I know this topic has been beat to death, so dont kill me. Im just looking for your opinion on whats best.
I have an '04 fatboy with 20k miles. Im guna replace the cam tensioners this winter because they look worn.

From what I understand, I have 3 options.
1. replace just the tensioner pad with the same style but a better material (claims to be). cheapest option ($75), but will need to be checked in another 20k miles.
http://twincamtensioner.com/product/...tensioner-kit/
2. Hydraulic plate conversion. More expensive, but better wear life and higher oil flow. ($350)
3. Gear drive. Most expensive but will last life of bike. (right?) ($???)

I plan on doing it myself and dont necessarily want to break the bank. What option do you suggest?
Also, what else should I change while Im in there? Inner cam bearings and what else?
My buddy offered me his andrews 26g cams for free. I like the way the bike runs now and dont know if I should change the stock cams. Not to mention worse gas mileage, would it really give noticeable more hp? I ride in town and do lots of touring. But since Ill have it broken down, would it be worth it to put these in?

Whats everyones opinion? What works best/worse?
Changing just the tensioner shoe is cheap and seems to be the easiest. Plus, I wouldnt mind checking it every 20k miles since i would probably do it anyway with the other two options.
Thanks.
Heres a picture of my bike for dealing with a question that probably been asked 1000 times.

 

As you mentioned, the gear drive option is "the best" in terms of longevity of the fix...

There is one important caveat... you MUST have crank runout of .003 (some claim .004 is OK, too) or less to use a gear cam. Anything over that, and the gears will just self destruct over time.....

The '03+ cranks aren't as bullet proof as the '99-'02 cranks, so make sure to measure before buying the parts for gear conversion, if you want to go that way...

I would strongly suggest that while you are in the cam chest, replace the inner cam bearings from the OEM, INA bearings to the Torrington (now Koyo-Torrington) bearings. Those bearings are a weak spot and worth changing when you are in the cam chest....

I did the '07+ cam plate upgrade on my '03 and it cost a bit more in parts than you have listed. I bought my parts from an online HD discount vendor (BoardTracker). The cam plate and new oil pump were $366. The new cam sprockets and new chains for the cams- $188. These new cam chains are one of the advantages of the cam plate upgrade, as you get the newer o-ring chains. Then you need to buy "conversion cams" that will fit the newer cam plate, but older engine case. I used Andrews 26N cams that I got for $257. I also replaced the inner cam bearings- $12.00, and I replaced the OEM lifters with Johnson-Hylift from WFO Larry (Larry's Motorcycle Machine)- $139. You might need a couple specialty tools, and a gasket set, etc.. I believe I was around $1K in parts... maybe a little less..

If you go Gear drive cams, you will need a set of "G" cams, and a gear drive kit They cost around $700, but you save the cost of the cam sprockets & cam chains ($188). And, I believe they make gear drive kits for '99-'06 engines and '07-'16 engines. If I remembered that correctly, you could use your current cam plate & oil pump... another $366 saved.

I've known many Twin Cams with the hydraulic lifters and o-ring cam chains ('07+) that have gone 50K-70K miles with no work needed in the cam chest... If you go gear drive, or '07+ cam plate conversion, you will have no need to check the tensioners every 20K miles, unless you are really bored...

Good luck with your decision & the repair...

 

Checked mine at 30K , looked like New , I'll check-um again at 50K ,.

 

 

Good point....!!!

OP, if you are going to use adjustable pushrods, never mind this tip.... But I used fixed pushrods and removed my rocker box covers to get the pushrods out. While in there, I switched to the new style breathers... that's a worthwhile (and cheap) update if you are in the rocker boxes...

 

Drill those oil return holes in the rocker plate as well.

 

Allot depends on your budget and how long you plan on keeping the bike...
With that said hattitude hit the nail on the proverbial head.
My old 01 was a stepping stone bike, I was going to go for broke and put the gear drive in.
A buddy talking me out of it.
I bought the gasket set, pulled her appart, used CYCO shoes and tool.
I think I was around $125 for everything and Friday night after work and by Saturday afternoon it was back together.
Last time I talked to the guy that bought her she was doing great, he checks them every 20.
The spring rate is what kills the shoes along with the chain edges (some are sharper) some have more pressure than others.
My 01 had 40,XXX on her and the shoes were 2/3 wore out (but brittle).

 

 

thanks for the help guys. finally got around to ordering stuff.
i dont mind checking every 20k miles and dont want to spend too much. so i decided to go with the cyco pads, the tool and adjustable pushrods.
ive read to change the inner cam bearings to the torringtons. anyone have any thought to this? or a link to the part?
my buddy has a hydraulic press, so getting the cams out should be ok.
do the andrews 26g cams only work with gear drive or would it work with the original set up? ive got the power commander III, so im tempted to swap my buddys cams in if he hasnt sold them yet.

 

No, can't use them with original chain set-up