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I Love Harley Davidson, But You Must Know This.Here is the ignored elephant in the cornerThere is a potential major issue in the Harley Davidson Twin Cam engines.This is a statement of fact, not a bunch of wild guesses.Im not here to bash Mother Harley, but you should be educated to its causes, and possible solutions.Okay, what issue are we looking at Its a very serious one that is enough to alarm you.However, you can fix these defects and end up with a nice bike.Our objective today is to educate, and we are also going to outline some ways to fight back.Yes, even the new Harleys have serious, potential problems.Even the expensive CVO Custom Vehicle Operations bikes have issues not to be taken lightly.Here we go. The problem is the design of the cam chain system.It uses plastic shoes riding on the cam chains that can and do wear out.XUPUzY3ixg/0.jpg' alt='How To Install Rear Sprocket On Motorized Bike Engine' title='How To Install Rear Sprocket On Motorized Bike Engine' />2stroke 66cc80cc motorized bike kit with 26 bicycle power pipe Parts for Go Karts, Mini Bikes Go Kart Kit, Mini Bike Kit, Go Kart Frame, Mini Chopper Clutch, Wheels, Tires, Frames, Sprockets, Brakes, Spindles, Exhaust.Harley has made some changes in later model bikes, but even with the new hydraulic tensioning system, it is not a true fix.What is the problem The shoes rub against the two chains and the plastic shoes wear out.When they wear in extreme cases, there will be metal to metal contact and this grinding creates metal shavings that can result in a catastrophic engine failure.If not caught soon enough, this can be so bad that the entire engine can be destroyed cams, pistons, crankshaft and even engine cases broken.It is a wickedly serious possible engine problem.Be aware it can fail as soon 1.Even the newer hydraulic system can fail at 5.The cam chain tensioners have a section in every service manual that covers the Twin Cam engines and is very enlightening.If your pipes are loud, you may not hear or get any warning.The oil pump passages can clog up without making any noise whatsoever except when the engine starts tearing itself to pieces.The scary thing is every Twin Cam engine has the potential to have the cam chain follower issue, even the new models.Check things out before this happens to you.If it has a cam chains, it has the potential problem.It is our intent to make you aware that pre 0.Dynas and the 1. Twin Cam Harley Davidson engines have possible, serious issues and they can mess up.How In the most severe cases, as the spring loaded cam chain follower fails it shreds plastic material that fouls the rotary gear oil pump cutting off oil flow to the engine that can cause sudden catastrophic engine failure and destruction.Also, metal to metal contact in these shoes produces metal filings to disperse into the oil prior to being filtered by the oil filter.If this happens be prepared worst case to buy a completely new motor as rebuilding the engine may not be feasible.This is not a likely situation, but a realistic possibility.Are the 2. 00. 7 and newer, updated Twin Cam engines immune No.Do not be fooled.Hydraulic cam chain followers are now used to get rid of the stiff spring that put too much pressure on the followers rubbing on the cam chain, but this is no cure as it only delays the problem.Instead of the engine failing at 1.There is only one true cure getting rid of the chain system entirely and switch to gear driven cams.Harley Davidson should, in my opinion, make this a standard fix and not an after the fact option.If you cant afford to install the gear drive system, then you need to disassemble and inspect the inner and outer shoes every 1.The shoe material can also clog the oil pump destroying the engine.There are plenty of motorcycle magazines explaining how to fix this problem and they can fail beyond the factory warranty period.The problem has not been fixed only delayed to fail above 5.Check the fine print in your extended warranty as this cam chain related failure may not be protected.Dealers will tell you it is a failed maintenance issue unless you take the steps we suggest.You wont even get a straight, honest answer from Harley dealers regarding this engine defect.As I did research for this article, I called a local dealership, and the service writer would not answer my questions, and frankly gave me quite a song and dance, refusing to forward my questions and concerns to the mechanic or management.Disturbed and curious, I read a number of different service manuals, and while the drawing of what is good and bad with the cam tensioner shoes is published, there is no inspection interval listed.This leads me to believe Mother Harley knows a problem exists and Harley Davidson dealers are actively not giving straight answers to customers.How can they not have published inspection intervals The only mention of this possible failure is in the troubleshooting guide under Valve train noise.You will not hear any rubbing sounds or receive any indications the cam follower has failed even if you have quiet stock exhaust pipes on the bike.This is an issue that nobody wants to talk about, but is a real threat to your pocket book.OK, now that we have ruffled everybodys feathers, how can we combat this S S has truly been visionary in solving this issue.They had the foresight to develop a gear drive system to combat this very issue.It is my opinion, that all Twin Cam engines should have this conversion done, so you can rest easy on your higher mileage TC engines.The gear drive replacement is an excellent and the only true bulletproof solution.As an alternative to gear drive, our only choice would be periodic tensioner shoe inspection.While not outlined in any Harley Service manual Ive seen, looking at them and replacing as needed should be done every 1.There are nice pictures of what to look for, but no recommended inspection interval.If you decide not to go gear drive, this is emphatically recommended.This periodic inspection can make any future warranty claim valid.On earlier engines, an update to the later style hydraulic tensioners will relive pressures and delay required service, but periodic inspection is still recommended.Check things out before this happens to you.One way to help understand what may be happening inside your engine is to cut apart your oil filter at each oil change.Look through the pleats for any metallic or plastic debris.If you see junk, its time for your engine to come apart.You may be able to save your engines life by doing this.Another thing to consider is better oils.Todays better performing premium oils can delay the destruction.While a bit more expensive than conventional oils, oil is still cheaper than engine rebuilds.Here, synthetics, such as the Bel Ray Synthetic part number 9.Revtech MTP Synthetic part number 7.Lucas Synthetic part number 9.As we have a decent oil filtration system in our TC engines, a way to help the filter is to apply a magnet such as PN 7.This will help trap any metallic grunge that may be floating in our oil.Remember though, most of the bad stuff is plastic, and the magnet will not capture that.I have tried not to bash Harley regarding this, and Im sure they dont care about my opinions.It has been my objective here to educate, not to assassinate the dealer network.Being forewarned is to be forearmed.As we pointed out earlier, if you have a higher mileage TC, you might want to inspect the tensioners before they bite you.Motorized Bicycle From Scratch 8.Steps with PicturesIntroduction 7.Motorized Bicycle From Scratch.Hello again everyone In this instructable I will be showing you how to build a 7.The bicycle we will be building is far superior to kit motors in pretty much all areas, including speed minimum 3.EPA emission standards, and reliability.Lets get started PS sorry for the crappy quality video, Ill upload a better one at some point once I figure out how to do editing and stuff.Step 1 Part 0 Laws.Before you begin, it is a good idea to check the laws in your state or country, as motorized bicycles are not legal everywhere.Here are a few links to help you out http motorbicycling.Motorizedbicycle.Step 2 Part 1 Sources for Parts and Tools List.I have compiled a list of a few good sources from which to buy motorized bicycle parts.Affordablegokarts has an entire page dedicated to aftermarket parts specifically for 7.GTC makes a jackshaft which we use on our bike.MFG makes sprockets, chains, and mini hubs, among other things.Rebel Gears makes high quality custom motorcycle sprockets, allowing you to specify tooth count, chain size, center bore, mounting bolt pattern, color, and more.Amazon sells motorized bicycle gas tanks, and probably lots of other useful stuff.Custom Motored Bicycles sells a wide variety of parts for motorized bicycles, including a disc brake sprocket adapter.Orchard Supply Hardware, Home Depot, insert your local hardware store hereThese sell nuts, bolts, and steel shapes, as well as other useful stuff.Step 3 Tools List.Here is a list of the bare minimum of tools you will need to have access to.Other tools may be required depending on your situation.Drill Band Saw a grinder will work, but expect to go through at least a half dozen cutoff discs Grinder Oxy Acetylene Torch only needed for bending exhaust pipe, have someone do it for you if you dont have one Sockets Spanners Screwdrivers Taps Pliers Wire Cutters Utility Knife.Allen Keys. Step 4 Part 2 Choosing a Bike to Motorize.The first step and one of the most important in motorizing a bicycle is to choose a good bike to motorize.You cant just go slap a motor on any old bike and expect it to work, especially one as large and powerful as the motor well be using.A good bike to motorize has several key attributes, all of which must be fulfilled if the build is to be successful.I have outlined these attributes in the following steps.Step 5 Mini Parts List.Please note that I will not be going into detail on the more advanced bicycle repair stuff, such as how to replace a front fork or install a disc brake.If you do not know how, leave it to the professionals at your local bike store.Each mini parts list only covers one section of the instructable.Parts. Steel Frame Bicycle Disc Brake Front Suspension Fork Indestructible Wheels Puncture Resistant Tires and Inserts Grip Shifts Brake Levers Shift Cable Brake Cable Shift Cable Housing Brake Cable Housing Single Speed Conversion Kit.Tools. Allen Keys Pliers Wire Cutters Grinder optional, although you will need one later so might as well go buy one now if you dont have it already Lubricant tri flow, WD 4.Step 6 The Frame.First, the bike must have a large enough frame gap to fit the engine we will be using, which is the 7.This is a fairly large engine to be cramming into a bicycle, so as far as frame gaps go, the bigger the better.Remember that the pedals must still be able to turn after the engine is placed into the frame.The frame must not be made of carbon fiber, as carbon fiber will crush and splinter if we try to mount the motor to it.Aluminum is not great, but it will do if you dont intend to ride it much.Be warned that if you do use an aluminum frame, the frame will eventually develop cracks and break from metal fatigue.Steel is great, by far the best.Some specific frames that work well are the older models of the Trek 8.Trek 8. 20 frame with lots of aftermarket parts, this is one of the bikes I will be motorizing for this instructable and the older steel frame models of the Specialized Stumpjumper and Hardrock.Look for a 2. 1 frame or larger if they exist.Bear in mind that if you find a good frame with a bunch of junky parts on it, you can often swap out the other parts.Picture 3 is of the red and black bike before I stripped it down to the frame and rebuilt everythingStep 7 Good Brakes.One of the most important features of a motorized bicycle is good brakes.Because you will be going faster, you need more stopping power than an average bike.Id recommend getting a disc brake for the front, however you can not have any sort of disc brake in the back, as the sprocket that drives the bike will be mounted to the disc brake mount.In order to compensate for having normal although still good bicycle brakes on your bike, we will be setting up the engine in such a way that letting off on the throttle makes the engine act as a secondary brake.Pictured is the red and black bike, sporting a top of the line disc brake with a 2.The brake cost me just over 1.I did myself. Step 8 No Rams Horns You will want to avoid using a bicycle with rams horns or other handlebars with curved ends, as it will force you to use a thumb throttle instead of a twist throttle, the former of which makes your thumb get tired fairly quickly on long rides.If you have a road bike and dont want to spend the money on a new frame, however, there are workarounds.For example, I have a motorized road bike which has a thumb throttle and also has the rear shifter converted into a second throttle control that locks in place.Step 9 Wide Rear Hub Clearance.The rear sprocket will be mounted to a disc brake mount on the rear wheel, so we need enough clearance that the chain does not rub against the frame this will kill a bike frame very quickly.Step 1. 0 Crank Clearance.The cranks must be able to clear the engine and jackshaft once it is mounted in the bicycle.If you have a 2. 1 frame, this probably wont be an issue.Dont worry about not being able to put your feet on the pedals with the engine in place, we can extend the pedals with pieces of metal if necessary.Step 1. 1 Nothing on Top Bar.It is helpful, although not absolutely necessary, to not have cables running along the top of the top bar, as they get in the way of mounting the gas tank.If your bike does have cables on the top bar like the Trek 8.Step 1. 2 Sturdy Wheels.Because weight is not really an issue now that you wont have to propel the bike yourself, you should make sure to beef up the bikes wheels.They will be hitting bumps and rocks at much higher speeds than they normally would, and normal bike wheels wont hold up too well to prolonged riding. Super Duty Ball Joints Installed Games . I recommend getting wheels with 1.Double walled rims also help, but are not really necessary unless you plan to ride a lot.UPDATE 182. 01. After riding with the wheels in the first picture, I found them to not be strong enough for prolonged use.Therefore, I recommend using mag wheels such as teny rims.I now use mag wheels for all my builds.Step 1. 3 Rear Disc Brake Hub.You will need a rear hub with a disc brake mount.Step 1. 4 Good Tires.Get some puncture resistant tires.Also, try to choose thick tires with a lot of tread, as this will both reduce your risk of crashing and provide you with a more comfortable ride.Puncture resistant inserts and tubes are also good.Step 1. 5 No Rear Suspension.Rear suspension makes motorizing a bicycle much more complicated.Stay away from this unless you have built these bikes already and want a challenge.Step 1. 6 Front Suspension Fork.If you want a smoother ride, get a good front suspension fork.Optional but recommended.Remember youll be hitting bumps and potholes at 3.Step 1. 7 Part 3 Preparing a Bicycle for Motorizing.So, youve chosen a bicycle, now you want to slap a motor on it, right Hold on there, you still need to make several changes to the bicycle itself in order to prepare it for motorizing.Lets get started Step 1.Strip Everything Off the Handlebars.If your bike has anything other than grip shifts, youre going to want to take them off.If there are shifts built into the brakes, take off the brakes as well.If you have a grip shift on the left side, off it goes. |
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November 2017
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