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1. Installation Instructions Big Twin Camshatt For 1948 1965 Panhead Engines And 1965 1984 Shovelhead Engines These instructions are a guide to assist in the installation of your new Crane camshaft in your Big Twin Harley Davidson This instruction guide is not designed to perform as a complete service manual If you are not sure about dimensions torques timing setting etc not included in this material refer to your service manual for your model of motorcycle It is important to remember that the concept of a bolt in camshaft with no inspection from the engine builder does not really exist It is the engine builder s responsibility to be sure that the component parts that he is using will be compatible with one another and provide prop er running clearance It is generally accepted that camshafts with valve lifts greater than 455 may require modifications to either the valve spring assembly valve guides valves and or pistons to provide proper clearance The increase in lift may be itself not cause a problem but is used with other components such as new thick margin valves with new valve seats in the head in combination may not provide the clearance necessary Mocking up of the parts with careful inspection is always advised For example some engines may require that the crankcase be ground in order to clear the innermost lobe on a high lift camshaft If you feel that you do not have2. and riding on the heel of the lobe For example When the exhaust tappet on the rear cylinder is at full lift all the way up in the guide block you will then adjust the exhaust tappet on the front cylinder which will be all the way down Do one tappet at a time to avoid confusion 3 Install the pushrod and adjust Be sure to use new gaskets and seals on the pushrod tubes REMEMBER THE STOCK TAPPETS MUST BE CLEAN AND DRAINED OF OIL TO DO THE ADJUST ING PROCEDURE Turn one pushrod adjusting screw down until the hydraulic unit is completely compressed Then turn it back up 1 amp 1 2 turns nine flats on the adjusting hex Lock it in place by tighten ing the locknut An adjusting gauge part HD 94438 79 could be used at this point to double check the tappet adjustment 4 Follow this procedure of rotating the engine and adjusting the tappets until all four are adjusted properly 5 Extend pushrod tubes and insert keepers in place Note Improper lifter preload is probably the most common cause of hydraulic tappet noise Different manufacturers of hydraulic tappets may have their own method for arriving at the desired reload for their particular tappet design Therefore you must follow the meth ods that the manufacturer of your tappets rec ommends SOLID LIFTERS Follow the procedures already described in the preceding sections but naturally since you will be using a solid tappet there will be no oil in the tapp
3. the gear is off the camshaft double check the keyways for burrs or raised areas Deburr keyways and lightly hand finish face of gear with fine emery cloth on a flat sur face BREATHER GEAR PINION GEAR NON ADJUSTABLE STYLE CAM PINION GEAR CHECKING FOR VALVE TO VALVE CLEARANCE The design of the Harley Davidson hemi spherical cylinder head with its existing valve angles can cause the edge of the intake and exhaust valves to touch one another during the overlap period on certain camshafts You must check to be sure that the valves are not touching There are many sophisticated tools and meth ods for checking this clearance but what we will describe here is the basic way Since the valve spring tension could cause a hydraulic tappet to bleed down during the test and give you a false reading we recom mend using solid tappets when performing this inspection If you do not have solid tappets available then you must disassemble your hydraulic tappets drain the oil and clean them Replace the tappets in the guide and lengthen the pushrods to the full extent of the hydraulic tappet s plunger travel With the hydraulic tap pet completely compressed it will act as a solid tappet and allow you to do the test properly You must make yourself a tool out of 030 diameter wire then put a 90 degree bend approximately 3 8 long on any convenient length of wire Now rotate the engine so the piston is at T D C dur
4. 8 Idler gear later models 7 Generator fastening screw 2 19 Gear shaft nut 3A Spring 1963 and later 8 Gear cover 20 Pinion gear 4 Oil screen 21 Pinion gear key 5 Oil screen seal 2 10 Idler gear spacer 22 Pinion gear spring 1963 66 1 used on 11 Intermediate gear spacer 23 Gear shaft pinion spacer 1963 models 12 Breather valve spacing 24 Oil pump pinion shaft gear washer 25 Oil pump pinion shaft gear key 13 Cam gear 26 Breather screen 14 Cam gear spacing washer 27 Breather separator 28 Oiler drive gear shaft spring ring 29 Oiler drive gear 30 Oiler drive gear key 31 Needle roller cam shaft bearing 32 Circuit breaker gear stud 33 idier gear stud 34 Idier gear bushing 35 Circuit breaker gear bushing 2 36 See item 35 37 Gearcase cover cam shaft 2 bushing Figure following name of part indicates x 38 Gearcase cover pinion gear quantity necessary for one complete assembly a bushing 6 Gear cover screw 12 A Cam gear thrust washer 9 Gear cover gasket DIAGRAM REPRINTED COURTESY OF HARLEY DAVIDSON MOTORCYCLES 4 00 4 327E
5. IGNITION DRIVE GEAR ignition system compo o nents are shown in this 3522 21 Hlustration 20 1 Oil screen cap 2 O ring 13 Gear cover screw 1 in 2 14 Gear cover screw 1 1 4 in 3 3 Oil screen spring 15 Gear cover screw 1 3 4 in 1 4 Oil screen 16 Gear cover 5 Outer cover and rivets 2 17 Gear cover gasket 6 Inner cover screw 2 18 Breather gear washer 7 Inner cover 19 Breather gear 8 Gasket 20 Cam gear 9 Sensor plate screw and 21 Cam gear spacing washer iockwasher 2 22 Cam gear thrust washer 10 Sensor plate 23 Gear shaft nut 11 Rotor bolt 24 Pinion gear 12 Rotor 25 Pinion gear key 26 Pinion gear spacer 27 Oil pump pinion shaft gear 28 Oil pump pinion shaft gear key 29 Oil pump drive gear lock ring 30 Oi pump drive gear 31 Oil pump drive gear key 32 Gear cover camshatt bushing 33 Gear cover pinion shaft bushing 34 Camshaft oil seal 35 Camshaft needle bearing 36 Cover dowel pin 2 37 Wire clip 38 Welch plug 39 Oil line fitting 40 Oil pump shaft 32 CUT TO BOTTOM OF TEETH This modification must be made In 1948 to 1969 models with ignition drive gear to clear front cylinder exhaust lobe NOTE 1980 and later ignition system components are shown in this illustration 1 Oil screen cap 2 Cap gasket 6A Gear cover oil passage screw 18 Breather valve and gear 3 Oil screen bod 1963 17 Circuit breaker gear not used on 1963 and 6B Screw brass washer 1963 1
6. after any grinding process 2 Camshaft must be installed with the timing marks lined up on both the pinion gear and the breather gear To install in a 4 degree advance or a 4 degree retard position the gear must be pressed off of the camshaft and key lined up with the respective mark The camshaft is then pressed back into the gear Make sure the camshaft is lined up straight during the pressing operation Use of an arbor press is recommended The timing marks on the camshaft gear are then lined up with the marks on the pinion and breather gears 3 Camshaft end play must be checked at this point With camshaft and original thrust washers installed in the crankcase install the gear case cover with a gasket and tighten down the screws Reach through the tappet guide hole Fig 15 and slide the camshaft back and forth There should be a slight drag indicating proper fit of the nose of the cam and the bushing in the gear case cover Try to rotate the camshaft to see if there is too much lash in the cam and pinion gears See setting gear lash section If you have a dial indicator available measure the amount of movement end play at the nose of the camshaft as you slide it back and forth in the case If no indicator is available insert a feeler gauge between the hardened thrust washer and the thrust face of the camshaft Do NOT measure between the case itself and the thrust washer Depending on the year of the engine the e
7. et to drain and no pre loading Instead you will run a slight amount of clear ance between the tappet and pushrod 3 Fig 12 When the engine is properly rotated so that the tappet is riding on the heel of the cam length en the adjusting end of the pushrod until the slack is taken up When the engine is cold you should be able to spin the pushrod with your 327E Fig 13 fingers but not be able to move it up or down up the cylinders will grow approximately 040 in length due to heat expansion This will increase the valve lash clearance and create the ticking sound of a solid lifter engine Tighten the pushrod locking nut and recheck by FINISHING THE INSTALLATION by more than 002 When the engine heats 1 Replace ignition components in the reverse order of disassembly Refer to your service manual for proper setting If your ignition cover was fastened with riv ets replacement rivets are available at your Harley Davidson dealer system and any other components you may have removed during the camshaft installation You are now ready to start your motorcy cle Run the engine before riding and check for any oil or fuel leaks loose screws or bolts etc spinning the pushrod with your fingers A slight 9 drag but no up and down play is acceptable on a cold engine Reinstall air cleaner assembly brake pedal and footrest assembly the exhaust INSTRUCTIONS FOR ALTERING NOTE 1980 and later
8. ferent sizes of gears are identified by color codes on both gears Check the color code chart in your Harley Davidson manual for the exact sizes It is advisable to match the color code of the cam gear if available to the color code of the origi nal pinion gear Crane offers three cam gear sizes which are 001 difference in pitch diame ter They are identified as color code yellow smaller size red medium size and blue larger size If the gears are not matched prop erly you may witness some gear noise If the gears are too loose you will hear a gear clat ter much like a lifter noise if the gears are too tight you will hear a gear whine When the gears are properly fitted you will hear a very slight gear whine when the engine is hot You can also fine tune the gear lash by chang ing the stock pinion gear to the next size larger or smaller as necessary ADJUSTABLE CAM GEAR Crane offers many of its camshafts with multi index cam gears This allows you to install the cam in either the original straight up zero degree 0 position 4 degrees advanced A or 4 degrees retarded R Advance the cam pulls the power range down a few hundred RPM creating better bottom end power Retarding the cam raises the power band up creating better top end power A small arbor press and a simple holding fixture will be required to remove the gear and to relocate it to your desired keyway position NOTE When
9. ft and used a long nose approximately 1 5 16 long camshaft IMPORTANT NOTE CONCERNING CAMSHAFT GEARS Harley Davidson used two different style cam gears in the engines between 1948 through 1984 These gears and matching pinion and breather gears are NOT INTERCHANGE ABLE You must be sure that your cam gear is CRANE CAMS INC 530 Fentress Blvd Daytona Beach FL 32114 www cranecams com Tech Line 904 258 6174 4 00 1 Fax 904 258 6167 327E Fig 7 properly mated to the other components for compatibility The 1948 through early 1977 engines use a cam gear with a straight cut tooth This gear is plain in appearance with no identification 4 00 KEY LOCATIONS BREATHER BREATHER GEAR GEAR PINION GEAR PINION GEAR ADJUSTABLE STYLE CAM marks required by Harley Davidson Its matching pinion gear has teeth across the full width of the pinion gear body The matching breather gear has a slash mark I to identify its timing position The late 1977 through 1984 non Evolution engines used a cam gear with a curved tooth This gear is identified by a groove cut into the face of the gear The matching pinion gear had teeth across only half of the width of the pinion gear body The matching breather gear had a cross to identify its timing position SETTING GEAR LASH In order to establish the proper gear lash cam gears and pinion gears are made in different pitch diameters The dif
10. ing the overlap period This is when the exhaust valve is closing and the intake valve is opening and both valves are off the seat at the same time We want to check to be sure there is at least 030 clear ance between the valves as they pass by one another Put the checking wire through the spark plug hole and position it between the valves Use a flashlight to shine into either the intake or exhaust port while looking into the other port If the wire will not pass between the valves the valves and or the valve seats must be modified to provide this clearance If necessary the valves can be modified by reducing their head diameter or by machining a 45 degree angle on the portion of the valve head that faces into the combustion chamber If this does not correct the situation then the valve seats in the heads will need to be ground deeper This will sink the valves into the heads providing extra clearance at overlap CHECKING VALVE TO PISTON CLEARANCE There must be at least 080 between the valve and piston clearance 327E GENERAL INSTRUCTIONS 1 Install spacing washer and thrust washer on camshaft Fig 13 Install camshaft Check to make sure the innermost lobe clears the engine case Fig 14 If not clearance must be made by removing case material with a cutter or grinding wheel Care must be taken to keep chips or grindings out of the cam bearing The inside of the gear case must be thorough ly cleaned
11. nd play can be between 001 to 016 with an ideal situation of 003 to 005 If using a point type ignition sys tem you must maintain the cam end play between 003 to 008 To arrive at the proper end play different thickness spac ing washers are available from a Harley Davidson dealer Also be sure the thrust washer is installed properly with the ears facing down and the cutoff portion of the washer towards the rear cylinder SETTING PRELOAD USING STOCK HYDRAULIC TAPPETS AND PUSHRODS 1 Remove tappets from guide drain oil and clean one at a time then reassemble Replace tappets in guide with oil hole flats on the side of the tappet body fac ing towards the center of the guide block Install guides into case being careful not to drop the tappets into the gear case Install new tappet block gasket and for engine models 1977 and later use an aligning tool Crane part 9 0021 or 4 00 Fig 8 H D 33443 to position the tappet guide block in the case and tighten all the screws 2 The engine must be rotated so that the tappet you are adjusting is riding on the heel of the cam lobe no lift involved To determine this you will watch the same valve intake or exhaust on the opposite cylinder the cylinder opposite the one you re working on If the same valve on the opposite cylinder is at full lift tappet all the way up in the guide block then the one you re adjusting will be all the way down
12. the knowledge or experience for this inspection and possible modification of component parts then seek assistance from a qualified dealer REMOVING THE OLD CAMSHAFT ALL MODELS 1 Disconnect the battery Secure the motor cycle on a suitable stand with the rear wheel off the ground if no kickstarter is on the model Remove components neces sary for easy access to pushrod covers an gear case cover i e exhaust system Fig 1 right footrest Fig 2 brake pedal Fig 3 and air cleaner 2 Remove pushrod cover keepers and lift covers Fig 4 amp 5 Remove spark plugs and rotate engine with kicker or by moving rear wheel with motorcycle in gear Turn engine until both valves are closed on the front cylinder This is found when you can see both front cylinder tappets in the down position and see the piston at the top through the spark plug hole Loosen the locknuts on each pushrod adjuster and adjust shorter until pushrod can be lifted out Fig 6 Repeat this same procedure Fig 3 for the rear cylinder Keep pushrods in order for re assembly Remove ignition cover on gear case cover Drilling out of two rivets may be neces sary Remove adjusting plate Remove bolt and rotor Figs 7 amp 8 Your model may have point ignition 4 Remove the gear case cover screws and remove cover and gasket Fig 9 5 Remove tappet guide screws and lift out tappet guide assemblies Be careful not to drop the tappets o
13. ut of the bottom of guides Fig 10 amp 11 6 Remove camshaft assembly spacing washer and thrust washer Fig 12 Save the spacing washer and thrust washer for re assembly on new camshaft IMPORTANT NOTES FOR 1948 THROUGH 1969 MODEL ENGINES 1 The 1948 through 1957 engines used a pushing in the crankcase to align the camshaft in position The 1958 and later engines used a needle bearing All Crane camshafts are ground for the nee dle bearing dimension and can not be used with a bushing If your engine has the crankcase bushing it must be convert ed to the needle bearing by a qualified dealer 2 The earlier model engines 1948 through 1969 drive the ignition system by use of a series of gears These engines require a camshaft with a short nose approximate ly 3 4 long The circuit breaker gear is positioned very close to the front lobe of the camshaft It is possible that this gear can hit the lobe of a high lift camshaft You must inspect the clearance between the lobe and the circuit breaker gear to be sure it s at least 030 or more If not this gear must be removed and modified in a lathe to provide the proper clearance Ina lathe the teeth can be machined down and narrowed only in the area where the lobe is hitting in order to allow for the nec essary clearance and still keep enough width for the gear to drive the ignition sys tem The 1970 and later engines drove the ignition off the end of the camsha
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