Instruction Sheet For Tool #1177
Contents
1. 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 JIMS parts are designed exclusively for use in HarleyDavidson motorcycles JIMS shall have no warranty or liability obligation if JIMS part is used in any other application Any parts or tool replaced by JIMS becomes the property of JIMS and will not be returned under any circumstance 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 62. 32 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422 No 1177 1S LA REv D 4 05 INSTRUCTION SHEET FOR TOOL 1177 PARTS LIST TITLE OR DESCRIPTION PART NUMBER MOUNTING PLATE 1177 1 ASE PLATE 1177 2 LIGNMENT PLATE 1177 3 ORING HEAD BORING ASSEMBLY 1177 4 f a N QTY lo N lo la la lo Im R WE eal EE ail LOCATING PLATE BORING ASSEMBLY 1 177 5 4 UPPORT PLATE BORING ASSEMBLY 1177 6 ES HIELDED BEARING 8149 EE ULL OUT DOWEL 1685 o 3 8 16 x 1 SHCS 1686 10 2133 11 4 power Pin 1 4 x3 i 093 12 1681 13 2405 14 1 T PIN 38 SHANK i tc 87 15 1ese 16 6 174 28 x 1 2 setscrew sd 89 17 1683 18 1 1 4 20x 1 3 4 SeTScrewSCSCSCSC d CG 79Q 19 1 174 20 3am vur CCCs ee 20 174 20 x172 Bues leow 21 power PIN 1 2 x 3 172 i 80 22 1265 23 INSTRUCTION SHEET 1177 IS 1 1175 5 is not covered under warranty if locating plate displays cutter marks from improper adjustment 1688 Non serviceable wear item no warranty 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 Me
3. 5 Ne INSTRUCTION SHEET FOR TOOL 1177 machine is not running Damage may result to the tool and the Cylinder Dowel Reliefs crankcase Note If the base plate assembly is not nnd flat to the press table adjust ae table or head flat before clamping down the tool assembly Depth adjustment screw 10 Set the machine s speed to approximately 600 800 RPM s Before running the machine make sure the quill is at the top of its travel Start the machine to make sure head or table are not vibrating If no vibrations the RPM s can be increased If vibra tions occur RPM s will need to be reduced JIMS has found that 600 800 RPM is best when using a drill press although results may vary Caution Always wear safety glasses 11 Start boring with a slow even pressure while applying cutting fluid Slower feed rate will yield a cleaner finish until the Borin Assembly Stop bottoms out Shut down the machine and wai until it Comes to a complete ep en retract the borin assembly untill it clears the case Replace the wood block an remove the Boring Assembly from the case CAUTION It is recommended that you use a well maintained and dependable machine for this type of work If you use a drill z press or milling machine that is not up to normal standards Note Place a 1 1 2 to 2 wood block between boring you take the chance of damage to your work and or injury to assembly plates to keep top plate from dropping
4. N DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 2 REV D 4 05 No 1177 IS NOTE JIMS recommends removing no more that 125 on the diameter of material at a time Case machining may require more than one pass and more than one set up of the cutters to obtain your desired bore Failure to follow this could result in a ruff finish and or damage to the bore and cutters Once you have determineed the cutter dimensions install the cutters in the boring head as shown in Fig 5 Fig 6 amp Fig 7 Using a 1 8 Allen wrench adjust the adjustment screws No 1689 to set the cutters dimensions from your calculations Fig 7 Use a caliper for accurate measurements Ensure that the cutters are held mg against the adjusting screws as the lock down screws are tightened Torque the lock down screws an order shown Fig 7 to 90 in Ibs to secure the cutters in place WARNING If cutters are set beyond 4 40 the cutters may come in contact with the I D of the locating plate 1177 5 No 5 voiding the warranty of 1177 5 7 umga 1 8 allen wrench and a 7 16 wrench set the borin depth to 1 850 03 00 by adjusting the stop depth adjust ment screw yee on the Boring Assembly top plate as shown in Fig 5 amp Fig 8 measured from the finish tool cutter to the bottom of the locating plate No 5 spigot Depth Note If using other than JIMS 4 cylinders add 03 06 to
5. REV D 4 05 No 1177 IS TWIN CAM ALPHA amp BETA CASE BORING TOOL The JIMS Twin Cam Case Boring Tool takes all the guess work out of boring Twin Cam engine cases to accept JIMS 4 bore cylinders 100 big bore kit and 113 and 116 flywheel stroker kits Will also work on cylinders up 4 125 with stock cylinder stud pattern This tool is designed to be used in a heavy duty 15 drill press or milling machine Note Please read all instructions completely and thoroughly before performing any work IF YOU DO NOT KNOW WHAT YOU ARE DOING DO NOT DO IT None of the information in this instruction sheet pertaining to motorcycle repair is represented as fool proof or even altogether safe Some people can ruin a mechanic s vise with a tack hammer Even something safe done incorrectly or incompletly can and will backfire You and only you are responsible for the safety of your repair work and for your understanding and application with the use of repair equipment components methods and concepts Each and every step that this tool is designed to do must be carefully and systematically performed safely by you All information listed in this instruction sheet has been tested re tested and used daily in JIMS Research and Developement Department JIMS IS NOT RESPONSIBLE FOR THE QUALITY AND SAFETY OF YOUR WORK Tools required for boring 1 8 3 16 1 4 amp 5 16 Allen wrenches 7 16 Wrench Calipers Torq
6. SCREW 1689 3 8 16 SHCS No 9 using cylinder alignment pins HD No 16595 99A to locate assembly Make sure the Boring Assembly is sitting flush on the motor case mee 5 16 allen sS N wrench torque the mounting bolts to 18 20 ft 9 Place the Case Boring Fixture onto a drill press or milling f Tighten these screws machine table Center shaft of Boring Head No 4 in chuck or I Finish CutSideliliii nist collet ni Rough Cut Side i Tighten these screws Note If using a chuck be sure the chuck jaws locate on the flats on the second boring head shaft Tighten the chuck or collet depending on j machine being used and remove the wood block Clamp the base No 2 to the drill press table using the provided holes if 03 posible If unable to use provided holes be sure to clamp the BORING 24 220 ixture using C Clamps or comparable clamps Before running o machine lube the two guide dowels with a light oil and run the quill up and down to make sure the Boring Assembly is not LOCK DOWN SCREWS binding Caution When checking to make sure the tool action is correct be aware not to strike the cutters against the crankcase while the CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 3 No 1177 IS REV D 4 0
7. T INSIDE DOING SO CAN AND WILL CAUSE PRE MATURE WEAR AND DAMAGE JIMS IS NOT RESPONSIBLE FOR YOUR WORK SO PLEASE USE YOUR BEST JUDGEMENT AND ALWAYS DOUBLE AND EVEN TRIPLE CHECK YOUR WORK DOING SO WILL HELP ENSURE A POSITIVE EXPERIENCE AND OUTCOME CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 4 No 1177 IS REV D SET UP SHEET FOR 4 BORE A 385 FNS ROUGH LOU 320 B Lg E da 2A B g pa BORING HEAD DIAMETER BORING HEAD DIAMETER 3 45 4 20 Step 1 Measure your cylinder spigot diameter S and add 02 Step 2 Measure the boring head diameter T as shown above Subtract boring head diameter D OVERALL CLEARANCE from answer obtained in step 1 this is your S CYLINDER SPIGOT DIAMETER e cal clearance by 2 This De BORING HEAD DIAMETER P 3 y g C CASE BORING DIAMETER is your A dimension Step 4 Subtract 065 from your A dimension This is you B dimension Step 1 S 02 C 4 20 02 4 22 Step 2 C T D 4 22 3 45 77 Step 3 D 2 A TTY 2 BBS Step 4 A 065 B 385 065
8. hardware with 20w50 H D oil 3 Place the Engine Case in the Cradle and rotate the case so either the Front or Rear cylinder deck is horizontal and fac ing up Fig 3 4 Install 2 lubed 1 4 20 SHCS No 10 into the holes marked with F or R depending on the spigot bore you are modi fying in the plate No 3 as shown in ig 2 Do not tighten Install 3 lubed 5 16 18 SHCS No 13 into plate No 7 holes marked with letter of the spigot bore you are modify ing Do not tighten 5 Install lubed T Pin No 14 into hole in No 3 as shown in Fig 2 amp Fig 4 marked F for Front or R for Rear depending on which spigot bore you are modifying This will align the spigot bore perpendicularly to the machine spindle You may need to rotate the case slightly to get the T Pin to locate propery in the hole osing a 3 16 allen wrench torque the 4 20 SHCS No 10 to 90 120 in lbs and all 5 16 18 SHCS No 9 to 13 15 ft lbs using a 1 4 allen wrench 6 INSTALLING CUTTERS Note Boring Head SA shown is for reference only Your set up will vary depen ingan cylinder bore and cylinder manufacturer Instruction sheet is written for boring clear ance for 4 bore cylinders Again if your cylinders are from a different manufacturer or you are Maung for other than a 4 bore you will need to calculate your cutter dimensions see set up sheet on page 5 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 555 DAWSO
9. rchandise 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 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 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 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 JIMS shall not be liable for any consequential or incidental damages resulting in the failure of a JIMS
10. re to do so will result in damage to the cutting tool 1B Option 1 You may use the stock case bolt and modify the case bolt diameter similar to the bolt shown in Fig 1A NOTE Failure to do so will result in damage to the cutting tool 1B Option 2 You may use a 5 16 x 5 long stud or allen bolt with nuts and washers You may drill a 5 16 hole through the right case with normal bolt clearance You should spot face the right side case hole as shown in Fig 1B to maintain flatness You will need to provide more clearance for the 5 16 allen bolt or stud similar to 4 bore bolt as shown in Fig 1A NOTE Failure to do so will result in damage to the cutting tool 1B Option 3 You may use a 1 4 x 5 long stud or an allen bolt both with nuts and washers Drill 1 4 hole with normal clear ance through the right side of the case You should spot face the hole as shown in Fig 1B to maintain flatness You will then need to check your allen or stud bolt for the proper clearance and it may need to be modified to be similar to the bolt as shown in Fig 1A NOTE Failure to do so will result in dam age to the cutting tool 2 Assemble Engine Cradle No 7 No 2 amp No 3 with all nine 3 8 allen screws as shown in Fig 2 Torque the nine 3 8 allen screws to 10 ft Ibs Make sure all mating surfaces are clean Position Plate poy with the appropriate lettering A for Alpha B for Beta acing outboard NOTE Lube all
11. the length of your es spigot This will be the depth you need to bore your cases to Example out oy ot is 1 600 add 03 06 and your bore depth will be 1 630 0 7200 Alignment Pin Note On the bottom of the support plate No 5 there are machined reliefs to clear the opposite cylinder s agamen pin ae In some motor cases the alignment pins are installed higher or ower so you will need to check to make sure that they do not interfere with the mounting of the support plate No 5 to the case To check the alone pin clearance place the Boring Head Assembly on case with a 1 1 2 to 2 wood block between boring assembly plates to prevent Rough Cut Side the top plate from ropping and or resulting in the cutter contactin 7A your case See Fig 9 Without tightening the two screws No 1668 03 Step place a piece of paper between the neighboring cylinder s alignment pin and the support plate Once you have torqued the screws make r 7 sure that the paper moves freely between the alignment pin and the Dimensions for 4 Bore support plate If the alignment pin is too nigh the paper will not move the pin can be installed deeper or removed If the pin is caged dur ing removal it will need to be replaced Failure to check the alignment pin clearance may result in the final spigot bore being out of center Finish Cut Side H 3 835 015 325 a 8 Mount the Boring Assembly onto motor case with 2 lubed x ADJUSTMENT
12. ue wrench 1 2 socket Cutting Fluid Drill press or Milling machine Follow instructions in H D Service Manual for removal of engine for your year and model With engine removed from frame and safe ly mounted in one of JIMS Twin Cam motor stands refer to JIMS catalog for stands follow the engine disassembly instructions in the service manual including removing and installing cylinder studs Mask off all bearings and oil holes to prevent chips from contam inating those areas Bolt cases together with HD hardware using sequence and torque specs stated in H D service manual except top center case bolt between cylinders Install this bolt last and torque to 50 90 in lbs maximum Read Step 1 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 1 REV D 4 05 No 1 177 IS INSTRUCTIONS 1A 4 BORE INFORMATION BEFORE STARTING Prior to boring your case you must modify your top center 5 16 case bolt that is located between the spigot holes as shown in FIG 3 see arrow You need to modify the 5 16 case bolt as shown in Fig 1A for 4 bore NOTE Failure to do so will result in damage to the cutting tool 1B 4 1 8 BORE INFORMATION BEFORE STARTING Prior to boring your case you must decide on how to obtain the paper clearance for your top center case bolt as shown in Fig 3 See arrow NOTE Failu
13. yourself This is why we recommend you use a safe and well maintaned drill press or milling machine Make sure your machine is in good working order before starting any project ALWAYS WEAR SAFETY GLASSES OR OTHER FACE AND EYE PROTECTION SUCH AS FULL FACE SHIELD 12 Remove 2 1 4 20 SHCS No 10 3 5 16 18 SHCS No 13 and T Pin No 14 Rotate_case so opposite spigot bore is straight up and repeat steps 3 11 13 Wash cases as needed to remove all chips CAUTION Be sure to remove any case material from the top center case bolt holes of both left and right cases that are not attached well enough to stay in place during motor operation See Fig 10 and Fig 1C Fig 1C on page 2 NOTE This is mostly a judgment call as to how much material will be removed DO NOT REMOVE ANY MORE MATERIAL THEN NEEDED FOR A SAFE RUNNING MOTOR NOTE When re assembling cases tighten case bolts to factory specs except top center case bolt between cylinders Tighten this bolt last after you have cylinders and heads installed and torqued to H D specs Apply Hylomar or equivalent sealer to shoulder of top center case bolt and torque to 50 90 in Ibs maximum on 1 4 or 5 16 center bolt stud CAUTION BEFORE RE ASSEMBLY OF YOUR ENGINE MAKE SURE THE THE INSIDE OF THE CASE SPIGOT BORE AND ALL INTERIOR AND EXTERIOR POCKETS AND HOLES ARE FREE FROM ANY CONTAMINANTS STOP DOUBLE CHECK AND THEN TRIPLE CHECK YOU DO NOT WANT ANY CONTAMI NANTS LEF
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