Harley Davidson Twin Cam 88 Cam Chain Tensioner Upgrade Cost

If you’re a Harley Davidson enthusiast, you likely know the importance of regular maintenance, especially when it comes to the cam chain tensioner in your Twin Cam 88 engine. The cam chain tensioner plays a crucial role in your bike’s operation, and any issues with it can lead to severe engine damage. Knowing when to upgrade the cam chain tensioner and how much it will cost can save you from costly repairs in the long run. So keep reading and let’s dive into the Harley Davidson Twin Cam 88 cam chain tensioner upgrade cost!

Another upgrade worth checking out: Best Tuner for Harley 88 ci Engines: An Expert’s Picks

Table of Contents

What’s The Deal With Harley Twin Cam Motors?

Harley Davidson introduced the Twin Cam motor in 1999 as a replacement for the previous Evolution engine. The Twin Cam offered improved power and performance. However, it had a significant design flaw related to the cam chain tensioner which was not rectified until 2007. Harley Davidson then introduced hydraulic cam chain tensioners in their Twin Cam motors, starting with the 2006 Dyna models and extending to other models in 2007.

Why Do You Upgrade The Cam Chain Tensioner?

The principal reason for upgrading the cam chain tensioner is to prevent potential engine failure. The cam chain tensioner in the Twin Cam 88 engine is known for its design flaws. The stock tensioner has a tendency to wear out over time, leading to engine damage if not addressed promptly.

Harley cam chain tensioner exposed from an open engine casing. This particular image is the updated, hydraulic cam chain tensioner.

The cam chain tensioner’s failure is mainly due to the sharp edges on the outer plates of the original chains, which wear down the plastic tensioner shoes. The plastic particles then mix with the engine oil, causing low oil pressure and an increased chance of engine failure.

Keep reading: Harley Davidson Clutch Replacement Cost

Explanation Of The Harley Twin Cam Problem (Failing Cam Chain Tensioners)

The primary issue with the Twin Cam 88 engine is the design of the cam chain tensioner. The tensioner shoes, made of plastic, can wear down over time due to the sharp edges of the cam chains. This wear leads to plastic shavings mixing with the engine oil, clogging the oil pump, resulting in low oil pressure and potential engine failure.

This problem is particularly prevalent in Twin Cam 88 engines manufactured before 2007. Models produced after this year were equipped with a hydraulic tensioner that significantly reduced the rate of wear and the risk of engine failure.

second example of a worn cam chain tensioner, including a close up view of the cam plate.

How Much Does It Cost To Replace The Cam Chain Tensioner On An 88ci Motor?

The cost of upgrading the cam chain tensioner in a Twin Cam 88 engine can vary. If you opt to have the upgrade performed at a Harley Davidson dealership, you can expect to pay between $1200 to $2000, including parts and labor. These costs can be broken down into the hydraulic cam chain tensioner kit (around $500), a Spacer Kit, Cam Service Kit, and Drive Gear Retention Kit (around $220 together).

Keep in mind that this is the cost for the basic upgrade. Additional replacements of parts like cam bearings, cams, tappets, and pushrods can add another $500 to your final bill.

Should You Replace The Tensioner or Upgrade With an Aftermarket Option

While you can choose to replace the tensioner shoes alone, many riders opt for an upgrade to a hydraulic tensioner or even a gear drive system. The hydraulic tensioner lasts significantly longer than the original spring-loaded tensioners and is an excellent addition to an engine modified for improved performance.

However, if you want a completely maintenance-free solution, consider converting to a gear drive system. Although it’s more expensive and noisier, a gear drive system eliminates worries about chain tensioner failure or the chain coming loose.

On the topic of aftermarket options: Best Cam for 88 Cubic Inch Harley Revealed (+Buying Guide)

example of the failure point on harley davidson twin cam motors - the cam chain tensioner. This is prior to the hydraulic cam chain tensioner used in later models.

How To Know If Your Cam Chain Tensioner Is Failing

The only surefire way to determine if your cam chain tensioner is failing is to open the cam chest cover and visually inspect the tensioner shoes. This task takes about 15 minutes and can be performed yourself. If you see significant wear marks on the follower shoes, it’s time to replace them.

FAQs

What year did Harley start using hydraulic cam chain tensioners?

Harley Davidson began using hydraulic cam chain tensioners in 2006 for their Dyna models and in 2007 for the rest of the Twin Cam engines.

Can I just replace the tensioner shoes instead of upgrading to a hydraulic tensioner?

Yes, you can replace just the tensioner shoes, especially if your bike has low mileage and you’re comfortable checking the shoes regularly. However, for longevity and peace of mind, upgrading to a hydraulic tensioner or a gear drive system is recommended.

Can I perform the cam chain tensioner upgrade myself?

Yes, technically, if you’re a competent DIY mechanic, you can carry out the upgrade yourself. However, it’s a complex task, and if you’re not confident in your abilities, it’s best to have a professional handle it.

Keep reading: What’s Considered High Mileage For A Harley Davidson

In conclusion, upgrading the cam chain tensioner on your Harley Davidson Twin Cam 88 is not only a smart decision but a crucial one. It prevents your engine from serious damage and saves you money in the long run. Whether you opt for a hydraulic tensioner upgrade or a gear drive system, the peace of mind you gain is well worth the investment.