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From 1999 to 2005, Harley Twin Cam TC and TCb motors had maintenance-prone spring tensioners on the cam chains.
From 1999 to 2005, Harley Twin Cam TC and TCb motors had maintenance-prone spring tensioners on the cam chains.
Harley never addressed the issue, issued a recall, or officially established a maintenance schedule for the tensioners.
Some Dyna models started receiving hydraulic tensioners and roller chains in 2006, and by mid-year, all Dynas were getting them.
In 2007, all models were getting them.
Multiple choice on your thoughts regarding the early TC tensioner issues (select all that apply):
No AI. Your experiences and opinions....
Info from my experience and others on here.
From the HDFORUM USERs
My tensioner at 30K. Bike rarely ran over 3000 on tac. Never been WOT by me. My tensioner at 30K. Bike rarely ran over 3000 on tac. Never been WOT by me. My tensioner at 30K. Bike rarely ran over 3000 on tac. Never been WOT by me. Link chain cam sprocket. Unsure of source. Roller chain cam sprocket. Unsure of source.
[img alt="HDFORUM USER on here with aftermarket hydraulic tensioner and didnt replace cams to get roller chain on back tensioner.
Think he had less than 15K on them."]https://cimg1.ibsrv.net/gimg/www.hdforums.com-vbulletin/1024x766/tensioners_outer_roller_inner_link_chain_2420db260 715aa2f6c627223d676f73eb56e3b0b.jpg[/img] HDFORUM USER on here with aftermarket hydraulic tensioner and didn't replace cams to get roller chain on back tensioner. Think he had less than 15K on them.
HDFORUM USER. Wear from the link chain. It never stops wearing. HDFORUM USER. Roller chain at 90K. You can see the roller touching. Wear practical stops then in this USER's opinion. HDFORUM USER. Roller chain at 90K.
Service limit for the link chain. The hydraulic tensioner service requirement is different. Service manual.
Last edited by Jackie Paper; Apr 27, 2026 at 07:50 PM.
Light wear at 19k. Replaced the OEM pads with Cyco pads and all is good. It's just a maintenance item plain and simple Just like many other items on motorcycles. Take care of them and they take care of you.
So, there was no vote option for my situation.
Last edited by MarlinSpike; Apr 27, 2026 at 07:37 PM.
Light wear at 19k. Replaced the OEM pads with Cyco pads and all is good. It's just a maintenance item plain and simple Just like many other items on motorcycles. Take care of them and they take care of you.
So, there was no vote option for my situation.
Thank you. I have yet to see a update on the Cyco pad and if pad outlast a OEM spring tensioner pad. Not even sure you can get a OEM one from Harley dealer.
Been watch for years. Ever winter from 2012, I had planned to replace my original since they eventually will probably get brittle but by the time we got back from down south, it was time to ride.
When and if ever my son licenses the bike, we will replace them. I know he's not going to ride like I did for the first 50k.
Last edited by Jackie Paper; Apr 27, 2026 at 08:04 PM.
Replaced tensioners on my wife's '05 Dyna at 25,000 miles. Rear one showed some wear. Used H-D's "hybrid" kit (actually made by Andrews, relying on the aftermarket to save their bacon, and then taking credit for it), and also replaced pushrods with adjustables. For some, gear drive was the solution (not listed in your poll).This is typical of the bullshit engineering from the Moco, just like the base gaskets and INA cam bearing on the previous Evo engines. Once these are addressed, the bikes are pretty bulletproof. I have 3 generations of H-Ds (including an AMF Shovel), all of which run better than when new.
M-8's have had their own gremlins too...H-D never gets it right the first time.
My 2001 bike I changed at 30K miles. My 2005 bike changed at 40K miles. Both showed plenty of wear and needed to be changed. The 2001 pads were brittle and cracked easily after they were out. No catastrophic fails luckily and now all is good. Went back with stock setup w/Cyco pads on both. I will re-check both after 20K more miles. Note: my 2014 bike (sold) had 60K miles on it and never opened the cam chest.
Thank you Rob Harper.. @Rob Harper That kind of knowledge information from USERs here that do there own work is very valuable.
Looking forward seeing that 20k on the Cyco. How many years did it take the 2001 to get brittle? Do a lot of hot weather driving it?
I am looking for someone on here to supply a couple dimensions from a late model roller chain. I need the roller diameter and the height of the link. Trying to determine how deep the link will groove in the tensioner before rollers roll.
The wear spec on the late model trnsioners is stated differently.
Know on car motors I have overhauled, once links groove in, rollers roll and wear stops. They easly last the life of the motor but the shoes are bigger and Toyota's was hard black rubber.
Harley's little tensioner is not very thick.
Last edited by Jackie Paper; Yesterday at 08:30 AM.
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From 1999 to 2005, Harley Twin Cam TC and TCb motors had maintenance-prone spring tensioners on the cam chains.
