Instruction Manual

ManualsBrandsS&S Cycle ManualsFor motorcycles2006-Up Gear Drive Cams for Harley-Davidson Twin Cam 88 Engines

S&S

Cycle, Inc.

235 Causeway Blvd.

La Crosse, Wisconsin 54603

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

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

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

IMPORTANT NOTICE:

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



WARNING

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

CAUTION

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

NOTE

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

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

WARRANTY:

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

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

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

ADDITIONAL WARRANTY PROVISIONS:

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



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

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

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

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

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

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

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

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

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

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

SAFE INSTALLATION AND OPERATION RULES:

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

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

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

 





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

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



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

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



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

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

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

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



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

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



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

           

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



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

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

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

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

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

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



DISCLAIMER:

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

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

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

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

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

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

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

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

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

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



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Installation Instructions for S&S® 2006-Up Gear Drive Cams

for Harley-Davidson® Twin Cam 88® Engines

Instruction 51-1234

12-15-08



 .



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Because every industry has a leader

Summary of content (12 pages)

PAGE 1
Instruction 51-1234 12-15-08 S&S Cycle, Inc Copyright © 2006, 2008 235 Causeway Blvd. La Crosse, Wisconsin 54603 by S&S® Cycle, Inc. ® . 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: sstech@sscycle.com Website: www.sscycle.
PAGE 2
S&S® Gear Drive Camshaft Specifications for Harley-Davidson Twin Cam 88® Engines Valve Timing Valve Duration Cam Name Intake Exhaust Intake 510G 20°/38° 52°/20° 570G 20°/40° 585G 20°/45° 625G 640G Centerline Lift @ TDC Exhaust Valve Lift Intake Exhaust Intake Exhaust 238° 252° .510" 99° 106° .187" .179" 55°/20° 240° 255° .570" 100° 107.5° .187" .179" 60°/20° 245° 260° .585" 102.5° 110° .186" .179" 20°/55° 60°/20° 255° 260° .625" 107.5° 110° .189" .
PAGE 3
INSTALLATION 1- Removing the Cam Chain Drive System. NOTES Changing camshafts and cam drives in the 2006-up Harley-Davidson® Twin Cam 88® engines is different than in pervious engines. Procedures require use of some special tools. Installation should be done by an experienced mechanic with access to factory service manual and required tools. Tighten all fasteners to the correct specifications and in order described. Always use an accurate torque wench.
PAGE 4
G- Remove bolts and washers from the cam drive sprocket and crankcase sprocket. NOTE: S&S recommends using H-D® sprocket locking tool H-D# 42314 to secure sprockets while bolts are being removed. See Picture 2. Picture 2 H- Working gradually around the edge of the sprocket, carefully pry the sprockets loose. Remove the sprockets and chain assembly. I- Remove the front hydraulic chain tensioner assembly. See Picture 3.
PAGE 5
CAUTION Failure to remove and install the bolts accordingly to the correct procedures may result in parts damaged not covered under warranty. L- Carefully remove the cam support plate from the assembly. NOTE: If grinding is to be done all gear case components must be removed and all holes taped off with duct tape to avoid contamination of the engine with chips. M- Remove the rear hydraulic chain tensioner assembly. See Picture 4.
PAGE 6
C- When using 585G, 625G, or 640G camshafts (33-5248, 33-5249, 33-5250) clearance between the pinion bearing boss and the rear cam lobe must be checked. See Picture 7 & 8. 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.
PAGE 7
I- Align the camshafts with the needle bearings in the case and carefully side the support plate over the crankcase dowels. See Picture 10. Picture 10 NOTE: The support plate assembly should slide into place without resistance. If resistance is encountered, determine the cause and correct the problem before proceeding. Do not force the support plate into position. The camshafts must be installed into the cam support plate before installation.
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P- Place the .188 x 150 x .57 key into the rear cam shaft keyway. Position the outer dive gear on the rear camshaft with the timing mark facing outward. Rotate the drive gear and camshafts until the drive gear and crankshaft gear timing marks are aligned. See Picture 11. Picture 11 Q- Ensure that the gear is properly aligned with the timing mark on the crank gear and the key on the rear camshaft.
PAGE 9
U- Carefully remove the cam cover. Determine the cover to gear clearance by measuring the impression left in the clay by the gear at its thinnest point. Clearance should be .030” or more. If clearance is less than .030”, or if the cover contacts the gear, remove only enough material from the cam cover to obtain the correct clearance. Repeat Steps T and U if necessary. CAUTION Be careful not to grind too deeply and break through to the outside of the cam cover.
PAGE 10
4- Pushrod Adjustment Procedure For Tappet With HL2T Kit Installed. A- Bring piston to TDC on compression stroke in the cylinder to be adjusted. Normally both tappets will be at their lowest point of travel. B- Extend the pushrod adjustment, collapsing the lifter until the piston assembly is in contact with the HL2T spacer and the pushrod is tight.
PAGE 11
S&S® 2006-UP GEAR DRIVE CAM REPLACEMENT PARTS FOR HARLEY-DAVIDSON® TWIN CAM 88® ENGINES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Pinion Gear..........................................................................................33-4160 Pinion Gear, Undersized....................................................................33-4160X Pinion Gear, Oversized....................................................................... 33-4160Z Outer Cam Gear ..........................
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Because every industry has a leader 12