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[longlast]

I'm back and so is the primary noise. All was good for 3 days after resetting the tensioner but now it's returned.
Diagnostic, when running in 1st, 2nd, 3rd slowly it's the loudest. When I pull the clutch and come to a stop the noise stops as l start letting out the clutch and moving the noise is back. If l pull the clutch and coast a bit before gearing up the noise stops l shift up let out the clutch it comes back when I put it in N and let out the clutch it comes back but not as loud, almost can't hear it but like I said when the clutch is disengauged no noise at all. BTW, when in top end no noise that l can hear.

I'm thinking maybe the chain has gone tight again (l haven't pulled the cover yet) if it has  could it possibly be a warn inner primary case clutch bearing?
If the bearing has failed I'm thinking that maybe that's why the tensioner over tightened.
What l don't get is why does the noise stop when the clutch is disengauged unless it stops in the bearing??
The compensater has been mentioned as a cause for primary noise, but by the noise stopping when the clutch is disengauged is taking me to the clutch end as l can't see by disengauging the clutch it would effect the compensater.
The thing is, is l don't know how long I've been running with the chain being too tight until it started making noise.

Any thoughts and what l should look at this time l got it apart would be a step closer to clearing this up.
I have got the bearing and related parts. I'm hopping to have whatever is needed l don't want to strip it down again if l can avoid it.
Need your expert advice with this boys.

[FlaHeatWave]

From your description, also thinking Clutch related

Were / are there any witness marks from the Clutch Basket on the Inner Primary? The witness marks will be in front of the the Clutch (comp side) from the Chain running too tight..

When inspecting the Bearing take a good look at the inner splines of the Clutch Hub, sometimes they will degrade / strip...

'Been told by some experts that they have had no issues re-using the hi-$$ OP Gasket.

How many miles on the Bike / Primary Components??

And just to verify,,, when you are re-installing / setting the Tensioner you are setting tension at the "tightest" point?? 

[longlast]

From your description, also thinking Clutch related

Were / are there any witness marks from the Clutch Basket on the Inner Primary? The witness marks will be in front of the the Clutch (comp side) from the Chain running too tight..

When inspecting the Bearing take a good look at the inner splines of the Clutch Hub, sometimes they will degrade / strip...

'Been told by some experts that they have had no issues re-using the hi-$$ OP Gasket.

How many miles on the Bike / Primary Components??

And just to verify,,, when you are re-installing / setting the Tensioner you are setting tension at the "tightest" point??

Didn't notice any marks or  scrapings the first time I had the cover off that l could see.
I'll be looking at all the components this time seeing as I'm striping it all down.

Gaskets, I'll be making myself.
Just under 19k on the bike.

Not sure about setting the tension at its highest point.  I set it up at 5/8" free play run the motor and recheck it.

Like I said, l haven't pulled the cover yet so I don't know if the chain has gone tight again. I'm assuming it has, and I'm assuming that the inner case bearing is at fault?? Do too the over tightened chain putting off center stress on the bearing.

What I'm not getting my head around is why the noise stops when the clutch is disengauged? Does that inner case bearing stop or it's more that it's​ relieved of any pressure being exserted on the bearing?
Bottom line is does the shank that the bearing supports stop when the clutch is disengauged??

[FlaHeatWave]

Didn't notice any marks or  scrapings the first time I had the cover off that l could see.
I'll be looking at all the components this time seeing as I'm striping it all down.

Gaskets, I'll be making myself.
Just under 19k on the bike.

Not sure about setting the tension at its highest point.  I set it up at 5/8" free play run the motor and recheck it.

Spark Plugs out, The primary cover off, Trans in top gear, rear wheel off of the ground, rotate the wheel, there will be tight spots, less play / loose spots, more play, in the Chain,, always check Cold 

Like I said, l haven't pulled the cover yet so I don't know if the chain has gone tight again. I'm assuming it has, and I'm assuming that the inner case bearing is at fault?? Do too the over tightened chain putting off center stress on the bearing.

What I'm not getting my head around is why the noise stops when the clutch is disengauged? Does that inner case bearing stop or it's more that it's​ relieved of any pressure being exserted on the bearing?  thinking that's it relieved pressure

Bottom line is does the shank that the bearing supports stop when the clutch is disengauged??

[longlast]

Thanks mate, I'll be doing that on the high point setting. I'll also be putting it through the gears with it running and watching it. Then a tension recheck.

[longlast]

                                        UPDATE ON THE RETURN OF PRIMARY NOISE!

Well after some considerable test on when the primary noise would come and go and what maybe the cause I've determined it's the inner case main shaft bearing.

Why l came to the decision is, when I was doing some testing the one thing that stood out that was when in "N" there was noise, then when I pulled the clutch and put it in gear the noise stops,..Main shaft turning,.. Noise,... shaft not turning,...No noise.
So I went to my local Sycamore Harley dealer and got all the bits required for the repair.

Today I started the strip down. I got the compensater and clutch unit off. I turned the main shaft and sure enough there were flat spots as l turned it.

I thought great I'll have this done today,...... WRONG!,.....As l was doing inspection of each component l found bits of metal,..Knew exactly what it was when I saw them,....Bits of spline out of the inner clutch hub. The inner ends of the splines closest to the bearing where all broken off.
Now I need a clutch hub. Got it ordered up today but it's going to be another week before it comes in.

I'm suspecting this all came about do to the primary chain being overly tightened putting excessive pressure on the main shaft bearing and also excessive pressure on the ends of the hub splines by it running out of line.
There was signs of this of some slight scrapping on the inner primary case by the starting ring gear.

Pics of the my fun day.

[longlast]

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[longlast]

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[FlaHeatWave]

                                        UPDATE ON THE RETURN OF PRIMARY NOISE!

Well after some considerable test on when the primary noise would come and go and what maybe the cause I've determined it's the inner case main shaft bearing.

Why l came to the decision is, when I was doing some testing the one thing that stood out that was when in "N" there was noise, then when I pulled the clutch and put it in gear the noise stops,..Main shaft turning,.. Noise,... shaft not turning,...No noise.
So I went to my local Sycamore Harley dealer and got all the bits required for the repair.

Today I started the strip down. I got the compensater and clutch unit off. I turned the main shaft and sure enough there were flat spots as l turned it.

I thought great I'll have this done today,...... WRONG!,.....As l was doing inspection of each component l found bits of metal,..Knew exactly what it was when I saw them,....Bits of spline out of the inner clutch hub. The inner ends of the splines closest to the bearing where all broken off.
Now I need a clutch hub. Got it ordered up today but it's going to be another week before it comes in.

I'm suspecting this all came about do to the primary chain being overly tightened putting excessive pressure on the main shaft bearing and also excessive pressure on the ends of the hub splines by it running out of line.
There was signs of this of some slight scrapping on the inner primary case by the starting ring gear.

Pics of the my fun day.

The type of "witness marks" I was referring to...(2nd picture)

As far as the Inner Clutch Hub Splines,,, 'Just discovered the same condition on my '05 SEEG while upgrading the Charging System at 61k miles...

Note that the '05 SEEG has a Manual Primary Chain Adjuster,,, No witness marks on Inner Primary...

[longlast]

The type of "witness marks" I was referring to...(2nd picture)

As far as the Inner Clutch Hub Splines,,, 'Just discovered the same condition on my '05 SEEG while upgrading the Charging System at 61k miles...

Note that the '05 SEEG has a Manual Primary Chain Adjuster,,, No witness marks on Inner Primary...

I didn't/couldn't see any marks when I had the cover off the first time.
When I removed the cover this time the chain was good it hadn't retighten itself.
Tomorrow I'll be pulling the inner primary case to replace the bearing. I had to make myself a little press to do the job

[longlast]

Got things pulled down and found that was making all the noise.
Now I have to wait until next week for the parts to come in.
(1) clutch hub
(1) main shaft bearing
(1) bearing inner race
(1) bearing oil seal
(1) compensater bolt
(1) package of 5 inner primary case bolts
Parts cost over £320 
Glad I'm going my own repair. Hate to think what the cost world have been for labour added on if it had to go in the shop

[longlast]

Bearing

[longlast]

Here's a  Q.    This is a pic of the oil supply hole to the bearing.

This supply hole to me seems to be quite small for oil to enter the hole sufficiently to lube the bearing.
Has anyone done any modified this hole?
I'm thinking of drilling a counter sink on the top of the feed hole to channel the oil ( catch more of the oil ) into the hole.
Good or bad thing to do?

[King Glide]

I don't think there is a such thing as too much oil around a bearing or bushing. I would not counter sink it as that theoretically could weaken the hole walls and cause premature wear , but drilling the hole a few thousands ( millimeters for you metric guys) of an inch bigger couldn't hurt if you make sure not to leave a burr on the inner side.

[Dan_Lockwood]

                                        UPDATE ON THE RETURN OF PRIMARY NOISE!

Well after some considerable test on when the primary noise would come and go and what maybe the cause I've determined it's the inner case main shaft bearing.

Why l came to the decision is, when I was doing some testing the one thing that stood out that was when in "N" there was noise, then when I pulled the clutch and put it in gear the noise stops,..Main shaft turning,.. Noise,... shaft not turning,...No noise.
So I went to my local Sycamore Harley dealer and got all the bits required for the repair.

Today I started the strip down. I got the compensater and clutch unit off. I turned the main shaft and sure enough there were flat spots as l turned it.

I thought great I'll have this done today,...... WRONG!,.....As l was doing inspection of each component l found bits of metal,..Knew exactly what it was when I saw them,....Bits of spline out of the inner clutch hub. The inner ends of the splines closest to the bearing where all broken off.
Now I need a clutch hub. Got it ordered up today but it's going to be another week before it comes in.

I'm suspecting this all came about do to the primary chain being overly tightened putting excessive pressure on the main shaft bearing and also excessive pressure on the ends of the hub splines by it running out of line.
There was signs of this of some slight scrapping on the inner primary case by the starting ring gear.

Pics of the my fun day.

What I think is puzzling is that the clutch hub has what appears to be around 3/8" to 1/2" of the splines sheared off.

To do that I would have to think that the main shaft stopped at that point and there wasn't any further engagement of the shaft and clutch hub.

How far into the clutch hub does the main shaft go?  I can't believe that with the length of splines on both the clutch hub and the main shaft that there's only that short length of engagement.

I would have to assume it's further in than just the worn off splines.  So how does just a short distance of splines get worn when the shaft goes in further than the worn off section?

I may be missing something or I'm miss reading the pictures.

Thanks and I'm glad you found the problem.

I agree on the oil hole, counter sink the top side and that cannot hurt a thing.