Next step(s) Clutch/trans/bearing(s)?
Here’s my situation with my 2003 FLHTCI.
I am not a hard rider.
58K miles and had been running flawlessly.
AMSOIL 20W-50 in engine and primary, 75W-110 Synthetic Extreme Pressure Lubricant GL5 in trans.
Bike started making a weird hollow clunking early this season. Almost sounded like there were no fluids. The noise occurs when:
1) Down shift through 2nd and 1st gear.
2) Roll off throttle in 2nd or 1st gear.
Started to notice or imagine slipping in clutch: RPM @ 2K doing 50 MPH in 5th.
Last week I took an uneventful ride to grocery store.
Heading back home l left the parking lot and caught a light.
Take off smoothly, shift to 2nd, roll on the throttle and horrible grinding.
I try shifting through all the gears to see if there is any difference but same result.
I was able to limp home, without stopping, by staying below 2K RPM. If I revved higher it would slip/grind
Fortunately I only stopped rolling when I made it home. The bike would/could not get going again. I could let the clutch completely out in any gear and it would just emit a grinding noise.
Drained primary and recovered virtually every drop of normal capacity. Less than 5K miles on the oil.
No metal on the drain plug.
Refilled with fresh oil and did a ‘by the book’ clutch adjustment, twice with the same result; full release on clutch, slight nudge forward and grinding in all gears.
Removed primary cover and pulled the clutch pack, pictures attached. Upside down, sorry.
Spotless. No scoring, bluing or other obvious damage to metal or fiber discs.
No sludge or debris.
I have to measure the discs to see I they are just at end of life.
Out of curiosity I tried turning the main shaft with the trans in gear and the rear wheel turns, in all gears. So I think it’s reasonably safe to conclude that the trans is ok. BTW, the fluid level is normal.
With the trans in neutral I tried spinning the main shaft/basket. I noticed a pulsing in the primary chain. I reached back to the main drive pulley and it was pulsing/wobbling as well. I took video. Search for "video of wobble in a 2003 flhtci" on youtube you can see the video. It’s only 9 secs.
So now I wonder what I am dealing with.
Are the clutch discs ok or do they need to be replaced (measuring will tell)
Even so, do I have a bearing/bushing issue with the pulsing/wobbling?
What to do? Ideas or recommendations?
Thanks, Tom