Differences
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| techtalk:ref:genmsr05 [2024/01/17 17:31] – hippysmack | techtalk:ref:genmsr05 [2025/07/31 02:06] (current) – [Heads] hippysmack | ||
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| **Condition**. \\ | **Condition**. \\ | ||
| - | Slightly loose fuel tank mounts will cause the tank to vibrate especially at higher RPM and may sound like the top end is about to come apart. ((Ironmick of the XLFORUM | + | Slightly loose fuel tank mounts will cause the tank to vibrate especially at higher RPM and may sound like the top end is about to come apart. ((Ironmick of the XLFORUM |
| Of course, a good way to see if it is your gas tank making noise is to press your hand down on it while riding. \\ | Of course, a good way to see if it is your gas tank making noise is to press your hand down on it while riding. \\ | ||
| If the noise stops then you've found it. \\ | If the noise stops then you've found it. \\ | ||
| Line 225: | Line 225: | ||
| When tightened, the rubber squishes into the space - no more vibration. \\ | When tightened, the rubber squishes into the space - no more vibration. \\ | ||
| You may have to re-tighten a couple of times after riding as the rubber finds its way in. | You may have to re-tighten a couple of times after riding as the rubber finds its way in. | ||
| - | |Homemade fuel tank mount isolators. ((photo by Ironmick of the XLFORUM | + | |Homemade fuel tank mount isolators. ((photo by Ironmick of the XLFORUM |
| |{{: | |{{: | ||
| Line 251: | Line 251: | ||
| The snaps holding the visor on the helmet can slap against it in the wind. | The snaps holding the visor on the helmet can slap against it in the wind. | ||
| The metal clasp on the chin strap can also do this if you forget to tighten it. \\ | The metal clasp on the chin strap can also do this if you forget to tighten it. \\ | ||
| - | This can result in metallic crackling noises coming from one side or the other of the bike. ((Len PA of the XLFORUM | + | This can result in metallic crackling noises coming from one side or the other of the bike. ((Len PA of the XLFORUM |
| You can add a few rubber washers stretched around the snaps to stop the noise. \\ | You can add a few rubber washers stretched around the snaps to stop the noise. \\ | ||
| Line 264: | Line 264: | ||
| The spring on the kick stand gets weak over time. This allows the stand to reside lower while riding. \\ | The spring on the kick stand gets weak over time. This allows the stand to reside lower while riding. \\ | ||
| During left hand corners, it will scrape the ground. Replacing the spring is pretty simple though. \\ | During left hand corners, it will scrape the ground. Replacing the spring is pretty simple though. \\ | ||
| - | When you check the side stand spring, be sure to look at the bushings as well (if applicable). They are also a wear item. ((sportsterpaul of the XLFORUM | + | When you check the side stand spring, be sure to look at the bushings as well (if applicable). They are also a wear item. ((sportsterpaul of the XLFORUM |
| Have someone hold the bike up, fold the kickstand up and shake it. There should be almost no movement at the pivot. ((Toejam503 of the XLFORUM https:// | Have someone hold the bike up, fold the kickstand up and shake it. There should be almost no movement at the pivot. ((Toejam503 of the XLFORUM https:// | ||
| Line 430: | Line 430: | ||
| **Condition**: | **Condition**: | ||
| Head gasket leak. \\ | Head gasket leak. \\ | ||
| - | You can feel around the heads for air leaks while the engine is running. | + | You can feel around the heads for air leaks while the engine is running. You can also perform a leak down or compression test on the cylinders. Or you can use a stethoscope or rubber hose to listen for air leaks around the gaskets. \\ |
| - | You can also perform a leak down or compression test on the cylinders. | + | |
| - | Or you can use a stethoscope or rubber hose to listen for air leaks around the gaskets. \\ | + | |
| **Symptom**: | **Symptom**: | ||
| Line 440: | Line 438: | ||
| Loose head bolt. \\ | Loose head bolt. \\ | ||
| + | **Symptom**: | ||
| + | A muffed bumping noise (1991-up models). \\ | ||
| + | |||
| + | **Condition**: | ||
| + | Loose or missing head breather bolt(s). ((hogluvr of the XLFORUM https:// | ||
| + | The sound is 1:1 with engine speed (each time the pistons go down). It may sound and feel like the pistons are bumping into something but there will be no metal to metal contact noise. This can happen if a head breather bolt backs out while riding or if the bolt(s) have been removed. This will also alter engine breathing and could result in puking oil out the heads. \\ | ||
| + | |||
| + | |Video: Bumping noise on 1991 Sportster \\ from missing head breather bolts ((hogluvr of the XLFORUM https:// | ||
| + | |{{ : | ||
| ===== Pistons ===== | ===== Pistons ===== | ||
| **Symptoms**: | **Symptoms**: | ||
| Line 474: | Line 481: | ||
| | Short video (L) and Pics of a 2000 Sportster with rear piston hitting the head. ((video and photos courtesy of groovemeisterus of the XLFORUM https:// | | Short video (L) and Pics of a 2000 Sportster with rear piston hitting the head. ((video and photos courtesy of groovemeisterus of the XLFORUM https:// | ||
| - | |{{:video:piston_slap_on_2000_sportster_by_groovemeisterus.mp4|}}| {{: | + | |{{video:100-noise_piston_slap_on_2000_sportster_by_groovemeisterus.mp4|}}| {{: |
| | Light witness marks from piston contact with valve. ((photos by BlackBikeDave of the XLFORUM https:// | | Light witness marks from piston contact with valve. ((photos by BlackBikeDave of the XLFORUM https:// | ||
| Line 496: | Line 503: | ||
| **Symptoms**: | **Symptoms**: | ||
| - | A loud rod rapping sound up top. ((smokenjoep01 of the XLFORUM | + | A loud rod rapping sound up top. ((smokenjoep01 of the XLFORUM |
| It may sound like the noise is half the speed of the engine RPM (if counting both cylinder lopes). But it's actually at 1 revolution speed. \\ | It may sound like the noise is half the speed of the engine RPM (if counting both cylinder lopes). But it's actually at 1 revolution speed. \\ | ||
| - | Rod noise should be loudest when the engine is floating (not accelerating and not decelerating)as in cruising down the highway. ((milmat1 of the XLFORUM | + | Rod noise should be loudest when the engine is floating (not accelerating and not decelerating)as in cruising down the highway. ((milmat1 of the XLFORUM |
| That's when the rods have the least pressure holding them against the bearing surface. \\ | That's when the rods have the least pressure holding them against the bearing surface. \\ | ||
| Line 507: | Line 514: | ||
| **Verification**: | **Verification**: | ||
| Removing the pistons and grabbing each rod bypasses the error factor of piston side play. \\ | Removing the pistons and grabbing each rod bypasses the error factor of piston side play. \\ | ||
| - | Also, you can hold the rod just under the piston with one hand like choking a chicken and pull up on it. ((wedge of the XLFORUM | + | Also, you can hold the rod just under the piston with one hand like choking a chicken and pull up on it. ((wedge of the XLFORUM |
| Then use your other hand in a fist to hit the top of piston like a hammer action. A bad crank will make a very loud knocking sound as you do it. \\ | Then use your other hand in a fist to hit the top of piston like a hammer action. A bad crank will make a very loud knocking sound as you do it. \\ | ||
| Henceforth known as the "Wedge Test". \\ | Henceforth known as the "Wedge Test". \\ | ||
| - | |||
| - | |||
| In the (L) video below, you can hear the rapping at 1:1 engine speed. \\ | In the (L) video below, you can hear the rapping at 1:1 engine speed. \\ | ||
| The (R) video is a bearing test as described by XLForum member " | The (R) video is a bearing test as described by XLForum member " | ||
| - | | Video: Lower front rod bearing failure ((video by onadraw of the XLFORUM | + | | Video: Lower front rod bearing failure ((video by onadraw of the XLFORUM |
| - | |{{ :video:connecting_rod_noise_-_rapping_lower_front_rod_by_onadraw.mp4 |}}|{{ | + | |{{ video:100-noise_lower_front_connecting_rod_rapping_by_onadraw.mp4 |}}|{{ video:100-noise_lower_rod_bearing_test_by_onadraw.mp4 |}}| |
| \\ | \\ | ||
| **Symptom**: | **Symptom**: | ||
| - | A deep grinding sound on the bottom. ((smokenjoep01 of the XLFORUM | + | A deep grinding sound on the bottom. ((smokenjoep01 of the XLFORUM |
| - | A deep internal sounding ' | + | A deep internal sounding ' |
| **Condition**: | **Condition**: | ||
| Line 529: | Line 534: | ||
| Engine shakes bad enough to tear up some parts. \\ | Engine shakes bad enough to tear up some parts. \\ | ||
| - | **Condition**: | + | **Condition**: |
| - | If fly wheels were out of balance, it'd vibrate like hell all the time even sitting still just raising the rpm's. ((ezmerf of the XLFORUM | + | If fly wheels were out of balance, it'd vibrate like hell all the time even sitting still just raising the rpm's. ((ezmerf of the XLFORUM |
| **Verification**: | **Verification**: | ||
| - | |||
| ===== Cylinders ===== | ===== Cylinders ===== | ||
| - | |||
| Ironhead cylinders bolt to the case, then the heads bolt to the cylinders. \\ | Ironhead cylinders bolt to the case, then the heads bolt to the cylinders. \\ | ||
| A loose cylinder bolt can make a clanking sound. \\ | A loose cylinder bolt can make a clanking sound. \\ | ||
| ===== Cams / Cam Cover ===== | ===== Cams / Cam Cover ===== | ||
| - | |||
| **Symptoms**: | **Symptoms**: | ||
| - | A spinning or whirling sound. ((milmat1 of the XLFORUM | + | A spinning or whirling sound. ((milmat1 of the XLFORUM |
| **Condition**: | **Condition**: | ||
| - | Loose fitting sounds near each cam, the pinion shaft bushing or the idler gear (if applicable). ((hcrashster of the XLFORUM | + | Loose fitting sounds near each cam, the pinion shaft bushing or the idler gear (if applicable). ((hcrashster of the XLFORUM |
| Too much end play, worn cover / case bushings or case roller bearings (respectively). \\ | Too much end play, worn cover / case bushings or case roller bearings (respectively). \\ | ||
| Noise can also come from an unmatched cam set including idler gear (if equipped). \\ | Noise can also come from an unmatched cam set including idler gear (if equipped). \\ | ||
| Line 551: | Line 553: | ||
| **What causes cam gear noise?**: \\ | **What causes cam gear noise?**: \\ | ||
| - | Whenever a roller lifter in a Sportster engine passes through maximum cam lift, the forces on the cam gear teeth change direction. ((dragstews of the XLFORUM | + | Whenever a roller lifter in a Sportster engine passes through maximum cam lift, the forces on the cam gear teeth change direction. ((dragstews of the XLFORUM |
| If there is more than .002" backlash, the change of force and direction will result in an audible " | If there is more than .002" backlash, the change of force and direction will result in an audible " | ||
| Gear noise always occurs at idle and lower engine RPM. Stock EV Sportster cams are made with different gear sizes. \\ | Gear noise always occurs at idle and lower engine RPM. Stock EV Sportster cams are made with different gear sizes. \\ | ||
| Line 578: | Line 580: | ||
| **Symptom**: | **Symptom**: | ||
| - | High pitched clacking / tapping sound attenuated by engine speed. ((jessearias of the XLFORUM | + | High pitched clacking / tapping sound attenuated by engine speed. ((jessearias of the XLFORUM |
| Noise will probably travel to the rocker box and will be at half engine rpm. \\ | Noise will probably travel to the rocker box and will be at half engine rpm. \\ | ||
| Line 586: | Line 588: | ||
| Check with a stethoscope or other for the same approximate noises at each lifter. \\ | Check with a stethoscope or other for the same approximate noises at each lifter. \\ | ||
| - | A collapsed / bad lifter will cause a moderate to severe clacking or tapping noise depending on how bad the lifter is. ((jessearias of the XLFORUM | + | A collapsed / bad lifter will cause a moderate to severe clacking or tapping noise depending on how bad the lifter is. ((jessearias of the XLFORUM |
| It would be rare if all of the lifters were collapsed. \\ | It would be rare if all of the lifters were collapsed. \\ | ||
| Listen for one to sound very different from the others. \\ | Listen for one to sound very different from the others. \\ | ||
| - | Lifters are oil pressure dependent. ((tich of the XLFORUM | + | Lifters are oil pressure dependent. ((tich of the XLFORUM |
| A noisy lifter at idle may quiet down with throttle applied. \\ | A noisy lifter at idle may quiet down with throttle applied. \\ | ||
| An over heated engine might carbonize an oil way or similar oil path. \\ | An over heated engine might carbonize an oil way or similar oil path. \\ | ||
| - | There are 2 major causes of solid lifter failures, oil temperature, | + | There are 2 major causes of solid lifter failures, oil temperature, |
| If you suspect a lifter failure, first cut open the oil filter and look for metal debris. \\ | If you suspect a lifter failure, first cut open the oil filter and look for metal debris. \\ | ||
| If debris is found, then pull the cam cover and start looking for the source of the debris. \\ | If debris is found, then pull the cam cover and start looking for the source of the debris. \\ | ||
| Line 600: | Line 602: | ||
| Any other repair may just be a patch job at best. \\ | Any other repair may just be a patch job at best. \\ | ||
| - | In the event you don't happen to have an oil filter installed, scrape out the bottom of your oil tank and see what's living in the sludge down there. ((doodah man of the XLFORUM | + | In the event you don't happen to have an oil filter installed, scrape out the bottom of your oil tank and see what's living in the sludge down there. ((doodah man of the XLFORUM |
| The sooner you catch it the better. \\ | The sooner you catch it the better. \\ | ||
| Line 608: | Line 610: | ||
| This will send some normal oil flow straight to the gearcase-crankcase and back out the scavenger pump to the oil tank. \\ | This will send some normal oil flow straight to the gearcase-crankcase and back out the scavenger pump to the oil tank. \\ | ||
| (instead of thru the normal engine passages) \\ | (instead of thru the normal engine passages) \\ | ||
| + | |||
| ===== Pushrods ===== | ===== Pushrods ===== | ||
| ==== Adjustable Pushrods ==== | ==== Adjustable Pushrods ==== | ||
| - | |||
| **Symptoms**: | **Symptoms**: | ||
| Same sounds as a ticking lifter. \\ | Same sounds as a ticking lifter. \\ | ||
| Line 617: | Line 619: | ||
| Pushrod adjustment. \\ | Pushrod adjustment. \\ | ||
| - | With adjustable pushrods, the rod adjustment can be an issue. ((planesane of the XLFORUM | + | With adjustable pushrods, the rod adjustment can be an issue. ((planesane of the XLFORUM |
| Too tight will leave the valves open off their seat. \\ | Too tight will leave the valves open off their seat. \\ | ||
| (which will be even more noisier as the valve(s) slap against their seat) \\ | (which will be even more noisier as the valve(s) slap against their seat) \\ | ||
| Too loose will cause noise when the valve slaps onto the seat. \\ | Too loose will cause noise when the valve slaps onto the seat. \\ | ||
| - | For an exhaust pushrod, you can hear at the exhaust, the sound of the fuel burning almost as if it were exploding. ((IronMick of the XLFORUM | + | For an exhaust pushrod, you can hear at the exhaust, the sound of the fuel burning almost as if it were exploding. ((IronMick of the XLFORUM |
| If a pushrod is too loose you will hear a louder click sound at it's lifter block. \\ | If a pushrod is too loose you will hear a louder click sound at it's lifter block. \\ | ||
| If you adjust the pushrods on the looser side, you will hear this click on the exhaust pushrods. \\ | If you adjust the pushrods on the looser side, you will hear this click on the exhaust pushrods. \\ | ||
| (slightly louder than at the intakes) \\ | (slightly louder than at the intakes) \\ | ||
| - | Also check for a loose locknut. ((jessearias of the XLFORUM | + | Also check for a loose locknut. ((jessearias of the XLFORUM |
| ==== Solid Pushrods ==== | ==== Solid Pushrods ==== | ||
| Line 631: | Line 633: | ||
| ===== Valves ===== | ===== Valves ===== | ||
| **Symptom**: | **Symptom**: | ||
| - | Popping noise in the exhaust (or intake) along with a misfire. ((jessearias of the XLFORUM | + | Popping noise in the exhaust (or intake) along with a misfire. ((jessearias of the XLFORUM |
| **Condition**: | **Condition**: | ||
| Line 650: | Line 652: | ||
| ====== Primary ====== | ====== Primary ====== | ||
| - | The primary is a big hollow chamber and it will amplify any noise coming from anywhere in the engine. ((KevinJ of the XLFORUM | + | The primary is a big hollow chamber and it will amplify any noise coming from anywhere in the engine. ((KevinJ of the XLFORUM |
| - | * **Symptom: Whining or Chirping Noise** \\ A primary chain that's adjusted too tight can make a whining or chirping noise. Reportedly, the chirping noise can come on after some full throttle and hard shifting when the primary chain is too tight / bike hot. ((Gcram399 of the XLFORUM | + | * **Symptom: Whining or Chirping Noise** \\ A primary chain that's adjusted too tight can make a whining or chirping noise. Reportedly, the chirping noise can come on after some full throttle and hard shifting when the primary chain is too tight / bike hot. ((Gcram399 of the XLFORUM |
| - | * **Symptom: Rattling noise**. \\ A rattle that you cannot adjust out is a sign of a stretched chain. ((bitpusher of the XLFORUM | + | * **Symptom: Rattling noise**. \\ A rattle that you cannot adjust out is a sign of a stretched chain. ((bitpusher of the XLFORUM |
| - | * **Symptom: Rattling or Squeaking Noise**. \\ The sprocket nut can work loose and the noise is from the rotor eating itself up on the crank splines. If it's bad enough, it can end up breaking the end of the crankshaft off. ((JstColli of the XLFORUM | + | * **Symptom: Rattling or Squeaking Noise**. \\ The sprocket nut can work loose and the noise is from the rotor eating itself up on the crank splines. If it's bad enough, it can end up breaking the end of the crankshaft off. ((JstColli of the XLFORUM |
| - | * **Symptom: Squeaking Noise**. \\ A squeaking noise seemingly from the area of the generator. ((jmmarks70 of the XLFORUM | + | * **Symptom: Squeaking Noise**. \\ A squeaking noise seemingly from the area of the generator. ((jmmarks70 of the XLFORUM |
| - | | 75 primary adjuster damage. ((photos by jmmarks70 of the XLFORUM | + | | 75 primary adjuster damage. ((photos by jmmarks70 of the XLFORUM |
| |{{: | |{{: | ||
| Line 663: | Line 665: | ||
| * **Symptom: Rattling Noise**. \\ Conv90 submitted video of noise from the primary side: \\ | * **Symptom: Rattling Noise**. \\ Conv90 submitted video of noise from the primary side: \\ | ||
| - | {{:video:buell_noise_video_by_conv90.mp4|}} | + | {{video:100-noise_on_buell_by_conv90.mp4|}} |
| * **Symptom: Rattling Noise**. \\ The tensioner shoe can be loose and rock side to side enough to sound like a lifter problem. It will rock fore and aft into the primary cover. \\ From the cam side of the bike, it'll sound like it's a lifter bouncing around. It's a slow intermittent hollow banging noise. It may only make noise at idle when the chain is least tight. \\ | * **Symptom: Rattling Noise**. \\ The tensioner shoe can be loose and rock side to side enough to sound like a lifter problem. It will rock fore and aft into the primary cover. \\ From the cam side of the bike, it'll sound like it's a lifter bouncing around. It's a slow intermittent hollow banging noise. It may only make noise at idle when the chain is least tight. \\ | ||
| * **Condition: | * **Condition: | ||
| - | {{:video:primary_chain_adjuster_shoe_noise_by_conv90.mp4|}} | + | {{video:100-noise_primary_chain_adjuster_shoe_by_conv90.mp4|}} |
| \\ | \\ | ||
| - | * **Symptom: An extra and constant noise inside of the primary case**. \\ An extra and constant noise inside of the primary case (even / after adjustment of the primary chain adjuster). ((Spor-T-1 of the XLFORUM | + | * **Symptom: An extra and constant noise inside of the primary case**. \\ An extra and constant noise inside of the primary case (even / after adjustment of the primary chain adjuster). ((Spor-T-1 of the XLFORUM |
| ====== Transmission / Clutch ====== | ====== Transmission / Clutch ====== | ||
| - | Cyclical noises longer in duration than engine revolutions could be primary chain, compensator sprocket or clutch basket bearings. ((wedge of the XLFORUM | + | Cyclical noises longer in duration than engine revolutions could be primary chain, compensator sprocket or clutch basket bearings. ((wedge of the XLFORUM |
| **Symptom**: | **Symptom**: | ||
| - | A pronounced " | + | A pronounced " |
| - | It's fairly normal to hear it when moving from neutral to 1st gear. It doesn' | + | It's fairly normal to hear it when moving from neutral to 1st gear. It doesn' |
| It shouldn' | It shouldn' | ||
| But, sometimes you'll hear it while shifting too slow. \\ | But, sometimes you'll hear it while shifting too slow. \\ | ||
| Line 694: | Line 696: | ||
| **Symptom**: | **Symptom**: | ||
| - | Squealing like a car's serpentine pulley bearing going bad. ((rejeanprimeau of the XLFORUM | + | Squealing like a car's serpentine pulley bearing going bad. ((rejeanprimeau of the XLFORUM |
| The noise is louder with the primary inspection plug removed. \\ | The noise is louder with the primary inspection plug removed. \\ | ||
| Line 700: | Line 702: | ||
| Bad clutch throw-out bearing. \\ | Bad clutch throw-out bearing. \\ | ||
| Usually a bad throw out bearing is most noticeable when pulling in the clutch lever. \\ | Usually a bad throw out bearing is most noticeable when pulling in the clutch lever. \\ | ||
| - | Ride around a bit and keep pulling the clutch lever and see if the noise coincides. ((wedge of the XLFORUM | + | Ride around a bit and keep pulling the clutch lever and see if the noise coincides. ((wedge of the XLFORUM |
| **Condition**: | **Condition**: | ||
| - | Warped clutch discs or worn clutch hubs can also cause clunks because the clutch cannot totally disengage. ((XLXR of the XLFORUM | + | Warped clutch discs or worn clutch hubs can also cause clunks because the clutch cannot totally disengage. ((XLXR of the XLFORUM |
| ====== Drive Belt / Chain ====== | ====== Drive Belt / Chain ====== | ||
| - | |||
| **Symptom**: | **Symptom**: | ||
| Clunk sound in the drive train with initial on or off throttle. \\ | Clunk sound in the drive train with initial on or off throttle. \\ | ||
| Further description: | Further description: | ||
| - | At any speed and in any gear, you can roll on the throttle firmly and hear a clunk sound from the drive train. ((Gone of the XLFORUM | + | At any speed and in any gear, you can roll on the throttle firmly and hear a clunk sound from the drive train. ((Gone of the XLFORUM |
| Then when you abruptly let off the throttle, you hear the same clunk sound. \\ | Then when you abruptly let off the throttle, you hear the same clunk sound. \\ | ||
| This has happened on a brand new bike and has been noted on many others as well. | This has happened on a brand new bike and has been noted on many others as well. | ||
| Line 719: | Line 720: | ||
| It may simply be backlash on the tranny gears due to varying forces of on/off throttle. \\ | It may simply be backlash on the tranny gears due to varying forces of on/off throttle. \\ | ||
| - | Putting the bike on a stand / rear wheel off the ground and in gear while turning the rear wheel, ((2cvandy of the XLFORUM | + | Putting the bike on a stand / rear wheel off the ground and in gear while turning the rear wheel, ((2cvandy of the XLFORUM |
| There' | There' | ||
| Obviously, there has to be some give in the transmission line somewhere. \\ | Obviously, there has to be some give in the transmission line somewhere. \\ | ||
| There' | There' | ||
| - | Some clunk is normal, too much clunk is not. ((XLXR of the XLFORUM | + | Some clunk is normal, too much clunk is not. ((XLXR of the XLFORUM |
| The only way to tell is to ride a few other bikes, or get someone who has ridden a few other bikes to ride yours. \\ | The only way to tell is to ride a few other bikes, or get someone who has ridden a few other bikes to ride yours. \\ | ||
| Make sure all the sprockets are tight. \\ | Make sure all the sprockets are tight. \\ | ||
| They all have some rotational play, but should not have lateral play (twist) on the shaft. \\ | They all have some rotational play, but should not have lateral play (twist) on the shaft. \\ | ||
| Some have had the nut on the front rubber belt drive loosen up. \\ | Some have had the nut on the front rubber belt drive loosen up. \\ | ||
| - | Running the belt with more slack may help absorb some of the shock. ((2cvandy of the XLFORUM | + | Running the belt with more slack may help absorb some of the shock. ((2cvandy of the XLFORUM |
| Primary chain adjustment seems to have no affect on the clunking noise. \\ | Primary chain adjustment seems to have no affect on the clunking noise. \\ | ||
| Check for play in the clutch basket. \\ | Check for play in the clutch basket. \\ | ||
| Line 736: | Line 737: | ||
| The clunk is worse if you snap on / off the throttle quickly. \\ | The clunk is worse if you snap on / off the throttle quickly. \\ | ||
| And those bumps in the road can sometimes jerk the throttle, so having the cable adjustment set right does help. \\ | And those bumps in the road can sometimes jerk the throttle, so having the cable adjustment set right does help. \\ | ||
| - | Running the belt a little on the loose side helps. ((2cvandy of the XLFORUM | + | Running the belt a little on the loose side helps. ((2cvandy of the XLFORUM |
| - | ===== Belt ===== | + | |
| + | ===== Belt ===== | ||
| **Symptom**: | **Symptom**: | ||
| Squealing noise. \\ | Squealing noise. \\ | ||
| **Condition** \\ | **Condition** \\ | ||
| - | Dirty belt. ((need2understand of the XLFORUM | + | Dirty belt. ((need2understand of the XLFORUM |
| **Condition**: | **Condition**: | ||
| - | Loose pulley. ((tattoowho of the XLFORUM | + | Loose pulley. ((tattoowho of the XLFORUM |
| - | Noise may not be noticeable at low speeds. ((need2understand of the XLFORUM | + | Noise may not be noticeable at low speeds. ((need2understand of the XLFORUM |
| If the pulley gets loose, inspect the pulley, bearing and race for possible replacement. \\ | If the pulley gets loose, inspect the pulley, bearing and race for possible replacement. \\ | ||
| - | Also check the teeth on the sprocket for sharp edges which can break the belt. ((Sweet Terry Smoove of the XLFORUM | + | Also check the teeth on the sprocket for sharp edges which can break the belt. ((Sweet Terry Smoove of the XLFORUM |
| **Symptom**: | **Symptom**: | ||
| - | Chirping sound at the belt. ((wedge of the XLFORUM | + | Chirping sound at the belt. ((wedge of the XLFORUM |
| **Condition**. \\ | **Condition**. \\ | ||
| Line 760: | Line 761: | ||
| If you get it too loose it will chirp from sliding sideways on the front sprocket. \\ | If you get it too loose it will chirp from sliding sideways on the front sprocket. \\ | ||
| If it doesn' | If it doesn' | ||
| - | Some run the drive belt a little looser than what the manual calls for. ((Toejam503 of the XLFORUM | + | Some run the drive belt a little looser than what the manual calls for. ((Toejam503 of the XLFORUM |
| - | The belt's not going to " | + | The belt's not going to " |
| - | When the belt is about to break (i.e., from stone damage), the ' | + | When the belt is about to break (i.e., from stone damage), the ' |
| - | A tight belt doesn' | + | A tight belt doesn' |
| ===== Chain ===== | ===== Chain ===== | ||
| - | |||
| Look for witness marks where the chain may be slapping nearby objects. \\ | Look for witness marks where the chain may be slapping nearby objects. \\ | ||
| - | Slack in the chain can make it slap the oil tank. ((RochesterIron of the XLFORUM | + | Slack in the chain can make it slap the oil tank. ((RochesterIron of the XLFORUM |
| You may not be able to make it hit the tank by hand when lifting the chain when parked. \\ | You may not be able to make it hit the tank by hand when lifting the chain when parked. \\ | ||
| But while riding, the chain can move more than by hand. \\ | But while riding, the chain can move more than by hand. \\ | ||
| It also sounds like marbles in a can. On hard acceleration, | It also sounds like marbles in a can. On hard acceleration, | ||
| - | The chain can also slap on the chain guard. ((IronMick of the XLFORUM | + | The chain can also slap on the chain guard. ((IronMick of the XLFORUM |
| **Symptom**: | **Symptom**: | ||
| Line 783: | Line 783: | ||
| Worn teeth on the drive sprocket. \\ | Worn teeth on the drive sprocket. \\ | ||
| - | Putting a new chain on a badly worn sprocket and it will be a junk chain in a few miles. ((wedge of the XLFORUM | + | Putting a new chain on a badly worn sprocket and it will be a junk chain in a few miles. ((wedge of the XLFORUM |
| With bad sprockets the chain will stretch to match the sprockets. \\ | With bad sprockets the chain will stretch to match the sprockets. \\ | ||
| The opposite, a stretched chain will carve the sprockets. \\ | The opposite, a stretched chain will carve the sprockets. \\ | ||
| Line 789: | Line 789: | ||
| It's cheaper in the long run, and less annoying. \\ | It's cheaper in the long run, and less annoying. \\ | ||
| - | | Worn sprocket. ((photo by iNSaNeSHaNe of the XLFORUM | + | | Worn sprocket. ((photo by iNSaNeSHaNe of the XLFORUM |
| |{{: | |{{: | ||
| Line 795: | Line 795: | ||
| ===== Tire Rub ===== | ===== Tire Rub ===== | ||
| - | |||
| Clearance is important between the tires and fenders, fender / light / saddlebag bolts etc. \\ | Clearance is important between the tires and fenders, fender / light / saddlebag bolts etc. \\ | ||
| It is especially important to check when swapping to bigger tires than stock sizes. \\ | It is especially important to check when swapping to bigger tires than stock sizes. \\ | ||
| Tires can expand when heated. \\ | Tires can expand when heated. \\ | ||
| An " | An " | ||
| - | Any tire rub is dangerous. There is no such thing as minor tire rub. ((XLXR of the XLFORUM | + | Any tire rub is dangerous. There is no such thing as minor tire rub. ((XLXR of the XLFORUM |
| - | The shocks are meant to bottom out (before the rear tire rubs) and prevent tire rubbing. ((XLXR of the XLFORUM | + | The shocks are meant to bottom out (before the rear tire rubs) and prevent tire rubbing. ((XLXR of the XLFORUM |
| If your rear tire is rubbing / contacting the underside of the fender, you have the wrong shocks. \\ | If your rear tire is rubbing / contacting the underside of the fender, you have the wrong shocks. \\ | ||
| If you take the shocks off and lower the bike gently, you can measure the distance between the shock mounts at the lowest position. \\ | If you take the shocks off and lower the bike gently, you can measure the distance between the shock mounts at the lowest position. \\ | ||
| Line 809: | Line 808: | ||
| One problem with lowering blocks is the possibility of bending, especially the cheaper ones, loosing tire clearance, and causing a blow out. \\ | One problem with lowering blocks is the possibility of bending, especially the cheaper ones, loosing tire clearance, and causing a blow out. \\ | ||
| - | It should be noted that one tire manufacturer' | + | It should be noted that one tire manufacturer' |
| **Symptoms**: | **Symptoms**: | ||
| Line 820: | Line 819: | ||
| Bent fender. \\ | Bent fender. \\ | ||
| - | Wrong or worn wheel spacers. ((IronMick of the XLFORUM | + | Wrong or worn wheel spacers. ((IronMick of the XLFORUM |
| Check front alignment from wheel to fork on both sides before adjusting the fender. \\ | Check front alignment from wheel to fork on both sides before adjusting the fender. \\ | ||
| For the rear, the wrong spacer(s) throws out the alignment on the rotor and belt alignment. \\ | For the rear, the wrong spacer(s) throws out the alignment on the rotor and belt alignment. \\ | ||
| - | |Tire rub from belt due to wheel misalignment. ((photo by manpotato of the XLFORUM | + | |Tire rub from belt due to wheel misalignment. ((photo by manpotato of the XLFORUM |
| |{{: | |{{: | ||
| **Condition**: | **Condition**: | ||
| - | Loose belt rubbing the belt guard / debris deflector. ((Sweet Terry Smoove of the XLFORUM | + | Loose belt rubbing the belt guard / debris deflector. ((Sweet Terry Smoove of the XLFORUM |
| Remove the belt guard, check for witness marks inside it. \\ | Remove the belt guard, check for witness marks inside it. \\ | ||
| Inspect anything that could have contact with the belt. \\ | Inspect anything that could have contact with the belt. \\ | ||
| Line 841: | Line 840: | ||
| The tire below is an Avon MT90 16 (same as stock Dunlop size 130). \\ | The tire below is an Avon MT90 16 (same as stock Dunlop size 130). \\ | ||
| It is slightly wider than the Dunlop. \\ | It is slightly wider than the Dunlop. \\ | ||
| - | Bridgestones are reportedly almost 1/2" wider than others. ((IronMick of the XLFORUM | + | Bridgestones are reportedly almost 1/2" wider than others. ((IronMick of the XLFORUM |
| The shocks were also lowered on this bike. \\ | The shocks were also lowered on this bike. \\ | ||
| However, the bolt for the rear sissy bar attachment rubbed into the tire. \\ | However, the bolt for the rear sissy bar attachment rubbed into the tire. \\ | ||
| - | |Tire rub from docking hardware bolt. ((photo by BadHabit of the XLFORUM | + | |Tire rub from docking hardware bolt. ((photo by BadHabit of the XLFORUM |
| |{{: | |{{: | ||
| Line 853: | Line 852: | ||
| Condition: \\ | Condition: \\ | ||
| Only one part of the tire rubbing the fender. \\ | Only one part of the tire rubbing the fender. \\ | ||
| - | Possible causes are the bead seat uneven or spoke wheels 'out of true'. ((SportsterBart of the XLFORUM | + | Possible causes are the bead seat uneven or spoke wheels 'out of true'. ((SportsterBart of the XLFORUM |
| ===== Bearings ===== | ===== Bearings ===== | ||
| - | |||
| **Symptom**: | **Symptom**: | ||
| Screeching noise. \\ | Screeching noise. \\ | ||
| Line 864: | Line 862: | ||
| **Condition**: | **Condition**: | ||
| Dry / damaged bearings. \\ | Dry / damaged bearings. \\ | ||
| - | A bad bearing will usually transfer heat to the hub and as it gets worse. ((sportsterdoc of the XLFORUM | + | A bad bearing will usually transfer heat to the hub and as it gets worse. ((sportsterdoc of the XLFORUM |
| If you suspect a bearing, feel the hub during / after a ride for heat buildup. \\ | If you suspect a bearing, feel the hub during / after a ride for heat buildup. \\ | ||
| ===== Tread Noise ===== | ===== Tread Noise ===== | ||
| - | |||
| **Symptom**: | **Symptom**: | ||
| - | Low level moaning sound over some surfaces (may sound like a snare drum). ((PrettyHipsMcGee of the XLFORUM | + | Low level moaning sound over some surfaces (may sound like a snare drum). ((PrettyHipsMcGee of the XLFORUM |
| **Condition**: | **Condition**: | ||
| Line 886: | Line 883: | ||
| ===== Front wheel specific ===== | ===== Front wheel specific ===== | ||
| - | |||
| **Symptom**: | **Symptom**: | ||
| - | Rattling noise from wheel area. ((guitarfish of the XLFORUM | + | Rattling noise from wheel area. ((guitarfish of the XLFORUM |
| **Condition**: | **Condition**: | ||
| Loose right leg pinch bolt. \\ | Loose right leg pinch bolt. \\ | ||
| - | When the axle (and wheel) is assembled, the pinch bolt in the right leg is completely loose. ((IXL2Relax of the XLFORUM | + | When the axle (and wheel) is assembled, the pinch bolt in the right leg is completely loose. ((IXL2Relax of the XLFORUM |
| This allows the axle to fully clamp the hub bearings (inner races) tightly to the left leg. \\ | This allows the axle to fully clamp the hub bearings (inner races) tightly to the left leg. \\ | ||
| (holding the axle itself with a screwdriver thru the hole in the axle head and tightening the axle nut) \\ | (holding the axle itself with a screwdriver thru the hole in the axle head and tightening the axle nut) \\ | ||
| Line 904: | Line 900: | ||
| ===== Rear wheel specific ===== | ===== Rear wheel specific ===== | ||
| - | + | You need 2 people, 1 to roll the bike and 1 to see where the noise is coming from. ((Outtakes of the XLFORUM | |
| - | You need 2 people, 1 to roll the bike and 1 to see where the noise is coming from. ((Outtakes of the XLFORUM | + | |
| Or, it would be easier if you could lift the wheel and spin the tire to find the noise. \\ | Or, it would be easier if you could lift the wheel and spin the tire to find the noise. \\ | ||
| **Symptom**: | **Symptom**: | ||
| - | Rubbing noise. ((manpotato of the XLFORUM | + | Rubbing noise. ((manpotato of the XLFORUM |
| **Condition**. \\ | **Condition**. \\ | ||
| Line 916: | Line 911: | ||
| It's important, when installing the rear wheel, to center the wheel using a homemade alignment tool as in the FSM. \\ | It's important, when installing the rear wheel, to center the wheel using a homemade alignment tool as in the FSM. \\ | ||
| Else, the tire can rub against the belt which eats at the rubber on the tire. \\ | Else, the tire can rub against the belt which eats at the rubber on the tire. \\ | ||
| - | |||
| - | |||
| ===== Brakes ===== | ===== Brakes ===== | ||
| - | |||
| **Symptom**: | **Symptom**: | ||
| Squealing sound coming from the wheel area. \\ | Squealing sound coming from the wheel area. \\ | ||
| Line 932: | Line 924: | ||
| A few thousandths difference will mean that the pads and disc need to wear together to mate up again. \\ | A few thousandths difference will mean that the pads and disc need to wear together to mate up again. \\ | ||
| You may hear a harmless light contact at the new "high spots" that will go away as the disc and pads mate up again. \\ | You may hear a harmless light contact at the new "high spots" that will go away as the disc and pads mate up again. \\ | ||
| - | You will hear the same thing (only much more pronounced) when you install new pads because the disc and pads have to wear in to one another again. ((Oldwrench of the XLFORUM | + | You will hear the same thing (only much more pronounced) when you install new pads because the disc and pads have to wear in to one another again. ((Oldwrench of the XLFORUM |
| Always check for loose brake calipers. \\ | Always check for loose brake calipers. \\ | ||
| - | If the wheel isn't centered exactly where it was before a tire swap, you may get a little noise for a while (from the brake dragging). ((83XLX of the XLFORUM | + | If the wheel isn't centered exactly where it was before a tire swap, you may get a little noise for a while (from the brake dragging). ((83XLX of the XLFORUM |
| - | If noise does not stop with the application of the front or rear brake, then it may not be a brake issue. ((sportsterdoc of the XLFORUM | + | If noise does not stop with the application of the front or rear brake, then it may not be a brake issue. ((sportsterdoc of the XLFORUM |
| - | Pull the caliper, hang it off the fork leg in a safe manner and ride the bike around the block. wedge of the XLFORUM ((http:// | + | Pull the caliper, hang it off the fork leg in a safe manner and ride the bike around the block. wedge of the XLFORUM ((https://www.xlforum.net/ |
| You can put a block between the pads and tape it inside so that you can't push the pucks out too far by mistakenly using the brake. | You can put a block between the pads and tape it inside so that you can't push the pucks out too far by mistakenly using the brake. | ||
| Keep aware that you now only have brakes on the other wheel. | Keep aware that you now only have brakes on the other wheel. | ||
| Line 947: | Line 939: | ||
| Make sure the clip springs are in correctly and lightly greased with anti seize too. \\ | Make sure the clip springs are in correctly and lightly greased with anti seize too. \\ | ||
| (wheel bearing grease will do the job also) \\ | (wheel bearing grease will do the job also) \\ | ||
| - | |||
| - | |||
| ====== Exhaust ====== | ====== Exhaust ====== | ||
| - | |||
| **Symptoms**: | **Symptoms**: | ||
| The exhaust note (pitch) changes to a more hollow sound. \\ | The exhaust note (pitch) changes to a more hollow sound. \\ | ||
| - | A blown gasket or a header that worked its way loose will be noticeably louder. ((thatdirtykid of the XLFORUM | + | A blown gasket or a header that worked its way loose will be noticeably louder. ((thatdirtykid of the XLFORUM |
| **Condition**: | **Condition**: | ||
| Line 967: | Line 956: | ||
| Check for loose heat shields and mounting bolts. \\ | Check for loose heat shields and mounting bolts. \\ | ||
| You can use a stethoscope or a piece of oil line to listen for leaks at the mounts and joints. \\ | You can use a stethoscope or a piece of oil line to listen for leaks at the mounts and joints. \\ | ||
| - | Or, you can put an old damp towel over the exhaust pipe and run your scoot for a few minutes. ((ridinfool of the XLFORUM | + | Or, you can put an old damp towel over the exhaust pipe and run your scoot for a few minutes. ((ridinfool of the XLFORUM |
| After the engine cools down, look carefully over the engine for the telltale smudge of black soot which points to an exhaust leak. \\ | After the engine cools down, look carefully over the engine for the telltale smudge of black soot which points to an exhaust leak. \\ | ||
| **Symptom**: | **Symptom**: | ||
| - | Popping noise in the exhaust (or intake) along with a misfire. ((jessearias of the XLFORUM | + | Popping noise in the exhaust (or intake) along with a misfire. ((jessearias of the XLFORUM |
| **Condition**: | **Condition**: | ||
