1551 - Jims
Contents
1. No 1457 Big bore center case bolt washer amp nut kit No 880 1 Big bore tappet cover gasket No 1902 1 1 1 1 1 4 Wrist pin clip 2 1 2 Piston oil jet assembly CAUTION No 1457 Big bore center case bolt washer amp nut kit No 1902 N NIA eS Piston oil jet assembly WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Feria fot arkey Davidsoni Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 the following engine components All checking and removal of material will be performed on the left case first After you are satisfied with all your clear ance checks any modifications made to the left case must be done on the right case The best way to indicate where to make modifications to right case is with cases bolted together held with two case bolts Mark a line where material was removed from left case to right case Remove the marked material from right case to match the left case After you have bored the engine case for cylinders and before installing the Timken Case Bearing Conversion insert on 2003 and up clean cases o2. A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 120 Beta Silver Kit Qty Description 120 Front silver cylinder No 1506 2 120 Rear silver cylinder No 1548 Part No No 1505 1 REV A 10 13 120 Beta Black Kit Qty Description 120 Front black cylinder No 1611 1 120 Front piston w pin No 1505 2 120 Rear black cylinder No 1611 2 120 Rear piston w pin No 1611 1 120 Front piston w pin No 1286 1354 117 two piston ring set No 1611 2 120 Rear piston w pin No 1604 Wrist pin clip No 1286 1354 117 two piston ring set No 880 1 Big bore tappet cover gasket No 1604 Wrist pin clip No 1457 Big bore center case bolt washer amp nut kit No 880 1 Big bore tappet cover gasket No 1902 No 1528 Part No No 1506 1 Piston oil jet assembly 124 Alpha Silver Kit Description 124 Front silver cylinder Qty No 1457 Big bore center case bolt washer amp nut kit No 1506 2 124 Rear silver cylinder No 1902 Part No No 1505 1 No 1527 Qty Piston oil jet assembly 124 Alpha Black Kit Description 124 Front black cylinder No 1617 1 124 Front piston w p
3. No 1614 1 106 Front piston w pin No 1503 2 106 Rear black cylinder No 1614 2 106 Rear piston w pin No 1614 1 106 Front piston w pin No 1286 1354 106 two piston ring set No 1614 2 106 Rear piston w pin No 1604 Wrist pin clip No 1286 1354 106 two piston ring set No 880 1 Big bore tappet cover gasket No 1604 Wrist pin clip No 1457 No 1524 Part No No 1504 1 Qty 1 Big bore center case bolt washer amp nut kit 117 Silver Kit Description 117 Front silver cylinder No 880 1 Big bore tappet cover gasket No 1504 2 117 Rear silver cylinder No 1457 No 1523 Part No No 1503 1 Qty Big bore center case bolt washer amp nut kit 117 Black Kit Description 117 Front black cylinder No 1616 1 117 Front piston w pin No 1503 2 117 Rear black cylinder No 1616 2 117 Rear piston w pin No 1616 1 117 Front piston w pin No 1286 1354 117 two piston ring set No 1616 2 117 Rear piston w pin No 1604 Wrist pin clip No 1286 1354 117 two piston ring set No 880 1 Big bore tappet cover gasket No 1604 Wrist pin clip No 1457 Big bore center case bolt washer amp nut kit No 880
4. 1491 100 Two piston ring set No No 1522 1604 Part No No 1518 1 Wrist pin clip 110 Silver Kit Description 110 Front silver cylinder Qty No 1518 2 110 Rear silver cylinder No 1615 1 110 Front piston w pin No 1615 2 110 Rear piston w pin No 1491 No 1604 Wrist pin clip No No 1520 Part No No 1504 1 1902 Qty 1 1 1 1 1 1 110 two piston ring set 4 2 Piston oil jet assembly 106 Silver Kit Description 106 Front silver cylinder No 1501B 100 Black Kit Part No Qty Description No 1515 1 100 Front black cylinder No 1515 2 100 Rear black cylinder No 1603 1 100 Front piston w pin No 1603 2 100 Rear piston w pin No 1491 100 Two piston ring set No No 1521 1604 Part No No 1517 1 Wrist pin clip 110 Black Kit Description 110 Front black cylinder No 1517 2 110 Rear black cylinder No 1615 1 110 Front piston w pin No 1615 2 110 Rear piston w pin No 1491 110 two piston ring set No 1604 Wrist pin clip No No 1519 Part No 1902 Qty Piston oil jet assembly 106 Black Kit Description No 1504 2 106 Rear silver cylinder No 1503 1 106 Front black cylinder
5. e Check to make sure the wrist pin clip is fully seated in its groove See Fig 15 16 Piston Ring Inspection and Preparation NOTE Do this work away from the engine assembly Wipe excess oil from the piston rings Run the rings through your fingers to feel for any burrs If burrs are discovered follow theses instructions on deburring Remove any burrs with a fine jewelers file Piston ring filings are often slightly magnetic Fig 19 and May be difficult to remove from the rings or steel tools like the jewelers file you might use to adjust end gap Piston ring end gap filing creates very sharp corners on the rings These must be removed before inserting the rings into the cylinder bores It is not necessary or desirable to bevel or break the corners of a modified piston ring Wash rings after debur ring Ta SS Press ring down e Lightly lubricate with clean H D 20W 50 oil and slip one piston pin into a piston either piston will do e Place a cylinder on the bench top end up e The cylinder s bore should be clean to the touch and lightly oiled Fig 20 Square ring ends Petfotmance Faia fot arkey Davidsoni Nlorowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 17 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 See Fig 16 17 End Gap Measur
6. tapping tool No 1169 1 for all other engines No 727K Use on all Big Twin Sportster and Buell See JIMS Catalog and or www jimsusa com for further information or call 805 482 691 3 Also available is the Screamin Eagle Automatic Compression Release Tool ACR H D No 94648 08 WARNING Beta Engine kits must never be revved any higher than 6 200 RPM Your Balanced flywheels ship with a pressed on balancer drive sprocket This sprocket has been tested and proven to protect against potential damage caused by over revving the engine past 6 200 RPM THIS GEAR WILL MOVE DUE TO OVER rewving Your flywheels will NOT be warranted against movement of this sprocket due to over revving In addition to this the pressed on sprocket is not available separately CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Tavis fot areg Davidsoni Nororcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 Recommended Tools Part No Description JIMS No 2234 Primary drive locking tool A must Not for 06 Dyna and all O07 to present Big twin models Use a primary locking bar JIMS No 1288 Crankshaft guide
7. e With the piston supported on the clean pad gently expand and guide the ring over the top of the piston and into its groove Do not expand the ring any more than is needed to get it over the piston Top ring installation e Select a top compression ring Remember it has a light colored hard chrome plated sealing edge face a smaller dimple and a beveled inside edge With the dimple and bevel up grasp the ring with the piston ring expander tool See Fig 30 e Expand the ring just enough to clear the piston and guide the ring into its groove See Fig 29 e Repeat the above procedure to install the remaining piston rings on the other piston Check the fit between piston rings and piston ring grooves by sliding each ring around in its respective groove There should be no tight spots Clean pistons and proceed to the next step See Fig 31 22 Piston Cylinder Assembly Note Please read the following notes carefully Piston Ring Orientation IMPORTANT All big bore cylinders have cutaways in their skirts No piston ring end can be allowed to drop into either of these cutaways If a piston ring end gets into one of the cutaways and the piston moves upward during installation the end may catch and destroy the ring e If you follow our piston installation directions the piston rings will be protected by keep ing the ring gaps out of the cylinder spigot cutaways Cylinder differences and orientation CAUTION WEAR SAFETY GLASSES OVE
8. hot water e Wearing your clean mechanics gloves thoroughly scrub the cylinder bores with the soapy pad and hot water See Fig 4 Rinse the bores with clean hot water until you can wipe the bore with a clean white cloth and show no signs of dirt e Dry with a low lint cloth or towel e Immediately coat the cylinder bores with a light film of clean H D 20W 50 oil to prevent rust Fi e Clean head amp base gasket surfaces with a lint free cloth and denatured or 19 Isopropyl alcohol Make sure you clean all oil from the gasket surfaces 3 Place both pistons without rings on their appropriate rod Notice laser markings on top of pistons for cor rect locations on rods You may install one wrist pin lock ring to help hold wrist pin in place Left Side Don t remove lock ring or reuse rings after they have been installed and removed 4 Gently place the front and rear cylinder over studs and pistons Slowly rotate flywheels so pistons are at T D C You can hold cylinders down by using two head bolts and two short pieces of 1 2 I D rubber hose placed between bolts and cylinder 5 Check Rod to case and cylinder spigot clearance both front and rear by slowly turning flywheel counter clock wise stopping so rod has moved closer to the case and cylinder spigot As you turn the flywheels back and forth you will see the rod moving closer to case Inspect and if necessary grind or file for a minimum clearance of 060 between the
9. let the engine rpm exceed 2500 e Do not exceed 50mph 7 Next 500 miles e Do not let the engine rom exceed 3000 Do not exceed 55mph Oil Change Intervals Break in e At 50 miles e 500 miles e 1000 miles Normal Oil change intervals e 1500 to 2000 miles depending upon usage e Change the oil filter every oil change Torque Checks e Re check the torque of all accessible engine and chassis fasteners at all oil changes Do not re torque the head bolts Detonation Detonation must be avoided A detonation event is combustion before piston reaches top of stroke Most of the time these explosions are so small that they do not immediately damage the engine however if they are energetic or frequent enough things break A piston can be destroyed in a few engine revolutions from the effects of severe detonation Detonation can be brought on by a variety of conditions including incorrect ignition timing poor quality gaso line overly lean air fuel mixtures too much cranking pressure for the particular combustion chamber or engine overheating CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Feifotmance Tavis fot tlatley Vavitdton Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 22 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWI
10. race installer Use per instruction sheet with tool With flywheel assembly checked in left case by using JIMS No 1745 Timken Bearing Simulator At this point you should have the center case bolt ready to be installed and center case material removed as needed Install one bearing on flywheel sprocket shaft with both Timken bearing races Fig 4 installed in a clean case Next place flywheel in left case with No 1745 Timken Bearing Simulator holding flywheel in position You can hold this mocked up engine in one of JIMS engine stands Install your new cylinder studs per the instruction sheet that comes with studs 2 Cylinder Inspection and Preparation e Inspection e Inspect the fins and spigots of both cylinders for damage e Closely inspect the cylinder bores CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Tavis fot tlatley Vavitlton Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 6 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 e There should be no scratches other than the normal hone cross hatch e Cleaning Note Be very careful when scrubbing the cylinders to avoid cutting your hands e Soak a non abrasive cleaning pad in dish soap and
11. 1 Big bore tappet cover gasket No 1902 Part No No 1506 1 No 1526 Qty Piston oil jet assembly 120 Alpha Silver Kit Description 120 Front silver cylinder No 1457 Big bore center case bolt washer amp nut kit No 1506 2 120 Rear silver cylinder No No 1902 Part No No 1505 1 NO N A Sa eS 1525 Qty Piston oil jet assembly 120 Alpha Black Kit Description 120 Front black cylinder No 1611 1 120 Front piston w pin No 1505 2 120 Rear black cylinder No 1611 2 120 Rear piston w pin No 1611 1 120 Front piston w pin No 1286 1354 117 two piston ring set No 1611 2 120 Rear piston w pin No 1604 Wrist pin clip No 1286 1354 117 two piston ring set No 880 1 Big bore tappet cover gasket No 1604 Wrist pin clip No 1457 Big bore center case bolt washer amp nut Kit No 880 1 Big bore tappet cover gasket No 1902 No N A eS Piston oil jet assembly Se 1457 Big bore center case bolt washer amp nut kit o 1902 1 1 1 1 1 4 2 1 2 Piston oil jet assembly Fetfotmance Taria for Maey Davidson Moioicycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 No 1551 I1S No 1549 Part No No 1506 1
12. 16 center case bolt must be re torqued prior to initial start up and again after the engine has cooled e All case bolts must be re torqued once the engine has cooled after initial start up Re torquing must be con tinued after each heat cycle until the case bolts can not be torqued any further than the torque specifica tion e Refer to your Twin Cam A or B H D Service Manual for the proper tightening sequence and torque specifications for all case bolts with the follow Ing exception Important The torque value for the center case bolt is 135 155 in Ibs Center case bolt torque specification During each case bolt re torquing sequence the H D pre scribed torque specification for the 1 4 center case bolt 1 in the H D Service manual diagram should be amended to 135 155 in lbs See Fig 8 amp Fig 9 for Alpha and Beta Engines 11 Assemble per H D Service Manual NOTE When assembling case halves together seal with High Performance Sealant H D No 99650 02 or equivalent 12 Tighten case bolts to factory Specs except top center case bolt between cylinders Install top cen ter bolt last after you have cylinders and heads installed and torqued to H D specs NOTE When installing 4 bore cylinders on cases they need to have the relief on bottom of skirt facing each other when installed as shown See Fig 10 amp 11 Fig 9 Case torque sequence 13 Apply High Performance Sealant H D N
13. A must JIMS No 1283 Cam chain tensioner tool A must for spring type tensioners JIMS No 1285 or No 994 Cam crank sprocket lock tool A must JIMS No 1276 Wristpin remover installer A must JIMS No 1047TP or No 995 Crank assembly removing tool A must JIMS No 1048 Hard cap A must JIMS No 39361 69 Motor sprocket seal installation tool A must JIMS No 1022 Engine stand see catalog for different engine applications A must JIMS No 97225 55 Sprocket shaft bearing installation tool A must JIMS No 1745 Timken bearing simulator As needed JIMS No 1169 Compression Release Drilling Tool JIMS No 1408 Case Boring Tool for all Twin Cam engines JIMS No 959 Timken Case Bearing Conversion Tool for all 2003 and up Twin Cam engines JIMS No 2246 Timken bearing race installer A must JIMS No 1458 Case Bolt Spot Facing Tool JIMS No 1235 Piston Ring Expander Tool JIMS No 1236 Piston Ring Compressor Set JIMS No 1255 Ring Gap Grinder Tool JIMS No 769 Piston Pin clip Installer Remover e Feeler gauge set including 0015 through 040 blades e 3 8 drive torque wrench 0 25 ft Ibs e 12 point 1 2 deep socket 3 8 drive e 13mm deep socket 3 8 drive e Non abrasive scouring pad amp dish soap for cleaning cylinder bores Clean pair of mechanics gloves The following is a list of JIMS parts that may be needed to build a Big Bore Kit Part No Description No 1457 Big bore center cas
14. ED TO BUY Petfotmance Feria fot areg Davidsoni Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 23
15. N CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 If you choose to alter the cranking pressure ignition timing or air fuel mixture of your new engine please be aware that any of these alterations improperly done can result in engine damage You should only consider such modifications if competition pressure demands them And make them only if you have the experience or expert assistance to deal with the possibility of detonation WARRANTY All JIMS parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and work manship for a period of 6 six months from the date of purchase Merchandise that fails to conform to these con ditions will be repaired or replaced at JIMS option if the parts are returned to us by the purchaser within the 6 six month warranty period or within 10 ten days thereafter In the event warranty service is required the orig inal purchaser must call or write JIMS immediately with the problem Some problems can be rectified by a tele phone call and need no further course of action A part suspected of being defective must not be replaced by a Dealer without prior authorization from JIMS If it is deemed necessary for JIMS to make an evaluation to deter mine whether the part is defective it must be packaged properly to prevent further damage and be returned pre paid to JIMS with a copy of the original invoice of purchase and a detailed
16. No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 re No 1453 No 1114 No 1454 Fig No 1 No 1457 Case Bolt Kit Alpha Applications 100 amp 106 Big Bore kits are for use on Alpha 99 06 or Beta 00 06 Twin Cam Engines with H D flywheels 110 amp 117 Use on Alpha 07 Pres Twin Cam Engines with H D Flywheels 120 Use with JIMS Alpha flywheels kits No 1881 1882 or Beta No 1886 124 Use with JIMS Alpha flywheels kits No 1883 1884 or Beta No 1888 ATTENTION Please read all instructions completely and thoroughly before performing any work Prior to installation of this kit please read and follow the procedures and safety precautions to reduce the risk of personal injury Read instructions completely so you understand before performing any steps Always disconnect battery cables to prevent injury Your work place should be clean and well lit wear safety glasses and protective clothing when working around power tools and compressed air Follow instructions in H D Service Manual for removal and disassembly of engine for your year and model With engine removed from frame and bolted to one of JIMS engine stands follow the disassembly instruc tions in the service manual to disassemble engine Clean all parts thoroughly including gasket surfaces and inspect all parts for visible damage Measure all p
17. R YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Tavis fot tlatley Vavitdton Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 14 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 The front and rear cylinders are different Both cylinders have reduced fin width on their right sides to allow for the pushrod tubes Both cylinders have notched skirts The front cylinder s notch goes toward the rear of the engine Toward the center of the V formed by the cylinders The rear cylinder s notch goes toward the front of the engine Again toward the center of the V formed by the cylinders When the front cylinder is correctly placed its shortened fins will be on the right and the spigot notch will be toward the rear of the engine When the rear cylinder is in place its shortened fins will also be on the right but the spigot notch will be toward the front of the engine Both cylinder notches go toward the center of the engine they face each other See Fig 32 Fig 31 e Piston differences and orientation The front and rear pistons are different The rear pis ton has a notch at the bottom of its skirt The rear piston s notch goes toward the front of the engine toward the c
18. amp 1548 THRU 1551 e It is not necessary to remove material from both ends e It is important to get the filed end square When the two ends are brought together they should be as nearly parallel as possible See Fig 20 e Devise a method to clamp or control the piston ring as you file it You could use a clean smooth jawed vise with soft jaws or a machinists vise See Fig 21 e An alternate method might be to use a flat hard sharp cornered object like a thick glass plate or even a piece of hard wood Place the ring end over the edge of this piece and hold it in place with the pressure of your hand as you gently remove a bit of material with the file Do not be tempted to do the work in the air using your hand as the vise As you Start to file be sure the file is at a right angle to the end of the ring Make the angle between file and ring square from both the top and side See Fig 22 Use light pressure as you file just enough to keep it cutting Let the file do the work Clean the ring and re check the end gap often as you work especially with your first ring Piston ring ends you have modified must be de burred A light back stroke of the file across a burred corner should knock the burrs down Do not be tempted to use abrasives Your fine file is good enough e When you have finished all the rings put the file away and thoroughly clean and lightly oil the piston rings Be especially careful to remove any magnetic steel particles t
19. arts for wear using the service wear limit section in the H D Service Manual Check all threaded holes JIMS suggest using the latest cylinder studs from H D or Screamin Eagle Replace any worn or damaged parts with JIMS engine parts or equivalent The installation of all Big Bore Kits will require the cases to be bored to accept 4 or 4 1 8 bore cylinders use JIMS No 1408 Case Boring Fixture Follow the instruction sheet No 1177 IS before machining cases NOTE IF YOU DO NOT KNOW WHAT YOU ARE DOING DO NOT DO IT ALWAYS WEAR SAFETY GLASSES OR OTHER FACE AND EYE PROTECTION SUCH AS FULL FACE SHIELD JIMS IS NOT RESPONSIBLE FOR DAMAGE INJURY OR YOUR WORK JIMS IS NOT RESPONSIBLE FOR THE QUALITY AND SAFETY OF YOUR WORK The following components are recommended by JIMS for use with JIMS Big Bore and stroker kits CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Faia fot tlatley Vavitlton Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 1 REV A 10 13 No 1551 I1S A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 Caution All 100 106 and 110 kits include pistons designed for Stock H D 85cc heads All 117 120 and 124 kits include pist
20. back side of both tappet covers Some 4 000 big bore kits may need a small amount of modifica tion made to tappet cover The best way to check for the amount if any of modification needed for 4 000 big bore kits is to install both cylinders no need to install base gaskets and hold in place with head bolts Try to install both tappet cov ers no gaskets by loosely installing all screws With the all screws threaded into the case 3 to 4 turns you will have enough clearance for both covers if you can move covers in and out by the amount of screw Fig 7 clearance to covers If you are unable to move the covers then it will be necessary to remove tappet cover material from the side that is up against the cylinders You can determine the amount of material to be removed by placing the supplied gaskets over the bottom side of cover and installing all 4 screws from the gasket side Next with a marker mark a line on the exposed tappet cover seal ing surface not covered by the new gasket You can sand up to this line or only sand half the amount and do a test fit until tappet covers fit without touching the cylinder Do the same with all 4 125 bore cylinder kits but sand up to your marked line then do a test fit See Fig 7 Caution Do not sand with gaskets in place or you will damage the gaskets You will be using these for final assembly Do not let any sanding material get on your new gaskets Wash tappet covers after you sand them an
21. cles will get into your new engine If at all possible use liquid cleaners soft brushes and clean lint free towels instead e Inspect the part numbers on the piston tops against the instruction sheet parts list for the kit you ordered to assure you have the correct pis ton set There should be no dents dings or gouges on any surface of the pistons Pay particular attention to edges and corners especially the cor ners formed by the wrist pin hole and the sides of the pistons They should be smooth with no nicks or deformities Inspect the piston ring grooves for any deformities Clean the pistons and proceed to the next step Piston and ring installation information Note Piston orientation Front and rear pistons are not the same in all kits and must be installed on the correct rod All rear pistons have a skirt notch some will come with a Fig 12 smaller notch than shown See Fig 11 All pistons have laser mark ings on the top Each piston Intake 1st Clip Left Side i REN 1st Clip Tis Left Side P Ar Fig 13 Front In stall left clip Fig 15 Fully seat left clip Feifotmance Fads fot areg Davidsoni Nororcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 10 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 will be marked Front or Rear Intake with an ar
22. d before final assembly 8 Cases must be cleaned of any foreign material before you begin reassembly of your engine The assembly will be the same as any Twin Cam engine except for the Timken bearing set up Note Refer to a pre 2003 manual for information needed to set up the Timken bearing end play 9 Install two new or known to be good piston oiling jets into right case half All 4 125 bore kits are provided with new piston oiling jets No 1905 All 4 00 bore kits will use the original H D jets Apply a very thin film of clean 20 50 engine oil to the new o rings Install the new o rings in the groove on the piston oiling jets and apply a drop of Loctite 222 purple to the last few jet mounting screw threads Torque to 20 30 inch Ibs Caution Keep all foreign material out of piston oiling jets e Use a Harley Davidson Twin Cam service manual specific to your application for general assembly procedures CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Feria fot arkey Davidsoni Norowycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 8 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 10 Center Case Bolt Torque Settings e The 1 4 or 5
23. e bolt kit included in all 4 1 8 bore kits optional for use on 4 Big bore kits See Fig 1 No 1458 Case bolt spot facing tool optional must order separately See Fig 2 No 857 Set of 4 000 bore head and base gaskets for 100 and 110 kits No 873 Set of 4 125 bore head and base gaskets for 106 117 120 and 124 The following parts have been included in the kits listed below Please make sure all parts have been included in the kit you have received Follow H D or Clymer Service Manual for installation of all parts that are not included in these Big Bore kits CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Faia fot areg Davidsoni Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 3 NO No 1551 I1S A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS REV A 10 13 SHIDO 1501B 1519 THRU 1528 amp 1548 THRU 1551 The following instructions are to be followed for checking the running clearances in a mock up style for No 1501 Part No 100 Silver Kit Description No 1516 1 100 Front silver cylinder No 1516 2 100 Rear silver cylinder No 1603 1 100 Front piston w pin No 1603 2 100 Rear piston w pin No
24. ement for all kits See Fig 17 e Piston Ring end gap range e Top ring 017 to 022 e Second ring 017 to 022 e Oil control rails 020 to 050 e Tilt and start a piston ring into the bore The most common and perhaps easi est way to do this is to first insert the side of the ring opposite the gap Then flex each ring end into the bore Use your fingers to control twist as you insert the ring See Fig 18 Fig 19A e When the ring is in the bore use the piston to push it down the bore until the piston pin is slightly below the top of the cylinder See Fig 19 e Remove the piston e The piston ring is now square with the bore and positioned for end gap inspection e Use a feeler gauge as pictured to measure the width of the gap You may stack two blades if necessary See Fig 17 e Remove each ring by hooking it with a finger on the side opposite the gap and pulling smoothly and gently out of the cylinder bore e Start measuring with all piston rings to one side of the cylinder e After each ring is checked place rings that passed the end gap test on the opposite side of the cylinder Place each of those failing the end gap test on a piece of paper and write their measured end gap on the paper When you have finished separate and cover the piston rings not requiring additional fitting 18 End Gap Adjustment e It is unlikely you will need to adjust the first and oil control ring end gaps However it is likel
25. engine 1000 1500 R P M until cylinder head temperature reaches about 200 degrees Shut engine off and let cool This procedure is necessary to properly seal top end components CAUTION Improper initial engine start up may cause head gaskets to fail prematurely Because most engine damage could occur during the first 50 miles keep the heat down by not exceeding 2500 R P M but do not lug engine Continue to vary speed for the next 500 miles and do not exceed 3500 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 side cars or racing etc Change oil and filter after the first 500 miles WARNING Beta Stroker kits must never be revved any higher than 6 200 RPM Caution f this kit is installed in a Softail or any model motorcycle that has its oil tank higher than the engine you will need to follow the instructions listed below Install the recommended amount of oil and type per your owners manual 1 Following the previous start up instructions Ride the motorcycle until the engine is up to operating tempera ture 2 Idle motorcycle on kickstand for 1 2 minutes Turn the motorcycle off With the motorcycle still on kickstand remove and check oil level on the dipstick Add oil if necessary until oil registers on the upper groove of dip stick Full Hot Line Oil Cooler Recommendation ALL MODELS All big inch engines must be fitted with ef
26. enter of the V formed by the cylinders The front piston does not have a notched skirt See Fig 33 e The front piston s larger valve relief goes toward the rear of the engine the intake side of the cylinder See Fig 34 rT 23 Ring Orientation Installation Procedure e Piston installation procedure differs from that found in Harley Davidson s Twin Cam shop manuals Our alternate procedure is commonly used and preferred by many engine builders e Assembly Rear Piston Cylinder e Place the rear cylinder on your bench Spigot or bottom up See Fig 35 e Place the rear piston assembly on your bench with top end up Arrange the piston rings so that the end gaps do not line up See Fig 36 for proper front and rear piston ring placement around piston This placement is very critical to piston installation you must be certain you have duplicated ring position per the diagram or piston and ring damage can occur Fig 33 Note piston notch aia REAR FRONT S A ALO f n D my A g gt d n ING AE PAIN Note f you find it useful take a magic marker and duplicate the numbers from the diagram AA SS onto your piston Be sure you have the rear cylinder with the rear piston e Fit the piston ring compressor with a light film of clean H D 20W 50 oil over the piston just far enough to capture all the rings See Fig 37 e Align the ring compressor s handle with the smaller exhaust valve relief Tighten the com
27. ets can be installed either of two ways only one is correct Incorrect installation will close off the oil drain hole from the head Incorrect head gasket installa tion requires a partial engine tear down to fix 33 Head Gasket Orientation e The gaskets have a seventh hole about 3 8 in diameter near one of the stud holes Install each gasket so this hole is over the oil drain hole in its cylinder See Fig 54 e The front cylinder s drain hole is located at the left front See Fig 55 e The rear cylinder s drain hole is located at the left rear See Fig 56 e Make sure each cylinder and gasket is clean and free of oil Place the gasket over the locating dowels Dry Note Do not apply sealant to gasket These gaskets do not require any other sealant than what has already been applied at the factory N i Fig 5 1 Pour 1 3 quart oil Fig 52 Fig 53 a Fig 54 Petfotmance Tavis fot areg Davidsoni Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 18 REV A 10 13 No 1551 I1S A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 e Double check to make sure the oil drain hole in the gasket aligns with the oil drain hole in the cylinder 34 Cylinder Head Installation on e Clean the head gasket sealing surface with a lint free cloth a and denatured isopropyl alcoho
28. f all machining material When checking for all running clearances do not skip any of the following checks Mask off all bearings and all oil holes Optional top center case bolt is offered as stock replacement for the center case bolt the one between both cylinders This new bolt is 1 4 x 4 3 4 long to clear both cylinder spigots You will need to drill the right case to clear for this bolt You will have to remove cen ter case material that has been left over from case boring Use JIMS Case Bolt Spot Facing tool No 1458 shown on page one for this function See tool s instruction sheet No 1458 IS on www jim susa com See instruction sheet No 1457 IS that comes with the center Case Bolt kit Also see instruction sheet No 1177 IS See web site or call sales and request info for more center case bolt information For all kits having a 4 125 bore we include a Center Case Bolt kit No 1457 shown above Optional for 4 000 bore kit When performing any case bolt hole modifications always remove any case mate rial that may fall or crack off during engine operation See Fig 3 Keep all parts and tools clean Keep bearings and oil passages masked off and or covered at all times Fig 3 1 Install a new Timken bearing H D No 9028 on the sprocket shaft Use JIMS No 97225 55 Sprocket shaft bearing installation tool per instruction sheet with tool Next install both Timken bearing races in case with JIMS No 2246 Timken bearing
29. fective oil cooler The Harley No 26155 11 is an example of such a cool CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Faia fot tlatley Vavitlton Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 21 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 er Chassis Oiling System Make sure that the entire oiling system is clean If you are fitting your new Big Bore kit into a chassis that has been used be sure to completely clean the oil tank and all lines and fittings leading to and away from the engine If the old engine has more than 20 000 miles of use or if it has suffered any unusual wear dismantle the oil pan and hoses and thoroughly clean them Break In Procedure Note Follow the engine break in procedures outlined in the Harley Davidson owner s manual per your application 1 Allow the engine to warm up before riding 2 Do not use full throttle 3 Do not idle the engine for more than two minutes Note Even less if the air temperature is above 80 degrees 4 Do not overload the engine at low rpm Note All engine loads must be moderate 5 Vary the rom frequently Note Do not hold a steady speed 6 First 50 miles e Do not
30. hat may be clinging to the rings A clean damp cloth works well If you had to adjust the ring end gaps make sure to deburr the ring ends prior to installation Cover cylinder and set aside as you proceed to the next step EXPANDER SPRING OIL CONTROL RAIL SSS OE SS ff OIL CONTROL RAIL Fig 23 Oil control rings 21 Piston Ring Installations e Wash all piston rings in warm water and dish soap prior to installation on the piston Wear safety glasses while installing all piston rings Install the rings from the top of the pistons Take care not to scratch the piston as you install the rings Place a piston top end up skirt end down on your clean pad Select one set of rings Set consists of two oil control rails one expander spring one second ring and one top ring See Fig 23 e Installation Oil Control Ring Sets Note that expander spring can be installed either way there is no top or bottom The oil control rails can be installed either way too Install the oil ring expander spring Make certain the ends of the expander spring butt against one another and do not overlap See Fig 24 TAs e Work one of the oil ring rails down over the piston with your fingers It is okay to slightly ON NS twist the ring as you do this Place the first rail on the lower side of the expander spring See Fig 23 e Position its gap about 90 degrees from where the ends of the expander spring meet Install the second rail with it
31. in No 1505 2 124 Rear black cylinder No 1617 2 124 Rear piston w pin No 1617 1 124 Front piston w pin No 1286 1354 124 two piston ring set No 1617 2 124 Rear piston w pin No 1604 Wrist pin clip No 1286 1354 124 two piston ring set No 880 1 Big bore tappet cover gasket No 1604 Wrist pin clip No 1457 No 880 1 Big bore tappet cover gasket Big bore center case bolt washer amp nut kit No 1902 No 1551 Part No No 1506 1 Ni NI A SS Piston oil jet assembly 124 Beta Silver Kit Description 124 Front silver cylinder Qty No 1457 Big bore center case bolt washer amp nut kit No 1506 2 124 Rear silver cylinder No 1902 No 1550 Part No No 1505 1 1 1 1 1 1 4 2 1 2 Qty Piston oil jet assembly 124 Beta Black Kit Description 124 Front black cylinder No 1617 1 124 Front piston w pin No 1505 2 124 Rear black cylinder No 1617 2 124 Rear piston w pin No 1617 1 124 Front piston w pin No 1286 1354 124 two piston ring set No 1617 2 124 Rear piston w pin No 1604 No 1286 1354 124 two piston ring set No 880 1 Big bore tappet cover gasket No 1604 Wrist pin clip
32. insert the pin into the rod See Fig 42 e Next make sure the cylinder base gaskets are properly positioned Fig 36 Arrange ring gaps in this pattern Note Do not apply any sealant to gasket check the oil return hole position in case make sure it lines up with the base gasket as pictured See Fig 43 e If you are using the recommended JIMS Engine Stand or a similar stand we recom mend you bolt it down before proceeding The engine is going to get taller and heavier and needs to be secured Carefully shield the crankcase so foreign objects like a dropped wrist pin clip cannot fall into the engine Materials such as clean lint free tow els can also be used 26 Installation Rear Cylinder e Lay the rear piston cylinder assembly on its side With the small spigot cutaway up Rotate the piston so the wrist pin hole aligns with the cutaway e Gently push the piston down the bore until the pin hole is exposed enough to receive the pin Prei Diae with a light film of clean H D 20W 50 oil or a good quality assembly lube the piston s wrist pin hole by inserting a lubed wrist pin into the pin hole Slide the wrist pin in until it bottoms out on the left side wrist pin clip and then remove the wrist pin See Fig 44 e Rotate the crankshaft until the rear connecting rod is at the top of its travel TDC Carefully position the cylinder over the rear studs so the short fins are on the right toward you The spigot bevel will be toward
33. is located on the dowels as you lower the cylin der into position See Fig 48 Note Use a short 1 2 I D oil or gas hose Thread the bolt onto one of the cylinder studs until the spacer is finger tight against the cylinder See Fig 49 27 Installation Front Cylinder See Fig 50 Ete idl Note Prior to front cylinder installation pour 1 3 of a quart of clean 20W 50 H D oil over the Fig 42 Insert wrist pin crankpin area See Fig 51 e Rotate the crankshaft until the front connecting rod is at TDC See Fig 52 e Front cylinder installation is similar to the rear There are a couple of differences in the parts The notch on the front cylinder spigot goes toward the rear of the engine The large valve relief goes toward the rear of the engine and the front piston has no skirt notch See Fig 34 28 Installation Cylinder Dowel Pins Note Make sure the tappet block cover bores remain sealed so nothing can fall into them Fig 43 Oil hole aligned e Lightly lube the larger beveled side of the dowel pin with clean H D 20W 50 oil Install 2 dowel pins per cylin der into cylinder gasket surface area as shown See Fig 53 29 Cylinder Head Inspection and Assembly Caution All 100 106 and 110 kits include Pistons designed for Stock H D 85cc heads If the heads you will be using have any different Valve sizes or combustion chamber size It will be your responsibility to check and confirm all piston to Valve Valve to Valve clea
34. l and allow the surface to dry prior to installation Select a head and place it over the fFjg 55 locating dowels and onto the cylinder Be sure the head gasket is properly positioned 35 Head orientation FRONT e The pushrod holes go to the right of the engine and make sure the head is fully seated on the cylinder Lay out the head bolts within easy A reach two short and two long bolts are used for each head Lightly lubricate with moly lube the internal threads of each bolt Also lightly lubricate with moly lube the underside of each head bolt flange This is the flat area under the bolt head that contacts the cylinder a head Thread the two short bolts into the stud holes on the left spark plug side of the head Thread the remaining longer bolts into the other two Gently snug all four bolts finger tight e Install the remaining head remember to align the hole in the gasket with the cylinder s oil drain hole za 36 Cylinder Head Torque Note Follow the tightening sequence exactly as it is described below Deviation from the proce dure can result in gasket failure or severe damage to the heads and cylinders n Pushrod Bores L LONG BOLT S SHORT BOLT LEFT SIDE RIGHT SIDE e Torque each lubed head bolt to 8 ft lbs follow ing the sequence and by using the figure See Fig 57 Pushrod Bores e Continuing in the same sequence torque each REAR bolt to 18 ft lbs With a grease pencil or si
35. letter outlining the nature of the prob lem 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 1 JIMS shall have no obligation in the event a JIMS part is modified by any other 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 from the failure of a JIMS part the breach of any warranties the failure to deliver delay in delivery delivery in nonconforming condition or for any other 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 a JIMS part is used in any other application 5 Any parts which have been replaced for any reason become the property of JIMS and will not be returned under any circumstances CAUTION Wear safety glasses Excessive force may damage parts and tool CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NE
36. mi Fig 57 lar marker mark a line on the smooth surface of all 8 head bolts continuing this line down to the head casting surface as pictured See Fig 58 e These marks will be used as a guide to tighten all head bolts an additional 1 4 of a turn or 90 degrees See Fig 59 Feifotmance Faia fot arkey Davidsoni Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 19 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 Note When torquing head bolts 90 work them up in small increments following the torque sequence shown in Fig 57 e After all 8 head bolts have been tightened an additional 1 4 turn or 90 degrees all 8 head bolts need to be loosened to allow seating in of the gaskets Loosen the head bolts using the same sequence described in 1 4 of a turn at a time until each is loose enough to turn with your fingers See Fig 57 e After all 8 head bolts can be turned with your fingers start the torque sequence again Fig 58 Mark bolt Torque each head bolt to 8 ft Ibs following the sequence as shown See Fig 57 and head e Continuing in the same sequence torque each bolt to 18 ft lbs Make a fresh mark on the head bolts as shown See Fig 58 e Tighten all 8 head bolts in sequence an additional 1 4 turn or 90 degrees as pictured in See Fig 59 37 The i
37. nstallation of the remaining top end components should be followed per your service manual for the year and model engine you are building Please follow the instruction sheets that have been provided with any other product you will be installing 38 Oil Flow Oil Pressure And Gasket Seating All Engines Important Notes e Before you install your new JIMS Big Bore Kit in its chassis thoroughly flush the motorcycle s complete oiling system Note This includes removing the oil tank and washing it out Be very careful that you do not tear small slivers of rub ber off the edges of the oil lines as you fit them to the engine s oil fittings e Do not connect the oil return line from the engine to the oil tank Fit a hose from the engine s oil return fitting and run the hose into a large catch pan Note Remove the spark plugs from the engine Attach the plug wires to the spark plugs and lay them on the cylinder heads to prevent damage to the coils e Be sure the oil tank is properly filled with the correct oil Use the electric starter to turn the engine over until the oil pressure light goes out or until the pressure guage reads 10 15 psi e Re install the spark plugs torque to 12 to 18 ft lbs Install plug wires Depress both compression release CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Feifotmance Tavis fot tlatley Vavi
38. o 99650 02 to shoulder of top center case bolt and torque to 50 CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Tavis fot tlatley Vavitlton Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 No 1551 IS REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 90 inch Ibs maximum Retorque after initial start up and check after a few heat cycles to 135 155 in Ibs 14 Piston inspection e Unwrap and work with the pistons over a padded surface such as a half dozen new clean shop towels e Always handle pistons with great care While they are capable of withstanding extreme acceleration loads they can also be destroyed by a two foot fall onto a hard surface e Piston ring end gaps must be checked and adjusted if required Use a ring gap tool and do the work away from the engine Piston ring parti cles are very hard and should not be allowed anywhere near the open engine Make sure you wash your hands after adjusting ring gaps or doing any other grinding e Avoid the use of sandpaper Keep all abrasives away from your work area and the internal components of your engine e Do not use pressurized air to clean anything Its use virtually guarantees damaging parti
39. ons designed for S E 95cc heads If the heads you will be using have different valve sizes or combustion chamber size it will be your responsibility to check and con firm all piston to valve valve to valve clearances and the compression ratio NOTE All stock 2003 Present Twin Cam engine cases must be built with JIMS 959 Twin Cam Timken Case Bearing Conversion Tool You will also need a Twin Cam Service Manual pre 2003 having information about setting up the left Timken bearing and torque specs for the motor sprocket nut Due to the higher compression ratio created by the above Big Bore kits your starter system efficiency may be reduced and may become prematurely damaged JIMS recommends installing high output starter components See JIMS website or catalog pages for our High Performance Super Flex heavy gauge battery cable sets JIMS 1 8K High Torque Starters JIMS High Torque starter ring and pinion gear set and JIMS No 727K Compression Release Valves Also recommended is a High Output battery Another issue you may need to address is to install a No 721 JIMS manifold spacer kit depending on the manifold used on your application COMPRESSION RELEASE VALVES Manual MCR Compression release valves are a must when building large displacement engines These valves will manually vent cylinder compression to the atmosphere at startup Install JIMS Compression Release Valves with JIMS installation tool No 1169 for Twin Cam or use JIMS
40. pressor See Fig 38 e Confirm all rings are compressed and lube skirt with the assembly lube Slide the piston into the bore of the cylinder See Fig 39 e Place the ring compressor s handle opposite the larger cylinder spigot notch and be careful to avoid damaging the piston skirts e Carefully push the piston into the bore with the palm of your gloved hand The ring compressor will release when the piston is completely in the bore Turn each piston to the right and left approximately one 1 inch this movement should be smooth See Fig 40 Fig 35 Align correctly Petfotmance Faia fot areg Davidsoni Norowycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 15 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 24 Assembly Front Piston Cylinder e Use the same assembly technique as the above steps Go back to LINE 22 and perform the same steps for other cylinder and piston A e Be sure you have the Front piston with the Front cylinder FRONT REAR 5 poten Rail 7 Expander Spring 25 Cylinder Installation C Top OCR Rail Note This step is best done by two people E oR e Work from the right side of the lower end One person should hold and position each piston cylinder assembly See Fig 41 e The second can then align the connecting rod with the wrist pin and
41. rances and compres Fig 45 Peifotmance Faia fot tlavley Vawidson ir 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 17 Fig 47 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 sion ratio The same applies to all 117 120 and 124 kits These kits have been designed for S E 95cc heads If the heads you will be using have any different Valve sizes or combustion chamber size it will be your responsibility to check and confirm all piston to Valve Valve to Valve clearances and compression ratio 30 Head Inspection e All sealing surfaces must be free of dents deep scratches or foreign material Clean the an cylinder gasket sealing surface with a lint free cloth and denatured isopropyl alcohol Fig 48 Verify gasket and allow the surface to dry prior to installation Note Before installing head gasket pm e f you are using a 3 layer riveted EST style head gasket and you have aftermarket heads you may find that you have interference with the rivet in the head gasket If so use a smooth jaw vice to reduce the thickness of the rivet before installation 31 Inspect the head gaskets e They should be smooth and clean and a small amount of curl is okay The surface coat ing should be intact See Fig 54 32 Head Gasket Installation e The head gask
42. rod case and cylinder spigot See Fig 5 Warning Only remove material from the case and not the rods 6 Check to see if necessary to grind or file for a minimum clearance of 050 between cylinder spigots and a minimum clearance of 060 between piston skirts See Fig 6 Fig 6 Note f it is necessary to remove material from piston skirt do so only to the rear piston Caution f you must remove material from the rear piston skirt do so only with the smoothest finish possible Only remove enough material to maintain the minimum clearance CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Tavis fot arkey Davidsoni Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 7 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 7 If you are satisfied with all your clearance checks now will be the time to check for tappet cover to cylinder clearance Because of the larger 4 1 8 bore cylinders they will use up some of the tappet cover sealing surfaces We have provided special gaskets that will seal the modified tappet cov ers These gaskets can also be used as a marking template All 4 125 big bore kits will require some modification to the
43. row The arrow of each piston must point towards the intake valve The front piston goes on the front rod with arrow pointing towards the rear of the engine or intake port The rear piston with the skirt notch goes on the rear rod with arrow pointing towards the front of the engine or intake port See Fig 12 Note that all 124 120 117 and 106 piston sets come with larger intake reliefs than the exhaust reliefs The 100 and 110 have the same size intake and exhaust z relie Fig 16 Clean cylinder bore 15 Piston Pin Clip Insertion IMPORTANT NOTE e Wrist pin clip insertion must be done carefully to avoid damaging the corners of the wrist pin hole e A crushed corner is a collection of cracks At the high stress levels these pistons were designed to withstand one or more of those cracks could grow and eventually Qr result in piston failure and severe engine damage Fig 17 Feeler gauge gap e Use JIMS tool No 769 wrist Pin lock ring Remover Installer This is an excellent tool and makes the task simple and safe for the pistons This tool can only be used for left side of piston Lock ring is to be installed on the left side at this time See Fig 13 e It is very important you do not scratch or gouge the wrist pin bore e Place the piston on a clean pad If using JIMS No 769 follow the directions in your H D service manual to insert a wrist pin clip into the left side of each piston See Fig 14
44. s gap roughly opposite the gap of the first rail Make sure the expander spring ends butt and do not overlap See Fig 24 Fig 26 Ring placement Installation Compression Rings CAUTION WEAR SAFETY GLASSES OVER YOUR EYES SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Tavis fot tlatley Vavitlton Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 13 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 Identification e The top two rings are different and each have an up side and a down side They must be installed correctly The first or top ring has a light colored hard chrome plated sealing edge face It has a very small dot on its top about 1 2 from one end Also one of its inside edges is beveled Both the dot and the bevel go up toward the top of the piston See Fig 26 amp 27 Installation Second Ring e The second ring is very dark almost black in color It is marked with dot or TOPC about 1 2 from one end This identifies the top side of the ring Bevel goes down Select a second ring Remember it is nearly black Make sure the top of the ring is fac ing up See Fig 28 TOPC Up e Grasp the ring with your piston ring expander tool JIMS No 1235 See Fig 29 a
45. the front of the engine See Fig 45 CAUTION Be careful not to scratch the base gasket sealing surface on the bottom with the cylinder studs during assembly Be careful not to bend the cylinder studs during cylinder installation e Lower the cylinder assembly over the studs while guiding the rod into the piston Align the wrist pin with the wrist pin bushing Slide the lubed pin through the rod until it is stopped by the left wrist pin clip See Fig 46 e Install the remaining pin clip Start one end of the clip into the wrist pin hole Use a hard plastic rod or wooden dowel to work the clip fully into its groove See Fig 47 Note Be sure to wear your safety glasses when installing wrist pin clips Fig 40 Petfotmance Tavis fot arkey Davidsoni Nlorowycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 16 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 e Verify the clip is fully seated in its groove Important Be very careful not to gouge nick dent or otherwise deform the cor ners of the wrist pin hole Remove the material protecting the case bore Apply a thin film of assembly lube to the front and back of the piston skirt Inspect the mat ing surfaces of the base gasket and cylinder to be sure they are clean Gently slide little curl so check that the gasket
46. tlton Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 20 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528 amp 1548 THRU 1551 plungers if applicable e Start the engine using the normal procedure outlined in the owner s manual Allow the return oil to run into the catch pan Run engine between 1000 and 1500 rpm until the tops of the cylinders have reached 200 degrees too hot to touch This normally takes between one and two minutes Note Do not allow the oil level in the tank to get too low while the engine is running Stop the engine and let it cool to ambient temperature Inspect the installation for any oil or gasoline leaks Top off the oil tank Repeat the warm up and cooldown procedure three additional times Note Watch and maintain the oil level in the tank Reconnect the oil return line to the oil tank after at least two Quarts of oil have been pumped into the catch pan Discard the oil in the pan as you would for any used oil 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 start up idle
47. y you will have to adjust the second ring end gap If you do the amount will be very small Take your time with this task and remove only a little material at a time e For the best result use a piston ring gap tool to remove material from the ends of the rings Do not work near the open engine 19 Piston ring gap tool Fig 22 Square ring end e Determine how much material must be removed from the ends of the ring It will probably be only a few thousandths of an inch For instance If the 2nd compression ring s end gap was 013 then you would need to remove a total of 004 from the ends to meet the minimum gap standard of 017 e Use a JIMS No 1255 piston ring end gap tool to file both ends of the ring Material removal can be very rapid Fit the ring into the tool according to the tool s instructions Gently rotate the cutter and remove a very small amount of ring material See Fig 19A e Remove and clean the ring Deburr if needed Then re insert it into the bore Square it using the piston as before and measure the end gap e Check the end gap often as you work especially when you work with your first ring 20 Flat Jewelers File Petfotmance Faia fot tlatley Vavitdton Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 12 No 1551 I1S REV A 10 13 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TWIN CAM BIG BORE KITS No s 1501 1501B 1519 THRU 1528
Download Pdf Manuals
Related Search