this is the offending oil hole
where the boss would be on B motors - note the pencil is pointing at open space
The next caution has to do with cam sprocket alignment. From what I have seen so far, I am led to believe that Harley has machined every pinion shaft from 1999 until now incorrectly. Every shaft is machined for the diameter of the cam chain drive sprocket just inboard from the portion that rides in the cam plate itself. This machining includes a "flat" on one side which positively locates the sprocket. This machined flat is the problem. Admittedly I have only checked a half dozen crank assemblies, but the range from 1999 to two brand new fresh out of the shipping crate 103" cranks. The specific problem is that the "flat" is machined deeper (further inboard) that the rest of the diameter for the sprocket by about .015". This causes the cam chain sprocket to pull in on that side when tightened. It gives said sprocket a similar amount of lateral runout, which in turn makes sprocket alignment between cam and pinion, shall we say ...interesting.
undercut deeper at the flat
There's not much you can do about the situation, as far as I can see, outside of being aware of the issue so that you can split the difference and minimise the misalignment between the two sprockets. If you were to simply follow the factory service manual and check the sprocket alignment, adjusting to within the Harley mandated .010, you may not think to turn the motor over 180 degrees and re-check. You may not think to, because the manual doesn't mention it. Whoever wrote the manual assumed (as most of us do) that the sprockets would install "square" on the shaft. Oops.
note gap between straight edge and top sprocket
rotate engine 180 degrees and note difference in gap
A comparison of a 1999 Twin Cam service manual with its 2009 counterpart is revealing. In 1999 the spec for flywheel runout was .002 maximum. By 2009 that spec was doubled to .004". Not only that, but the service wear limit (deemed acceptable by the factory before repair) in 1999 was .003 for flywheel runout, but .005" ten years later. Note that the .003" runout which was the limit before replacement in 1999 would be within new setup spec for 2009. In 1999 the spec for pinion shaft runout was .003, and no service wear limit was given. In 2009 that spec, though renamed (to protect the guilty?) is .010" with a whopping (or should I say wobbly) service wear limit of .012!
My conclusion? Harley reached its zenith for quality and engineering with the Evo motor. Of course they reached their zenith in just plain "class" much earlier with the Knucklehead!