TECH TIP - cam tensioner upgrade
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Tourer
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From: Dallas area
TECH TIP - cam tensioner upgrade
TECH TIPS
ENGINE
DOCUMENT CHANGE HISTORY:
--- date --------- changed by ----------------- recap of changes
--------------------------------------------------------------------------------------------------------------------------
04/18/2011 --- gtmalone ---------------- document created
12/7/2013 ---- gtmalone ----------------- remove references to Herko/FlyingW (no longer providing kits)
5/3/2014 ----- gtmalone/patrickp ------ add info and pics for SE hybrid conversion option, add list of specialty tools
9/18/2014 ---- gtmalone ----------------- add note for reusing original lifters
11/10/2014 -- gtmalone ------------------ add parts lists, update specialty tool list
1/4/2015 --- gtmalone ------------------- add parts list for SE upgrade (thanks to HuskerSpringer!)
12/22/2015 -- gtmalone ----------------- add note for Andrews no longer offering kits
2/15/2016 - gtmalone -------------------- update parts lists for gaskets and inner cam bearings, remove reference to Andrews kit (discontinued)
2/15/2016 - gtmalone -------------------- update parts lists for gaskets, inner cam bearings, and breather assy, added step 3.17 to clear oil from bolt holes
4/28/2016 - gtmalone -------------------- update inner bearing installation method, Section 3.8.1 and 3.8.2, added text to corresponding pic. Added Section 3.8.3 for cam plate oring mod with corresponding pic
5/12/2016 - gtmalone -------------------- update 3.16 for TDC positioning on front cylinder
KEYWORDS AND KEY PHRASES
cam - camshaft - tensioner - shoe - hybrid
tensioner upgrade - hydraulic tensioner - cam shoe - cam chain - cam gear
APPLICABLE YEAR/MODEL
2000-2003 TwinCam
This tech tip written for 2000-2003 Heritage Springer but can be adapted for any TwinCam with the spring loaded cam chain tensioners.
1. TECHNICAL AREAS ADDRESSED
1.1 - The spring loaded cam chain tensioner shoes on Twin Cam engines can wear prematurely and may cause significant engine damage. There is no specific mileage range when this can occur. In addition, some year models may experience inner cam bearing failure also resulting in significant engine damage.
The cam chain tensioner mechanism was upgraded from spring loaded to hydraulic in 2006 for Dyna models and 2007 for Softail and touring models. This upgrade also included a high volume oil pump.
1.2 - This tech tip along with the appropriate service manual covers upgrading the cam tensioner mechanism and replacing cam shafts using one of the following options:
1.2a - 2007-up HD version - Replaces cam plate, camshafts, tensioners, and oil pump as used on 2007-up twin cam models.
Andrews has since discontinued the kit but does list the HD parts required for the conversion.
Additional info on Andrews site: http://www.andrewsproducts.com/image...on-99-2006.pdf
Parts List - (HD items)
HD Part no. - Description
26037-06 Oil pump assembly
25355-06 Cam support plate assembly
4741A Cam Support plate mounting screws; (10 pcs req'd.)
11461 Retaining ring (for front cam)
25683-06 Inner roller chain
39969-06 Inner chain tensioner
4740A Inner chain tensioner mounting screws; (2 pcs req'd.)
25675-06 Outer roller chain
39968-06 Outer chain tensioner
942 Outer chain tensioner mounting screws; (2 pcs req'd.)
25244-99A Outer cover gasket
B148 Timken/Torrington inner cam bearing (2 pcs req'd)
top end gasket kit - Cyco, James, etc. (rocker box, breather, pushrod orings, lifter block, etc.)
OPTIONAL - 17025-03A breather assy (2 pcs req'd) - If you have the plastic breathers suggest replacing them with the new style.
25928-06 Cam spacer kit (contains the following items)
- 25731-06 Spacer (.110 for cam alignment; use as required)
- 25734-06 Spacer (.120 for cam alignment; use as required)
- 25736-06 Spacer (.130 for cam alignment; use as required)
- 25737-06 Spacer (.140 for cam alignment; use as required)
- 25738-06 Spacer (.150 for cam alignment; use as required)
Cam spacer (not part of above kit)
25729-06 Spacer (.100 for cam alignment; use as required)
25673-06 Crankshaft pinion shaft sprocket (17 teeth)
25728-06 Stock rear cam sprocket (34 teeth)
(2002-2006 only)
Camshafts of your choice to work with the '07-up cam plate.
Use of stock '06 sprockets on '99, '00 or 2001 conversion
cam installations will result in engine alarm light always ON!
Following part MUST be used with all '99, '00, '01 engines)!
216015 Andrews rear cam sprocket part number (34 teeth)
1.2b - HD SE Hybrid conversion - Replaces cam plate, tensioners, primary drive, and oil pump and reuses stock secondary chain and cams or stock compatible replacements. All parts are available from HD. Thanks to PatrickP for the SE pics!
Parts List - (HD items)
HD Part no. - Description
25284-11 Cam Plate Kit
25285-08 Cam Spacer Kit
17045-99D Cam Service Kit (gaskets, o-rings, etc)
25533-99A Cam Drive Retainer
0924-0011 Roller Bearing for Rear Cam
B148 Timken/Torrington inner cam bearing (2 pcs req'd)
Camshafts of your choice to work with the SE cam plate.
2. SPECIALTY TOOLS REQUIRED
The specialty tools are available from several sources. I found Heartland Products to have a good product at less cost than others.
http://mbsmfg.com/hadato.html
- TC cam/crank locking tool - original style (1999-2006 softail)
- TC cam tensioner release tool
- TC inner cam bearing remover
- TC inner cam bearing installer
- Oil pump alignment screws (also used to align lifter block on Evo)
This tool is available from George's Garage or other sources.
http://georges-garage.com/tc_engine_2.htm
- TC cam/crank locking tool - new style (2007-up softail) - item no. 320620
Tools required for the SE hybrid option
- TC cam and outer bearing remover/installer tool
3. HOW TO - CAM TENSIONER UPGRADE
This section includes only items that are not in the service manual or tips for clarification. Follow the service manual for the proper steps. In addition to the service manual for your specific bike you will need a 2006 or later Dyna or 2007 or later Softail or touring service manual for some of the installation information.
These items are in no particular order. These are suggestions for the most part and document what worked for me during my project.
3.1 - On disassembly and assembly, work on one cylinder at a time. This eliminates the need to reposition each cylinder at TDC for some of the steps.
3.2 - Organize parts removed by front/rear cylinder, left/right, top/bottom, etc. Many of the parts on each cylinder are the same but have taken a set to their installed positions. If you reuse the lifters make a note of which lifter came out of which hole and how it is oriented. Be sure to put them back in their original positions.
3.4 - Drape a piece of aluminum foil over the frame below the cam cover. This will keep oil off the frame and clutch cable making cleanup easier.
3.5 - Replace all gaskets and o-rings.
3.6 - Use the specialty tools. Having the correct tools makes the job much easier. One exception is the cam tensioner release tool for the Andrews upgrade. The primary tensioner can be released using large vise grips and a small allen wrench or nail to hold the tensioner. This method may not work on the secondary tensioner but that step is not required with the Andrews upgrade kit.
3.7 - Replace the old plastic breather assemblies with the new style (metal) from HD. They are inexpensive.
3.8 - Drill out the holes in the rocker arm plate to allow oil to better drain away from the breather. See pictures.
3.8 - Clean and chase the threads in the crank case for the cam cover bolts. Four of these bolt holes are used for the cam bearing installation tool. WD40, Q-tips and one of the cam cover bolts work well. Check the installation tool’s thumb screws for damaged threads. The thumb screws should turn easily by hand.
3.8.1 - The Heartland inner cam bearing installer tool comes with the HD usage instructions. These call out for using a torque wrench to install the bearings to the correct depth in the crankcase. It is not necessary to use a torque wrench with the Heartland tool. Drive the bearing into place with the tool. When the face of the driver head meets the crankcase the bearing is in the proper position. The driver screw will stop when it reaches this point. DO NOT force the driver any further. Use a flashlight and look over the top of the tool to see the position of the driver head. If the driver gets unusually tight BEFORE the bearing is seated, STOP and check for problems.
Loosen the driver screw about a half turn then remove the tool from the crankcase. The driver screw may feel tight when loosening. This is okay but DO NOT loosen the driver screw any further as damage to the threads will occur.
3.8.2 - When placing the new inner cam bearing on the installer driver head be sure the face of the bearing with the writing (mfg name, part no.) is facing the driver head. The rounded face of the bearing faces the crankcase.
3.8.3 - Optional modification to cam plate.
There is the potential for small oil leaks between the cam plate and the crankcase on five of the oil ports. One oil port already has an oring in the crankcase. The HD cam plates can be machined to accept o-rings to prevent the leaks. Contact Automotive Machine and Supply in Ft Worth, TX. Cost is about $30.
Cam plate oring mod example.
http://s471.photobucket.com/user/gtm.../2050.jpg.html
http://www.automotivemachine.com/
3.9 - Clean old thread locking compound from all bolts.
3.10 - New oil pump alignment. Follow the instructions in the 2006 or later Dyna or 2007 or later Softail or touring service manual. Those instructions are summarized here.
A. With the bike on a lift, place the transmission in 5th gear
B. Disassemble the oil pump and thoroughly coat all parts with engine oil or assembly
lube.
C. Install the oil pump.
D. Install the cam plate except do NOT install the bolts for the oil pump.
E. Loosely install the oil pump alignment screws into two diagonal bolt holes.
F. While rotating the engine via the rear wheel, alternately tighten the alignment screws to
45 in/lbs.
G. Install two of the oil pump bolts into the other two bolt holes and tighten to 45 in/lbs.
H. Remove the alignment screws and install the other two oil pump bolts and tighten to
45 in/lbs.
I. Tighten all oil pump bolts in a criss-cross pattern to 90-120 in/lbs.
3.11 - At each step of assembly, rotate the engine by hand via the rear wheel to ensure no parts are binding. DO NOT use the crank or cam sprocket bolts to turn the engine.
3.12 - DO NOT FORGET to install the anti-rotation pin in the lifter cavity.
3.14 - When installing parts, coat all parts liberally with engine oil or assembly lube.
3.15 - DO NOT guess at the cam/crank sprocket alignment. Follow the alignment instructions in the service manual and using the cam spacer kit from HD.
3.16 - Double check cam and crank timing marks. When properly installed, the cam shaft timing marks should face each other at the 3 o’clock (rear) and 9 o’clock (front) positions. When the cam sprockets are installed those timing marks should face each other at approximately 5:30 o’clock (cam) and 11:30 o’clock (crank) and the cam timing marks should still be at 3 and 9 o’clock. The rear cylinder should be at TDC (top dead center) on the compression stroke. You can now work on the rear cylinder.
To work on the front cylinder, the piston needs to be at TDC on the compression stroke. With the rear cylinder at TDC on the compression stroke, rotate the crankshaft one full turn clockwise plus 45 degrees (405 degrees total). Rotate the engine by hand via the rear wheel. DO NOT use the crank or cam sprocket bolts to turn the engine.
3.17 - Be sure to clear all oil and trash from all bolt holes. Installing a bolt with oil in the hole will probably crack the metal.
Pictures of upgrade project.
http://s471.photobucket.com/albums/rr79/gtmalone/cam%20tensioner%20upgrade/?albumview=slideshow
For pictures unique to the SE Hybrid option see this sub album.
http://s471.photobucket.com/user/gtm...0option?sort=9
ENGINE
DOCUMENT CHANGE HISTORY:
--- date --------- changed by ----------------- recap of changes
--------------------------------------------------------------------------------------------------------------------------
04/18/2011 --- gtmalone ---------------- document created
12/7/2013 ---- gtmalone ----------------- remove references to Herko/FlyingW (no longer providing kits)
5/3/2014 ----- gtmalone/patrickp ------ add info and pics for SE hybrid conversion option, add list of specialty tools
9/18/2014 ---- gtmalone ----------------- add note for reusing original lifters
11/10/2014 -- gtmalone ------------------ add parts lists, update specialty tool list
1/4/2015 --- gtmalone ------------------- add parts list for SE upgrade (thanks to HuskerSpringer!)
12/22/2015 -- gtmalone ----------------- add note for Andrews no longer offering kits
2/15/2016 - gtmalone -------------------- update parts lists for gaskets and inner cam bearings, remove reference to Andrews kit (discontinued)
2/15/2016 - gtmalone -------------------- update parts lists for gaskets, inner cam bearings, and breather assy, added step 3.17 to clear oil from bolt holes
4/28/2016 - gtmalone -------------------- update inner bearing installation method, Section 3.8.1 and 3.8.2, added text to corresponding pic. Added Section 3.8.3 for cam plate oring mod with corresponding pic
5/12/2016 - gtmalone -------------------- update 3.16 for TDC positioning on front cylinder
KEYWORDS AND KEY PHRASES
cam - camshaft - tensioner - shoe - hybrid
tensioner upgrade - hydraulic tensioner - cam shoe - cam chain - cam gear
APPLICABLE YEAR/MODEL
2000-2003 TwinCam
This tech tip written for 2000-2003 Heritage Springer but can be adapted for any TwinCam with the spring loaded cam chain tensioners.
1. TECHNICAL AREAS ADDRESSED
1.1 - The spring loaded cam chain tensioner shoes on Twin Cam engines can wear prematurely and may cause significant engine damage. There is no specific mileage range when this can occur. In addition, some year models may experience inner cam bearing failure also resulting in significant engine damage.
The cam chain tensioner mechanism was upgraded from spring loaded to hydraulic in 2006 for Dyna models and 2007 for Softail and touring models. This upgrade also included a high volume oil pump.
1.2 - This tech tip along with the appropriate service manual covers upgrading the cam tensioner mechanism and replacing cam shafts using one of the following options:
1.2a - 2007-up HD version - Replaces cam plate, camshafts, tensioners, and oil pump as used on 2007-up twin cam models.
Andrews has since discontinued the kit but does list the HD parts required for the conversion.
Additional info on Andrews site: http://www.andrewsproducts.com/image...on-99-2006.pdf
Parts List - (HD items)
HD Part no. - Description
26037-06 Oil pump assembly
25355-06 Cam support plate assembly
4741A Cam Support plate mounting screws; (10 pcs req'd.)
11461 Retaining ring (for front cam)
25683-06 Inner roller chain
39969-06 Inner chain tensioner
4740A Inner chain tensioner mounting screws; (2 pcs req'd.)
25675-06 Outer roller chain
39968-06 Outer chain tensioner
942 Outer chain tensioner mounting screws; (2 pcs req'd.)
25244-99A Outer cover gasket
B148 Timken/Torrington inner cam bearing (2 pcs req'd)
top end gasket kit - Cyco, James, etc. (rocker box, breather, pushrod orings, lifter block, etc.)
OPTIONAL - 17025-03A breather assy (2 pcs req'd) - If you have the plastic breathers suggest replacing them with the new style.
25928-06 Cam spacer kit (contains the following items)
- 25731-06 Spacer (.110 for cam alignment; use as required)
- 25734-06 Spacer (.120 for cam alignment; use as required)
- 25736-06 Spacer (.130 for cam alignment; use as required)
- 25737-06 Spacer (.140 for cam alignment; use as required)
- 25738-06 Spacer (.150 for cam alignment; use as required)
Cam spacer (not part of above kit)
25729-06 Spacer (.100 for cam alignment; use as required)
25673-06 Crankshaft pinion shaft sprocket (17 teeth)
25728-06 Stock rear cam sprocket (34 teeth)
(2002-2006 only)
Camshafts of your choice to work with the '07-up cam plate.
Use of stock '06 sprockets on '99, '00 or 2001 conversion
cam installations will result in engine alarm light always ON!
Following part MUST be used with all '99, '00, '01 engines)!
216015 Andrews rear cam sprocket part number (34 teeth)
1.2b - HD SE Hybrid conversion - Replaces cam plate, tensioners, primary drive, and oil pump and reuses stock secondary chain and cams or stock compatible replacements. All parts are available from HD. Thanks to PatrickP for the SE pics!
Parts List - (HD items)
HD Part no. - Description
25284-11 Cam Plate Kit
25285-08 Cam Spacer Kit
17045-99D Cam Service Kit (gaskets, o-rings, etc)
25533-99A Cam Drive Retainer
0924-0011 Roller Bearing for Rear Cam
B148 Timken/Torrington inner cam bearing (2 pcs req'd)
Camshafts of your choice to work with the SE cam plate.
2. SPECIALTY TOOLS REQUIRED
The specialty tools are available from several sources. I found Heartland Products to have a good product at less cost than others.
http://mbsmfg.com/hadato.html
- TC cam/crank locking tool - original style (1999-2006 softail)
- TC cam tensioner release tool
- TC inner cam bearing remover
- TC inner cam bearing installer
- Oil pump alignment screws (also used to align lifter block on Evo)
This tool is available from George's Garage or other sources.
http://georges-garage.com/tc_engine_2.htm
- TC cam/crank locking tool - new style (2007-up softail) - item no. 320620
Tools required for the SE hybrid option
- TC cam and outer bearing remover/installer tool
3. HOW TO - CAM TENSIONER UPGRADE
This section includes only items that are not in the service manual or tips for clarification. Follow the service manual for the proper steps. In addition to the service manual for your specific bike you will need a 2006 or later Dyna or 2007 or later Softail or touring service manual for some of the installation information.
These items are in no particular order. These are suggestions for the most part and document what worked for me during my project.
3.1 - On disassembly and assembly, work on one cylinder at a time. This eliminates the need to reposition each cylinder at TDC for some of the steps.
3.2 - Organize parts removed by front/rear cylinder, left/right, top/bottom, etc. Many of the parts on each cylinder are the same but have taken a set to their installed positions. If you reuse the lifters make a note of which lifter came out of which hole and how it is oriented. Be sure to put them back in their original positions.
3.4 - Drape a piece of aluminum foil over the frame below the cam cover. This will keep oil off the frame and clutch cable making cleanup easier.
3.5 - Replace all gaskets and o-rings.
3.6 - Use the specialty tools. Having the correct tools makes the job much easier. One exception is the cam tensioner release tool for the Andrews upgrade. The primary tensioner can be released using large vise grips and a small allen wrench or nail to hold the tensioner. This method may not work on the secondary tensioner but that step is not required with the Andrews upgrade kit.
3.7 - Replace the old plastic breather assemblies with the new style (metal) from HD. They are inexpensive.
3.8 - Drill out the holes in the rocker arm plate to allow oil to better drain away from the breather. See pictures.
3.8 - Clean and chase the threads in the crank case for the cam cover bolts. Four of these bolt holes are used for the cam bearing installation tool. WD40, Q-tips and one of the cam cover bolts work well. Check the installation tool’s thumb screws for damaged threads. The thumb screws should turn easily by hand.
3.8.1 - The Heartland inner cam bearing installer tool comes with the HD usage instructions. These call out for using a torque wrench to install the bearings to the correct depth in the crankcase. It is not necessary to use a torque wrench with the Heartland tool. Drive the bearing into place with the tool. When the face of the driver head meets the crankcase the bearing is in the proper position. The driver screw will stop when it reaches this point. DO NOT force the driver any further. Use a flashlight and look over the top of the tool to see the position of the driver head. If the driver gets unusually tight BEFORE the bearing is seated, STOP and check for problems.
Loosen the driver screw about a half turn then remove the tool from the crankcase. The driver screw may feel tight when loosening. This is okay but DO NOT loosen the driver screw any further as damage to the threads will occur.
3.8.2 - When placing the new inner cam bearing on the installer driver head be sure the face of the bearing with the writing (mfg name, part no.) is facing the driver head. The rounded face of the bearing faces the crankcase.
3.8.3 - Optional modification to cam plate.
There is the potential for small oil leaks between the cam plate and the crankcase on five of the oil ports. One oil port already has an oring in the crankcase. The HD cam plates can be machined to accept o-rings to prevent the leaks. Contact Automotive Machine and Supply in Ft Worth, TX. Cost is about $30.
Cam plate oring mod example.
http://s471.photobucket.com/user/gtm.../2050.jpg.html
http://www.automotivemachine.com/
3.9 - Clean old thread locking compound from all bolts.
3.10 - New oil pump alignment. Follow the instructions in the 2006 or later Dyna or 2007 or later Softail or touring service manual. Those instructions are summarized here.
A. With the bike on a lift, place the transmission in 5th gear
B. Disassemble the oil pump and thoroughly coat all parts with engine oil or assembly
lube.
C. Install the oil pump.
D. Install the cam plate except do NOT install the bolts for the oil pump.
E. Loosely install the oil pump alignment screws into two diagonal bolt holes.
F. While rotating the engine via the rear wheel, alternately tighten the alignment screws to
45 in/lbs.
G. Install two of the oil pump bolts into the other two bolt holes and tighten to 45 in/lbs.
H. Remove the alignment screws and install the other two oil pump bolts and tighten to
45 in/lbs.
I. Tighten all oil pump bolts in a criss-cross pattern to 90-120 in/lbs.
3.11 - At each step of assembly, rotate the engine by hand via the rear wheel to ensure no parts are binding. DO NOT use the crank or cam sprocket bolts to turn the engine.
3.12 - DO NOT FORGET to install the anti-rotation pin in the lifter cavity.
3.14 - When installing parts, coat all parts liberally with engine oil or assembly lube.
3.15 - DO NOT guess at the cam/crank sprocket alignment. Follow the alignment instructions in the service manual and using the cam spacer kit from HD.
3.16 - Double check cam and crank timing marks. When properly installed, the cam shaft timing marks should face each other at the 3 o’clock (rear) and 9 o’clock (front) positions. When the cam sprockets are installed those timing marks should face each other at approximately 5:30 o’clock (cam) and 11:30 o’clock (crank) and the cam timing marks should still be at 3 and 9 o’clock. The rear cylinder should be at TDC (top dead center) on the compression stroke. You can now work on the rear cylinder.
To work on the front cylinder, the piston needs to be at TDC on the compression stroke. With the rear cylinder at TDC on the compression stroke, rotate the crankshaft one full turn clockwise plus 45 degrees (405 degrees total). Rotate the engine by hand via the rear wheel. DO NOT use the crank or cam sprocket bolts to turn the engine.
3.17 - Be sure to clear all oil and trash from all bolt holes. Installing a bolt with oil in the hole will probably crack the metal.
Pictures of upgrade project.
http://s471.photobucket.com/albums/rr79/gtmalone/cam%20tensioner%20upgrade/?albumview=slideshow
For pictures unique to the SE Hybrid option see this sub album.
http://s471.photobucket.com/user/gtm...0option?sort=9
Last edited by gtmalone; May 12, 2016 at 12:38 PM.
Thread Starter
|
Tourer
Joined: Nov 2015
Posts: 497
Likes: 187
From: Dallas area
Added section 3.8.3 for cam plate mod to add orings to oil ports.
Cam plate oring mod example. More details first post.
http://i471.photobucket.com/albums/r...grade/2050.jpg
Cam plate oring mod example. More details first post.
http://i471.photobucket.com/albums/r...grade/2050.jpg
Last edited by gtmalone; May 12, 2016 at 12:39 PM.
Club Member
Joined: Oct 2011
Posts: 11,175
Likes: 2,483
From: Nor Cal
Go back to your original
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