to fail after warranty (as is the case for most riders) or just let the ESP cover the repairs. The same goes for the inner primary bearing. Most riders only put around 7000 miles a year and failures are happening at around 40000 miles. They're just playing the odds.