I have an 09 electra with a 96". I replaced the stock Harley compensator 2 years ago with a BDL compensator kit. After installing I had a few minor issues with noise and vibration that I sorted out. 2 weeks ago I went out for a ride and I shut off the bike, when I tried to restart it would just spin. There were no grinding sounds.

I got it home and took the primary cover off only to see that the splines were stripped on the BDL housing. I was able to remove most of it when I took the bolt out. The only part left is the gear itself and I can't remove it. It does have some play on the splined shaft. It stops when you try to pull the gear off the shaft. Any ideas how to remove it? I'm stumped at this point.

Thanks in advanced for your help.

 

Got any pictures? Does not sound good or cheap unfortunately. The splines on the sprocket shaft are very likely damaged as well. They're not going to be fixed with a file or a grinder. It won't come off because the splines have probably stripped on both sides and now its locked on. If there's a silver lining its a perfect time to do some nice upgrades...maybe a stroker or a 124 build??? Think positive.

 

I was thinking along those lines too about the splines. I just want to get the gear off at this point. Then I will think about the future of the bike.

 

WOW, THAT is bad! The alternator rotor has some really heavy duty magnets in it. I would take off the inner primary to get at the rotor surface facing the engine. Gonna need a modified 3 jaw gear puller to (hopefully) remove it. Grind down the ends of the 3 claws to fit between the block and the rotor. Crank it down slow. Best case scenario - it slides off slowly and no damage to the end of the crank. Sorry, I don't even want to think of worse case.

 

You might be able to find a set of bearing knives that can grab what's left of the BDL comp and pull it off.

Next idea would to use a die grinder and grind off the mushroomed part of the splines to the point where the bdl part slides off.

You could also try and install the sprocket backwards and use a gear puller. If no bite, Tack weld the sprocket in place and pull..

BTW find different comp. I don't see how a BDL comp can last much more than what you experienced..

 

Luckily a 3 jaw pulley puller got it off. To my surprise.... no damage!

 

Fanfkntastic!!!!!