Harley Twin Cam Years To Avoid [5 Years To Avoid]

In the world of motorcycles, few brands are as iconic as Harley-Davidson. Yet, even the most renowned have their share of less stellar moments. 

In this article, we will dive into the Harley Twin Cam models/years to avoid. 

While these motorcycles stand as monuments to Harley’s prowess in design and engineering, certain production years have proven to be problematic for riders. 

We’ll explore these years in detail, providing valuable insight for current owners and potential buyers.

Harley Twin Cam Years To Avoid

When it comes to the Twin Cam, there are a few years that enthusiasts might want to avoid. 

Notably, models produced from 1999 to 2006 have been reported to have some issues. 

Also, the years 19967, 1999, 2003, 2005, and 2006 are considered the years to avoid.

1. 1996 Model

The 1996 Harley-Davidson Twin Cam model has been known to have several issues, earning it a reputation as a model to avoid. 

The primary concern revolves around the cam chain system. Unlike its predecessor, which utilized gears, the Twin Cam engine was fitted with a cam chain system for the first time.

This system was intended to reduce engine noise, but it introduced a set of mechanical complexities.

The most notable problem was the tensioners, which had a tendency to wear out prematurely. 

These tensioners, made of plastic, wear down and send plastic shavings throughout the engine. 

This could lead to catastrophic damage if not caught early enough, expensive repairs, or even engine replacements.

Another problem was the motorcycle’s air vent system design. The idea was to separate oil and air, but it frequently didn’t work, causing the infamous Twin Cam “oil blow-by” problem. 

This issue pushes oil into the air cleaner, which lowers performance and possibly causes significant engine damage.

Lastly, the 1996 Twin Cam was also known for its crankshaft issues. 

The crankshaft was not welded, which could easily slip out of alignment, leading to vibration, reduced performance, and eventual engine failure.

Overall, these issues made the 1996 Harley-Davidson Twin Cam a risky investment, with potentially high maintenance and repair costs.

2. 1999 Model

The 1999 model of the Harley Twin Cam, known as the Twin Cam 88, has often been cited as one of the worst by enthusiasts and experts alike. 

This particular model was introduced with the intent of providing more power and an improved riding experience.

However, it was plagued by a number of issues that led to its unfavorable reputation.

One of the most significant issues was the cam chain tensioner. In the 1999 model, the cam chain tensioner was made of a material that wore out prematurely and required frequent replacement. 

This led to high maintenance costs and a high risk of engine failure if not addressed promptly.

Another issue was related to the motor itself. The Twin Cam 88 motor was prone to overheating due to the increased power and engine’s inability to dissipate heat efficiently. 

This often leads to performance issues and potentially severe engine damage.

Lastly, the 1999 model suffered from problems with its crankshaft. Due to a design flaw, the crankshaft had a tendency to slip, leading to poor performance and a need for frequent repairs.

The 1999 Harley Twin Cam 88, despite promising more power and a better ride, ended up being more trouble than it was worth. 

The frequent maintenance, potential for severe engine damage, and overall unreliability make this particular model a less desirable choice.

3. 2003 Model

The Harley-Davidson Twin Cam engine is renowned for its raw power and classic aesthetic. 

However, certain years of production have been singled out by riders as problematic, specifically the 2003 model year. 

The issues with the 2003 Twin Cam largely revolve around a major design flaw in the cam chain system. 

Harley-Davidson opted to use a spring tension system, which unfortunately has a tendency to fail prematurely, leading to catastrophic engine damage.

The spring tensioner pads were known to wear out, causing the chain to slack and create a host of problems, from noise to outright failure. 

If the chain fails, it can scatter debris throughout the engine, damaging the oil pump and other vital components. 

This design flaw was so prevalent that it led many riders to perform preventative upgrades by installing a hydraulic cam chain tensioner kit, an unnecessary expense.

The 2003 model also had notable problems with the fuel injection system.

Riders reported that the engine ran exceptionally hot, leading to discomfort during rides and potential long-term damage to the engine. 

This issue was attributed to a lean air/fuel mixture in the EFI system, another costly problem to fix.

These significant issues make the 2003 Twin Cam model flagged as one to avoid, especially if you’re not interested in undertaking extensive and costly preventative measures or repairs.

4. 2005 Model

The 2005 model of the Harley Twin Cam is often flagged by enthusiasts and experts alike as the worst year. 

This model is notoriously known for its problematic cam chain tensioner. 

The Twin Cam engine, introduced in 1999, initially used spring-loaded tensioners powered by engine oil pressure. 

In the 2005 model, these tensioners were prone to wear out quickly, which often led to catastrophic engine failure.

The primary issue lies in the tendency of these parts to wear out and shed plastic material into the oil of the engine, causing serious engine damage.

However, replacing the cam chain tensioner requires disassembling a significant part of the engine, which leads to costly repairs.

Another drawback of the 2005 model is its weak and inefficient oil pump. 

This often leads to lubrication issues, making the motorcycle run hot, thus impacting overall engine performance and longevity.

Due to these concerns, many riders and mechanics advise steering clear of the 2005 Harley Twin Cam model. 

If you own one or are considering purchasing one, it’s crucial to check the state of the cam chain tensioner and consider upgrading to the later models’ hydraulic design to avoid these notable issues.

5. 2006 Model

The 2006 model year of Harley’s Twin Cam is often mentioned among the ones to avoid. 

There are several reasons for this. Firstly, this model had a common issue with the cam chain tensioner. 

The 2006 Twin Cam was equipped with a spring-loaded cam chain tensioner, which had a tendency to wear out prematurely. 

As the tensioner wears, particles of plastic and metal clog the oil pump, potentially causing engine failure.

Secondly, the 2006 model was notorious for having problems with the crankshaft.

Some bikes experienced issues with crankshaft slippage, which led to significant engine damage. 

This issue was due to Harley using a pressed-together crankshaft instead of a one-piece crankshaft, leading to instability and potential slippage.

Lastly, the 2006 Twin Cam also had problems with heating and oil cooling. 

The Twin Cam engine runs hot, especially in the 2006 models. Overheating leads to wear and tear on components, and in severe cases, it causes engine seizure.

While the 2006 Twin Cam has its strengths, these significant issues make it one to be cautious about.