Broken Rear Cam Bolt
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Joined: Oct 2009
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Broken Rear Cam Bolt
Has anyone had this happen on an 09 or newer 96 in with 255 cams
I purchased these cams from a forum member and installed them myself; I made a mistake when installing them; I reused the cam bolts instead of purchasing new ones. The motor ran great for about 10,000 miles. I started on a 5,000 mile trip and about 700 miles into the trip the motor started rattling; I pulled into the Harley Dealer for repairs and was told the bolt in the rear cam had come loose, $ 800.00 and I'm on my way again. " warranty void " Thats another story. I thought that was a lesson learned and moved on, but now 10 months later the bolt has come loose again. I removed the cam cover; the bolt was loose when I removed it, the bolt was almost broke into. any ideas on what is going on.
Thanks for any and all ideas. I may have overlooked something.
I purchased these cams from a forum member and installed them myself; I made a mistake when installing them; I reused the cam bolts instead of purchasing new ones. The motor ran great for about 10,000 miles. I started on a 5,000 mile trip and about 700 miles into the trip the motor started rattling; I pulled into the Harley Dealer for repairs and was told the bolt in the rear cam had come loose, $ 800.00 and I'm on my way again. " warranty void " Thats another story. I thought that was a lesson learned and moved on, but now 10 months later the bolt has come loose again. I removed the cam cover; the bolt was loose when I removed it, the bolt was almost broke into. any ideas on what is going on.
Thanks for any and all ideas. I may have overlooked something.
Seasoned HDF Member
Joined: Mar 2009
Posts: 24,730
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From: Snow Hill, NC
Over toqued to start with? metal fatigue... Cam not trued properly? Did you torque then loosen then check the trueness of both gears with a straight edge? i had to buy a .010 over spacer to get it true? Did you use locktite?
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I used red locktite; oiled both surfaces of the washer and head of the bolt, torqed to 15 lbs; backed it out 360* then torqued to 34 lbs. the spacing is as good as you can get, both gears were alined with a straight edge; rotated and checked for alinement again. it all looks good there is no visible reason for this to happen.
I can understand me making a mistake I am not paid to do this type of work. I took this to the harley dealer and had my work redone while on a trip. The installation I performed lasted about 10,000 miles before it broke. The Harley dealers work lasted about the same amount of miles before it broke again. The only thing I can come up with is the dealer reused the same bolt again; I don't think they would do that for the money I paid to have the repairs done while on the road; but who knows what other people will do with your money?
I purchased a new cam bolt kit with washers and bolts; a new snap on torque wrench to make sure of my torque settings. The work is no big deal it only takes a few hours for this repair; If this happens agian I may not be so lucky the next time; so for no damage has been done, the gear has stayed in place.I have caught it before things went way wrong.
I can understand me making a mistake I am not paid to do this type of work. I took this to the harley dealer and had my work redone while on a trip. The installation I performed lasted about 10,000 miles before it broke. The Harley dealers work lasted about the same amount of miles before it broke again. The only thing I can come up with is the dealer reused the same bolt again; I don't think they would do that for the money I paid to have the repairs done while on the road; but who knows what other people will do with your money?
I purchased a new cam bolt kit with washers and bolts; a new snap on torque wrench to make sure of my torque settings. The work is no big deal it only takes a few hours for this repair; If this happens agian I may not be so lucky the next time; so for no damage has been done, the gear has stayed in place.I have caught it before things went way wrong.
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The local dealer told me the cam bolt and a few other bolts on the motor are one time use bolts because of the hardness and stretch of the bolt; I personally don't understand the load or forces placed on this bolt, it pulls the cam gear up tight against the cam and spacer. the front cam is held in place with a "C" clip. For $7.50 I will never take a chance on the old bolts again.
Elite HDF Member
Joined: Jun 2007
Posts: 3,873
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From: NW Arkansas
The local dealer told me the cam bolt and a few other bolts on the motor are one time use bolts because of the hardness and stretch of the bolt; I personally don't understand the load or forces placed on this bolt, it pulls the cam gear up tight against the cam and spacer. the front cam is held in place with a "C" clip. For $7.50 I will never take a chance on the old bolts again.
Road Captain
Joined: Sep 2007
Posts: 742
Likes: 4
From: Twin Cities, MN
I know I'm late to the party, but....
Last June, after rebuilding the top end only, I was on a trip home to see the family. The bike was running well, but there were some noises coming from the motor, but not too loud; just some lifter-type noises - or so I thought. At certain speeds, the bike seemed to be more quiet, but these were 'sleeper' cams and all seemed okay.
I rode about 3.5 hours at highway speeds, with some county blacktop roads mixed in. Nearing my destination, I slowed to a near stop at a red light, then a gentle roll-on to pull out into traffic. EVERYTHING siezed up!!! WTF!
The local Harley shop came and picked me up - called them 5 minutes before closing - and they opened up the primary the next day (Saturday). They said the problem was not there, but the primary oil was low and black as Hell, but the issue was interior. Said somethine else was siezed-up inside, so I should take it back to the builder.
Back at home, I tore down the entire top end, but couldn't find a thing wrong - a lot of work for no reason! I then removed the cam cover, and saw the rear cam bolt protruding about 1/4"... when I went to turn it, it was broken like yours in the picture. WTF???
The rear cam came loose and was pinned against the fly-wheel... and was the cause for siezing up the motor. Took it to the builder, who installed the cams, and he was as shocked as I was. He replaced the cams, and cam installation kit, with new bolts, etc, as long as I would do the labor. (It was more than a fair deal!) Bike is fine now, and everything went together smoothe as silk, thankfully!!
I was only out the hour of labor the HD Shop charged. (The pick-up/ride home after closing was Free!!)
.
Last June, after rebuilding the top end only, I was on a trip home to see the family. The bike was running well, but there were some noises coming from the motor, but not too loud; just some lifter-type noises - or so I thought. At certain speeds, the bike seemed to be more quiet, but these were 'sleeper' cams and all seemed okay.
I rode about 3.5 hours at highway speeds, with some county blacktop roads mixed in. Nearing my destination, I slowed to a near stop at a red light, then a gentle roll-on to pull out into traffic. EVERYTHING siezed up!!! WTF!
The local Harley shop came and picked me up - called them 5 minutes before closing - and they opened up the primary the next day (Saturday). They said the problem was not there, but the primary oil was low and black as Hell, but the issue was interior. Said somethine else was siezed-up inside, so I should take it back to the builder.
Back at home, I tore down the entire top end, but couldn't find a thing wrong - a lot of work for no reason! I then removed the cam cover, and saw the rear cam bolt protruding about 1/4"... when I went to turn it, it was broken like yours in the picture. WTF???
The rear cam came loose and was pinned against the fly-wheel... and was the cause for siezing up the motor. Took it to the builder, who installed the cams, and he was as shocked as I was. He replaced the cams, and cam installation kit, with new bolts, etc, as long as I would do the labor. (It was more than a fair deal!) Bike is fine now, and everything went together smoothe as silk, thankfully!!
I was only out the hour of labor the HD Shop charged. (The pick-up/ride home after closing was Free!!)
.
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Road Master
Joined: Aug 2007
Posts: 838
Likes: 35
From: Northern California
I am finishing up a 96 to 103 conversion and I did cams, too. I purchased a kit from H-D that came with two new bolts/washers. I also purchased new sprockets and a new snap ring for the front cam. Followed the service manual regarding torque. The tool that locks the two sprockets together was invaluable!
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Road Captain
Joined: Sep 2007
Posts: 742
Likes: 4
From: Twin Cities, MN
I am finishing up a 96 to 103 conversion and I did cams, too. I purchased a kit from H-D that came with two new bolts/washers. I also purchased new sprockets and a new snap ring for the front cam. Followed the service manual regarding torque. The tool that locks the two sprockets together was invaluable!
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