EVO BIG TWIN PISTON SET Instruction Sheets for JIMS® Forged
Contents
1. 5 4 25 No 1462 No 1555B Use on EVO Big Twin 80 1984 99 3 5 010 4 25 No 1463 Compression Ratio Approximate 0 792 Wrist pin O D EVO Big Twin 87 Stroker Piston Sets Application Bore Size Stroke Application Compression Ratio Rings No 1558 Use on EVO Big Twin 87 1984 99 No 1461 No 1558A Use on EVO Big Twin 87 1984 99 No 1462 No 1558B Use on EVO Big Twin 87 1984 99 No 1463 Compression Ratio Approximate 0 792 Wrist pin O D CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS NOTE IT IS THE ENGINE BUILDER S RESPONSIBILITY TO CHECK AND CONFIRM THE OPERATING CLEARANCES WHEN INSTALLING ANY OF JIMS PRODUCTS Performance Farts for Harley Davidson Noiorcyclar 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 D REV H 8 08 No 1530 IS A Division of Thiessen Products Inc INSTRUCTION SHEETS FOR JIMS FORGED ALUMINUM PISTONS EVO Big Twin 89 Stroker Piston Sets Part No Application Bore Size Stroke Use Compression Ratio Rings No 1561 Use on EVO Big Twin 89 1984 99 3 5 STD 4 625 No 1461 No 1561A Use on EVO Big Twin 89 1984 99 3 5 005 4 625 No 1462 No 1561B Use on EVO Big Twin 89 1984 99 3 5 010 4 625 No 1463 Compression Ratio Approximate 0 792 Wrist pin O D EVO Big Twin 96 Stroker Piston Sets Application Bore Size Stroke Use Compression Ratio Rings No 1576 Use on EVO Big Twin 96 1984 99 3020 S2. H D service manual 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 overheating 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 months warranty period or within ten 10 Days thereafter In the event warranty service is required the original purchaser must call or write JIMS immediately wit
3. IE 4 625 al No 1467 No 1576A Use on EVO Big Twin 96 1984 99 3 625 005 4 625 Ial No 1468 No 1576B Use on EVO Big Twin 96 1984 99 3 625 010 4 625 hd oa No 1469 Compression Ratio Approximate 0 792 Wrist pin O D EVO Big Twin 106 Stroker Piston Sets Part No Application Bore Size Stroke Use Compression Ratio Rings No 1584 Use on EVO Big Twin 106 1984 99 3 812 STD 4 625 10 1 No 1475 Compression Ratio Approximate 0 792 Wrist pin O D falve Pockets Directio Directional Pistons Only sayy Compression Height Figure 1 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS NOTE IT IS THE ENGINE BUILDER S RESPONSIBILITY TO CHECK AND CONFIRM THE OPERATING CLEARANCES WHEN INSTALLING ANY OF JIMS PRODUCTS Performance Farts for Harley Davidson Noiorcyclar 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 1530 IS REV H 8 08 A Division of Thiessen Products Inc INSTRUCTION SHEETS FOR JIMS FORGED ALUMINUM PISTONS Instructions 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 hon
4. No 1530 IS REV H 8 08 A Division of Thiessen Products Inc INSTRUCTION SHEETS FOR JIMS FORGED ALUMINUM PISTONS Instructions for EVO and Big Twin Recommended Tools Part No Application JIMS No 1235 Piston Ring Expander Tool JIMS No 1236 Piston Ring Compressor Tool JIMS No 1164 Piston Support Plate Read instruction sheet completely before performing work Also read H D Service Manual for piston and cylinder repairs Charts and Specifications JIMS has provided you with detailed information listing the applications and specifications of each JIMS Stroker kit applicable to this instruction sheet Please refer to this information throughout your installation for critical component combinations and specifications Do not attempt to install your Stroker kit without cross checking each component for compatibility EVO BIG TWIN PISTON SET JIMS Piston sets for EVO Big Twin motors are CNC milled from aerospace forged 2618 alu minum alloy Pistons are available in standard bore sizes of 3 1 2 to 3 5 8 as well as sever al common oversizes ranging from 005 to 010 with a 9 25 1 to 10 1 compression ratio Replacement wrist pin clips 4 pack JIMS No 1599K 2 rs LLAR ad EVO Big Twin 80 Piston Sets Part No Application Bore Size Stroke Application Compression Ratio No 1555 Use on EVO Big Twin 80 1984 99 39 SID 4 25 No 1461 No 1555A Use on EVO Big Twin 80 1984 99 3 5 00
5. bligation if JIMS part is used in any other application 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 amp
6. ed with 240 280 grit stone Follow the H D Service Manual for boring and honing procedures Use JIMS No 1073 Torque Plates when honing Big Twin cylinders D Check piston diameter at the point indicated in figure 1 Measure pistons at the widest point across the front and back perpendicular to wristpin bore See figure 1 Step 2 Piston Direction A 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 Note If there is no arrow on the top of your piston then they may be mounted in either direction B Ring Installation 1 Top compression ring has a silver tint on the outside face This ring must be installed with bevel facing up 2 Second compression ring has a darker outside face with a bevel on the inside face This ring also has an identifying mark a dot Install in second groove of piston with dot facing up 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 modified all burrs must be removed or engine damage can result 5 Ring gap placement must be per H D service manual 6 Install pistons per
7. h 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 by 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 damage 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 war ranties the failure to deliver delay in delivery delivery in non conforming condition or for any other breach of contract or duty between JIMS and a customer 4 JIMS parts are designed exclusively for use in HarleyDavidson motorcycles JIMS shall have no warranty or liability o
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