 | Disconnect electrical power from bike by removing negative (ground)
cable at the battery |
| Remove spark plugs |
| Remove air cleaner and air cleaner backing |
| Remove exhaust system |
| Remove Ignition cover. scribe a mark on the plate and on the inside
of the nose cone to help get the timing set when the bike is put back together |
| If Needed (if you have a Carlini Torque Arm)
Drain the oil from the transmission
Loosen the foot peg or brake pedal
Remove the Transmission cover |
| Remove the pushrod tubes. If you still have stock pushrods
cut them out with bolt cutters
or
Drain Gas
Remove gas tank
Remove Rocker Box Covers
Remove Pushrods
Mark pushrods location when the are removed |
| Remove ignition sensor or module. Remove timing cup. |
| Remove nose cone. Use rubber or polyurethane hammer to gently tap the
cover loose. You may have to use a screwdriver to "gently" pry the cover off the
alignment pins |
| Note the location of the camshaft. Locate the timing marks on the cam
and the pinion gear. Align the marks before you remove the old cam.
With the back wheel raised off the ground, You can rotate the engine by placing the
transmission in 5th gear, then rotating the rear wheel until the desired engine position
is reached |
| Carefully remove the cam by raising the lifters out of the way. The
lifters can be:
1. Removed, marking their position to make sure they are installed in the same position.
2. Removed and replaced with new lifters. Recommended if lifters are pre-1996 or have more
than 20,000 miles on them. Harley-Davidson OEM lifters are fine for all street
applications
3. Left in place using the tool provided in a cam installation kit
4. Left in place by allow alternating lifters to prevent each other from falling out |
| Remove breather and washer |
| Remove camshaft thrust washer |
| Remove old cam bearing. Use any small inside bearing or bushing
puller to remove the cam bearing. Replace the old cam bearing with a new Torrington
B-138. Do not use a late model H-D OEM bearing with any performance camshaft.
The old camshaft can be used as alignment tool and press for installation of the new
bearing. Make sure the cam bearing is pressed completely into the engine case. |
| Make sure the pinion gear timing mark is pointed straight up. If you
have calipers, measure length of old cam from front timing gear to forward most area of
cam rear bearing area. Measure new cam. Difference should be between .050 and .060 inches.
If no caliper available to measure with, install a .055 cam shim at rear of cam. This is
generally the correct cam shim to install. |
| Place the thrust washer on the cam at the bearing end. Place a
coating of assembly lubricant on the camshaft lobes, bearing, bushing areas and camshaft
gear. This will protect the camshaft and lifters during engine startup. If you do not have
assembly lube, use synthetic motor oil as a substitute. |
| If the lifters are being replaced in the engine, remove the old
lifters and insert the new engine lifters. If your engine is not new than 1996 or has over
10,000 miles on the current lifters, it is recommended that lifters be replaced. The new
style Harley-Davidson hydralic lifters are fine for a street or street-strip engines. |
| Carefully replace camshaft by raising lifters and moving cam into
place. Make sure camshaft alignment mark matches with mark on pinion gear. This job is
much easier when using a lifter holding tool like those available from Crane Cams,
Screamin Eagle or JIM'S. |
| Replace breather, making sure alignment marks on breather and cam
gear line up. Place nylon washer on end of breather. |
| Replace nosecone gasket. |
| Depending on age of bike or mileage, replacement of camshaft bushing
and camshaft oil seal in nose come should be considered. |
| Carefully replace the nosecone cover. Replace the nosecone cover
bolts and tighten to the proper torque. |
| If you are going to reuse the stock pushrods, install the pushrods in
the proper order, replace the rocker box cover and tighten all bolts to the proper torque
or
Install the Time Saver/adjustable pushrods. Replace the rocker box cover and tighten all
bolts to the proper torque. Adjust the pushrods according the the supplied instructions. |
| Install the timing cup on the end of the cam and carefully tighten
the bolt. Do not over tighten. |
| Replace the timing sensor plate. Remember to align your scribed mark
on the timing sensor plate with the mark in the nosecone cover. Tighten the timing sensor
plate in the proper place. |
| Carefully check all your work. Replace spark plugs, plug wires and
any other items that may have been disconnected or loosened. You may not believe it, but
the engine can be fired at this point. Go through your normal cold start procedures. If
you were careful, the engine should come to life with very little effort. |
