Service manual

3
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.
 S&S Camshaft Installation Kit 106-5896 is strongly recommended when
installing S&S gear drive cams. The kit includes gaskets and bearings
required for installation. It also includes the scavenge side oil pump
oring.
1999-'04 stock valve springs will accommodate cam shafts with up
to .510" lift. This includes S&S 475, 509 and 510 cams. 2005 and
later stock valve springs can accommodate camshafts with up to
.585" lift. If cams are installed that exceed the lift capacity of the
stock valve springs, a set of high performance valve springs must
be installed that can handle the additional lift. Stock 2005 and
later springs are good to S&S lifts.
 When using S&S gear drive camshafts with stock Harley-Davidson®
pistons, valve-to-piston clearance may need to be checked. Clearance
should be at least .060" intake and .080" exhaust.
 If stock Harley-Davidson® heads are decked, valve to piston clearance
must be checked. If insucient clearance is found, valve pockets must
be modied. Clearance should be a minimum of .060".
 When using S&S pistons with S&S heads which are unmodied or
have been decked no more than .062", no additional valve to piston
clearancing will be required.
INSTALLATION






1- Remove Cam Chain Drive
NOTES:
 Installation procedure is dierent than in previous engines. Procedure
requires use of a hydraulic press and some special tools. Installation
should be done by an experienced mechanic with access to a factory
service manual and all required tools.
 Tighten all fasteners to correct specications and in order described.
Always use an accurate torque wrench.
Incorrect installation can cause engine damage not covered
under warranty.
Failure to install components correctly can result in sudden
engine seizure. Engine seizure may result in serious injury to
motorcycle operator, passenger, or others.
 

    

 





NOTE: S&S 475, 509G, and 510G camshafts may be installed with stock
style non-adjustable pushrods instead of adjustable pushrods. If installing
non-adjustable pushrods, disassemble and assemble rocker box per
Harley-Davidson® instructions. All other S&S® gear drive cams require
adjustable pushrods. As a time-saving measure, the stock pushrods can be
removed with bolt cutters. Be sure to heed cautions and warnings in these
instructions.
 
       


       


Cutting pushrods with a saw or cuto wheel may result in debris
entering engine, causing extensive engine damage not covered
under warranty.
Cutting pushrods when they are under spring pressure can result in
pushrod parts being ejected with considerable force, and can cause
bodily injury.
          


           

See Picture 1
below left.
 

CAUTION
CAUTION
WA RNING
CAUTION
WA RNING
Picture 1
Picture 2