Harley Twin Cam Chain Tensioner Replacement with Push Rod Removal Complete - Part 1

Today we will be replacing the cam chain tensioners on this 2003 100aniv twincam. This will be done by the book with push rod removing them from the top, not with bolt cutters. At the time, the extent of wear was not apparent and is seen on the video as we open the cam cover. This bike already has the tank and carb removed as part of other work, link available below. The only other Item to remove before getting underway is the exhaust, though an account is made of all special parts tools and seals needed.

The cam cover is removed, immediately checking for any broken tensioner material. If that was found this might be a whole other project, however none was found, though an inspection shows there to be significant wear on the secondary tensioner, and decent wear on the primary.

We will be doing the by the book method whereas the pushrods will not be cut but reused, so they will be removed from the top end, this only accomplished when both valved are closed on the given cylinder. the rocker assembly removed along with the pushrods allows for the lifter blocks and lifters to also be removed.

It was opted to remove the lifters for inspection, noting their positions before removal, rather than securing them into position. With all lifters removed, along with the spark plugs out and the transmission in 5th gear. The tire could rotate the engine to TDC as annotated by the markings. Then the outer cam chain bolts can be loosened with the tensioner locked in the open position with the special tool. Once the chain is removed, the first of two tensioners comes out. At this point the entire assembly holding the cams and oil pump can be removed. Note that I am also disassembling the oil pump from the unit. If not needed this is not required nor recommended.

Once the Unit is removed, the secondary tensioner can be removed with the secondary tensioner removal tool.

This brings us to part II, reassembly.

Twincam rebuild kit jgi-25244-99-k
Cam chain tensioner 39954-99a
Cam chain tensioner 39964-99a

#twincam #harleydiy #camtensioner