Manual

ManualsBrandsS&S Cycle ManualsFor motorcyclesStandard and Easy Start Chain Drive Camshafts for Harley-Davidson Twin Cam 88 Engines 1999–2006 Big Twin, except 2006 Dyna models

S&S

Cycle, Inc.

14025 Cty Hwy G PO Box 215

Viola, Wisconsin 54664

  

Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

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

IMPORTANT NOTICE:





WARNING



CAUTION



NOTE

Other information of particular importance has been placed in italic type.

S&S recommends you take special notice of these items.

WARRANTY:

            

















          

            

           













ADDITIONAL WARRANTY PROVISIONS:











           

             





 





SAFE INSTALLATION AND OPERATION RULES:







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           

         

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 

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         

      



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 

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        

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

 

         





           

          



DISCLAIMER:

         

          



















        



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Instruction 106-6415

09-19-12



 





Summary of content (8 pages)

PAGE 1
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: sstech@sscycle.com Website: www.sscycle.com All rights reserved. Printed in the U.S.A.
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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.
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• 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.
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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.
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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.
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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.
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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.
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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.