Question about Harley Davidson FLHTCUI Electra Glide Ultra Classic Motorcycles

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2003 flht, 95" upgrade, s&s

2003 flht, 95" upgrade, s&s 510 cams with gear drive, feuling oil pump, 50,000 miles. Getting clunking noise in lower end that increases or decreases with rpm change. Compensator nut, rotor and primary chain adjustment all ok. Was told that main crank bearings that year were inferrior. Told if bearings are the problem that screaming eagle bearings were a good replacement. Also told that temken bearings were very pricey. Any input would be appreciated. Thanks, Fred

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Timken Bearings are good but, I have experienced problems with the compensator itself so I would inspect that before a rebuild. Pay particular attention to the splines and check for wear before tightening. Hope this helps and saves some time and money

Posted on Mar 16, 2011

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Posted on Jan 02, 2017

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2003 Harley Davidson FLHT Electra Glide Standard no oil pressure


Hi, Paul "OUCH" I feel your pain I too own a 2003 FLHTCUI Anniversary Edition I only have 25,000 miles on it but upgraded a long time ago to the S&S 510 gear drive kit eliminating the cam chain and shoes, it's a bit pricey $600. That design was not one of Harley's greatest hits and they refuse to change it. They did, however, reduce the inevitable shoe failure by eliminating the left spring actuated shoe and replacing the right one with a hydraulic version, but it's still a shoe with its own set of new issues like premature chain stretching according to fellow Harley Techs that I chew the fat with. My gut tells me that:
1. You still have oil pump issues.
2. Somewhere in the cam plate or oil passage in the engine case is a left over piece of shoe that is in between the pump, the connecting rods or lifters blocking adequate flow to the top end.
3. On the bright side, that same piece of the shoe could be in the passage way that goes to the oil pressure sending unit or gauge.
If it were me I would go back into the pump and double check the integrity of all seals and o-rings check the lobe clearance of the pump gears .004" max, check the bright side #3 and every night before you turn in drop to your knees and thank the Harley Gods for keeping your engine in one piece.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
NO OIL Pressure HELP
Harley Davidson 2003 Dyna Service Manual Same Engine
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http://mybikemanuals.com/harley-davidson/2005-harley-davidson-owners-manuals
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Jul 23, 2017 | 2003 Harley Davidson FLHT Electra Glide...

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On a dashbord flashing "oil


STOP the engine immediately !!! There is an oil pump failure of 2.0 TDI engines !
Remove the oil pan and the oil pump & balancer shafts assembly.

tdisline_456.jpg


Either the shaft driving the pump from the balance shaft rounds off or the balance shaft drive gears eat themselves.
The same issue ... low oil pressure warning light, noisy rattling engine, and the turbo has gone. Diagnosis: oil pump balancer shaft assembly ...


tdisline_457.jpg

tdisline_458.jpg
tdisline_459.jpg tdisline_460.jpg tdisline_462.jpg tdisline_463.jpg
Many 2.0 TDI engines show excess chain noise and wear anywhere from 50,000-100,000+ miles. Cars have broken the chains/tensioner as low as 65,000 miles. This is just a range of cars that have been reported, diagnosed, and repaired. The actual statistics on dealer repairs or failures is unknown and I've heard cars over 100,000 miles that, in my opinion as a non mechanic (most mechanics wouldn't recognize this sound and problem either), aren't noisy. From what has been reported, noticeable noise/chain-tensioner wear/greater risk of breaking is around 60,000-150,000 miles. Your case may vary. The most obvious symptom is a rattling loose noise from the oil pan. Unless you listen to a Passat TDI with a tight chain and one with a loose chain, it's hard to describe the difference other than rattling chain noise.
The reason the gear drive oil pump modification was started is because a few mechanics who specialize in TDI have seen many worn oil pump chains/sprockets/tensioners. There will always be a few defective parts that come off the assembly line and all mechanical components like chains wear out sooner or later, but in my opinion, the failure rate is abnormal considering the number of Passat TDI sold versus the number of reported oil pump failures. This does not necessarily mean that every or even most Passat TDI will have this problem, just that the reported failure rate is high enough to consider this part a design failure. Nobody, not even VW-Audi knows the average time between failure for these parts and the percentage of cars that will have this problem, but they changed this design and if you want to not have this specific failure, the only sure way is to swap to the geared module.


tdisline_464.jpg

Apr 17, 2011 | Audi A6 Cars & Trucks

1 Answer

Oil warning light on saying oil pressure pump STOP engine Oassat diesel 2.00litre First Reg Nov 2005 mileage 56,5000 approx.On standard servicing schedule not long life


STOP the engine immediately !!! There is an oil pump failure of 2.0 TDI engines !
Remove the oil pan and the oil pump & balancer shafts assembly.

tdisline_448.jpg
Either the shaft driving the pump from the balance shaft rounds off or the balance shaft drive gears eat themselves.
The same issue ... low oil pressure warning light, noisy rattling engine, and the turbo has gone. Diagnosis: oil pump balancer shaft assembly ...


tdisline_449.jpg tdisline_450.jpg tdisline_451.jpg tdisline_452.jpg tdisline_453.jpg
tdisline_454.jpg
Many Passat show excess chain noise and wear anywhere from 50,000-100,000+ miles. Cars have broken the chains/tensioner as low as 65,000 miles. This is just a range of cars that have been reported, diagnosed, and repaired. The actual statistics on dealer repairs or failures is unknown and I've heard cars over 100,000 miles that, in my opinion as a non mechanic (most mechanics wouldn't recognize this sound and problem either), aren't noisy. From what has been reported, noticeable noise/chain-tensioner wear/greater risk of breaking is around 60,000-150,000 miles. Your case may vary. The most obvious symptom is a rattling loose noise from the oil pan. Unless you listen to a Passat TDI with a tight chain and one with a loose chain, it's hard to describe the difference other than rattling chain noise.
The reason the gear drive oil pump modification was started is because a few mechanics who specialize in TDI have seen many worn oil pump chains/sprockets/tensioners. There will always be a few defective parts that come off the assembly line and all mechanical components like chains wear out sooner or later, but in my opinion, the failure rate is abnormal considering the number of Passat TDI sold versus the number of reported oil pump failures. This does not necessarily mean that every or even most Passat TDI will have this problem, just that the reported failure rate is high enough to consider this part a design failure. Nobody, not even VW-Audi knows the average time between failure for these parts and the percentage of cars that will have this problem, but they changed this design and if you want to not have this specific failure, the only sure way is to swap to the geared module.

tdisline_455.jpg

Apr 15, 2011 | 2006 Volkswagen Passat

1 Answer

2003 HD Roadglide, stock TC88 engine. HD just replaced the cam chain tensioners with new HD camplate and high flow oil pump. first 2 miles had highpitched noise, metal on metal sound then was quiet. now...


Hi Roadglidetas, no it is not normal, HD is incorrect, your new oil pump and or cam plate could have been defective from the factory.
I would take it back to the dealer and insist politely they fix the noise. If they start dancing around the issue and say it's something unrelated to your upgrade and will cost you big bucks contact Harley Davidson Motor Company directly and express your concerns. I was a technician for 35 years and used to work for the Motor Company it isn't right. Good luck

Aug 30, 2010 | Harley Davidson FLTR-FLTRI Road Glide...

1 Answer

Clunking noise when outting 95 jeep in gear


that will be worn u joints
grab the drive shaft and wiggle it by all u joints and see what ones have excessive play and replace them

Mar 07, 2010 | 1995 Jeep Cherokee 2 Door

1 Answer

2005 electra glide standard clunk on acceleration


check all the mountings are tight & not damaged
the main shaft bearings in the gear box may be worn allowing movement, & when under load then unloaded gives you that thump!
Cheers Rob

Aug 16, 2009 | 2003 Harley Davidson FLHT Electra Glide...

1 Answer

Clunking nois


there is a loud non-rythmic crunching/clunking noise. I suspected it would be either the clutch or transmission but I removed the oilpan and visually checked the transmission and oil pump and have completely disassembled the clutch, and none of these areas has any signs of malfunction. I also checked the chain/sprockets and nothing seems to be wrong there. Any ideas? The problem arose after a 600 mile road trip I took, which was the first long trip I had taken on the bike. I had used it for commuting for a few months prior to that. The first to second gear shift had gotten progressively more rough, to the point that sometimes it would not shift until I tried several times. I figured the transmission was having problems (this was my first bike so I had to learn now to use a clutch and not shift roughly), but it passed my visual inspection. The noise sounds as though there is a lose part that is getting tossed around inside the engine by a part that rotates with the engine rpm''s. If anybody has any ideas I would really appreciate it!,Cam Chain, Cam Bearings? Cam chain tensioner? these are likely suspects.,,,

Nov 10, 2008 | 2004 ATK 450 Enduro

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