SERVICE BULLETIN - WolfCrews Harley
Contents
1. Rear Cam Bore Enlarged qe Support Block Figure 4 Enlarge Rear Cam Bore Using 7 8 Inch Drill Bit 3 of 4 NOTE To reduce the likelihood of such contact occuring use 7 8 inch drill bit to enlarge rear cam bore in support block For best results radius top inside edge of bore after drilling See Figure 4 CAUTION Be sure that the tensioner shoe is clear of the secondary cam chain during the press procedure Contact can result in damage that requires replacement of the ten sioner assembly 6 Center end of front camshaft under ram and slowly apply pressure to driver just to start front camshaft into bearing ID CAUTION If rear camshaft is not properly aligned edge of installed inner race can catch on bearing rollers Bearing damage can result if contact occurs during the press procedure N Slowly apply pressure to driver on front camshaft while wiggling rear camshaft as necessary to guide inner race between bearing rollers When inner race on rear cam is started into roller bearing apply pressure to driver until front camshaft is fully seated If necessary keep finger pressure at top of rear camshaft to ensure that assembly remains square and inner race moves to installed position in roller bear ing Complete installation of cams See page 3 86 of the 2000 FLT Models Service Manual CAMSHAFTS CAMSHAFT BEARINGS INSTALLATION steps 14 15 IMPORTANT NOTE When installing crank and primary2. SERVICE BULLETIN M 1097 December 21 1999 MOTOR HARLEY DAVIDSON By NEW REAR CAM ROLLER BEARING ASSEMBLY General Effective December 14 1999 a new rear cam roller bearing assembly has been installed in both Twin Cam 88 and Twin Cam 88B engines To service these assemblies or to replace the earlier style ball bearing using the new parts proceed with the instructions below NOTE The new rear cam roller bearing assembly will retrofit all splined rear cams Removal CAUTION Cam bearings may be a loose fit in the cam support plate To avoid possible damage be aware that camshaft and bearing assemblies may drop out at start of press procedure 1 Press out camshafts and bearings following existing service procedures Regardless of model see page 3 83 of the 2000 FLT Models Service Manual CAM SHAFTS CAMSHAFT BEARINGS REMOVAL steps 1 8 NOTE Some bearing retainer plates may have circular marks if the bearing has turned Disregard these marks if observed as the retainer plate may continue to be used 2 Ifthe new style roller bearing is present slide bearing from end of rear camshaft Since bearing is a loose fit on cam no pressing tools are required NOTE Wherever the earlier style ball bearings are used use pressing tools following existing service procedures Regardless of model see page 3 84 of the 2000 FLT Models Service Manual CAMSHAFTS CAMSHAFT BEARINGS REMOVAL step 9 3 If
3. cam sprockets push on _ rear camshaft to remove end play and check alignment of sprocket faces as described in the 2000 FLT Models Service Manual and shown in the upper frame of Figure 5 If alignment exceeds 0 010 inch substitute existing spacer with one of those shown in Table 1 These spacers represent a new set and are to be used with the new rear cam roller bearing assembly only Do not attempt to use earlier design spacers as they will not work 1647x3x Table 1 New Primary Cam Sprocket Spacers H D Part Number 25722 00 25723 00 25721 00 25719 00 25717 00 Spacer Size 0 287 0 297 0 307 0 317 0 327 Figure 5 Use New Spacers to Align Crank and Primary Cam Sprocket Faces When ordering service parts for replacement please refer to Table 2 below Table 2 Fitment Information Part No Description Fitment 25267 99B Cam Support Plate w 99 00 TC 88 88B Bearings amp Oil Control Kit 24598 99B Cam Support Plate w 99 00 TC 88 88B CARB Cams CARB 24606 99B Cam Support Plate w 99 00 TC 88 88B EFI Cams EFI NOTE All kits come with the new rear cam roller bearing assembly but do not include the new spacers SERVICE MANAGER SALES MANAGER PARTS MANAGER LEAD ROUTING TECHNICIAN TECHNICIAN NO 1 TECHNICIAN NO 2 TECHNICIAN NO 3 TECHNICIAN NO 4 RETURN THIS TO INITIAL HERE 1999 Harley Da
4. lt until the desired result is achieved M 1097 g Remove flange bolt flat washer sprocket and spacer 3 Install new cam bearings in cam support plate following existing service procedures Regardless of model see page 3 85 of the 2000 FLT Models Service Manual CAMSHAFTS CAMSHAFT BEARINGS INSTALLA TION steps 1 5 NOTE Be aware that the front and rear cam bearings are no longer interchangeable The rear bearing is now the roller type while the front remains the ball bearing kind See Figure 3 NOTE Bearings may be a press to loose fit If deemed necessary clean bearing OD and apply Loctite Low Strength Threadlocker 242 Blue before installation but exercise caution to avoid getting compound on rollers or bearing ID 4 Start camshafts into cam bearings following existing service procedures Regardless of model see page 3 86 of the 2000 FLT Models Service Manual CAM SHAFTS CAMSHAFT BEARINGS INSTALLATION steps 6 10 NOTE Be sure not to mix camshafts during the press procedure The rear camshaft which can be identified by the splined shaft must go into the roller bearing at the rear of the cam support plate 5 Place cup of camshaft driver over end of front camshaft only CAUTION Verify that splined end of rear camshaft has been started into support block Damage to the camshaft and or support block can occur if end of camshaft catches top of block during the press procedure f 1809x3x
5. o avoid stretching or breaking the O ring Since the O ring is not sold separately damage will require purchase of a new roller bearing kit CAUTION The thrust washer will be offset to one side if the O ring is not installed in the grinding relief groove Damage to the bearing cage can occur if the thrust washer is not properly centered b Slide thrust washer down rear camshaft until cen tered over O ring in grinding relief groove c Slide bearing inner race down rear camshaft until contact is made with shoulder of machined area d Install primary cam sprocket spacer and sprocket on camshaft and secure using thicker flat washer and long flange bolt NOTE If not enough of the splined shaft is exposed to install the sprocket leave out the spacer and proceed to step 2 e Once the bearing inner race has been started onto the machined area remove the flange bolt washer and sprocket and then reassemble using the spacer Repeat step 2 e to fully install bearing inner race e Wrap a shop rag around camshaft to get a firm grip and also to protect hand from sharp edges of sprocket Using a 9 16 inch box wrench turn flange bolt in a clockwise direction Bearing inner race is fully installed when it makes firm contact with the thrust washer See B of Figure 2 f Verify that the thrust washer is locked in place and cannot be rotated If necessary install shaft in vise using brass jaw inserts and further tighten flange bo
6. r Race Onto Rear Cam 9 16 Inch Thrust Washer Figure 2 Remove install Bearing Inner Race With O Ring and Thrust Washer Fit hardened plug into end of camshaft Thread forcing screw into bridge until the steel ball at end of screw makes firm contact with cup of hardened plug Verify that the tool assembly is square Wrap a shop rag around camshaft to get a firm grip and also to protect hand from sharp edges of sprocket Using a 5 8 inch box wrench turn forcing screw until bearing inner race and thrust washer are pulled free of camshaft See A of Figure 2 A light interference fit allows the parts to be removed with little effort Discard inner race and thrust washer h If present remove O ring from grinding relief groove in camshaft Groove is on the splined end between the machined area and the secondary cam sprocket Discard O ring NOTE Since the O ring is not used in production it will only be found if the cams were serviced at the dealer level Installation 1 Obtain new rear cam roller bearing kit Part No 8983 See Figure 1 M 1097 Roller Bearing Rear Cam Ball Bearing Front Cam 1804x3x Figure 3 Cam Bearings 2 Install O ring thrust washer and bearing inner race onto rear camshaft as follows a To properly locate thrust washer first install O ring in grinding relief groove Groove is on the splined end between the machined area and the secondary cam sprocket Exercise caution t
7. reusing a rear camshaft that has the new style roller bearing installed remove the bearing inner race and thrust washer as follows a Position WEDGE ATTACHMENT HD 95637 46A on inboard side of thrust washer and turn hex nuts an equal number of turns to draw halves of wedge together M 1097 b Obtain two 3 8 16 inch bolts 3 1 2 inches long with flat washers Install flat washers on bolts Obtain bridge forcing screw and hardened plug from MAINSHAFT BEARING INNER RACE PULLER INSTALLER HD 34902B c Slide one bolt into channel on each side of bridge so that flat washer is between bridge and bolt head Thread bolts into wedge attachment an equal num ber of turns d Sparingly apply graphite lubricant to threads of forcing screw to prolong service life and ensure smooth operation Start forcing screw into center hole of bridge CAUTION Failure to use hardened plug may result in damage to forcing screw and or camshaft Part Description Number Roller Bearing 8984 Bearing Inner Race 8985 Thrust Washer 8986 O Ring 11350 Parts Not Sold Separately Thrust Washer Bearing Inner Race Roller Bearing f 1805x3x Figure 1 Rear Cam Roller Bearing Kit P N 8983 1 of 4 Thrust Washer Box Wrench 5 8 Inch B 1807x3x 2 of 4 1806x3x Pull Bearing Inner Race and Thrust Washer From Rear Cam Remove O Ring if Present Box Wrench Install O Ring and Thrust Washer Press Bearing Inne
8. vidson Motor Company 4 of 4 M 1097
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