I am replacing the chain tensioners on a 2004 Ultra with 60,000 miles. I was able to easily replace the outside tensioner after I took the outside gears and chain off. I have the cam plate off the bike and the dual cams are still mounted to it. Is there a special procedure to remove and replace the inside tensioner while the cams and inside chain are still in the cam plate? I cannot get the tensioner off because it is sitting against the chain and the spring is under tension.
Thanks.

 

No. You must take the cams out of the plate. Its not hard and can be done without the zillion$ tools.

WARNING - if you do as I did and break your ride, don't blame me! Make sure to look and follow the setting directions in the service manual.

The cams can be 'tapped' out fairly easily with the proper socket and a non-maring hammer (plastic/rubber head). Just take youe time.

Once the cams are out the replacement is trivial.

You can 'smack' the cams back in, just like you took them out. But make sure you have secured the inner tensioner away from the chain (I used a nail). Again, just be patient. I kept the cam plate in my hands so that nothing was 'forced'.

4K miles after, everything still works fine (though you can read about my noise in another forum. But it had nothing to do with the tensioner swap.

...gene

 

you should replace both inner and outer bearings.

Ron

 

I agree you should change the bearings while you have it apart.

 

...yea, and before you do any of that, take all tension off the pushrods either by cutting the puchrods, or at the rocker arms, before removing the cam plate. And you dont have to remove the cams from the plate to replace the tensioner (but you do have to remove the cam plate with cams attached).....

THat system really should have been designed so you could replace the tensioner without all that other bullsh_it

 

I have a full set of tools to replace cams, bearings, tensioners and oil pump alignment pins. Would rent them out to you if you need. PM me if interested.

 

The special tools make it far easier. Just a thought regarding the offer above. I used a Harbor Freight press $90 to press out the cams and press them back in. Now I have it for all my buddies bikes too. Definitely repalce the bearings if yoau re in there. Torrington b 184 for the inner cam bearings if I remember correctly. You can borrow a bearing puller from Autozone for nothing with a credit card imprint. You can also use the ehat/freezer method for installing the outer bearings if you wish. Cam plate inthe oven, bearings in the freezer or vice versa, but I had a friend who had all the special tools. God bless the forums. Tkae your time and don't kink the yellow oring up for the oil pump. Use the oil pump alignment screws too. they only cost $20 at George's garage.