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[Chopdoc]

Start by counting the teeth of the trans output sprocket and the rear wheel sprocket.  Stock numbers are 32 and 66, with a 137 tooth belt for the 2007 FLHTCUSE2.  The compensator sprocket is 34 teeth.  If a previous owner messed with the final drive ratio by changing sprockets and belt, and you replaced that belt with the correct one for your model, that might explain why your adjustment is near the end of it's travel. Btw, your gearing should be identical to your friends FLHX.

There are other items that could cause your box of rocks noise.  One would be a loose compensator bolt, another would be a primary chain adjuster failure.

Jerry

Thanks so much.

The compensator and tensioner are good.  Everything inside the primary is good, but we'll double check the tooth counts to make sure all that is original.  I think it is but we'll make darn sure.

Thanks for confirming my friend's FLHX has the same gearing.  I was assuming that.

We'll dig into it this weekend and see what's in there.

It's hard for me to judge the location of sounds due to hearing damage (incident with a .357 a long time ago), but it sure does sound like the noise is behind me when I am riding, not under me or in the primary.  I know...strange.

That made me question the rear wheel bearings, but we put new rear wheel bearings in it less than 5,000 miles back.

[Chopdoc]

So the bike makes the noise when I push it in neutral with the motor off.

Just noticed this.

Sort of a clicking and grinding.

It's a heck of a lot more when actually riding it, but it's definitely there when you push it in neutral with the engine off.

[Chopdoc]

It's the rear bearings.   They were new.

Turns out the bike has the IDS conversion.   66t stock size pulley.

We had put the stock size 07 bearings in after finding narrow bearings in it.  We thought they were wrong but didn't know the pulley mount was not stock.

Does the IDS conversion take a different bearing?

Where can I find asembly instructions and part numbers for this so I know we have it right?

The inside of my pulley is galled, so maybe we didn’t have it together right?

[Chopdoc]

 I have harley 37781-08 pulley.
That's the 08 66t.

And I have the matching harley 40560-05 inner part.

What bearings, spcars, etc do I need to make this work?

As I said, we put 07 bearings in it and tore everything up.

[Chopdoc]

Another complication.  The axle was changed to a metric axle.  Why?  AFAIK the conversion uses the original 1 inch axle.

Looks like someone did this conversion with a mixture of parts.

I got the service parts list, diagram, and instructions from Harley for the IDS conversion/upgrade.  I can scan and post them if anybody needs them.