1606 - Jims
Contents
1. Part No Application Bore Size Stroke Application Compression Ratio Rings No 1608 Use on Series Il Twin Cam 116 1999 Present 4 STD 4 5 4 625 10 19 1 No 1491 No 1608A Use on Series Il Twin Cam 116 1999 Present 4 005 4 5 4 625 10 19 1 No 1492 No 1608B Use on Series Il Twin Cam 116 1999 Present 4 010 4 5 4 625 10 19 1 No 1493 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Alpha amp Beta Twin Cam 117 Stroker Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Ratio Rings No 1616 Use on Alpha Twin Cam 117 2007 Present 4 125 STD 4 375 10 5 1 No 1286 1354 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Alpha Twin Cam 120 Stroker Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Ratio Rings No 1611 Use on Twin Cam 1999 Present 4 125 4 5 10 5 1 No 1286 1354 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Beta Twin Cam 120 Stroker Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Ratio Rings No 1613 Use on Twin Cam 1999 Present 4 125 4 5 10 5 1 No 1286 1354 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Alpha Twin Cam 124 Stroker2. No 1606 IS REV H 1 14 Recommended Tools 3 vg Is ums PartNo ODescription ES 2 JIMS No 1235 Piston Ring Expander gt JIMS No 1236 Piston Ring Compressor JIMS No 930 Cylinder Torque Plates Read instruction sheet completely before performing work Also read H D Service Manual for piston and cylinder repairs JIMS Twin Cam Piston sets are CNC milled from aerospace forged 2618 aluminum alloy Pistons are available in Big bore sizes and Stroker sizes of STD to 010 For 927 wrist pin clips use JIMS 4 pack No 1604K For 827 wrist pin clips use JIMS 4 pack No 1602K 7 a K f Alpha amp Beta Series Il Twin Cam 100 Big Bore Piston Sets H D Stock Stroke Flywheels Bore Size Stroke Application Compression Ratio Rings No 1603 Use on Twin Cam 100 1999 Present 4 STD 4 956 No 1491 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Alpha amp Beta Twin Cam 106 Stroker Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Ratio Rings No 1614 Use on Twin Cam 106 1999 2006 4 125 4 10 1 No 1286 1354 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Alpha Twin Cam 110 Stroker Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Rati
3. Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Ratio Rings No 1617 Use on Twin Cam 1999 Present 4 125 4 625 10 5 1 No 1286 1354 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Beta Twin Cam 124 Stroker Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Ratio Rings No 1618 Use on Twin Cam 1999 Present 4 125 4 625 oSI No 1286 1354 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Note It is the Engine builder s responsibility to check and confirm the operating clearances when installing any of JIMS products JIMS 555 Dawson Drive Camarillo Ca 93012 phone 805 482 6913 Fax 805 482 9224 www jimsusa com No 1 606 IS REV H A Division of Thiessen Products Inc 1 14 INSTRUCTION SHEETS FOR JIMS FORGED PISTON SETS Step 1 Piston to Cylinder Clearance 002 to 003 at 68 F a Maintaining a minimum clearance between the cylinder wall and the piston will require a longer break in period but will prolong the life of the pistons and rings b Maintaining a loose fit will not require as long of a break in period however the loose fit will decrease the pistons and rings life c Cylinders should be honed with 240 280 grit stone Follow the H D Service Manual for boring and honing procedures Use JIMS Torque Plates when boring
4. breach of contract or duty between JIMS and a customer 4 JIMS parts are designed exclusively for use in Harley Davidson motorcycles JIMS shall have no warranty or liability obligation if JIMS part is used in any other appli cation 5 Any damaged or defective product replaced by JIMS will not be returned under any circumstance JIMS 555 Dawson Drive Camarillo Ca 93012 phone 805 482 6913 Fax 805 482 9224 www jimsusa com 3
5. e can result Ring gap placement must be per H D service manual 6 Install pistons per H D service manual Valve Pockets Figure 1 pi Break In Procedure After final assembly the engine must be broken in Over revving or lugging engine could cause damage to pistons and or other engine components On the initial start up excessive heat build up can occur Do not over heat by revving engine or running at a fast idle too long To ensure proper head gasket seal upon first time engine start up idle engine 1000 1500 R P M until cylinder head temperature reaches about 250 degrees Shut engine off and let cool This procedure is necessary to properly seal top end components Because most engine damage could occur during the first 50 miles keep the heat down by not exceeding 2800 R P M but do not lug engine Continue to vary speed for the next 500 miles and do not exceed 3800 R P M for the balance of the first 1000 miles Avoid overheat ing engine Do not lug engine or idle for long periods of time No trailer towing racing etc Change oil and filter after the first 500 miles WARRANTY All JIMS parts are guaranteed to the original purchaser to be free of manufacturing defects in material and workmanship for a period of six 6 months from the date of purchase Merchandise that fails to conform to these conditions will be repaired or replaced at JIMS option the parts are returned within the six 6 mont
6. hs warranty period or within ten 10 Days thereafter In the event warranty service is required the original purchaser must call or write JIMS immediately with the problem Some problems can be rectified by a telephone call and need no further course of action A part suspected of being defected must not be replaced by a dealer without prior authorization b JIMS If it is deemed necessary for JIMS to make an evaluation to determine whether the part is defective it must be packaged properly to prevent further done age and be returned prepaid to JIMS with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem how the part was used and the circumstances at the time of failure If after an evaluation has been made by JIMS and the part was found to be defective repair replacement or credit will be granted ADDITIONAL WARRANTY PROVISIONS JIMS shall have no obligation in the event a JIMS part is modified by person or organization 2 JIMS shall have no obligation if a JIMS part becomes defective in whole or in part as a result of improper installation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the part 3 JIMS shall not be liable for any consequential or incidental damages resulting in the failure of a JIMS part the breach of any warranties the fail ure to deliver delay in delivery delivery in non conforming condition or for any other
7. o Rings No 1615 Use on Twin Cam 110 2007 Present 4 STD 4 375 10 1 No 1491 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Alpha amp Beta Series Il Twin Cam 113 Stroker Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Ratio Rings No 1607 Use on Series Il Twin Cam 113 1999 Present 4 STD 4 5 4 625 No 1491 No 1607B Use on Series Il Twin Cam 113 1999 Present 4 010 4 5 4 625 No 1493 Using a 040 thick head gasket Compression Ratio Approximate 0 927 Wrist pin O D Alpha amp Beta Series Twin Cam 113 amp 116 Stroker Piston Sets JIMS Stroker Kits Part No Application Bore Size Stroke Application Compression Ratio Rings No 1620 Use on Series Twin Cam 113 amp 116 1999 Present 4 005 4 5 4 625 9 56 1 No 1492 Using a 040 thick head gasket Compression Ratio Approximate 0 827 Wrist pin O D Note It is the Engine builder s responsibility to check and confirm the operating clearances when installing any of JIMS products JIMS 555 Dawson Drive Camarillo Ca 93012 phone 805 482 6913 Fax 805 482 9224 e www jimsusa com 1 No 1 606 IS REV H 1 14 A Division of Thiessen Products Inc INSTRUCTION SHEETS FOR JIMS FORGED PISTON SETS Alpha amp Beta Series Il Twin Cam 116 Stroker Piston Sets JIMS Stroker Kits
8. or honing T C cylinders d Check piston diameter at the point indicated in figure 1 Measure pistons at the widest point across the front and back per pendicular to wristpin bore See figure 1 e Piston Direction When installing your pistons onto your rods position the piston so that the arrow marked on the top will be pointed in the direction of the intake valve See figure 1 f Ring Installation use JIMS No 1235 ring expander tool to install rings 1 Top compression ring has a silver tint on the outside face If Direction this ring has an identifying mark dot install in top groove of Mirectional Pistons Oniy piston with dot facing up If there is no dot present install the silver tinted outer faced ring in the top groove with the beveled edge facing up 2 Second compression ring has a darker outside face with a bevel on the inside face This ring should also have an identifying mark a dot Install in second groove of piston with dot facing up If there is no dot install second ring with beveled edge fac ing down 3 Oil control rings are of three piece design One inside expander Do not shorten expander and two rails Install expander with a rail placed below expander and above expander 4 Ring Gap Inspection Both top and second compression ring end gap to be 016 to 022 With the two oil control rails end gap to be 010 to 050 Note If any ring gaps are modi fied all burrs must be removed or engine damag
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