Dealing With Harley Cam Chain Tensioner Problem Years
If you're looking for an utilized Twin Cam, you've probably heard some horror stories regarding the harley cam chain tensioner problem years and how they can basically turn a good engine into the very expensive paperweight. It's one of those topics that will comes up every single time someone mentions purchasing an older bicycle, and for good reason. For about a decade, Harley-Davidson used a design that worked well great on papers but had the nasty habit associated with wearing out too early in the actual world.
In the event that you own or even are looking in a bike produced between 1999 plus 2006, you're best in the strike zone. This isn't just "internet drama, " either; it's a legitimate mechanised quirk that every single owner should realize before they finish up stranded quietly of the road having a crankcase complete of plastic shavings.
The Period of the Spring-Loaded Tensioner
The main issue revolves across the early Twin Cam 88 engines. When Harley moved far from the Evolution engine and introduced the Twin Cam in 1999, they changed how the cams were powered. Instead of the gear-to-gear setup, they went with chains. To keep these chains tight, they will used spring-loaded tensioners with plastic (nylon/Delrin) shoes that apply directly against the particular chain.
The particular harley cam chain tensioner problem years specifically send to 1999 via 2006. In this window, the springs had been incredibly stiff. Imagine a piece associated with hard plastic being pressed with significant force against a moving metal chain for thousands of miles. Eventually, that will plastic will probably drop.
The real headaches is that there was no "scheduled" time for these in order to fail. Some men would open upward their cam chest at 20, 000 miles and locate the pads looked brand new. Other bikers would hit fifteen, 000 miles and find the pads worn down to the metallic. Once the plastic dons through, the metallic spring arm starts rubbing on the chain. That transmits fine metal bits through your oiling system, which generally leads to a total engine rebuild.
Identifying the risk Zone by Model
It's worth noting that not each Harley model "fixed" the issue from the very same period. If you're searching at a Dyna , the problem years technically end within 2005, because the particular 2006 Dyna had been the first to have the upgraded hydraulic tensioner system and the particular new 96-cubic-inch engine architecture.
However, if you're looking at a Softail or a Touring bicycle (like an Electra Slip or Road King), the 2006 versions still had the particular old spring-loaded design. For those heavier cruisers, the "safe" years didn't start until 2007. It's a common point associated with confusion—someone might purchase a 2006 Excess fat Boy thinking they're in the very clear, only to discover out they have got the exact same ticking time bomb as a 2001 model.
Why Did They Fail So Inconsistently?
One of the particular most frustrating points about the harley cam chain tensioner problem years is the inconsistency. You'll talk in order to one old-timer which has 100, 000 miles on their 2003 Ultra Vintage and says he's never touched the particular tensioners. Then you'll find a guy along with a 2004 Traditions Softail that wrecked through a cushion at 12k miles.
A big part of this particular comes down to the finish off of the chains themselves. In the particular early years, several of the stores had "silent" hyperlinks that were in fact quite abrasive. In the event that your bike occurred to get the chain with rougher edges, it might act like a saw against that will plastic pad. In case you got a "smooth" chain, the patches lasted a great deal longer. Since generally there was no method to find out which chain you needed without getting the bike apart, it became the game of mechanised Russian roulette.
Signs Your Tensioners Are Giving Upward
Honestly, the particular worst part about this whole circumstance is that presently there usually aren't numerous symptoms until it's too late. You won't necessarily hear a "clunk" or even feel a reduction of power. However, if you're delicate to your bike's sounds, you may notice a slight increase in mechanised whine or "whirring" from the right side of the engine.
The particular most reliable method to check is also the most annoying: you have to pull the cam cover up. Even then, you can only easily see the outer tensioner. The inner one is tucked behind the cam plate, plus that's usually the particular one that has on out faster since it's harder to see and gets a little more heat.
If you actually see small orange or black plastic pieces in your oil filter during an oil change, stop riding immediately. That's the tensioner pad actually disintegrating.
The Fix: Hydraulic vs. Gear Push
If you find yourself buying a bike from the harley cam chain tensioner problem years , there is a few methods to repair it permanently. Most people don't just "replace" the pads with the particular same factory parts because you're just resetting the clock on a bad design.
1. The Hydraulic Conversion
This is exactly what Harley do starting in 3 years ago. They ditched the heavy springs plus used oil stress to maintain the tensioners tight. Because the particular pressure is regulated, it doesn't mash the plastic contrary to the chain with almost as much force. You can buy a "Screamin' Eagle" conversion package that retrofits this particular system onto older bikes. It's the solid, reliable repair that most riders choose.
two. Cyco Gasket Patches
If you're on a tight budget, an organization called Cyco Gaskets makes replacement safeguards that are broadly considered much tougher than the unique Harley-Davidson plastic. It doesn't solve the "spring-loaded" design downside, but the material itself lasts significantly much longer. It's an inexpensive way to get peace of mind for another 30, 000 miles.
3. Gear Travel Conversion
This is the "nuclear option. " Companies like S& S Cycle present gear drive packages that remove the chains and tensioners entirely. No chains means nothing to tension, which means no plastic to wear out. It's the most long lasting fix, but there's a catch: crankshaft runout . To operate gears, your turn needs to become nearly perfectly direct (usually less compared to. 003" of wobble). If your turn is out of spec, the gears will whine or even bind upward.
Is it a Dealbreaker?
Does the harley cam chain tensioner problem years mean you should avoid an older Twin Cam 88? Not necessarily. Actually, these bikes a few of the greatest values on the market right now because people are scared of the tensioners.
If you find a clear 2002 Road Full for a great price, just factor the particular cost of the particular fix into your own offer. If the particular owner can't demonstrate they've upgraded the particular tensioners, assume you'll need to spend roughly $500 in order to $1, 000 (depending on if a person do the task yourself or carry it to a shop) to address it. Once it's fixed, those engines are incredibly stout and can effortlessly run for 100k+ miles.
Gift wrapping Up the Tensioner Talk
It's easy to get caught up in the horror stories on forums, but the reality is usually how the harley cam chain tensioner problem years are just a hurdle, not a complete line. Harley-Davidson offers always had its quirks—the Shovelheads leaked out, the Evos experienced some base gasket issues, and the early Twin Cams had the tensioners.
In the event that you're riding the 1999–2006 bike, don't panic, but don't ignore it either. Get a set associated with gaskets, pull that will cam cover, plus take an appearance. If those patches look thin, change them out just before they turn your own engine oil straight into plastic soup. It's less expensive to buy a few parts now than to purchase a whole new engine later this summer.