Have an 08 Fatboy with 45000 miles.

Doing a bunch of work on the bike and had the primary case off. Found a few pieces of metal. Looks like tips of gear teeth.

Removed clutch pack.

The clutch hubs mainshaft splines are chipping off. I mean in a big way. Really, I'm lucky I had the cover off and found this problem instead of 500 miles away from home.

Also, on the bottom of the outer and inner primary there is a wear spot caused by the primary chain in the casting. Look like at one time or more the primary chain tensioner and/or compensator didnt do its job upon acceleration and dragged there.

Also in the history/background.... My bike has had the periodical starting screech/clunk/grind problem that seems to be quite common with 07-08 models, and one of the reasons I'm in the primary is to change the compensator to SE compensator.

Anyone have anything to add about this? I've heard these problems are all related but the solutions given are varied. Some say the root is the starter. Some say its the starter clutch. Some say it's the compensator.

Hello?

 

Can't hlp u much there my friend. On my '09 Ultra Classic at 80K miles I lost all my gears in a police escorted rite on a very bz hwy. Got towed and found out my clutch hub was so worn, the spindle going into it had nothing to grab.

$900 later I had a new Clutch Hub. <-- Cause was probably my treating the bike as a crotch rocket and downshifting ALL the time. Nothing else found to ahve casued the problem.

Wish I could be of btr help to you.

BuzzCap7

 

Thanks. Yeah I hear ya on the riding it like a raped ape. I'm the same way. Matter of fact I believe my hard downshifting may have been the cause of that primary chain slacking enough to scrape the bottom of the chain case. Guess it was better to have the clutch hub splines go instead of the mainshaft. lol Bearings are all just fine. Putting in a Primo clutch and hub along with the SE comp sprocket.

 

Yep. Been there done that. Had a few bad starter clutches and finally my ring gear failed and the hub splines were cracked. I was lucky enough to find a used clutch out of a dyna with a good ring gear, hub and bearing. Didnt want to pay $500 for a complete clutch from HD as my only option. Going to an aftermarket starter clutch fixed it for me. 70k trouble free miles from the starter.

 

Check the trans mainshaft splines for any wear..You may have a poorly manufactured inner clutch hub which is a breeze to replace..Check the starter gear bushing in the outer primary cover and the starter gear bushing in the inner primary...If either of those are worn it will cause the starter gear to not track properly and consequently slip when it engages the ring gear on the outer clutch hub. You've gone in this far and you should have no probelm fixing it!!!

 

Dont get me wrong but an 09 wouldnt have bushings in the primary as the starter is one piece not like the pre 07 style that had a jack shaft. Am I missing something? http://partsfinder.onlinemicrofiche....N-CASE-HOUSING

 

Don't know for sure...Just passing along experience from an EVO!!!

 

I thought so. No dis respect. The new style eliminates starter to flywheel issues. Not only is the starter automotive style it is doweled and the nose cone has an O-ring. Pretty good set up. I knew what you were getting at though. +1 on anti seize. The hub is soft cast iron and is the sacrificial piece as opposed to the hardened steel shaft. Starter break down: http://partsfinder.onlinemicrofiche....ARTER-ASSEMBLY

 

WOW...No more support for the starter gear within the outer primary...That places all the load on the starter clutch! Thats gotta be a bitch for a big-inch stroker motor...Thanks for the heads up!

 

Yep. And the HD unit sucks. I went with a MEH lifetime warranty starter clutch after my third HD one. Been good so far. A shitty weak compensator doesnt do the starter any favors either.