I have an 03 harley with 6K miles. It started making a popping noise when I start of under medium acceleration, it is definately in the suspension, and only pops (clunks) once. Somestimes it comes from under the front of truck and sometimes from the rear, more from the rear than the front. If I drive it more than a few miles I can make it do it every time I start off. I did a search through the forums and could not find anything on this. Has anyone had a similiar problem and if so, what was the outcome? I hate to take the truck to the dealer without some kind of an idea of what the problem is.
Thanks
Mike

 

Some guys have had loose tie rods.

Take your truck to the dealership and have them check the jam(?) nuts ... mine were loose on the front passenger side.

jeff

 

Let us know what you find out. My 02 does the similar things under modest acceleration from a stop. Thanks

 

I have almost 90K miles on my SCrew and just noticed this same thing, but I usually only notice it when I am turning.

 

I have had the truck to the dealer a couple of times and they can't find anything. I just wonder if anyone else has experienced this problem as it has been over a year since I first posted this.
Thanks
Mike

 

My 03 didthe same thing at about 4000 miles after two months of going back and forth with the dealer took it to suspension shop and they told me the leaf springs were bad. Took dealership two more weeks to agree before replacing them.

 

Sounds like that could be the problem. Did that take care of it ?????
Thanks
Mike

 

At 50K miles, I've had my 2001 HD in the shop many times for this problem. One dealer greased the body mounts @ $225 which did not fix it. After several visits to different dealers, found that the rear pinion bearing was not seated properly causing backlash in the diff.; ordered the replacement parts but upon installation, dealer couldn't provide the spec for it...so the entire rear diff was replaced along with the drive shaft; Everything was covered under the extended warranty. Drove and handled tight until now and at 63K miles...same problem!! In addition, u-joints/trans. hits HARD when switching into reverse gear. I've heard them say "that's normal" for the last time. It's not normal is it?