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[porthole]

So, it was 60 degrees here yesterday, decided to go for a ride to warm up the engine for the winter fluid changes.

Got home a hundred miles later after dark, pulled in the garage and said to myself; WTF is that noise  [smiley=nixweiss.gif]

Didn't hear any noise riding, but that could be because I was wearing a 3/4 helmet and had the radio on.
My wife said she heard it from inside the house though.

Put the bike up on the jack, started it up and it sounds like noise is coming from wherever you listen. Using a wooden dowel it sounds like it is either coming from the primary or the rear cylinder head. Really odd that it is almost impossible to distinguish between the two.

Went and drained the oil anyway and found a couple of chunks of metal on the primary drain plug, and the oil (Royal Purple syn) had a putrid odor that I have not experienced before. I know what burnt clutches smell like, and it is not that. But, I have never smelled a burnt clutch with synthetic oil, so maybe.......

The picture is the primary plug with the 3 chunks I pulled off.

Three things come to mind;

1, I am not looking forward to going back to the dealer

2, I'm glad I put a winch in trailer

&

3, take that, all you naysyers to trailers  [smiley=xyxthumbs.gif]

[Chief]

So, it was 60 degrees here yesterday, decided to go for a ride to warm up the engine for the winter fluid changes.

Got home a hundred miles later after dark, pulled in the garage and said to myself; WTF is that noise  [smiley=nixweiss.gif]

Didn't hear any noise riding, but that could be because I was wearing a 3/4 helmet and had the radio on.
My wife said she heard it from inside the house though.

Put the bike up on the jack, started it up and it sounds like noise is coming from wherever you listen. Using a wooden dowel it sounds like it is either coming from the primary or the rear cylinder head. Really odd that it is almost impossible to distinguish between the two.

Went and drained the oil anyway and found a couple of chunks of metal on the primary drain plug, and the oil (Royal Purple syn) had a putrid odor that I have not experienced before. I know what burnt clutches smell like, and it is not that. But, I have never smelled a burnt clutch with synthetic oil, so maybe.......

The picture is the primary plug with the 3 chunks I pulled off.

Three things come to mind;

1, I am not looking forward to going back to the dealer

2, I'm glad I put a winch in trailer

&

3, take that, all you naysyers to trailers  [smiley=xyxthumbs.gif]

Damn, that sucks.

Is it aluminum or steel?

could the putrid smell be from a fried stator instead of the clutch? Those are the only two items in the primary that I can think of that could produce an odor upon failure.

Hope it all works out for you real quick.

Best of luck,

Chief

[hd-dude]

Looks like maybe teeth from the starter drive ring on the clutch hub? That would not make noise while running, only when the starter is enguaged. The pieces must be steel if they were stuck to the magnet. Can't think of what else would destruct in the primary.

Does the noise change with RPM's

[Chief]

Looks like maybe teeth from the starter drive ring on the clutch hub? That would not make noise while running, only when the starter is enguaged. The pieces must be steel if they were stuck to the magnet. Can't think of what else would destruct in the primary.

Does the noise change with RPM's

DOH! Wow, did I ever miss that one.  Thanks Jim. I guess we'll have to wait for the forensic analysis to get the real story. Only 32 miles on my bike right now, starting to develop anxiety syndrome with some of these problems cropping up.

Cheers

Chief

[Midnight Rider]

With the smell, makes me think of electrical...the stator will sort of balance itself when running at decent RPM's, but when idling, that's a different story.  Was the noise a heavy metallic rattling sound, like two pieces of metal clanging together?  My first thought is the Compensatin Nut has backed off.  Just had mine come loose, so the noise is distinct...not a slapping noise, but distinctly a metal to metal rattle.  Have they ever checked the Comp nut previously, or did they ever put a chrome inner primary on?  While you've got the oil drained, it only takes a few minutes to pull the primary cover off so you can see what's happening.  Did you notice anything weird on the voltage gauge reading when you pulled up to the house?

[porthole]

Looks like maybe teeth from the starter drive ring on the clutch hub? That would not make noise while running, only when the starter is engaged. The pieces must be steel if they were stuck to the magnet. Can't think of what else would destruct in the primary.

Jim,

After looking at the picture blown up, my thought is the pieces are from the ring gear, I'll take a look later. I have had problems in the past starting the bike, like a bad engagement, so I would not be surprised to see the ring gear chipped. Never gave it much concern because it is still still under basic warranty and I have the extended warranty.

Does the noise change with RPM's

Only slightly, as you rev the engine the the engine tends to drown out the "noise"

[porthole]

Was the noise a heavy metallic rattling sound, like two pieces of metal clanging together?

Yes.

My first thought is the Compensating Nut has backed off.  Just had mine come loose, so the noise is distinct...not a slapping noise, but distinctly a metal to metal rattle.

Mine too.

Have they ever checked the Comp nut previously, or did they ever put a chrome inner primary on?

No & no

Did you notice anything weird on the voltage gauge reading when you pulled up to the house?

No, didn't think to look until after I drained the oil

[ESJ JESTER]

from the serration marks on the inside of the curve i wonder if they are pieces of a lock washer from?  was there a chrome primary installed? clutch  hub retainer bolts? zip the derby off and look...or just use that nifty winch unit and get her fixed before york!  i remember teeth from ring gear and bendix drive being blackish in color.

[Midnight Rider]

Yes.



Mine too.



No & no



No, didn't think to look until after I drained the oil

Duane....they've just had so many of those things get loose, even after they supposedly "improved" the torqueing method.  Even the 06's have had the issue (me).  I caught mine when it first started so no harm was done, but it sounds like all hell is breaking loose when it's idling. Not a "rattle" or gravel type sound, but a distinct "clank"  I felt it in the left floorboard with my foot too.

[hd-dude]

It sounds like you have more than on issue here, The drive ring being one and the noise the other.

To check if its the comp nut you could start the engine, pull in the clutch and put it gear. Hold the front brake hard bring the rpms up a bit and slowly release the clutch to load the engine then pull it back in and let off the throttle quickly. If its the comp nut there will be very a obvious clunking when you do this......

[Midnight Rider]

It sounds like you have more than on issue here, The drive ring being one and the noise the other.

To check if its the comp nut you could start the engine, pull in the clutch and put it gear. Hold the front brake hard bring the rpms up a bit and slowly release the clutch to load the engine then pull it back in and let off the throttle quickly. If its the comp nut there will be very a obvious clunking when you do this......

Jim's the man, so listen to him!! [smiley=xyxthumbs.gif]

[VAZHOG]

Bad that it happened-But good it's still spring and you can haul it in the shop and be ready for the summer good and fresh.

How many miles are on it? Good luck and keep us posted.

[porthole]

Duane....they've just had so many of those things get loose, even after they supposedly "improved" the torqueing method.  Even the 06's have had the issue (me).  I caught mine when it first started so no harm was done, but it sounds like all hell is breaking loose when it's idling. Not a "rattle" or gravel type sound, but a distinct "clank"  I felt it in the left floorboard with my foot too.

It does sound like that.
Sounds like some little bastard hitting the side of the crank with a hammer!

[Hoist!]

So, it was 60 degrees here yesterday, decided to go for a ride to warm up the engine for the winter fluid changes.

Got home a hundred miles later after dark, pulled in the garage and said to myself; WTF is that noise  [smiley=nixweiss.gif]

Didn't hear any noise riding, but that could be because I was wearing a 3/4 helmet and had the radio on.
My wife said she heard it from inside the house though.

Put the bike up on the jack, started it up and it sounds like noise is coming from wherever you listen. Using a wooden dowel it sounds like it is either coming from the primary or the rear cylinder head. Really odd that it is almost impossible to distinguish between the two.

Went and drained the oil anyway and found a couple of chunks of metal on the primary drain plug, and the oil (Royal Purple syn) had a putrid odor that I have not experienced before. I know what burnt clutches smell like, and it is not that. But, I have never smelled a burnt clutch with synthetic oil, so maybe.......

The picture is the primary plug with the 3 chunks I pulled off.

Three things come to mind;

1, I am not looking forward to going back to the dealer

2, I'm glad I put a winch in trailer

&

[highlight]3, take that, all you naysyers to trailers  [smiley=xyxthumbs.gif][/highlight]

And to all you naysayers to Warranty too! Hoist!  8-)

[porthole]

It sounds like you have more than on issue here, The drive ring being one and the noise the other.

To check if its the comp nut you could start the engine, pull in the clutch and put it gear. Hold the front brake hard bring the rpms up a bit and slowly release the clutch to load the engine then pull it back in and let off the throttle quickly. If its the comp nut there will be very a obvious clunking when you do this......

Yeah at least two. I was waiting for the cold weather to bring it in for a few issues.

I'll give that "test" a try as soon as I get some oil. Yes I did, drained all my oil before I looked on the shelf.  [smiley=nixweiss.gif]