The two best options seem to be either gear drive cams (pricy and requires a straight crank) or the cyco shoes on stock tensioner arms (cheap and easy, but not sure if they're available for hydraulic upgrade).

 

I see an early spring, sticking up thru that mess! The whole system is contaminated, despite what H-D says! Years ago, H-D explained that a catastrophe like this, would be contained in the Cam Chest ONLY! Not True! Donny Petersen explained this Exact problem in a AIM article, 10/12 years ago? Donny said, it needs to be completely taken apart & inspected! No short cuts! Good Luck!

 

Got dam!

You showed me one I've never seen before. I'd pull the engine and do a complete rebuild AND R&R the pan and flush the passages.

 

Hey Durango, looking at the photo, I saw the end of the spring sticking up! When I went back, I noticed the Silent Chain (cheese grater), that's a 99 to 06 motor! If it was me, & that would never happen to me, I've known about this problem since 1999! If it WAS me, & I loved the Bike, & it was an 99 thru 02 with the forged crank, & they were true, i might go with the Gear Drive! Any other Scenario, I'd be going with the S&S 124T ! NO DOUBT !

PS, An Evo, would never do this !

 

Zipper's makes some pretty trick hydraulic tensioners as well:

http://www.zippersperformance.com/al...ensioners.html

 

I had an issue like this with my Buells primary chain when it got too loose. It wound up on itself and put a hole in my primary cover. I had to flush the trans a dozen times to get all the metal out. It sucks but you have little choice but to pull the motor apart and do it right. I wish you the best.

 

Yep this just confirms my decision to put the gear drives in sooner than later. Total tear down time.. sorry man.

 

Anyone gotta guess why the chain developed 2 ends?
Chain slack?
Chain "whip?"
Chain too tight?
Just worn out?

Or, are we blaming the chain adjustment device for the failure?

 

How could you have ripped those links into? There is nothing on the chain that looks like what grooved the cover out. How fast was it turning when it did that? How many miles?
Don't thing a Harley is an interference engine. Stock has valve reliefs in piston just for that.. Am I wrong?

 

I think your last guess is right. The adjuster wore out and failed causing the chain to break.