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[Kcoop]

 
I have a 2009 FLHTCUSE4 with over 40,000 miles. I have always had the bike serviced regularly, changing the oil every 5,000 miles, always used HD Syn3 20-50w. I constantly check to oil on long trips to ensure that it is at the proper level.

I was coming back from Milwaukee and the 110th anniversary. I had ridden the bike out from Washington State, the bike was running well and I was traveling back along Hwy2, was about 3,800 miles into this trip. I stopped in North Dakota for a break and noticed a chirping sound coming from the engine at idle. I checked the oil, it was slightly above the half way mark, no problem. I continued on my way, with the chirping occurring only at idle, not under power. I made my way into Billings, Mt and stopped at the HD dealer to have them check out the chirping noise. The dealer got me into the shop and started to check out the bike, they pulled the oil filter and cut it open, it was full of metal shavings. Needless to say I was lucky to make it as far as I did. The dealer discussed options with me and I decided to have the motor pulled and sent back to HD for remanufacture. the dealer provided assistance in finding accommodations and transportation home (600 miles).  So I am riding a cage for a while.

the interesting point of this adventure is that the motor was running strong, getting good fuel milage (40+) all the while eating its self. So be aware of how your ride sounds and immediately have any un-usual noises investigated.

[Buy early]

That's a b*tch! Sorry you had troubles.

[2k]

Gives me goosebumps. I got a CUSE4 with 39K........no noise...........yet?

[GregKhougaz]

I have a 2009 FLHTCUSE4 with over 40,000 miles. I have always had the bike serviced regularly, changing the oil every 5,000 miles, always used HD Syn3 20-50w. I constantly check to oil on long trips to ensure that it is at the proper level.

Same thing happened to a friend's '08 110 CVO Ultra.  Rear lifters took out valves with lead to scouring the cylinders.  He traded for an '11 Limited.   I would be tempted to say oil was your issue but he always used AMSOIL.

[cahdbiker]

Kcoop, thanks for the good info. My 09 has about 17k miles on it. I think I will replace the lifters at about 20k and have upgraded cam bearings installed. Ever since my bike was new I have had what sounds like valve train noise between 2200 and 2800 RPM. It sounds like valve train, but it could be piston slap. If it is piston slap I will leave it alone since my oil consumption is very minimal, however if it is in the valve train I think I will go with S&S lifters and S&S adjustable pushrods. My experience with piston slap on an S&S engine I used to have on my 95 Heritage was that if I revved it up I would hear a knocking just as it came down to idle. My 09 does not do that. I have mentioned this on the site before. I have a feeling what is happening on my 09 is that the engine expands at a greater rate when hot then the valve train does and that is what  causes  the noise in the valve train. Someone on the site has slightly overextended their adjustable pushrods to get rid of this problem. The only thing I don't understand is why it only does it between 2200 and 2800. It does not do it under a load. Any additional input would be appreciated. CAHDBIKER

[Hawgrider]

We just put on 6000 miles going to Sturgis and then to Vancouver, 2 up with 45 pounds of luggage. We ran hard until we got within 100 miles of home when I slowed down to the speed limit and passed no cars. At the first set of traffic lights when we got close to home my 2009 SEUC was making some noise, it just got worse as we made our way home through the city. Next day I took it to our local HD shop where told me to shut it down and leave it with them. Turns out the tappit on the rear intake had failed, they replaced the tappits, oil pump, cam backing plate, bearings etc. Thank you HD for extended warranty. They tell me they put in a new improved set of tappits and I must say that after a 2000 mile ride in 100 degree weather this week it has never run so quiet.
Funny thing was that at the last gas stop it was running fine.
Last summer a fellow passing through town had the same thing happen to the identical bike (same color and millage), only he didn't catch it soon enough and major damage.

[phato1]

Kcoop, thanks for the good info. My 09 has about 17k miles on it. I think I will replace the lifters at about 20k and have upgraded cam bearings installed. Ever since my bike was new I have had what sounds like valve train noise between 2200 and 2800 RPM. It sounds like valve train, but it could be piston slap. If it is piston slap I will leave it alone since my oil consumption is very minimal, however if it is in the valve train I think I will go with S&S lifters and S&S adjustable pushrods. My experience with piston slap on an S&S engine I used to have on my 95 Heritage was that if I revved it up I would hear a knocking just as it came down to idle. My 09 does not do that. I have mentioned this on the site before. I have a feeling what is happening on my 09 is that the engine expands at a greater rate when hot then the valve train does and that is what  causes  the noise in the valve train. Someone on the site has slightly overextended their adjustable pushrods to get rid of this problem. The only thing I don't understand is why it only does it between 2200 and 2800. It does not do it under a load. Any additional input would be appreciated. CAHDBIKER

My '11 Ultra made what seems to be, based on your description a similar noise in that RPM range. Your issue may actually be piston slap but mine turned out to be valve train related. I pulled the tappets(lifters) planning to install the S&S components (tappets and adjustable pushrods) and found one tappet that was scored indicating to me that perhaps it had been "skidding" on the cam lobe at that RPM    maybe because of a bad bearing assembly in it or maybe the fixed length pushrods resulted in incorrect preload because of "stacked" tollerances or perhaps excessive side loading of the roller surface.

  - the end result for me was replacement of the cams, cam plate, oil pump, upgraded cam bearings. adjustable pushrods and the latest edition of the Screamin' Eagle tappets. I also ended up with a freshly cleaned top end and oil pan. Thankfully all covered by warranty.

After the engine work was completed the noise I was hearing between 2200 and 2800 RPM disappeared. 

[cahdbiker]

Phato1, thanks for the encouraging information.CAHDBIKER

My '11 Ultra made what seems to be, based on your description a similar noise in that RPM range. Your issue may actually be piston slap but mine turned out to be valve train related. I pulled the tappets(lifters) planning to install the S&S components (tappets and adjustable pushrods) and found one tappet that was scored indicating to me that perhaps it had been "skidding" on the cam lobe at that RPM    maybe because of a bad bearing assembly in it or maybe the fixed length pushrods resulted in incorrect preload because of "stacked" tollerances or perhaps excessive side loading of the roller surface.

  - the end result for me was replacement of the cams, cam plate, oil pump, upgraded cam bearings. adjustable pushrods and the latest edition of the Screamin' Eagle tappets. I also ended up with a freshly cleaned top end and oil pan. Thankfully all covered by warranty.

After the engine work was completed the noise I was hearing between 2200 and 2800 RPM disappeared. 

[CVO2FIXUP]

I have a 2009 FLHTCUSE4 with over 40,000 miles. I have always had the bike serviced regularly, changing the oil every 5,000 miles, always used HD Syn3 20-50w. I constantly check to oil on long trips to ensure that it is at the proper level.

I was coming back from Milwaukee and the 110th anniversary. I had ridden the bike out from Washington State, the bike was running well and I was traveling back along Hwy2, was about 3,800 miles into this trip. I stopped in North Dakota for a break and noticed a chirping sound coming from the engine at idle. I checked the oil, it was slightly above the half way mark, no problem. I continued on my way, with the chirping occurring only at idle, not under power. I made my way into Billings, Mt and stopped at the HD dealer to have them check out the chirping noise. The dealer got me into the shop and started to check out the bike, they pulled the oil filter and cut it open, it was full of metal shavings. Needless to say I was lucky to make it as far as I did. The dealer discussed options with me and I decided to have the motor pulled and sent back to HD for remanufacture. the dealer provided assistance in finding accommodations and transportation home (600 miles).  So I am riding a cage for a while.

the interesting point of this adventure is that the motor was running strong, getting good fuel milage (40+) all the while eating its self. So be aware of how your ride sounds and immediately have any un-usual noises investigated.

   So, any idea what part of the engine failed? Was it the lifters?

[Steve_G]

When these engine parts are replaced, how do all the metal particles get removed?  Do they get trapped in the oil filter?

[sadunbar]

When these engine parts are replaced, how do all the metal particles get removed?  Do they get trapped in the oil filter?

Take it all apart and use good ole dish soap and hot water!   

[Kcoop]

I probably will never know what failed, since the motor will be disassembled and rebuilt at the factory. As far as particles in the engine, the engine is being totally disassembled, cleaned, and re-powder coated, so it will be a new engine with all of the latest upgrades.

Hopefully the rebuilt motor will last longer.

[Twolanerider]

I probably will never know what failed, since the motor will be disassembled and rebuilt at the factory. As far as particles in the engine, the engine is being totally disassembled, cleaned, and re-powder coated, so it will be a new engine with all of the latest upgrades.

Hopefully the rebuilt motor will last longer.

What about the oil cooler and oil pan?  Dealer cleaning the pan and cleaning and flushing the cooler as part of the job?  If not it won't matter how clean everything else is.

[Steve_G]

What about the oil cooler and oil pan?  Dealer cleaning the pan and cleaning and flushing the cooler as part of the job?  If not it won't matter how clean everything else is.

That's exactly why I felt forced to get rid of my beloved Heritage Softail.  I seriously doubt that this got done when my cam bearings went out -for the second time.  I just felt I was sitting on a time bomb.  Total lack of confidence.
I wonder how many have had more than one engine failure fixed and then having the same problem?

[sadunbar]

What about the oil cooler and oil pan?  Dealer cleaning the pan and cleaning and flushing the cooler as part of the job?  If not it won't matter how clean everything else is.

I'd not trust flushing the cooler will remove all potential particles.  Personally, I would replace the oil cooler...