harleydavidsontensioner.com
Note: All manufacturers names, numbers, symbols, trademarks and descriptions are used for reference purposes only.
It is not intended or implied that any product listed is the product of these manufacturers.
Our literature contained herein is compiled to the best of knowledge from reliable sources and we
cannot be liable for any possible errors

Harley Davidson Tensioner (Fits 1999-2005 Twin Cam Engines)

Cyco Gaskets & Manufacturing Link

6000 Lakeshore Road, Fort Gratiot, Michigan, 48059 (800) 777-6974, 810-385-9300

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Mechanic's Corner ( Latest Buzz)

Engineers at Cyco gaskets have recently developed the inner and outer cam chain tensioner service item

for Twin Cam engines from 1999 through 2005. Tensioner pad, pin and install tool

The Test

Cyco test vehicle was a 2001 DYNA with 13,000 miles on the original OEM cam chain tensioners.

We ran another 13,000 miles on the CYCO tensioners to duplicate the miles and conditions. Motorcycle

was run on full chassis dyno. Engine temperature range was from 230 degrees to 250 degrees at the base of the "V".

Cylinder Head temperature ranged from 320 degrees to 350 degrees at spark plug area.

The test was run with H-D 360 20w50 conventional (non-synthetic) oil.

We ran the Harley Maintenance schedule of oil changes at 5000 miles.

Results

Our CYCO chain tensioner pads exceeded the OEM tensioner pad utilizing a high performance Polymide-Stanyl that

surpasses all other plastics in high pressure-velocity (PV) situations for timing chain tensioners.

It simply withstands the demanding conditions for a longer period of time. The Cyco tensioner pads

have lower creep and lower fatigue especially at high temperatures and/or load (PV) conditions,

exceeding all othe engineered plastics. PA46 has the lowest coefficient friction of all other Polymide

based materials when lubricated with engine oil. Our tensioner pad gives you the best wear and fatigue

performance-substantially longer than the common commercial materials currently used (OEM).

This is extremely important when chain slap starts causing pitting wear. Installing the tensioner pad is

easy utilizing the tool made by Cyco. The tool easily removes old tensioner pin and allows for the

installation of new pad and pin. ( Our pin is customed made to allowed for peening)

Here is link for on how to use tool: click here

Here is a good link for Installing and checking shoes: click here

Installation of new Tensioner shoes (Should be done by qualified Mechanic)

Note: Tool has two reaches for front and rear tesioners

Removing of old pin and shoe. Place old tensioner on the longest pin (center) of the CYCO tool. Rotate tensioner to until shoe pin

rests on bored pin of same reach. Drive pin out and remove old shoe.

Installing new tensioner. Place pin and shoe in old assembly. Place new assembly with headed part of pin down.

Rotate until it rests on solid pin of tool. PEEN.

Install Tool # 9905T

Repair Kit # 9905

Spare Pins # 9905P

Spare Shoe # 9905 Shoe

Gasket Set to finish job - Quick Change Twin Cam 99-on
Cyco Gaskets & Manufacturing Link

Primary Cam Drive Chain Tensioner

Replaces OEM# 39954-99
Fits:
1999-2005 Harley Big Twin models

Secondary Cam Drive Chain Tensioner

Replaces OEM# 39964-99
Fits:
1999-2005 Harley Big Twin models

Note: All manufacturers names, numbers, symbols, trademarks and descriptions are used for reference purposes only.
It is not intended or implied that any product listed is the product of these manufacturers.
Our literature contained herein is compiled to the best of knowledge from reliable sources and we
cannot be liable for any possible errors

Issues
Next came the chain tensioner issue, and this is why don‘t worry about mileage.
There are motors with 2000 miles on them with two broken or worn tensioners.
Some motors with 75K on them have virtually no wear whatsoever on the tensioners.
The way you ride or what oil you use doesn’t necessarily have anything to do with wear on the tensioners.

One possibility could be on how the cam chain itself is worn. The pitch on the cam gears can vary
from bike to bike or more so cam to cam. When the gear pitch varies the cam chain will wear prematurely
and can cause the chain to develop burns and cause the chain to stiffen up. This can eat into the oem soft phenolic cam chain tensioner shoes like a chain saw. Replacing the cam chain if you experience any wear on the
tensioner itself definetly helps

Another thing you should do is inspect the oil pump for scratches on the return side of the pump,
because once you have any wear on the internal engine components the oil pump on the
Twin Cams can really suffer. Remember the Harley motors are really dry sump motors like what racecars have.
The oil is held in a remote location, and if the pump gets worn or has any scratches in the return side,
the motor will retain oil and cause rapid power loss. It is recommend checking the cam chain tensioners every 10,000 miles.