S&S Cycle, Inc .

Instruction 106-6415
09-19-12
S&S Cycle, Inc
®
.
14025 Cty Hwy G PO Box 215
Viola, Wisconsin 54664
Copyright © 2009, 2011, 2012
by S&S® Cycle, Inc.
Phone: 608-627-1497 • Fax: 608-627-1488
Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: [email protected]
Website: www.sscycle.com
All rights reserved.
Printed in the U.S.A.
Installation Instructions: S&S Standard and Easy Start
Chain Drive Camshafts for Harley-Davidson® Twin Cam 88® Engines
1999–2006 Big Twin, except 2006 Dyna® models
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
• Chain drive cams front and rear
Instruction Contents:
A. Introduction & Specifications
• Inner cam bearings
B. Securing Motorcycle
• Retaining ring
C. Disassembly
• Cam cover gasket
D. Installing New Cams and Reassembly
• 5ml tube of Loctite® 262
E. Pushrod Adjustment
• 5ml tube of Loctite 243
A.Introduction & Specifications
The S&S® chain drive cams outlined in this instruction sheet are intended for 1999-2006 Harley-Davidson® Twin Cam 88® models.
Timing
Cam
Name
475
509C
510C
551C (E)
570C (E)
583C (E)
585C (E)
625C (E)
640C (E)
675C (E)
Lobe
Open
Close
Duration
Int
2°
34°
216°
Exh
36°
4°
220°
Int
18°
18°
216°
Exh
46°
11°
237°
Int
20°
38°
238°
Exh
52°
20°
252°
Int
17°
19°
216°
Exh
41°
17°
238°
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°
255°
Exh
60°
55°
20°
260°
Int
25°
60°
265°
Exh
65°
25°
270°
Int
25°
60°
269°
Exh
74°
275°
25°
Lift
0.475"
0.509"
0.510"
0.550"
0.570"
0.583"
0.585"
0.625"
0.640"
0.675"
Centerline
TDC Lift
106°
.060"
106°
.060"
90°
.0174"
107.5°
0.140"
99°
0.187"
106°
0.179"
91°
0.178"
102°
0.170"
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"
107.5°
0.228"
110°
0.214"
109.5°
0.235''
112.5°
0.205"
99-04
Models
Works with
stock valve
springs
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
NOTES
• 1 999–2004 stock springs will handle camshafts with lift up to 0.510". If a camshaft with higher lift is installed, high performance valve springs capable
of handling a greater lift must be used.
• 2 005–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. Cams with over 0.585" of lift will cause interference between the valve spring top collar and the valve
seal with stock cylinder heads.
• P
iston 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"
• I nstallation of S&S chain drive cams requires special tools. See Picture 1 on page 3 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.
• P
ossible 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.
• S &S® chain drivecams are compatible with the stock splined chain sprocket used in 2000–up Twin Cam 88 engines, but may be used in 1999 engines if
the Harley-Davidson 2000–up splined rear cam sprocket and appropriate 2000-up sprocket spacer are used.
• C
hanging camshafts in the Twin Cam 88® engine requires use of hydraulic press and special tools. This installation should be undertaken only by
experienced mechanic with access to Harley-Davidson® service manual and all required tools or equivalent. Tightening fasteners to correct specifications
with accurate torque wrench is mandatory.
• F or lifts over .510" S&S strongly recommends that the stock chain drive cam be upgraded to the S&S gear drive or to the H-D® part number 25284-08. This
kit upgrades the problematic spring loaded chain tensioners to more reliable hydraulic tensioners, and also upgrades the oil pump.
• T he S&S® chain drive cams outlined in this instruction sheet are intended for 1999-2006 Harley-Davdison Twin Cam 88 models, except 2006 Dyna®
models.
OVERVIEW OF EASY START CAMSHAFTS (IF EQUIPPED):
General Notes On Cam Installation
S&S® has developed Easy Start cams to assist starting with a built in
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 move the lever to a retracted position, allowing the
engine to run normally.
• Whenever new camshafts are installed, it is highly recommended
that new tappets be installed. If tappets are reused, they must be
reinstalled in the same position they were removed from.
Cam
Important Notes Regarding Easy Start Camshafts:
• Stock EFI engines require a minimum of 80 PSI cranking compression,
checked with the throttle open, for the ECU to fire the spark plugs.
• 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 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.
88–106
9.0–10.0
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
640
95+
10.5–11.5
675
120+
11+
• Attempting the cam change operation without the required tools
will be difficult and can easily result in damage to the components
not covered under warranty.
• 1999 models used interchangeable ball bearings on the outer end
of both cams. For 2000 and up, the rear bearing is a roller type and
the front bearing is a ball bearing type. It is highly recommended
to update 1999 models to the 2000 and up bearing set, which is
included in the S&S Cam Installation Kit. These instructions are for
2000–up installation. See Picture 2, next page.
• 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.
• If your bike is carbureted, the starting routine may be slightly different,
allow yourself time to experiment to find the best method.
• Possible failure may result if Loctite® is not applied to cam drive
sprocket flange bolts. Always prepare threads for Loctite according
to instructions on container.
• When the engine is turned off, you may hear a slight click as the
decompression lever resets. This is normal and does no harm.
• 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.
CAUTION
Failure of fasteners or parts caused by incorrect installation can
cause extensive damage not covered under warranty.
Special Tools Required: See Picture 1, below
Intended Displacement Intended Compression Ratio
551
WARNING
H-D #42314 Crankshaft/Camshaft Sprocket Locking Tool
H-D #42325 Camshaft Needle Bearing Remover/Installer
H-D #43644 Camshaft Remover/Installer
H-D #42313 Cam Chain Tensioner Unloader
Failure of camshaft related parts caused by incorrect installation
can cause immediate seizure of engine. Engine seizure can result in
serious injury to motorcycle operator, passenger, or others.
• Original cam bearings will likely be damaged during removal. S&S
strongly recommends installing new bearings at same time as
cam change. S&S camshaft installation kit 33-5175 provides parts
needed to install S&S chain drive camshaft sets. The installation
kit also includes a new oil pump scavenge o-ring. The oil pump
scavenge o-ring should never be reused since it can become stiff
from heat and exposure to oils. This often results in poor sealing
and inadequate oil scavenging.
H-D #43644
CAUTION
For 2000 models and up, the front and rear cam bearings are not
interchangeable! Ball bearing in front, roller bearing in rear.
H-D #42325
B. Securing Motorcycle
CAUTION
Motorcycle must be adequately secured to avoid falling over during
the cam change operation! Use of tie down straps on both sides of
motorcycle is recommended.
H-D #42313
H-D #42314
1. Place motorcycle on a suitable repair stand so that motorcycle is
stable and secure with the rear tire elevated. Shift transmission in
Picture 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 Harley-Davidson part number shown.
3
Roller Bearing
Ball Bearing
Picture 2
4th or 5th 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.
Picture 3
2. Disconnect negative terminal of battery to eliminate potential
sparks and inadvertent engagement of starter while working on
motorcycle.
CAUTION
Do not pull the retention pins from the primary or secondary cam
chain tensioners when the chain and sprockets are removed! The
primary and secondary cam tensioner springs exert 35–40 pounds
of pressure when retained. Removing a retaining pin without
supporting the shoe will cause the spring to snap open through its
full travel, damaging it, and/or the tensioner shoe. The tensioner
can also injure hands and fingers in its path.
NOTE: S&S® 475, 509, and 510 cams are compatible with stock pushrods.
However, replacing stock pushrods with S&S adjustable pushrods 93-5096
will simplify cam set installation.
C. Disassembly for Early (99–06 excluding 06 Dyna)
1. Removing pushrods
NOTE: If cam chain tensioner retaining pins interfere with cleaning or
service procedures when the cam support plate is removed, use cam chain
tensioner unloader tool (H-D #42313) to hold against spring pressure, then
remove retaining pin and ease spring assembly into the unloaded position.
a. If stock pushrods are to be reused, remove motorcycle gas tank
and top rocker covers. Remove rocker assemblies and pushrods
according to procedure described in the Harley-Davidson®
Service Manual.
7. Working gradually around edge of sprocket, carefully pry
sprockets off cams until loose on shaft. Remove sprocket/chain
assembly and mark chain with magic marker to indicate direction
of travel. Chain should be reinstalled in same direction.
b. To remove stock pushrods which will not be reused, remove
pushrod cover clips, collapse pushrod covers, place motorcycle
in gear, and rotate rear tire (see Step B securing motorcycle) to
place lifters and pushrods for either cylinder at lowest point on
camshaft. Piston for same cylinder will be at TDC on Compression
stroke and pushrods will spin with light finger pressure. Use bolt
cutters to cut pushrods.
8. Remove chain guide. See Picture 6, above left.
9. Gradually loosen and remove four oil pump bolts according to
sequence shown in Figure 1, below left.
WARNING
10. Gradually loosen and remove six support plate bolts according to
sequence shown in Figure 2, below right.
Cutting pushrods when they are under spring pressure can result in
pushrod parts being ejected with considerable force, and can cause
bodily injury.
NOTE: Failure to remove or install bolts according to correct procedure may
result in parts damage not covered under warranty.
CAUTION
11. Carefully remove cam support plate assembly from crankcase. Use
unloading tool H-D #42313 to swing secondary cam tensioner
away from chain. Secure tensioner with second retention pin
inserted through front of support plate. Do not remove pin until
support plate assembly has been reinstalled in engine.
Cutting pushrods with saw may result in metal chips entering
engine and causing extensive engine damage not covered under
warranty.
2. Remove engine gear cover and gasket. It is not necessary to
remove ignition sensor from cover. Secure lifters with magnetic
tappet tool or one made from large binder clip spring. See Picture
3 above right.
3. Rotate rear tire (see Step B securing motorcycle) to align timing
marks on the pinion shaft sprocket and the rear cam sprocket.
NOTE: S&S recommends using Harley-Davidson Sprocket Locking Tool
H-D® #42314 to secure sprockets while bolts are removed or installed. See
Picture 4 right.
4. Remove bolt and washer from 17-tooth crankshaft sprocket.
5. Remove bolt and washer from 34-tooth rear camshaft sprocket.
6. Use tool H-D® #42313 (Cam Chain Tensioner Unloader) to swing
primary cam chain tensioner away from chain. Secure with
retention pin. See Picture 5, next page.
Picture 4
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
Picture 6
Picture 5
NOTE: It is not necessary to remove oil pump from engine to complete
installation. However, it is highly recommended that new o-rings be
installed when ever the oil pump is loosened or disturbed. The cost of
replacing them at this point is minimal, but will be considerable if the engine
must be disassembled again to replace them.
• If upgrading from keyed rear camshaft to splined rear camshaft,
further steps require use of 2000 and up splined rear sprocket and
spacer. Spacer style used with keyed cams is not compatible with
splined cams. Spacers are available in five different thickness.
Prepare cam for installation:
12. Remove screws that secure bearing retainer to support plate and
remove retainer from plate.
NOTE: When using 551C, 583C, 585C, 625C, or 640C camshafts clearance
between pinion bearing boss and rear cam lobe must be checked. See
Pictures 9 & 10 next page. Remove just enough material to provide .030"
clearance between top of cam lobe and pinion bearing boss when camshaft
is rotated in inner needle bearing. Also check clearance between all cam
lobes and tappet guide bosses. To avoid contamination of engine with
chips, we recommend that all holes in the gear case be taped off with duct
tape and that gear case be thoroughly cleaned with parts cleaner or solvent
after clearancing is performed.
13. Support cam support plate on table of hydraulic press. Using
camshaft remover/installer tool H-D® #43644, remove stock cams
and bearings from plate. Mark chain with magic marker to indicate
direction of travel. See Picture 7, next page.
CAUTION
Do not attempt to remove cams from bearings while bearings are
in bearing plate. Cams and bearings must be removed from plate
together. See Picture 7, next page.
D. Replacing Cams ONLY — Early (99–06 excluding 06 Dyna)
NOTE: Not recommended for cams above .510 lift. If replacing cams and
upgrading cam plate (recommended), follow instructions included with
H-D® Kit #25284-08. After cam plate and cams have been installed, go
to Section E for pushrod adjustments and special notes on compression
releases.
Cam and bearings may press out easily. Use care to support cams so
they don’t unexpectedly fall to the floor.
NOTES: Bearings are usually damaged during removal and should not be
reused. If S&S® Cam Installation Kit (33-5175) is not used, new cam bearings
should be obtained from other source and installed with new cams.
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.
• Check primary and secondary cam shoes for wear and/or damage.
Do not re-use either shoe if more than 1⁄2 the shoe thickness is worn, or
if there is any evidence of melting, burning, or cracking.
1. Test fit front and rear bearings into bearing bores. If either bearing
will slip into the bore, use red Loctite® 271 on bearing outer race
during installation. If either bearing will not slip into bearing
bore, use assembly lube on bearing outer race during installation.
Using tool H-D #43644 and hydraulic press, install cam bearings in
support plate, roller bearing in rear location, and ball bearing in
• Replacement shoes are installed per appropriate Harley-Davidson®
service manual.
3
6
2
5
2
4
4
1
3
1
Figure 1
Figure 2
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.
5
5. Install new retaining ring in groove at end of front cam.
6. Remove cam needle bearings from crankcase with tool H-D #42325
and replace with new bearings provided in S&S installation kit 335175 or obtained from other source. Lubricate with clean engine
oil.
7. Apply thin layer of assembly lube to cam journals and lobe
surfaces. Align cams with needle bearings and carefully slide
support plate assembly over crankcase dowels. See Picture 14
below right.
8. Apply Loctite® 243 (blue) to six support plate screws, install screws,
and gradually tighten to 95 in-lbs. in sequence illustrated in Figure
2 on page 7.
NOTE: Support plate assembly should slide into place without resistance. If
resistance is encountered, determine cause before proceeding. Do not force
plate assembly!
Picture 7
CAUTION
front location. See Picture 11 next page.
.055” Thrust Washer
S&S® has stripped holes for support plate screws when using
maximum 120 in-lb. maximum torque spec recommended by
Harley-Davidson®. Holes stripped are those which pass through
alignment dowels, Positions #1 & #2 in Harley-Davidson diagram of
Cam Support Plate/Oil Pump Torque Sequence.
2000-Up Style
OEM Sprocket Spacer
9. Apply Loctite® #243 (blue) to threads and reinstall four oil pump
bolts according to following procedure:
a. Gently bottom screws, then back out 1⁄4 turn.
Inner
Bearing Race
b. Center pump by rotating engine while snugging screws.
c. Rotate engine by turning rear wheel (see Section B securing
motorcycle).
d. Tighten bolts to 90-120 in-lbs. in sequence illustrated in Figure
1 on page 5.
CAUTION
“O”-ring
Do not use primary cam sprocket or crank sprocket bolt heads to
rotate engine.
Bearing Assembly
Figure 3 - Rear Cam Detail
10. Carefully remove secondary cam tensioner retaining pin.
2. Using Loctite® 243 (blue) on screw threads, reinstall bearing
retainer and tighten screws to 20-30 in-lbs.
11. Check front to back alignment of outer drive sprockets.
a. Place rear cam sprocket spacer next to rear bearing race.
3. Align cam timing marks and install secondary cam chain in original
direction of travel. See Picture 12 next page.
b.Install rear camshaft and crankshaft sprockets.
c. Temporarily install crankshaft and camshaft sprocket bolts.
Temporarily use a smaller diameter washer under the head of
the crankshaft bolt. (This will allow a straightedge to fit on the
sprocket face for Steps 13 d and e.)
4. Apply thin film of assembly lube to bearing surface of S&S®
camshafts and inner race of cam bearings in cam plate. Support
bearings by inner race. Using tool H-D® #43644, align both cams
with bearings, install into cam bearings by pressing on front cam
only, guide slip-fit rear cam into bearing. See Picture 13 next
page.
d.Torque crankshaft and rear camshaft sprockets to 25 ft-lb. Do not
use Loctite® at this time.
e. Push on rear camshaft to remove end play.
clearance
clearance
Picture 9
Picture 10
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.
6
Timing Marks
Picture 12
Picture 11
f. Place a straightedge across the cam and crankshaft sprockets.
sprockets and verify the timing marks are in alignment.
NOTE: If timing marks are not in alignment, the sprocket and chain
installation must be removed and reinstalled. Misaligned sprockets will
cause the engine to run erratically.
g.Try to slide a .010" thick feeler gauge between the straightedge
and each sprocket face. If the feeler gauge does not fit at either
location, the front to rear alignment of the sprockets is correct.
In most situations, re-using the original crankshaft and camshaft
sprockets, the alignment will be correct. Mis-alignment is
generally because a different camshaft sprocket is used at reassembly. In cases where the alignment front to back is not within
.010", spacing washers are available from the OEM or aftermarket
sprocket manufacturer to align the gears. Gear alignment must
be within .010" before proceeding.
13. Replace cam chain guide. See Picture 6 on page 5.
14. Apply red Loctite® to threads of rear cam sprocket bolt and
crankshaft sprocket bolt and a drop of clean 20W-50 engine
oil beneath bolt heads. Place original large washer onto crank
sprocket bolt. Use sprocket tool H-D® #42314 to secure sprockets.
Tighten rear cam sprocket bolt to 34 ft./lbs. Tighten crank sprocket
bolt to 24 ft./lbs.
h.After verifying correct sprocket spacing, remove camshaft and
crank sprocket bolts, remove both sprockets, and discard smaller
diameter washer used under head of crank sprocket during
alignment check.
15. Using H-D #42313 (Cam Chain Tensioner Unloader) relieve spring
pressure on retaining pin and remove pin.
16. Install outer cover with new gasket and tighten bolts to 90-120
in-lbs. in sequence shown in Picture 16, next page.
12. Installing outer sprockets and drive chain.
a. While holding rear cam sprocket vertically in one hand, place
drive chain over sprocket with timing mark pointing down. Then,
with the other hand place the crank sprocket in the chain loop
with the timing mark pointing up. See Picture 15, next page.
17. Release lifters and slide them down the tappet bore to contact
cams. If using stock pushrods or S&S Quickee pushrods, tappet
covers may be left in place. If using S&S standard adjustable
pushrods, tappet covers must be removed.
b.Maintaining the position of the sprockets in the chain, rotate the
rear drive sprocket until it slides on the splines of the rear cam.
(The sprocket will only go onto the splines in one position.)
E. Pushrod Installation And Adjustments
1. Using Stock Non-Adjustable Pushrods
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 475, 509, and 510 cams
are bolt-in.
c. Continue to maintain the position of the sprockets on the
chain. Rotate the rear cam and sprocket until the flat on the
crank sprocket aligns with the flat on the crankshaft. Slide drive
sprocket onto crankshaft.
a. 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 travel, and the cylinder is at TDC, the cylinder
is at TDC compression.
d.Rotate engine by turning rear wheel to align the timing marks as
close as possible. (See Section B Securing Motorcycle.)
e. Lay a straight edge across the centers of the crank and cam
Picture 13
Picture 14
7
7
6
1
4
9
10
5
8
3
Picture 15
2
Picture 16
b.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.
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.
c. 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.
b.Loosen locknuts on adjustable pushrods and turn adjusters to
make all rods as short as possible. Z. When installing pushrods,
note that longer S&S® pushrods are for exhaust valves, and shorter
ones are for intake. Pass one long and one short pushrod through
assembled pushrod covers.
d.Insert the top of the pushrod into the hole in the head, then drop
the bottom into the tappet cover.
e. Apply assembly lube or suitable clean engine oil to the pushrod
tips where they will contact the rocker arms.
c. Place pushrod and cover assemblies through lifter cover. Inner
tappet hole is for intake pushrod, and outer tappet hole is for
exhaust pushrod. If using S&S standard adjustable pushrods, hold
a new gasket under lifter cover and install push rod, pushrod cover,
lifter cover, and gasket as an assembly on crankcase. Tighten lifter
cover screws to 95 in-lbs. torque. Stock pushrods or S&S Quickee
pushrods, can be installed without removing tappet cover.
f. Insert the rocker arm support assembly into the rocker box.
g.Ensure that the pushrod tips are fully engaged in the rocker arms.
h.Apply Loctite® 243, then evenly snug the four 5/16" bolts which
hold the rocker arms in place just finger tight at this time.
i. Start the two breather cover bolts at this time, but do not tighten
them.
d.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.
j. 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.
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.
k. Tighten the two breather cover bolts to 90-120 ft-lbs.
l. Allow lifters to bleed down, then check to ensure both pushrods
rotate freely by hand.
e. Allow the tappet to bleed down until you are able to rotate the
pushrod freely by hand, before adjusting the next pushrod.
m. Install pushrod cover keepers.
n.Install new rocker box gasket, and rocker box top cover.
f. Repeat steps 5 and 6 for the other pushrod on the same cylinder.
o.Apply blue threadlocker to the six rocker cover bolts and tighten
in a star pattern to 15-18 ft-lbs.
g.Ensure both pushrods rotate freely, then repeat steps 1 through 6
for the other cylinder.
p.Repeat for the other cylinder, following steps 1 through 15.
h.Install pushrod clips.
q.Install the gas tank.
i. Shift transmission into neutral.
r. Shift transmission into neutral.
j. Lower motorcycle onto lift and remove jack.
s. Lower motorcycle onto lift and remove jack.
k. Install spark plugs and plug wires.
t. Install spark plugs and plug wires.
l. Reconnect negative battery cable.
u.Reconnect negative battery cable.
NOTE: The tappets may be noisy upon initial start-up after installing cams.
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.
2. Using Adjustable Pushrods
a. Place transmission in high gear and turn rear wheel to rotate
engine until both lifters for front cylinder are at lowest point in
their travel. The front piston is now at TDC of compression stroke. If
equipped with S&S Easy Start cams, you must use extra care when
adjusting pushrods. Because the decompression lobe is near TDC,
you must make sure that the tappet is not on the lobe. This will
cause incorrect exhaust pushrod adjustment. To verify correct
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