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Don't let the Harley heat monster ruin your riding.
Reduce  Engine Surging
Improve Throttle Response
Reduce Engine Ping


HD 2007/2008 Engines

High Heat on 2007/08 HD engines

HD 2007/08 Performance Recommendations

Cool your exhaust temperature with the Wide Band O2 upgrade for 2007/08 HD

Harley Camshaft Specification Tables

HD Twin Cam Engine Builds
TC 128 HP 95 CID
TC 100HP Street Engine

The basics of Fuel Injection explained

Rammer Performance Air Cleaners
TC Performance Heads 100+HP

Pro Tuning on a Shade Tree Budget


Step by Step instructions
Installing a Camshaft in your Evolution motor

Detailed Instruction:

Here are step-by-step instructions for the installation of a camshaft in a Harley-Davidson Big Twin engine.

bulletDisconnect electrical power from bike by removing negative (ground) cable at the battery
bulletRemove spark plugs
bulletRemove air cleaner and air cleaner backing
bulletRemove exhaust system
bulletRemove 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
bulletIf 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
bulletRemove the pushrod tubes. If you still have stock pushrods
cut them out with bolt cutters
Drain Gas
Remove gas tank
Remove Rocker Box Covers
Remove Pushrods
Mark pushrods location when the are removed
bulletRemove ignition sensor or module. Remove timing cup.
bulletRemove 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
bulletNote 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
bulletCarefully 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
bulletRemove breather and washer
bulletRemove camshaft thrust washer
bulletRemove 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.
bulletMake 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.
bulletPlace 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.
bulletIf 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.
bulletCarefully 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.
bulletReplace breather, making sure alignment marks on breather and cam gear line up. Place nylon washer on end of breather.
bulletReplace nosecone gasket.
bulletDepending on age of bike or mileage, replacement of camshaft bushing and camshaft oil seal in nose come should be considered.
bulletCarefully replace the nosecone cover. Replace the nosecone cover bolts and tighten to the proper torque.
bulletIf 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
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.
bulletInstall the timing cup on the end of the cam and carefully tighten the bolt. Do not over tighten.
bulletReplace 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.
bulletCarefully 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.



Table of Contents
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Modification, Installation, Maintenance and Tuning Index  will help you find most of the information you want on one page.

How to get Professional Tuning Results at home
Testing the Innovate Motorsport LM-1 portable air fuel meter

Profession Tuning on a Shade Tree Budget

Veypor VR2 Data Logger and Instrument Panel
Video Installation and Demo
Purchase VR2

Engine Performance
How to Build a
TC96 2007 Engines
TC88 70HP Stage1  
TC95 128HP Stage 3
TC95 100HP Street
TC96 2007 Stage 1/2
EVO 64 HP Stage 1
EVO 74 HP Stage 2
EVO 82 HP Stage 3
EVO 95 HP Stage 3
883 to 1200 Upgrade
Shovelhead Modifications

New EFI for EVO and TC

Performance Gallery
Horsepower Gallery
Evolution 80
Twin Cam 88/95
Evolution Unlimited
Sportster Unlimited
Drag Strip Gallery
Land Speed Racing Gallery
CV Carburetor
Modifying the CV carb
Tuning a CV carb
Selecting a cam
Install a TC 88/95 cam
Install a Big Twin cam
Install Sportster cams

Camshaft Specifications
Twin Cam

Exhaust Systems
EVO Exhaust Testing
TC Exhaust Testing
Khrome Werks AR100 test
Making Drag Pipes Work

Shop Manual
Carburetor Troubleshooting
Finding Manifold Leaks
Cylinder Heads
Pistons and Cylinders
Belt Drive
Shop Manual Appendix
$20 Bike Lift
Plug Wires
Spark Plugs
Engine Tuning
Nitrous Oxide
Motor Oil
Stutter Box
General Information
WEB Links
Buy Books and Manuals
Performance Calculations
Estimate Horsepower
Estimate 1/4 Mile Time
Estimate Top Speed

Engine Displacement
Exhaust Length
Gear Ratios
Air Density

The Nightrider Diaries
The ramblings of a genius a, a madman and something in between.

Where is Sifton Cams?

Autocom Active-7 tested

Harley-Davidson EFI
-EFI basics explained
-EFI modifications explained

183 HP, 2 carbs, 2680cc

Copyright 1997-2006  Stephen Mullen, Oldsmar, FL -+-