1. To take away stock pushrods which won't be reused, remove pushrod cover clips, collapse pushrod covers, place bike in gear, and rotate engine to put lifters and pushrods for either cylinder at lowest point on camshaft. Piston for identical cylinder can be at TDC on Compression stroke and pushrods will spin with gentle finger pressure.
CAUTION - Cutting pushrods with noticed might end in metal chips entering engine and inflicting extensive engine injury not lined below warranty.
WARNING - Proceeding with out pushrods in proper position can cause bodily injury. Reduce pushrods with bolt-cutter and take away from engine. Rotate engine to position pushrods for other cylinder at lowest level and repeat procedure.
If stock pushrods are to be reused, remove motorbike gas tank and high rocker covers. Take away rocker assemblies and pushrods according to process described in Harley-Davidson TC88 Service Manual.
2. Take away engine gear cover and gasket. It's not necessary to remove ignition sensor from cover. Safe lifters with magnets or device constructed from massive binder clip spring.
3. Rotate engine to align camshaft timing marks.
4. Take away bolt and washer from 17 tooth crankshaft sprocket.
5. Take away bolt and washer from 34 tooth main camshaft sprocket.
NOTE - Use H-D Sprocket Locking Device HD42314 to safe sprockets while bolts are removed.
6. Use H-D software HD42313 (Cam Chain Tensioner Unloader) to swing major cam chain tensioner away from chain. Secure with retention pin.
7. Working gradually round edge of sprocket, carefully pry sprockets off cams till loose on shaft. Remove sprocket/chain meeting and mark chain with arrow to point course of travel. Chain needs to be reinstalled in similar direction.
8. Take away chain guide. Steadily loosen and take away four oil pump bolts in accordance with sequence described in "Backside End Overhaul" section of H-D Twin Cam 88 Service Manual. Regularly loosen and remove six help plate bolts in accordance with sequence described in "Bottom Finish Overhaul" part of Service Manual.
NOTE- Failure to take away or set up bolts in response to correct process may end in components damage not coated below warranty.
9. Rigorously take away cam assist plate assembly from crankcase. Use tool HD42313 to swing remaining cam tensioner away from chain. Secure tensioner with second retention pin inserted by entrance of support plate. Do not take away pin until support plate assembly has been reinstalled in engine.
NOTE - It isn't essential to take away oil pump from engine to finish installation. However, installer should insure that oil pump o-rings are in good situation and stay in place during procedure. It's installer’s duty to interchange o-rings if necessary.
10. Remove screws that safe bearing retainer to support plate and remove retainer from plate.
11. Fastidiously help cam help plate on desk of hydraulic press. Using Harley-Davidson camshaft remover/installer device HD-43644, take away inventory cams and bearings from support plate.
NOTES: Bearings are often damaged throughout elimination and shouldn't be reused. New cam bearings ought to be obtained from other supply and put in with new cams. Mark secondary cam chain to indicate path of travel. Chain must be reinstalled in same direction.
12. Apply meeting lube to outer race of cam bearing and inside race of help plate. Utilizing device HD-43644 and hydraulic press, install cam bearings in assist plate.
13. Apply thin film of meeting lube to bearing surface of camshafts and inner race of latest cam bearings. Assist bearings by inside race. Utilizing device HD-43644, press cams into bearings.
14. Align cam timing marks and install secondary cam chain in original direction of travel. Apply thin movie of assembly lube to outer bearing race and bearing floor of cam assist place and press cam/bearing assemblies into cam assist plate.
NOTE: Rear cam has tapped hole in finish of shaft. Front cam is slightly longer than rear cam. Place ram of press over entrance cam space of cam installation software when starting installation. Place ram over heart of cam installation tool after both cams have engaged bearings and reached similar set up height.
15. Utilizing Loctite 243 (blue) on screw threads, reinstall bearing retainer and tighten screws to 20-30 in-lbs.
16. Take away cam needle bearings from crankcase with Harley-Davidson software HD42325 and exchange with new bearings. Lubricate with clean engine oil.
17. Apply thin layer of meeting lube to cam journals and lobe surfaces. Align cams with needle bearings and thoroughly slide help plate assembly over crankcase dowels. Apply Loctite 243 to 6 assist plate screws, set up screws, and gradually tighten to 95 in-lbs. in correct sequence ill.
NOTE - Support plate meeting ought to slide into place with out resistance. If resistance is encountered, decide trigger before proceeding. Don't drive plate assembly!
CAUTION - It is attainable to strip holes for help plate screws when using most one hundred twenty in-lb. maximum torque spec beneficial by H-D. Holes stripped are those which go by alignment dowels, Positions 1 & 2 in H-D diagram of Cam Help Plate/Oil Pump Torque Sequence.
18. Apply Loctite 243 to threads and reinstall 4 oil pump bolts in keeping with procedure in H-D service guide: Gently backside screws, then back out 1/4 turn. Heart pump by rotating engine whereas snugging screws. Tighten bolts to 90-one hundred twenty in-lbs. in sequence.
19. Instructions from Andrews Products have to be adopted to install new A/P sprocket:
One three/sixteen drive key and three shims are supplied in every 34 tooth sprocket kit. Three shims are: .005", .010", and .020" thick. Andrews Merchandise 34T sprockets are same length as stock sprockets plus .350" spacer (approximately .690" length). If inventory sprocket used .350" spacer, no shim is required. If stock spacer is .355", use A/P .005" shim. If inventory spacer is .360", use A/P .010" shim. If stock spacer is .365", use .005" and .010" A/P shim. If inventory spacer is .370", use A/P .020" shim. Key offered in kit would require gentle submitting for proper, tight slot in rear cam and sprocket.
CAUTION: Forcing or driving key into position can damage elements and lead to extensive engine harm not covered beneath warranty. Length of key must not intervene with retaining washer. Shorten key if necessary.
NOTE - Following above procedure should lead to appropriate sprocket alignment. Nonetheless, S&S recommends checking alignment before proceeding. Briefly set up sprockets with out chain and tighten sprocket bolts with out Loctite to 25 ft-lbs. Straightedge can then be positioned throughout sprocket faces and gap (if present) between straightedge and low sprocket measured with feeler gauge. Gap must be less than .005 in. If needed, remove gear and set up A/P shims to correct gap. Remove sprockets after alignment is confirmed and continue installation as described below.
20. Change cam chain guide. Rotate cams until cam marks align. Verify alignment with straightedge.
21. Insert screwdriver by means of hole in high of support plate and thoroughly pry up on tensioner. Remove retaining pin from secondary cam chain and ensure position of cam marks.
22. Maintaining authentic path of travel indicated by arrow drawn in Step 7, place primary cam chain over sprockets. Rotate sprockets until marks align and slide sprockets over pinion shaft and rear cam.
NOTE - Flat floor on finish of pinion shaft should face up towards middle of rear cam for timing marks to align.
23. Apply pink Loctite to threads of sprocket bolt and pinion bolt and a drop of fresh 20W-50 engine oil beneath bolt heads. Use HD sprocket tool to secure sprockets and tighten bolts to 25 ft-lbs.
24. Fastidiously remove retaining pin.
25. Install outer cowl with new gasket and tighten bolts to ninety-a hundred and twenty in-lbs.Replace any remaining elements eliminated to facilitate cam installation. Begin engine and verify for leaks.