106-5912 easystart chain 20140221

106-5912 easystart chain 20140221
Instruction 106-5912
02-21-14
S&S Cycle, Inc
®
.
Copyright © 2009–2014
by S&S® Cycle, Inc.
14025 Cty Hwy G PO Box 215
Viola, Wisconsin 54664
Phone: 608-627-1497 • Fax: 608-627-1488
All rights reserved.
Printed in the U.S.A.
Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: [email protected]
Website: www.sscycle.com
Installation Instructions: S&S Standard and Easy Start Chain Drive
Camshafts for 2006 Harley-Davidson® Dyna® models and
all 2007-up Big Twins
DISCLAIMER:
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.
SAFE INSTALLATION AND OPERATION RULES:
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
dissipate.
IMPORTANT NOTICE:
Statements in this instruction sheet preceded by the following words are of
special significance.
WARNING
Means there is the possibility of injury to yourself or others.
CAUTION
Means there is the possibility of damage to the part or motorcycle.
NOTE
Other information of particular importance has been placed in italic type.
S&S recommends you take special notice of these items.
WARRANTY:
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.
ADDITIONAL WARRANTY PROVISIONS:
(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.
Contents Of Chain Drive Camshaft Kit 106-5929:
Instruction Contents:
• Chain drive cams front and rear
Introduction and Specifications
• Inner cam bearings
Securing Motorcycle
• Retaining ring
Disassembly
• Cam cover gasket
Reassembly
• Oil pump scavenge o-ring
•• Crankcase Preparation
• 5ml tube of Loctite® 262
•• Cam Installation
• 5ml tube of Loctite 243
•• Rear Cam Endplay Adjustment
•• Final Assembly
•• Pushrod Installation & Adjustment
Complete Chain Drive Camshaft Kit
Introduction and Specifications
The S&S® chain drive cams outlined in this instruction sheet are intended for 2007-up big twin and 2006-up Harley-Davidson® Dyna® models.
Cam Name
510C
551C (E)
557
570C (E)
583C (E)
585C (E)
625C (E)
635
640C (E)
HP103
MR103
Timing
Lobe
Open
Close
Duration
Int
20°
38°
238°
Exh
52°
20°
252°
Int
17°
19°
216°
Exh
41°
17°
238°
Int
6°
27°
212°
Exh
39°
12°
231°
Int
20°
40°
240°
Exh
55°
20°
255°
Int
5°
18°
203°
Exh
58°
24°
262°
Int
20°
45°
245°
Exh
60°
20°
260°
Int
20°
55°
255°
Exh
60°
20°
260°
Int
19.5°
43.5°
243°
Exh
58.5°
37.5°
276°
Int
25°
60°
265°
Exh
65°
25°
270°
Int
20°
49°
249°
Exh
26°
251°
Int
13°
33°
226°
Exh
50°
22°
252°
45°
Lift
0.510"
0.550"
0.557"
0.570"
0.583"
0.585"
0.625"
0.635"
0.640"
0.575"
0.585"
Centerline
TDC
Valve Lift
99°
0.187"
106°
0.179"
91°
0.178"
102°
0.170"
100°
0.113"
103°
0.146"
100°
0.187"
107.5°
0.179"
96.5°
0.113"
107°
0.206"
102.5°
0.186"
110°
0.179"
107.5°
0.189"
110°
0.184"
102°
0.186"
100.5°
0.284"
107.5°
0.228"
110°
0.214"
102.7°
0.199"
101.5°
0.206"
100°
0.097"
104°
0.191"
05-UP Models Works
with stock valve springs
Works with
stock pushrods
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NOTES:
• 2005-up stock valve springs will handle camshafts with lift up to 0.585". If a camshaft with higher lift is installed, high performance valve springs
capable of handling a greater lift must be used.
• A cam with over 0.585” of lift will cause interference between the valve spring top collar and the valve seal with stock valve springs.
• Piston to valve clearance will need to be confirmed when using a cam with over 0.585" of lift. Clearance should be at least 0.060" intake and .080"
exhaust.
• Valve to valve clearance will need to be confirmed when using a cam over 0.585" lift. Clearance should be a minimum of 0.060".
• Installation of S&S chain drive cams requires special tools. See Picture 1 for the required tools. Attempting the cam change operation without these
tools will be difficult. Damage can result which will not be covered under warranty.
• Possible failure may result if thread locking compound is not applied to the cam drive sprocket flange bolts. Always prepare threads according to the
instructions on the container.
• 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 numbers.
2
2
1 Crankshaft/Camshaft Sprocket Locking Tool,
H-D® Part Number: 47941
2 Camshaft Needle Bearing Remover/Installer,
H-D Part Number: 42325
1
•• 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 HarleyDavidson part numbers.
Picture 1
Overview of Easy Start camshafts (if equipped):
for occasionally an engine may not build the required compression
to start the bike.
•Cranking compression numbers are no longer a valid health check
of the engine. We recommend performing a leak down test.
•If the lifters have been disassembled or bled down for any purpose,
the starter may have difficulty with the initial start. Although the
decompression lobe lifts the lifter body, the lifter is not pumped up
and it will not lift the exhaust valve. You may need to remove the
spark plugs and crank the engine to get oil pressure to the lifters.
•Easy Start cams require no special service. If they are ever removed
for any reason however, inspect the mechanism for wear and verify
that the lever operates smoothly.
•When the engine is turned off, you may hear a slight click as the
decompression lever resets. This is normal and does no harm.
Easy Start Chain Drive Cams
•If engine speed drops below 900 RPM, you may hear clicking as
the decompression lever starts engaging. Idle speed should be
adjusted higher. The engine idle should be set at 1000-1100 RPM.
S&S® has developed Easy Start Cams to assist starting with a
centrifugally operated compression release. The operation is simple:
at cranking speeds a spring loaded decompression lever holds the
exhaust valve open slightly. Once the engine fires and exceeds 750
RPM, centrifugal force takes over and sends the lever to a retracted
position, allowing the engine to run normally.
Securing the motorcycle
CAUTION
Motorcycle must be adequately secured during the cam change
operation! Use of tie down straps on both sides of the motorcycle
is recommended.
Important Notes Regarding Easy Start Camshafts:
Cam
Intended Displacement
Intended Compression Ratio
551
88–106
9.0–10.0
557
96-103
9.6-10.0
570
88–106
9.0–10.0
583
88–106
9.0–10.0
585
88–106
9.2–10.5
625
95+
10.0–10.75
635
106-124
10.2-10.8
640
95+
10.5–11.5
675
120+
11+
HP103
103
9.6-10.0
MR103
103
9.6-10.0
1. Place motorcycle on a suitable repair stand so that the
motorcycle is stable and secure with the rear tire elevated.
2. Disconnect the negative terminal of the battery to eliminate
potential sparks and inadvertent engagement of the starter
while working on the motorcycle.
3. Place motorcycle in top gear. Remove spark plugs. These
steps are necessary so that the rear tire can be used to rotate
the engine to correctly align the cam timing marks during
installation, and align the oil pump during reassembly.
Disassembly
CAUTION
Cutting the pushrods with a saw may result in metal chips
entering the engine and causing extensive damage which will
not be covered under warranty.
CAUTION
•Stock EFI engines require a minimum of 80 PSI cranking
compression, checked with the throttle open, for the ECU to fire the
spark plugs.
Cutting pushrods without relieving valve spring force on the
pushrods may result in injury.
•S&S easy start cams were designed to work with specific
compression ratio and displacement combinations. If an Easy Start
cam set is used in an application other than what it was designed
3
1. Remove pushrods.
Cam Support Plate and Cam Removal
a. Remove pushrod cover clips with a small screwdriver and
compress pushrod covers to expose pushrods. Lift rear tire of
motorcycle with a suitable jack. Rotate the engine until one
of the cylinders is on “top dead center compression stroke”
(TDCC). TDCC can be found by rolling the rear tire forward
while watching or feeling the pushrods move through their
travel. When BOTH pushrods are at the lowest point of their
travel and the piston for that cylinder is at TDC, the engine is
at TDCC. Rotate the pushrods to ensure there is no load on
them. If the pushrods will not rotate freely by hand, either
the engine is not on TDCC, or the lifters need to bleed down.
It may be necessary to let the lifters bleed down for a few
minutes before the pushrods will rotate freely.
1. Gradually loosen and remove the four oil pump bolts/washers
according to the sequence shown in Picture 3, below.
2. Gradually loosen and remove the six support plate bolts/
washers according to the sequence shown below.
3
6
2
5
b. If stock non-adjustable pushrods will not be re-used, they
may be removed by cutting them. When cutting pushrods,
S&S recommends a bolt cutter be used as it is the cleanest
method. Be sure to only cut the pushrods that are not loaded
and rotate freely by hand.
1
2
4
4
1
c. If stock one piece pushrods are to be re-used, they must be
removed using the factory procedure. Remove the gas tank
and rocker box covers. Remove the rocker arm support by
first removing the two smaller bolts which hold the breather
cover in place. Next break loose the four bolts holding the
rocker arm support plate in place with an alternating pattern.
Remove the four rocker arm support plate bolts, and then
the rocker arm support assembly. The pushrods may now
be removed by sliding them up into the head slightly and
then pulling the bottom of the pushrod towards you. Mark
the original pushrod location as it is removed to ensure it is
replaced in its original position. The intake pushrod is shorter
than the exhaust pushrod. Interchanging the intake and
exhaust pushrods upon reassembly, will cause the intake
valve to stay open on the compression stroke and the engine
will not run.
3
Picture 3
3. Remove spacer from rear cam, this spacer is thicker than the
front spacer.
4. Remove cam plate and cams from engine.
5. Remove retaining ring and spacer from front cam. This spacer is
0.100" thick.
6. Remove the secondary cam chain tensioner.
7. Remove the cams and cam chain. Mark the direction of the cam
chain so that it is installed in the original direction of rotation
with the new cams.
d. Rotate the engine so the other cylinder is on TDC
compression and repeat the above procedure.
Reassembly
Crankcase Preparation
2. Remove cam cover and gasket. Secure lifters with a magnetic
tappet tool or a tool made from a large binder clip spring. See
Picture 2, below.
1. When using 551G, 570G, 583G, 585G, 625G, or 640G camshafts
clearance between the pinion bearing boss and the rear cam
lobe must be checked. See Pictures 4 & 5, top of next page.
Remove just enough material to provide .030" of clearance
between the top of the cam lobe and the pinion bearing boss
when the camshafts are rotated in the inner needle bearing.
Also check clearances between the cam lobe and the tappet
guide bosses. To avoid contamination of the engine with chips,
we recommend that all holes in the gear case be taped off with
duct tape and that the gear case be thoroughly cleaned with
parts cleaner or solvent after clearancing is performed.
2. Replace inner cam needle bearings. Be sure to use a full
complement needle bearing such as those supplied with the
chain drive installation kit. These bearings offer a higher load
carrying capacity associated with high lift camshafts. Refer to
the H-D® service manual for proper installation procedure.
Picture 2
3. Rotate rear wheel to align timing marks on the primary cam
chain.
NOTE: Before reinstalling cam support plate, replace oil pump scavenge
o-ring (supplied in kit) even if the original appears to be in good condition.
The stock o-ring can become brittle and provide a poor seal if reused. This
can cause poor oil scavenging, oil carry-over and loss of power.
4. Remove the primary chain tensioner by removing the two
retaining bolts and install sprocket locking tool.
5. Remove the crank sprocket bolt and flat washer.
6. Remove rear cam sprocket bolt and flat washer.
7. Remove sprocket locking tool.
8. Gently pry off crank sprocket and rear cam sprocket.
4
Picture 4
Picture 5
Rear Cam Endplay Adjustment
Cam Installation
1. Install the spacer over the end of the rear cam. Install the
primary cam sprocket to the rear cam and hand tighten bolt.
1. Place the cam support plate on a flat surface with the outside of
the support plate facing down. Place supports under the cam
support plate so that the cams can be easily installed.
2. Install the crank sprocket to the crankshaft and hand tighten
bolt.
2. Install the secondary cam chain around the front and rear cam
sprockets. Ensure that the timing marks are still aligned. Also,
the timing chain should be installed in its original direction of
rotation. See Picture 6, below.
3. Align the timing marks and install the sprocket locking tool and
torque each bolt to 15 ft-lbs.
4. Push crank sprocket towards the drive side of the motorcycle to
eliminate end play. Push the rear cam inwards to eliminate end
play.
3. Lubricate the cam bearing cavities on the cam support plate
with engine assembly lube, or suitable clean engine oil.
4. Install the cams into the cam support plate. Be careful not to
damage the cam support plate while installing the cams.
5. Lay a straight edge across the face of the crank sprocket and
the primary cam sprocket. If the gap between the straight edge
and the sprocket faces is smaller than 0.010", no adjustment of
the spacer behind the rear cam sprocket is necessary. Select
the proper spacer for the rear cam so that this gap is no greater
than 0.010". Spacers are available from Harley-Davidson® in the
following sizes and part numbers:
.100" thick H-D® Part Number 25729-06
.110" thick H-D Part Number 25731-06
.120" thick H-D Part Number 25734-06 .130" thick H-D Part Number 25736-06
5. Install the secondary cam chain tensioner. Apply Locite® 243
and torque bolts to 100-120 in-lbs.
6. Turn the cam support plate over. Take care so that the cams do
not slide out of the support plate. Install the 0.100" spacer over
the end of the front cam. Install the new retaining ring.
7. Double check to make sure the oil pump has not pulled out of
the crankcase.
8. Lubricate the cam needle bearings and decompression lever, if
equipped, with assembly lube and install the cam support plate
assembly.
6. Remove sprockets so that the outer drive chain can be installed
for the final assembly.
9. Apply a small amount of Loctite 243 to the six bolts that hold
on the cam support plate and torque in the sequence shown in
Picture 3, page 4. Torque to 100-120 in-lbs.
Final Assembly
1. Place primary chain over the rear cam sprocket. Install the crank
sprocket into the primary chain so that the timing marks on
both sprockets are aligned as shown in Picture 7.
10. Apply a small amount of Loctite 243 to the four bolts that hold
the oil pump to the cam support plate. While rotating the
engine, alternatively tighten bolts 1 and 2 until the bolts are
snug. Tighten bolts 3 and 4 until they are snug. Finally, torque
the four bolts in the sequence shown in to 90-120 in-lbs. This
procedure ensures that the oil pump is properly centered.
2. Install the primary timing chain assembly onto the crankshaft
and rear cam.
NOTE: Align the crankshaft and rear cam so that the primary timing
chain assembly fits so that the timing marks are aligned.
Timing Marks
Picture 6
Picture 7
5
3. Thoroughly clean the flange bolts and apply a small amount of
Loctite® 262, 271, or 272 to the threads. Apply a drop of clean
20W-50 engine oil under the bolt flanges.
5. While holding the top of the pushrod into the cup of the rocker
arm, extend the bottom end into the tappet until the pushrod is
just making contact with the cup of the tappet. From this point,
extend the pushrod 24 flats (4 full turns). Move the jam nut on
the threaded portion of the pushrod to lock the end in place
and tighten.
4. Install the sprocket locking tool and tighten the crankshaft gear
bolt to 25 ft.-lbs. torque. Torque the camshaft gear bolt to 34
ft.-lbs.
5. Install primary cam chain tensioner, tighten fasteners to 100-120
in-lbs.
NOTE: S&S® adjustable pushrods have 32 threads per inch, and 24 flats
will place the pushrod in the optimal position of the stock style tappet.
If pushrods other than S&S adjustable or quickee's are used, refer to the
manufacturer's instruction sheets to find the number of flats needed.
6. Inspect the blind tapped holes for the cam cover in the
crankcase for cleanliness. Remove any foreign debris.
7. Install cam cover with new gasket. Torque the 10 bolts to 125155 in-lbs in the sequence shown below in Picture 8.
6. Allow the tappet to bleed down until you are able to rotate the
pushrod freely by hand, before adjusting the next pushrod.
8. Remove the clips holding the tappets in place.
7. Repeat steps 5 and 6 for the other pushrod on the same
cylinder.
8. Ensure both pushrods rotate freely, then repeat steps 1 through
6 for the other cylinder.
9. Install pushrod clips.
10. Shift transmission into neutral.
7
11. Lower motorcycle onto lift and remove jack.
6
1
12. Install spark plugs and plug wires.
4
13. Reconnect Negative battery cable.
9
10
5
CAUTION
If the engine is rotated before the tappets have bled down and
the pushrods can be rotated by hand, valve to valve or valve to
piston contact may occur. Serious engine damage could result.
8
3
2
Stock Non-Adjustable Pushrod Installation
NOTE: Using stock pushrods is only possible if the camshafts installed
have the same base circle as stock, and no more than .585" lift. S&S® labels
these cams as "Bolt-In" for easy reference. Currently S&S 510, 551 and 583
cams are bolt-in.
Picture 8
1. Rotate engine so one piston is at TDC compression, by rotating
the rear tire while feeling the tappets. When both tappets are at
the bottom of their lift, and the cylinder is at TDC, the cylinder
is at TDC compression. If equipped with compression releases,
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 base circle. This is the proper point
to adjust the pushrods.
Adjustable Pushrod Installation And Adjustment
1. Rotate engine so one piston is at TDC compression, by rotating
the rear tire while feeling the tappets. When both tappets are
at the bottom of their lift, and the piston is at TDC, the cylinder
is at TDC compression. If equipped with compression releases,
you must use extra care when installing 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 base circle. This is the proper point
to install the pushrods.
2. Insert the pushrods into the collapsed pushrod tubes. Make
sure the proper o-rings are installed in the tappet covers, and
on the cylinder head end of the pushrod covers.
2. Insert the adjustable pushrods into the collapsed pushrod
tubes. Make sure the proper o-rings are installed in the tappet
covers, and on the cylinder head end of the pushrod covers.
3. Verify the correct locations for the pushrods that were removed.
The longer pushrods go in the exhaust locations and the
shorter pushrods are for the intakes.
3. If the pushrod kit contains different length pushrods, the longer
pushrods go in the exhaust locations and the shorter pushrods
are for the intakes.
4. Insert the top of the pushrod into the hole in the head, then
drop the bottom into the tappet cover.
5. Apply assembly lube or suitable clean engine oil to the pushrod
tips where they will contact the rocker arms.
4. Insert the top of the pushrod into the hole in the head, then
drop the bottom into the tappet cover.
6. Insert the rocker arm support assembly into the rocker box.
6
7. Ensure that the pushrod tips are fully engaged in the rocker
arms.
8. Apply Loctite® 243, then evenly snug the four 5/16” bolts which
hold the rocker arms in place just finger tight at this time.
9. Start the two breather cover bolts at this time, but do not
tighten them.
10. Begin tightening the rocker arm bolts. Following the sequence
of lowest bolt on spark plug side, highest bolt on intake side,
lowest bolt on intake side, then highest bolt on spark plug side.
Tighten each bolt ¼ turn at a time following this sequence until
they have reached a torque of 18-22 ft-lbs.
11. Tighten the two breather cover bolts to 90-120 in-lbs.
12. Allow lifters to bleed down, then check to ensure both pushrods
rotate freely by hand.
13. Install pushrod cover keepers.
14. Install new rocker box gasket, and rocker box top cover.
15. Apply blue threadlocker to the six rocker cover bolts and
tighten in a star pattern to 15-18 ft-lbs.
16. Repeat for the other cylinder, following steps 1 through 15.
17. Install the gas tank.
18. Shift transmission into neutral.
19. Lower motorcycle onto lift and remove jack.
20. Install spark plugs and plug wires.
21. Reconnect negative battery cable.
NOTE: The tappets may be noisy upon initial start-up after installing
cams and adjusting pushrods. This is normal after the tappets have
all been bled down, and will go away shortly as long as the proper oil
pressure is available to the tappets.
7
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