Ulysses Engine Noise

[rdkingryder]

Hi, new guy here. I own a 2007 Ulysses, 30K with engine noise. I've removed the engine and have found the rear rod with play in it causing the knocking sound. I spend most of my time on Advrider and posted it there and on Badweb. There seems to be quite a few of us with crank failure, the fix, an '08 crank and bearings. We are trying to get a running balance on the miles and years the cranks are failing. Seems '07's, with over 19K are the most prevelant. Please go to Badweb and look under "Big Bad and Dirty". Seems none of the other XB's are exhibiting the problem and while it is a handful of us Uly owner's, they share the same engines as the other XB's.

 

[rdkingryder]

Ok, here is the video I made of the engine noise. Noisier as I rev it.
http://www.youtube.com/watch?v=EDqI1mgtiRw

 

[rdkingryder]

 

[jomartijr]

I'd like to add the more failure as well as non failure 2007 Uly info we can post over on that thread " Official 07 Crank Failure List" the more we'll possibly all benefit from understanding the extent of the problem potential.

 

[jomartijr]

If anyone would prefer to post their info here instead of over at badweb that would be helpful also. We could combine into one database.

Info we are looking for is only for 2007 Ulys (as well as other XBs failures) that have developed engine knocking due to rod bearing failure or crankshaft issues. We're tracking build date, mileage and whether failed or not as well as VIN number if possible.

 

[wolfo68]

you for sure diagnosed that as the crank? my noise was a lot like that and it was the cams

 

[rdkingryder]

Yes, as I've already removed the engine and was able to check each rod. The rear rod has excessive play in it. Check Badweb's "My Uly Sounds Terminal". Mine didn't sound quite as bad as his, but it was noisy.

 

[BuellyBagger]

hope ebr puts out the AX b4 my uly reaches high mileage then

 

[rdkingryder]

My crank came today and now I've got to get the rest of the parts to put it back together.

 

[rdkingryder]

Ok, I disassembled the engine a bit more and ordered up some parts.

You can see I put blood, sweat and tears into this project. Yep, that's from cutting my hand on the sharp edge of the case.

I had to order a b/a socket for the b/a nut on the sprocket. Took a few days and look what I got.

 

[rdkingryder]

Took a long time with my good I/R impact and it's left hand thread, but it finally came off along with about a tube's worth of red Loctite.

Also, I noticed the new crank was only threaded on the right side and fluted on the left, leading me to think it slides into some shaft to drive the primary. So I will be trying to leave as much in place as possible. Hope I'm right.

 

[thumpin1203]

How much have the new parts ran you ($$) so far?

 

[rdkingryder]

I've spent just under $800. If you go through Chicago Harley, it's discounted 20%. Just waiting under the rest of the parts arrive, it's been a month so far.

 

[twoscoops]

Doh! you didn't have to remove the pulley nut to split the cases.. But since it's off you can now replace the seal!

 

[rdkingryder]

Oh well, went cookbook with the service manual and it states to remove it. That's ok, on $10 for the socket and some effort from the IR244. LOL! When the parts arrive, I'll be pulling off the clutch pack and the stator assembly. Still waiting on the parts from Chicago Harley.

 

[thumpin1203]

Still waiting on the parts from Chicago Harley.

Yeah, you'll most likely be waiting a while with those guys, but, I've done plenty of business with them & they have yet to botch an order.. I always ask for "eric", he is pretty knowledgeable when it comes to Buells..

Be sure to keep us posted on your progress with photos, etc. as I'm sure there will more of us going down the crank replacement path in the future, unfortunately..

 

[rdkingryder]

Will do.

 

[rdkingryder]

Ok, no luck from Chicago Harley and refuse to give them a good word with my experience. I went to ASB and got all the parts in 3 weeks.

So I removed the clutch pack and stator bell/primary. The clutch pack uses a left hand nut, so be careful. I found this out on Youtube.

And it's off.

 

[rdkingryder]

I separated the cases and made sure I got the bolt under the shifter and it's finally out!

I had to play with the pilot bearing as they come in assorted sizes. Good thing I ordered 4 of them, I ended up using the 2nd smallest and it fit slighty tight, but spun smoothly and the smallest had some play in it.

It's in...

 

[rdkingryder]

Here's the reason for all my grief.
http://www.youtube.com/watch?v=xwGo1yD_BiM

Now that the new '08 crank is in, the nose of the crank that goes on the left is larger, so the primary I had will not fit. So I found an '08 XB9 primary kit to work. I've been wondering about doing this mod since the 1st gear seems a little high and taking off on hills is hard on the clutch.

You can see the size difference...

I'm just waiting for the primary to get here and another gasket and hopefully up and running in two weeks.