Used Harley-Davidson for Sale - Twin Cam Buyer's Guide

Initially the hardcore Harley-Davidson Evolution owners were resistant to accepting the Harley-Davidson Twin Cam, much like the diehard Shovelhead riders were resistant to the Evos 15 years prior. We are all passionate about our Harley-Davidsons and often have trouble accepting design changes. In most cases, mechanical and design changes or upgrades are intended to be changes for the better. As we know, this is not always the case. When looking at ads for, Used Harley-Davidson for Sale, watch this video, Mike covers positive upgrades as well as common issues with Twin Cam models from 1999 to late model Twin Cams.

1999 – Used Harley-Davidson for Sale – know what to look for:
• 1st year of the Twin Cam for Touring & Dyna models.
• Spring style Cam chain tensioners are a terrible design. Prone to failure anywhere between 15k to 30k miles. Not remedied until 2007 (2006 Dyna models) when assembly was changed to hydraulic cam chain tensioners.
• 1999 to early 2000 did not have side load Cam plate bearing. It was a conventional ball bearing style which was prone to failure.
• Cam shaft had only 1 spline and woodruff key for locating Cam gear. Was not corrected until 2000 when the Cam shaft end was fully splined all around cam end.
• Still equipped with Evolution style front and rear brake systems.
• The 5 speed transmission does not begin to see upgrades until 2000 and later.
• 1999 to 2001 has Magnetti Marelli injection. Usually temperamental and difficult to repair with age.
• Magnetti Marelli injection. Very problematic. Idling issues.

2000/01
• 1st year Twin Cam motor for Softail models. However the Softail is equipped with a “B” motor. “B” stands for balanced. The bottom end of this motor has two balance assemblies. The balancers work well, but if the Softail has high miles, it has more parts & bearings that may need replacing during a motor rebuild.
• More parts = more cost
• Conventional wheel bearings are replaced with non-serviceable, sealed wheel bearings.
• 1st year of 4 piston brake calipers.
• CVO models are released with 95 Cu. in. engine.

2002
• Delphi fuel injection system. Far superior to the Magnetti Marelli injection. Easily tuned with quality tuner.
• Injection wiring harness was secured too tightly from the factory. Often resulting in broken wire at socket connector (2002 to 2006)
• Cartridge style, left side fork assembly on fairing models. Difficult to service & need specialty tools (2002 to 2005).
• Updated swingarm, Touring.
• Last year of the Timken engine main bearing.

2003
• No more Timken main bearing on crank.
• Issue with compensator nut loosening. Corrected by adding a .090″ shim beneath nut.
• CVO models are issued with a 103 stroker crank.

2004
• Changed from a 1 1/2″ belt to a 1 1/8″ belt which allows for a wider (140) rear tire. Can even stuff a 150 tire up in the rear fender with some light modifications; Touring.
• Updated speedometer allows owner to view possible trouble codes in odometer display.

2005
• Changed to 7mm valve stems with new style valve seals. Valve seals were prone to failure resulting in excessive oil consumption.
• 1st year for Dot 4 brake fluid.

2006
• Upgraded stereo system, Touring.
• 2 different injectors issued this year: 8° or 25° Important to know for tuning.
• Dyna models get hydraulic cam chain tensioners, 6 speed transmission, and revised compensator assembly.
• Softer clutch spring.

2007
• All models (except XL) now issued with a 6 speed transmission and hydraulic cam chain tensioners.
• 96 cu in engine
• Last year for throttle cables on Touring models.
• Compensator change leaves us with compensator issues for the next 4 or 5 years, ~2012.
• Poor gearing ratios. Have to ride, at least, 70 mph in order to use 6th gear.
• CVO models get 110 cu in engine. Known for issues with loose valve seats.
• Beginning of poorer quality crank assemblies.

2008
• Rear sprocket cush drive.
• 1st year for throttle by wire for Touring models. Some issues with original twist grip sensors.
• 1st year for ABS brake system & Brembo brake calipers.
• 1st year for 25mm sealed wheel bearings.
• New handlebar controls and switch housings.

2009
• New frame accommodates 180 rear tire.
• Poor transmission output bearing design. A plastic bearing cage is prone to failure. Was not corrected until around 2013.
• The touring engine is now supported by 4 rubber mounts.
• Better transmission gearing ratios.

2010
• Updated helical cut gears in 6 speed transmission.

2011
• Optional 103 engine from factory.
• Marginal quality lifters.

2012
• Compensator assembly is updated to the Screamin’ Eagle design.

2013
• Last year before frame change (Touring)

2014
• New frame. Touring
• Large radio infotainment screen display.
• Updated front end suspension
• Touring models issued as Twin cooled or with oil cooler.
• Early water pumps were prone to fail.

Some added notes when looking at Used Harley-Davidson for Sale ads – know what to look for:

1999 to 2001
• If looking to purchase a 1999 to 2001 Harley-Davidson Twin Cam, it is much more beneficial to purchase a bike that is carbureted rather than injected.

2002 to 2006
• Harley secured the wiring for fuel injectors too tight. This often led to damaged/broken wiring at the injectors. Sometimes hard to diagnose, as a wire would often break internally or pull back from its socket but the wire insulation would stay intact.

2006 (Dyna) to 2012/13
• Six speed transmissions had a poorly designed main bearing. Sometimes prone to fail in under 30k miles.

Watch all Buyers Guides:

HD Buyers Guide
1984-1999 Harley-Davidson Evolution Buyers Guide
Buying a Harley Knucklehead: What to Look For
Panhead for Sale: Buyer’s Guide
How To Buy Used Choppers
Used Sportster Buyers Guide
Ironhead XL 1957 – 1985 – What to Look for