Cam chain tensioner failure
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5th Gear
Joined: Jul 2017
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From: Hawaii
Cam chain tensioner failure
my 2006 ultra classic has suffered the dreaded cam chain tensioner failure. I heard the clacking noise and had no oil pressure. Now that I have researched it, I realize that I should have gotten the tensioner checked and replaced long ago. I've opened the cam cover and found a loose pin, a bent tensioner, and a broken piece of black plastic. I don't see the orange plastic shoe anywhere.
Wondering what people think is the best fix at this point. Should I change to the hydraulic tensioner with the kit from Harley? Is it better to change to a gear drive mechanism? Do I have to do anything to make sure the plastic bits and pieces are not somewhere stuck in the engine?
I assume I have to take out the push rods and lifters regardless of which fix I choose. Do I need a special tool to push out (and back in) the cams?
thanks for the advice.
Wondering what people think is the best fix at this point. Should I change to the hydraulic tensioner with the kit from Harley? Is it better to change to a gear drive mechanism? Do I have to do anything to make sure the plastic bits and pieces are not somewhere stuck in the engine?
I assume I have to take out the push rods and lifters regardless of which fix I choose. Do I need a special tool to push out (and back in) the cams?
thanks for the advice.
Popular Reply
Jun 11, 2018, 07:15 PM
Elite HDF Member
Joined: Nov 2013
Posts: 4,377
Likes: 647
From: Santa Clarita
Before you start getting swept away by all the dreamy things you can do with that engine, you' best get back to the basics and come up with a plan to get all that plastic and metal shavings outta that motor!
Tourer
Joined: Nov 2013
Posts: 475
Likes: 55
From: SC
Friend of mine just put a S&S 509 gear drive cam in his 05 ultra, he says it is a huge difference, great torque all through the rpm range. If it was me, i would do a gear drive cam while you are in there, not further concerns with tensioners
Elite HDF Member
Joined: May 2007
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From: Bear Flag, lower end
I did the S&S gear drive with 510 cams on my 04 RK ten years ago. Been running fine for 75,000 miles since, had 15,000 at install.
Elite HDF Member
Joined: Nov 2013
Posts: 4,377
Likes: 647
From: Santa Clarita
Before you start getting swept away by all the dreamy things you can do with that engine, you' best get back to the basics and come up with a plan to get all that plastic and metal shavings outta that motor!
Seasoned HDF Member
Joined: Jun 2017
Posts: 5,315
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From: Granville New York
Yes what veekness said and before you place that order for those gear drives you might want to measure your crank runout, .003 or less for gear drives...hope it works out for you
Seasoned HDF Member
Joined: Sep 2008
Posts: 14,158
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From: San Diego, CA
I hate to be the one to say it, but..... you lost oil pressure, heard clacking noise, and destroyed your cam tensioners... Make no mistake.... you had a major engine failure...
Without seeing the damage first hand, I can't give good advice other than.... If you put your motor back together, without getting ALL the destroyed pieces out of the engine, you run the risk of destroying all your new parts.... and having to do it all again. AND you need to find any collateral damage caused by those pieces before you shut the engine down.
Many will tell you it's time to pull the engine and split the cases to ensure you have them flushed out properly, inspect all, and probably do a rebuild.... some may say time for a remanufactured engine... and there are those who may say to just flush and reassemble with new cam plate, oil pump, oil pan, etc....
Converting to hydraulic tensioners or gear cams is in your future, but there are many things to deal with and decide on, long before that....
If you have a Dealer/Indy/Competent gear-head friend, who's opinion you trust, it's time to get their advice.....
Sorry for your misfortune but good luck on the repair....
Without seeing the damage first hand, I can't give good advice other than.... If you put your motor back together, without getting ALL the destroyed pieces out of the engine, you run the risk of destroying all your new parts.... and having to do it all again. AND you need to find any collateral damage caused by those pieces before you shut the engine down.
Many will tell you it's time to pull the engine and split the cases to ensure you have them flushed out properly, inspect all, and probably do a rebuild.... some may say time for a remanufactured engine... and there are those who may say to just flush and reassemble with new cam plate, oil pump, oil pan, etc....
Converting to hydraulic tensioners or gear cams is in your future, but there are many things to deal with and decide on, long before that....
If you have a Dealer/Indy/Competent gear-head friend, who's opinion you trust, it's time to get their advice.....
Sorry for your misfortune but good luck on the repair....
Last edited by hattitude; Jun 11, 2018 at 10:51 PM.
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From: Wisconsin, USA
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From: PA
I hate to be the one to say it, but..... you lost oil pressure, heard clacking noise, and destroyed your cam tensioners... Make no mistake.... you had a major engine failure...
Without seeing the damage first hand, I can't give good advice other than.... If you put your motor back together, without getting ALL the destroyed pieces out of the engine, you run the risk of destroying all your new parts.... and having to do it all again. AND you need to find any collateral damage caused by those pieces before you shut the engine down.
Many will tell you it's time to pull the engine and split the cases to ensure you have them flushed out properly, inspect all, and probably do a rebuild.... some may say time for a remanufactured engine... and there are those who may say to just flush and reassemble with new cam plate, oil pump, oil pan, etc....
Converting to hydraulic tensioners or gear cams is in your future, but there are many things to deal with and decide on, long before that....
If you have a Dealer/Indy/Competent gear-head friend, who's opinion you trust, it's time to get their advice.....
Sorry for your misfortune but good luck on the repair....
Without seeing the damage first hand, I can't give good advice other than.... If you put your motor back together, without getting ALL the destroyed pieces out of the engine, you run the risk of destroying all your new parts.... and having to do it all again. AND you need to find any collateral damage caused by those pieces before you shut the engine down.
Many will tell you it's time to pull the engine and split the cases to ensure you have them flushed out properly, inspect all, and probably do a rebuild.... some may say time for a remanufactured engine... and there are those who may say to just flush and reassemble with new cam plate, oil pump, oil pan, etc....
Converting to hydraulic tensioners or gear cams is in your future, but there are many things to deal with and decide on, long before that....
If you have a Dealer/Indy/Competent gear-head friend, who's opinion you trust, it's time to get their advice.....
Sorry for your misfortune but good luck on the repair....
Thread Starter
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5th Gear
Joined: Jul 2017
Posts: 9
Likes: 0
From: Hawaii
Thanks for the advice. I've started the project in my own since my trusted independent Harley mechanic has had some issues. I've gotten the rocker box covers off, the rockers off, the push rods and lifters out, and drained the oil. Found some pieces of plastic in the cam box. Found metal debris in the oil.
my next plan is to pull the pistons and get the cam plate off so I can get to the oil pump. I assume I need to see if there is debris in the pistons and the cylinders.
This might sound dumb, but do I have to replace the oil pan? How do I "flush" things out? I was planning on wiping everything clean but are ther other tricks and tips?
my next plan is to pull the pistons and get the cam plate off so I can get to the oil pump. I assume I need to see if there is debris in the pistons and the cylinders.
This might sound dumb, but do I have to replace the oil pan? How do I "flush" things out? I was planning on wiping everything clean but are ther other tricks and tips?