Service manual

ManualsBrandsS&S Cycle ManualsAutomotiveTwin Cam 88

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

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

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

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



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

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

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

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

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

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



DISCLAIMER:

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

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

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

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

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

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

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

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

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

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



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

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

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Instruction 106-5893

07-10-13



 





Summary of content (8 pages)

PAGE 1
Instruction 106-5893 S&S Cycle, Inc Copyright © 2009–2013 by S&S® Cycle, Inc. 14025 Cty Hwy G PO Box 215 Viola, Wisconsin 54664 07-10-13 ® . 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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SPECIFICATIONS FOR S&S® GEAR DRIVE CAMSHAFTS FOR HARLEY-DAVIDSON® TWIN CAM 88® ENGINES Timing Cam Name Lobe 475G 509G 510G (e*) 99-04 Models Duration Open Close Int 2° 34° 216° Exh 36° 4° 220° Int 18° 18° 216° Exh 46° 11° 237° Int 20° 38° 238° Exh 52° 20° 252° 551G (e*) Int 17° 19° 216° Exh 41° 17° 238° 570G (e*) 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°
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•• •• the stock chain cam drive. S&S Gear Drive Cams must be used with S&S gear drive camshafts. Except for the 475G, 509G, and 510G, the S&S® driven camshaft kits are not compatible with stock pushrods or valve springs. S&S adjustable pushrod kit 93-5095 is recommended for engines with stock length cylinders. Longer pushrods are available for engines with longer than stock cylinders. See the S&S catalog for pushrods and valve springs.
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NOTE: S&S® recommends using Harley-Davidson® sprocket locking tool H-D® #42314 to secure sprockets while bolts are being removed. See Picture 2 previous page. CAUTION Failure to remove and install bolts according to correct procedure may result in parts damage not covered under warranty. M. Carefully remove cam support plate assembly from case. N. Check pinion shaft runout. Place an indicator on the end of pinion shaft at cam support plate bushing surface and rotate engine; reading must be .
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Picture 5 Picture 6 securing inner gears to cams. Remove material from retainer, to provide .030" clearance between key and retainer. See Picture 9 below. R. Use Harley-Davidson® cam chain tensioner unloader H-D® #42313 to remove retention pin from either tensioner. Allow tensioner to completely relax. Remove retaining ring and tensioner assembly from cam support plate. Repeat this procedure for remaining tensioner. D. Align hole in bearing retainer with oil passage in support plate.
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camshaft and inner race of rear bearing. Support bearing by inner race and with camshaft gear timing marks aligned (See Figure 3 below), press camshaft all the way into bearing. 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. NOTES: Crankshaft and cam drive gears have a light press fit on their respective shafts.
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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. a. Rotate engine so one piston is at TDC compression, by rotating the rear tire while feeling the tappets.
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S&S® GEAR DRIVE CAMS ASSEMBLY PARTS 1234- 567- 89- Gasket, Cam Cover........................................................................31-2032-S Bearing, Needle, Inner Cam (2)................................................... 31-4080 Bearing, Outer Cam, Ball............................................................... 31-4081 Gear, Pinion Standard Diameter................................................. 33-4160 Undersized...........................................................................