S&S Cycle | Twin Cam 88 | - S&S Cycle

Instruction 106-6046
S&S Cycle, Inc
Copyright © 2012–2014
by S&S® Cycle, Inc.
14025 Cty Hwy G, PO Box 215
Viola, Wisconsin 54664
All rights reserved.
Printed in the U.S.A.
Phone: 608-627-1497 • Fax: 608-627-1488
Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: sstech@sscycle.com
Website: www.sscycle.com
Installation Instructions for S&S Adjustable Pushrods
S&S parts are designed for high performance, closed course, racing
applications and are intended for the very experienced rider only. The
installation of S&S parts may void or adversely affect your factory warranty.
In addition such installation and use may violate certain federal, state, and
local laws, rules and ordinances as well as other laws when used on motor
vehicles used on public highways, especially in states where pollution laws
may apply. Always check federal, state, and local laws before modifying your
motorcycle. It is the sole and exclusive responsibility of the user to determine
the suitability of the product for his or her use, and the user shall assume all
legal, personal injury risk and liability and all other obligations, duties, and
risks associated therewith.
The words Harley®, Harley-Davidson®, H-D®, Sportster®, Evolution®, and
all H-D® part numbers and model designations are used in reference only.
S&S Cycle is not associated with Harley-Davidson, Inc.
Before installing your new S&S part it is your responsibility to read and follow
the installation and maintenance procedures in these instructions and
follow the basic rules below for your personal safety.
•• Gasoline is extremely flammable and explosive under certain conditions
and toxic when breathed. Do not smoke. Perform installation in a well
ventilated area away from open flames or sparks.
•• If motorcycle has been running, wait until engine and exhaust pipes
have cooled down to avoid getting burned before performing any
installation steps.
•• Before performing any installation steps disconnect battery to eliminate
potential sparks and inadvertent engagement of starter while working
on electrical components.
•• Read instructions thoroughly and carefully so all procedures are
completely understood before performing any installation steps.
Contact S&S with any questions you may have if any steps are unclear or
any abnormalities occur during installation or operation of motorcycle
with a S&S part on it.
•• Consult an appropriate service manual for your motorcycle for correct
disassembly and reassembly procedures for any parts that need to be
removed to facilitate installation.
•• Use good judgment when performing installation and operating
motorcycle. Good judgment begins with a clear head. Don’t let
alcohol, drugs or fatigue impair your judgment. Start installation when
you are fresh.
•• Be sure all federal, state and local laws are obeyed with the installation.
•• For optimum performance and safety and to minimize potential
damage to carb or other components, use all mounting hardware that is
provided and follow all installation instructions.
•• Motorcycle exhaust fumes are toxic and poisonous and must not be
breathed. Run motorcycle in a well ventilated area where fumes can
Statements in this instruction sheet preceded by the following words are of
special significance.
Means there is the possibility of injury to yourself or others.
Means there is the possibility of damage to the part or motorcycle.
Other information of particular importance has been placed in italic type.
S&S recommends you take special notice of these items.
All S&S parts are guaranteed to the original purchaser to be free of
manufacturing defects in materials and workmanship for a period of twelve
(12) months from the date of purchase. Merchandise that fails to conform to
these conditions will be repaired or replaced at S&S’s option if the parts are
returned to us by the purchaser within the 12 month warranty period or within
10 days thereafter.
In the event warranty service is required, the original purchaser must call or
write S&S immediately with the problem. Some problems can be rectified by a
telephone call and need no further course of action.
A part that is suspect of being defective must not be replaced by a Dealer
without prior authorization from S&S. If it is deemed necessary for S&S to
make an evaluation to determine whether the part was defective, a return
authorization number must be obtained from S&S. The parts must be packaged
properly so as to not cause further damage and be returned prepaid to S&S
with a copy of the original invoice of purchase and a detailed letter outlining
the nature of the problem, how the part was used and the circumstances at
the time of failure. If after an evaluation has been made by S&S and the part
was found to be defective, repair, replacement or refund will be granted.
(1) S&S shall have no obligation in the event an S&S part is modified by any
other person or organization.
(2) S&S shall have no obligation if an S&S part becomes defective in whole or
in part as a result of improper installation, improper maintenance, improper
use, abnormal operation, or any other misuse or mistreatment of the S&S part.
(3) S&S shall not be liable for any consequential or incidental damages
resulting from the failure of an S&S part, the breach of any warranties, the
failure to deliver, delay in delivery, delivery in non-conforming condition, or
for any other breach of contract or duty between S&S and a customer.
(4) S&S parts are designed exclusively for use in Harley-Davidson® and other
American v-twin motorcycles. S&S shall have no warranty or liability obligation
if an S&S part is used in any other application.
••S&S Quickee Pushrods for all big twin engines contain two
It is recommended that S&S Quickee Pushrods have a minimum
.500" thread engagement (adjuster to pushrod body) or failure
to maintain proper thread engagement may result in engine
long and two short pushrods. All Sportster® model and 1999–up big
twin pushrods are the same length.
••If S&S® adjustable pushrod kit contains four different length
pushrods, the longest pushrod is for the front exhaust, next longest
is the rear exhaust. Of the two shorter pushrods, the longer one is the
front intake, the shortest pushrod is the rear intake. The pushrod kits for
the 1999–up big twin engine have two different lengths—short for the
intakes, long for the exhausts.
••All installation and adjustments must be made when engine
is cold. Read instructions thoroughly and follow all recommended steps
and procedures.
••The following instructions are for installing S&S adjustable
pushrods with the stock-style hydraulic lifters. If the S&S HL2T (Hydraulic Lifter Limiter Travel) kit is to be used, refer to that section of this
instruction sheet for installation of the kit, and pushrod adjustment.
••If unsure that the HL2T kit is installed in the lifters of an assembled engine, take note of the following: After the hydraulic piston
assembly is compressed 4 complete turns of the pushrod, and after 20
minutes the pushrod is unable to be spun with fingers, the HL2T kit is
installed in the lifters and the adjustment procedure for this kit must be
followed. Detailed instructions for the HL2T kit are listed in Section C,
Page 3.
••1966–’84 big twin engines with hydraulic conversion require
the use of S&S tappets and tappet guides.
••Pushrods with oil holes are for use with S&S rocker arms.
••Pushrods without oil holes are for stock rocker arms.
••When adjusting Quickee Pushrods, count flats on the 6 sided
female adjuster, not the 4 sided male part.
••S&S adjustable pushrods have a thread pitch of 32 threads
per inch. This means that one complete turn equals .031" of change in
pushrod length and one flat is .005".
••S&S hydraulic lifters have .200" of hydraulic plunger travel.
••When adjusting pushrods, the plunger should be moved near
the center of its travel. This would be 4 turns or 24 flats which is equal
to .125".
1. Remove pushrod cover clips and lift cover assemblies to view
2. Remove spark plugs and rotate engine until front piston is at the
top of its stroke, with both front lifters at their lowest position
(TDCC—top dead center compression).
NOTE: To ensure that the cylinder is at the correct position to remove
pushrods, rotate the engine forward and watch the intake pushrod. The
intake pushrods are the two closest to the center of the engine. Watch
the intake pushrod rise and fall as the engine is rotated. When the intake
pushrod is at its lowest position, the cylinder is on its compression stroke.
Check to see if the piston is at TDC. If it isn't, rotate the engine a few more
degrees to bring the piston to the top of the cylinder.
3. Remove front pushrods. If installing standard adjustable pushrods,
disassemble the rocker cover and rocker arm assembly, as per the
appropriate service manual. If installing Quickee pushrods, stock
pushrods may be cut out with a bolt cutter to save time. See NOTE
and CAUTION below.
NOTE: Since S&S Quickee pushrods do not require rocker arm disassembly for installation, stock pushrods may be cut out of the engine to save
time. S&S recommends that they be cut with a bolt cutter.
If pushrods are cut with a saw, metal chips may enter engine and
cause extensive damage not covered by warranty.
Standard Adjustable Pushrod
Make sure tappet is at lowest point of travel and pushrod is not
under valve spring pressure before cutting pushrods. Sudden
release of valve spring pressure may cause cut pushrods to fly
out of motor, potentially causing serious injury.
Quickee Pushrod
4. Clean and inspect the pushrod tubes. Replace all o-rings. Apply a
light coat of engine oil to the o-rings.
5. Insert new pushrods through tube assemblies and install in
appropriate positions.
6. Reinstall rocker assemblies according to appropriate service
manual procedures if they were removed.
7. Holding pushrod so the top ball end is in the rocker arm cup,
extend adjusting screw until the bottom ball end just contacts the
tappet cup. Compress hydraulic unit in exhaust lifter an additional
4 complete turns (24 flats) and tighten locknut. Allow sufficient
time for lifter to bleed down (20 to 30 minutes) before adjusting
intake pushrod. Pushrods must spin freely with fingers.
Picture 1
Failure to follow recommended steps and procedures may result
in damage to engine components.
NOTE: If pushrods can not be turned between fingers after 20 minutes,
tappets contains S&S HL2T spacers. Detailed instructions for the HL2T kit
are listed in Page 3.
Installing or adjusting pushrods while engine is hot could result
in burns from contact with hot engine parts.
Failure to allow hydraulic unit to bleed down before rotating engine or adjusting the other pushrod could result in valve-to-valve
contact and serious valve train damage. Lifters are bled down
when pushrod can be turned with fingertips.
8. Repeat above procedures for rear cylinder, this time bringing rear
cylinder to TDCC (top dead center compression).
9. Replace spark plugs and pushrod tube clips. Start motorcycle and
check for leaks.
Picture 2
In order to access the pushrod adjustor screws in 1991 and later HarleyDavidson® Sportster® and Buell® models, it will be necessary to use pushrod cover assembly kit for 1986–'90 Sportster® models, S&S part 93-4038,
and the appropriate length pushrod cover keepers. 1991-'03 models will
also require pushrod cover adapter kit, S&S part 33-5355.
On 1991 and later models, it is necessary to disassemble the rocker arm/
rocker box to remove the stock one piece pushrod cover.
The S&S HL2T kit is designed to limit the travel of the hydraulic lifter
making it impossible for the lifter to collapse. Stronger valve springs are
often used to avoid valve float at high rpm. The HL2T kit prevents high
valve spring pressure from collapsing lifters. With the HL2T kit installed,
stock hydraulic lifters work like solid lifters at high rpm, while retaining
normal hydraulic function for minimal noise and maintenance under
normal conditions. Another advantage of the HL2T kit is that if a valve is
held open when the engine is not running, valve spring pressure will not
cause lifters to bleed down and collapse. Collapsed lifters can cause hard
starting and excessive valve train noise when engine is restarted. Adjustable pushrods must be used with the HL2T kit.
••S&S pushrod kits for the Twin Cam 88®, Twin Cam 96™, and Twin Cam
103™ engines are available as a kit containing pushrods only, however,
it will be necessary to use S&S pushrod covers, or similar aftermarket
product, in order to be able to access the adjuster units on the pushrods.
S&S has a kit available, part number 106-6051, for stock height 1999–up
big twin engines that contains the four adjustable pushrods, pushrod
tube set, gaskets and o-rings for a complete assembly.
••If equipped with S&S Easy Start compression release cams, you must use
extra care when adjusting pushrods. Because the decompression lobe is
near TDC, it is possible to adjust the pushrod while the tappet is on the
lobe if it is not exactly at TDC. This will cause incorrect exhaust pushrod
adjustment. To verify correct position, you can rotate the engine in the
forward direction and feel for the exhaust tappet to slightly lift (about
.030") and set back down on the base circle. This is the proper point to
adjust the pushrods.
••Remove lifter cover from crankcase to install regular adjustable pushrods.
••Reinstall rocker assembly if removed in above step, following procedures
& torque specifications recommended in appropriate service manual.
••Insert pushrods through pushrod cover assemblies. Install intake and exhaust pushrod assemblies, along with the tappet cover and new gasket,
into position in front cylinder. See Picture 2, above.
••&S Limited Travel Kit 33-5338 fits all S&S tappets and all Harley-Davidson®
replacement tappets for 1999-'14 big twins (18538-99C & 18572-13) and
1991-'14 Sportster® models (18526-89A & 18538-99C).
••S&S Limited Travel kit does not fit Harley-Davidson® replacement tappets
(18523-86B) for 1984-'99 big twins and 1986-'90) Sportster® models.
••If using aftermarket tappets, consult the manufacturer to determine
compatibility. See Limited Travel washer dimensions below.
.605 OD
.440 ID
1. If tappets are installed in the engine, it is recommended that they
be removed. Be sure that each tappet is kept with its original
tappet block and bore.
NOTE: This procedure is the preferred method of installation. However,
kit can be installed without removing lifters from engine.
2. Remove hydraulic piston retaining wire clip from one assembly at
a time.
Be careful not to bend wire clip during disassembly.
3. Completely disassemble tappet removing all parts.
All reference to Harley-Davidson® part numbers is for identification purposes only. We in no way are implying that any of S&S® Cycle’s products are original equipment parts or that they
are equivalent to the corresponding Harley-Davidson® part number shown.
4. Thoroughly clean all parts including tappet body. Remove any oil
which might prevent hydraulic unit from fully collapsing during
5. Insert one spacer from S&S HL2T kit in tappet body.
6. Reassemble tappet in reverse order making sure original parts are
returned to their original positions. See Picture 3 below.
7. Replace wire retaining clip in tappet body.
8. Put tappet back in original tappet block.
9. Repeat Steps 2 through 8 for three remaining tappets.
10. Reassemble engine with modified tappets.
11.Adjust pushrods.
e. Tighten lock nut.
f. Repeat above procedures for rear cylinder, this time bringing rear
cylinder to TDCC (top dead center compression).
g. Replace spark plugs and install pushrod clips.
NOTE: Perform this operation on one cylinder at a time. Do not turn
engine until pushrod adjustment is complete, and pushrod can be spun
with fingers.
NOTE: In all cases engine must be cold and lifter must be at lowest point
of travel for pushrod adjustment.
a. Remove sparkplugs.
b. Remove spark plugs and rotate engine until front piston is at the
top of its stroke, with both front lifters at their lowest position
(TDCC – top dead center, compression).
NOTE: To ensure that the cylinder is at the correct position to adjust
pushrods, rotate the engine forward and watch the intake pushrod. The
intake pushrods are the two closest to the center of the engine. Watch
the intake pushrod rise and fall as the engine is rotated. When the intake
pushrod is at its lowest position, the cylinder is on its compression stroke.
Check to see if the piston is at TDC. If it isn't, rotate the engine a few more
degrees to bring the piston to the top of the cylinder.
Picture 3
c. Extend front pushrod until it contacts the hydraulic piston
assembly in the lifter body, then extend pushrod an additional
four complete turns, until piston assembly is in contact with HL2T
spacer and the valve is lifted off of its seat. If tappets contain oil,
as when pushrods are readjusted after engine has been run, or if
all oil was not removed during installation, allow at least 20–30
minutes for piston assembly to bleed down. If pushrod can be
turned between the fingers, tappet piston is not in contact with
HL2T spacer. Lengthen pushrod one additional turn and test again
after 20 minutes.
d. Loosen pushrod adjustment until pushrod can be rotated with the
fingers with slight drag. Continue loosening (shortening) pushrod
one full turn (6 flats).
NOTE: Shortening adjuster an additional six flats or full turn from zero
lash often results in quieter pushrod operation. This provides additional
travel for the hydraulic piston assembly, which can improve the ability of
the hydraulic unit to maintain zero lash under normal operating conditions.
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