Question about Harley Davidson FLHT - FLHTI Electra Glide Standard Motorcycles

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I have a 1999 HD Electra Glide FLHTPI. There is a pronounced rattle in the primary case when I crack the throttle or run the engine at higher rpm than idle. I have adjusted the chain in the primary, but that has not quieted the rattle. What would you suggest might be the problem?

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There's more than one right answer to this question. But first you need to do a little digging to see what the real problem is. With the primary cover off you can see the primary chain and the clutch. There's no oil in there so you can just take it off. The pramary chain has a tansioner that may need to be replaced or just adjusted . If the bike has mare than 40 thusand miles on it the chain and even the gears may be worn out or damaged. Next this may not be the problem the clutch has bolts to adjust the tension on the clutch plates. Normal clutch pull at the handle is nearly a hand exercizer but this adjustment it can be backed off to an easy pull but the clutch may slip if you set it too loose. If it's fairly loose it can loosen up on it's own and on racing machines in some classes the clutch bolts are required to be securied with safty wire it's possible thea only some of the bolts are loose. Loosen them all till their not pushing down at allthen tighten each one till it just starts to put pressure on the clutch, then pump the clutch handle and it will be real easy, thenevenly tighten the bolts a half a turn at a time getting them all and then, work the handle again. Keep tighting half turn at a time till you get it as tight as you want it to be with out wereing out you hand. A loose clutch will pull sometimes just fine but they tend to be noisey ( some peaple just don't care) The next thing that can do this is the starter drive, ot has a spring that returns it away from the gear it meshes with on the clutch and the spring can fall off braek, be missing and or the bushing that the drive pivoits on can fall out , be broken and or gone and then all thest parts sort of flop around and make all kinds of noises as the parts run into other moving parts. With the cover off you can start and run the motor just stay out of harms way as thest moving parts can act as a meat grinder. Watching it run including as it starts you will likly see the loose parts even the clutch bolts. Realise with the cover off the thing can shoot the loose parts at you and also as the cover is removed parts that fell off already may fall out on the ground. so lookaround good for loose parts and try to identify them. Everything can fall off the clutch basket bearing can be bad and you may see this assembly wobbling around when it's running and also with it off you may be able to wobble the parts with your hand. The chain shouldn't be string tight but close. I know how to fix all of the things that go wrong in here but, anythingand everything has and will go wrong. Don't fix anything that not broken as you can break more stuff for no good reason. IF the chain can be lifted off the sprocket in the middle of the gaer the chains wore out. Look at it good and you can change it yourself and once you've fixed it yourself you can fix it for others even on the side of the road as all this stuff goes wrong and all the big twins the revtech and the s&s all use the same basic parts fix one and you can fix all the american and clone big twins. Victory is different but the same too.

Posted on Sep 11, 2010

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