Motorcycle Repair: Gear Drives for TC-88, train noise, catastrophic failure


Question
2001 FLHR-I  43,000 MILES Very regular service only have had cam and crank sensors (electrical) replaced this past year.  Starting to hear "valve train noise"-getting louder.  My suspicions are that the cam tensioner shoes are junk and I am afraid of a catastrophic failure.  I contacted the local h-d shops and both of them said this needs to be checked.  I have a shop manual, and nowhere does it have this item as a service item.  I guess the moco wants these two small parts to drive in more service..  I have done some research, and am thinking about a gear drive set up.  Bob Wood has a direct swap out (TW 6 G) that is close to stock but requires no special springs or head work.  I just want to fix the tensioner thing once and for all.  If I go to gear drives and the new cams, will I have to remap the ecm ( another 150 )?  Need your opinion

Answer
You are right. There is no regular service to the cam tensioner, but somthing that is rubbing is going to wear out.
There are advantages and disavantages to the direct drive. The advantages are no cam tensioner, no lash due to no chain. The only disavantage I can think of is it is a little louder than normal.
If you are going to a cam set that is the same or very close as stock then you will not have to remap since the cams open and close the valves at the same time and at the same heigth.
Good luck and happy riding
Mike