Ok, don't please don't pound on me, I have searched the threads for 3 days but cannot find anything specific to my dilemma..... I have a 2003 stock Ultra, 75,000 miles, I pulled the rockers, push rods, lifters and cams to replace my worn out chain tensioners. Put everything back together, lined all the timimg marks up but the bike will not start. It acts like the timig is off, but I have taken it all back down 4-5 times, re-lined it all to no avail. I even tried to rotate the crank in case I was off 180 degrees (like an automobile)..... What am I missing??? I have the manual, am a decent wrench but admit I know little about the V twin from a mechanical standpoint. Bike was running great before and I didn't change anything out just went back with the stock parts except the new tensioners. Please give me some guidance so I don't have to drag this thing to the stealer and pay someone $1,000's just to fix what should be a simple thing. Thanks in advance or any help and advice!!!

(I wanted to add, do I need to get one cylinder up on TDC? The manula doesn't specify at all. When all the marks are lined up; cams and gears, should one of the cylinders be up on TDC? I know on older Chevy's you would get #1 cyl up on TDC of the firing stroke, line the timimg marks up and you were good to go. I have no clue where the pistons would be in relation to the marks being lined up on the V twin....)

 

Just so you know someone is sharing your pain, I have read through my Dyna manual. The crank position is determined by the flat which the crank sprocket fits on and cam position is determined by the key in the camshaft. So with the timing marks on the two sprockets in line it seems to me the engine is timed.

By following those instructions in the manual it seems to me you are setting engine timing. I cannot see any way of getting that part wrong! That was how the engine was first built. Perhaps something else is not right?

Hopefully someone else with first-hand experience will call by.

 

I win the "dumbass of the forum" award....I got back on it early this morning, pulled it back down and sure enough, the rear cylinder push rods were reversed.....! What a frigging idiot I am! I guess that's what you get for trying to put it back together into the wee hours, tired as hell and not thinking with a clear head. I did everything by the book, marked everything, etc. but I guess my mind was cloudy since it was 2 AM when I installed the push rods and rockers. Thanks for all the help and advice.....she's running like a champ now!!

Grbrown, if you're going through something similar, check the push rods, I swear I would have never dreamed I installed the one cylinder backwards!

 

Brilliant! Well done. At least you diagnosed and fixed it yourself. I just happened to have my Dyna manual in view when I read your post, haven't actually done any engine work on it myself, so I am just an armchair mechanic!

Best wishes from across the pond.