Different Belt Noise

Energy One
M

motosman1

New Member
New to the forum. Yes, I've already searched this topic but have something different. I have a 2003 BD Chopper in my shop, just recently purchased by a friend of mine. Has a squeal/squeak/chirp at steady speeds and acceleration. Stops when you roll off throttle. It will make the noise as one pushes the bike through the shop, even does it on the lift when rotating wheel by hand. Have absolutely pinpointed to the outside edge of belt trying to ride up on outer guard of front pulley. First used a stethoscope to pinpoint then applied Triflow to outer edge of belt, ahead of rear pulley. As soon as Triflow section reaches pulley, noise stops. After a few rotations to distribute the Triflow, noise is completely gone. First, establish proper belt tension and "spot-on" wheel alignment in swingarm. Axle parallel with pivot shaft, tire is centered in fender. Loosened all engine/trans mounts and shifted everything to the left. Rear edge of primary housing actually moved .125" to left. Now, a visible gap of appx. .0625" can be seen between belt and outer guard/stop of pulley. GOOD TO GO! Wiped Triflow from belt with solvent/rag. 30 miles later, noise is back! I have found numerous suggestions on this site. I don't think the "Supermax" rear pulley mod is going to help with frt. pulley issue. Can't "guarantee" that a Panther belt will fix it and periodic application of a graphite, or Teflon based lube, is only addressing the symptom. I have double checked wheel bearings/hub/spacing as well as front pulley and main drive gear bearing. As a 25 year certified H-D tech, I have had this issue before. Always rectified with a thorough cleaning of belt and pulleys (touring bikes with saddlebags) or setting proper belt tension and alignment. The only way, I see, to guarantee the noise goes away is with a chain conversion. BTW...it also has a noise/shudder under hard acceleration. One would imagine the belt jumping teeth on the pulley. A chain conversion would solve this also, IF that's what the noise/shudder actually is. Am I overlooking something here? Thanks in advance for any help.
 
Mr. Wright

Mr. Wright

Knows some things
Supporting Member
Being that it is an 03, it probably has the Mad Clown wheels on it. I've had to change a couple belt pulleys out for that design.
Call Derek and Donna @bigdogpartsking at
(620) 257-2009
They have an upgraded Teflon coated pulley with the Mad Clown design.
 
M

motosman1

New Member
NEWS FLASH!!! For anybody else not wanting to spend 500+ dollars on pulleys and chain conversions. I dug back through my many years of notes and found a couple instances of belt squeal/chirp on some early-to-mid 90's CMC and Titan motorcycles (anybody remember those?). A 2" diameter, 36 grit Rolock sanding disc in a die grinder held at a 60 degree angle to the outer edge of the belt while rolling the rear wheel with bike on stand. Form a slight (60 degree) bevel just on the teeth of the belt. Do not decrease the actual width of the belt. This keeps the belt from trying to ride up the side of the pulleys and squeaking as it slides down into the pulley. Yes, I know there is still an alignment issue that I am simply circumventing, not correcting. Instead of aligning the wheel in the swingarm, using the parallelism of the axle and pivot shafts, I shifted the wheel right-to-left-to-right until I found the "happy place" where the belt tracked the straightest. Bike does not "catwalk" down the road AND it is quiet. The customer with this bike picked up the bike for a song and does NOT want to spend any more than he has to, on anything. So...I had to be resourceful. I know some will condemn and ridicule me, even call me a hack, but until the belt breaks I'm not proven wrong. If the belt breaks? There's the reason for the chain drive! I hope this helps someone out there who maybe just doesn't have the greenies for the other fixes. BTW...never had any of the other bikes breaking belts.
 
ground pounder

ground pounder

Active Member
On some of the big dog bikes you have to move the rear axle a little to make the belt ride where you want too. I run my belt to the outer edge of rear pulley to clear everything and have had no issues so far with bad tire wear etc. by doing this. Sounds like the pulley and belt have worn aq little, so you may have to move the axle a little more. Rotate the tire forward untill you get the belt where you want it by moving the axle. Don't rotate it backwards to watch the movement. Remember we don't drive these bikes in reverse. LOL!!!
 
HMAN

HMAN

I just like my Freedom
Supporting Member
As much as the new owner wants to do cheap, this will prolly be the cheapest thing he EVER has fixed. These are fantastic rides, but when they break, and they will, parts just aint cheap. Mabe he be better with a ricer, unless he just bought it to flip?
 
Rottweiler

Rottweiler

Well-Known Member
Supporting Member
motosman1,
The only way, I see, to guarantee the noise goes away is with a chain conversion. BTW...it also has a noise/shudder under hard acceleration. One would imagine the belt jumping teeth on the pulley. A chain conversion would solve this also, IF that's what the noise/shudder actually is. Am I overlooking something here? Thanks in advance for any help.

I have a 2004 same thing. I am very interested in the noise/shudder under hard acceleration. One would imagine the belt jumping teeth on the pulley.
Did this go away after the 60 degree belt adjustment?
 
M

motosman1

New Member
All I had time for, last night, was a quick 40 mph run in my 'hood to verify noise was gone. Will find time/place to check the "go hard shudder" tonight and let you know. This bike would actually make the squealing noise with a "fat jack" under the frame to get the rear tire off the ground and rolling wheel by hand. As I was removing material from the belt teeth I could hear the noise diminish until it was nonexistent. AND...I stand corrected. The noise was coming PREDOMINANTLY from the front pulley until I shifted the entire drivetrain to the left. As the Triflow wore off, and the noise returned, it was coming from the rear pulley. So, the Supermax pulley may be the answer hear but it came down to money.
 
Mr. Wright

Mr. Wright

Knows some things
Supporting Member
Supermax makes a great pulley, yes, but for a third of the price call Donna and get the upgraded pulley they offer, and be done with it. It's not rocket science here, do the job right.
 
M

motosman1

New Member
I have a 2004 same thing. I am very interested in the noise/shudder under hard acceleration. One would imagine the belt jumping teeth on the pulley.
Did this go away after the 60 degree belt adjustment?[/QUOTE]

Sorry, lost track of time. Beveling the belt helped nothing. Customer called last week to say noise has returned after a couple hundred miles. I adjusted belt tension to tight side of specs and adjusted alignment numerous ways. Still "sounds/feels like" belt is jumping teeth under hard acceleration, but only in 1st gear @ 15 mph or below. Only way I can "GUARANTEE" the elimination of these two conditions is by chain conversion. Customer is up for it. Cheaper than Supermax pulley and new Panther belt. Plus, this motor will NEVER break a properly maintained chain. Now I need to research if anyone has done a chain on these bikes. I know I can measure and fab needed spacers but would prefer not having the bike down in MY garage, on MY lift, during the process of parts sourcing and shipping. I would like to get specs and part #'s from a successful conversion. Good luck with yours!
 
tcrowelljr

tcrowelljr

Member
I have an 2004 Chopper RT with Mad Clown wheels doing the same thing. Shipped the pulley to SuperMax yesterday. I will let everyone know if this is the fix. Also felt the belt jumping recently. We will see.
 
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