knight prowler belt drive® installation instructions
Contents
1. PRORLER a NVC BROW i KNIGHT PROWLER BELT DRIVE INSTALLATION INSTRUCTIONS gt Twin Cam models using KNIGHT PROWLER BELT DRIVE GEAR DRIVE cams with our Helical gears or S amp S inner gears gt Twin Cam belt drive systems 1999 thru 2006 models using the old belt chain drive system gt All 06 dyna and 2007 amp UP roller link chain drive models gt All 06 DYNA and 2007 amp Up gear drive models KNIGHT PROWLER BELT DRIVE Installation Procedures Professional Mechanics ONLY Harley Davidson Twin Cam engine mechanics Read installation instructions thoroughly so that you have a complete understanding of the task before proceeding with each step STEP 1 Place bike on suitable stand where rear wheel can be rotated in 4 or 5 gear when necessary STEP 2 Remove front exhaust pipe If necessary remove as a one piece unit Tip Removing front floorboard will help a lot STEP 3 Using easiest method bolt cutter etc remove pushrods and discard We recommend using the S amp S Quickee install pushrods and S amp S roller tappets WITHOUT travel limiters Remove tappet covers and tappets STEP 4 Hemove outer cam cover and rotate engine until timing marks are aligned together STEP 5 Using Harley Davidson service manual procedure retract the outer chain tension shoe STEP 6 Hemove crankshaft and crankshaft sprocket retaining bolts using Harley Davidson service manual proced2. or 5 gear Using a 3 8 12 point socket tighten the 5 16 18 x 1 1 4 bolt to make sure the crank gear is seated properly You may now remove the crank gear retaining bolt and belt flange Note Check for minimum 010 to 020 clearance between base plate and rear flange of crank pulley STEP 19 Install the supplied 3 16 key in the rear camshaft Install the KNIGHT PROWLER BELT DRIVE cam gear using the 3 8 24 x 1 94 stainless steel bolt with the 3 8 12 point head and the special 1 heavy duty washer PLACE THE 055 SHIM IN THE CAM GEAR FIRST THEN THE 1 WASHER Always use this bolt and washer on the initial install of the cam gear as it will draw the cam gear into the cam while keeping it in alignment not tilted etc After starting several threads of this bolt rotate cam pulley drive gear to ensure it is rotating evenly 4 Installation Picture Reference PR e PICTURE 1 e Note block off plate is black only for identification PICTURE 2 fm i P Note machined surface 15 Note Shown as a 2007 Shown in black model 5 Installation Picture Reference PICTURE 5 WT 003 Crank pulley removal 2 7 m F we PICTURE 6 n A Note Any tool that uses threaded rod or bolts you should use lubricant on threads WT 001 amp WT 002 You may use a 1 open end wrench or adjustable crescent wrench to hold tool while using the removal or installation tools R
3. the belt guard cover by leaving approximately 1 8 clearance DO NOT ATTEMPT TO MODIFY PIPE WHILE IT IS ON THE BIKE Recommended procedure is to mark pipe and use a small torch and a suitable round object to gently compress pipe to get the needed clearance Many pipes will vary by MFG After installing complete exhaust system you may install the complete belt guard cover MAKE SURE TO USE ANTI SEIZE ON THE ENDS OF THESE 4 1 4 20 X 1 STAINLESS STEEL SCREWS TORQUE TO 30 INCH LBS IF YOU STRIP ONE OF THESE 4 20 HOLES YOU GET TO BUY A NEW BASE PLATE STEP 25 Install spark plugs with anti seize and torque to Harley Davidson specifications Kick the tires and light the fires you re ready to go HAVE SOME FUN 8 SPECIAL NOTES BELT QUICK CHANGE PROCEDURE Take plugs out and jack up bike and place in 5 gear Simply rotate engine until timing belt is slightly slack on both sides Place a small dot of whiteout or correction fluid on cam and crank gear as if they were new timing marks J ust remove belt install new timing belt and erase the dots xxx BELT CHANGE INTERVALS Recommended Change annually END NOTE We all like to have fun while working on our bikes These instructions may often have a little humor but written in average everyday layman terms Don t ever be intimidated or afraid to call when you are not sure of any portion of this install manual My brain like everyone else s from time to
4. use Shim kit 301120 that has standard 005 010 020 shims used in Twin Cam gear drive kits Use ONLY between factory thrust washer and our Cam Spider gear When alignment is correct make sure cam is recessed at least 010 or more below inside shoulder of the spider gear 1999 THRU 2008 MODELS amp UP If cam is recessed 015 below the cam gear you may discard the 055 washer Then install 1 1 8 x 225 hardened washer and 3 8 24 x 1 3 4 12 point retaining bolt Note NEVER ATTEMPT TO REMOVE CAM GEAR OR CRANK GEAR BY PRYING OR USING FORCED METHODS ANY DAMAGE WHATSOEVER VOIDS ALL WARRANTY STEP 21 With both gears on but not yet torqued align cam and crank timing marks together CRANK TIMING MARK ALIGNED WITH THE SINGLE DOT CAM TIMING MARK THIS WILL PLACE THE 2 CYLINDER OR REAR CYLINDER ON ITS COMPRESSION STROKE See picture 6 Start by placing timing belt on lower portion of crank gear lower teeth While holding belt slightly taut engage belt on right side of cam gear While holding the belt teeth engaged walk belt teeth around in a counter clockwise direction This may take a time or two but keeping the belt taut while doing this will make it easier Once you have the belt on the cam gear check cam and crank timing marks and make sure they are still aligned You will find it easier pressing the belt on the crank gear first and rotating to the top in a back and forth motion Make sure timing belt is flush with end of ca
5. Secure bearing retainer plate Note We recommend using the S amp S heavy duty bearing retainer plate part no 33 5212 STEP 13 PROCEDURE FOR HELICAL OR S amp S INNER GEARS Drive gears can now be installed on both the front and rear camshafts Note that there is a front gear for the front cam and a rear gear for the rear cam Gears can be assembled by pressing camshafts into drive gears with drive keys in place Note The gears must be pressed into the camshafts with the timing marks facing the cam lobes STEP 14 After drive gears and bearings have been assembled both camshafts can be installed into the cam support plate Cam lobe surfaces should be coated with engine oil or assembly lube Note At this point timing marks on both cam drive gears must be correctly aligned DO NOT PLACE ANY OIL OR LUBE ON INNER GEARS AT THIS TIME HELICAL GEAR NOTE When using HELICAL GEARS we recommend that you press the front cam in the support plate approximately 4 Install the rear camshaft making sure the timing marks are going to be together when both cams are fully pressed into the plate You will notice while pressing in either camshaft the HELICAL GEARS will rotate the other cam at the same time STEP 15 CHECKING CAM GEAR BACKLASH DOES NOT APPLY TO HELICAL GEARS Once the new cams and gears are installed backlash for S amp S inner cam drive gears 34T must be checked Using a wooden rod or you may machine yourself a nice al
6. eference only Center tool WT 002 shown installed on cam spider gear Removal tool WT 003 shown mounted to crank pulley The 5 16 18 x 1 5 set screw is to be inserted in crank until flush with end of crank gear Note Wood Performance has special tools for removing and installing the cam gear and crank gear assemblies Use WT 001 for installing the cam gear and WT 002 for removing the cam gear Use the WT 003 tool for removing the crank gear When using the WT 001 tool you need only to tighten the cam gear onto the camshaft until it is fully seated Do not torque at this time See Picture 5 STEP 20 Using any small straight edge See picture 4 place on end of crank gear and check alignment with end of the cam gear A variance or 010 is OK Shims of 005 010 and 020 are supplied If the cam gear does not protrude far enough remove cam gear with WT 002 tool CHAIN DRIVE CAMS DO NOT REQUIRE USE OF THE WT 002 TOOL AS THEY ARE NOT PRESSED ON AND DO NOT USE THE WOODRUFF KEY Remove key from keyway and install necessary shim Reinstall cam gear and check alignment SPECIAL NOTE 1999 THRU 2008 amp UP 06 DYNA and 2007 amp UP models have special thrust washers from 110 to 150 thick If you cannot get alignment to fall in the or 010 with our supplied shims YOU MUST PURCHASE THE CORRECT THRUST WASHER FROM HARLEY DAVIDSON Should you need them we usually have these thrust washers in stock You may also
7. m and crank gear CHECK TIMING MARKS AGAIN STEP 22 Place inner and outer furnished O rings on removable flange Note grooved on both sides They will normally stay in place Place the flange into the front of the crank gear Place small amount of Loctite 242 Blue on the 5 16 18 x 1 12 point bolt and torque to 25 ft lbs max Transmission still in gear Install cam retaining bolt with hardened washer 3 8 24 x 1 94 12 point bolt using small amount Loctite 242 Blue and torque to 35 ft Ibs Note You should always start with cam and crank gear ADVANCE RETARD marks set at the O point You may now torque the 4 5 16 24 12 point nuts to 120 Ibs STEP 23 ADJUSTING PUSHRODS We recommend you turn crank until 1 cylinder front is at TDC Top Dead Center on its compression stroke Adjust your pushrods to recommended number of turns by MFG Now turn engine until 2 cylinder is at its Top Dead Center compression stroke position SPECIAL NOTE Some technicians prefer to adjust pushrods on 2 cylinder since its already on TDC compression stroke when timing marks are aligned This is OK too STEP 24 You may now install the belt guard and the outer cover Do not tighten completely at this time Install front head pipe loosely and allow it to rotate down until it touches the belt guard cover Using a suitable marker note where pipe is touching the belt guard cover REMOVE and modify pipe to clear
8. spect support plate for wear and ensure it is the latest Harley Davidson part number STEP 7a Put transmission in 4 or 5 gear at this time Place the dial indicator on round portion near end of crankshaft CHECK THE CRANK RUN OUT It should be 000 to 004 Call Wood Performance if more than 004 STEP 8 Using Harley Davidson service manual procedure remove all cams chains tensioners bearings etc STEP 9 Hemove both front and inner shoe tensioner mounting studs They are pressed in cam support plate and will press out easily DO NOT ATTEMPT TO PLUG HOLES IT IS NOT NECESSARY Remove front chain guide on front cam support cover Note The two mounting bosses that secure the front chain guide must now be machined down to the even surface of the cam support plate See picture 3 STEP 10 At this time if you are going to use any camshaft over 510 Lift you must clearance the cases to provide ample 030 min rotating clearances at any of the cams 360 degrees rotation points This can be achieved easily by installing the cams one at a time and rotating by hand STEP 11 Clean entire inner cam case cavity Remove the original inner cam case bearings and install the new B148 Torrington bearing with approved Harley Davidson installation tool STEP 12 Thoroughly clean and inspect cam support plate using Harley Davidson service manual procedure Install new cam bearings furnished in the installation kit
9. time does not become fully engaged before speak There is a good possibility that may have left something out on this install manual For goodness sakes if you have any suggestions on how may improve it call me right now Phone number 205 525 4949 P S If you have any better install photos please send them at once and I ll make sure you get the courtesy of credits Thanks and good luck Bobby Wood ALE Mad 490 PULMA C uc AG TE 0v69 Sc S0c KVA 6767 908 900 SA Jeuygejuesng jAleu4 g sjenue y Uo9 sqieopoom Qqoq eu NOD 88 V9 q0Q0 M M MN 76066 VNYSVIV TIJMdOYI HLAOS 99819 NILUYN OPPE 80 38f 88 V 9 SONVMEOdusd GOOM 20 GOOM AGO AG 9 919210 PALO 5 0119192530 W31I _ 0 33SV9 1 E 3iv d 1509915 3AIHO 1138 SM3HOS dVO G V3H 133205 W3S L3JVHSWVO 7 35 L4VHSYNVYO G 0115 NOIIN3I3HM H3dIdS 9 A3lind L3VHSWVO A3lind LJVHSXNVHO 8 quvno 1138 St WONINQTIV 1138 LAVHSWVO ld Lisi dis dA OG LASIN I from the BadLands tothe HighLands sls is OurLand KNIGHT PROWLERS get me there FIRST Wood Performance Carburetors 3440 Martin Street South Ste 6 Cropwell AL 35054 205 525 4949 Fax 205 525 4940
10. uminum rod approximately 8 long that will fit into the lifter bore press down on the front cam through the exhaust lifter bore and hold the front cam from rotating Rotate the rear cam back and forth to check gear backlash Some backlash must be present Recommended operating backlash for cold gears is 0005 to 001 Cams should roll freely with NO binding Cams with a 0 000 backlash too tight may whine when running Backlash greater than 002 is too much and can sound like noisy lifters at lower RPM Either of these conditions must be corrected before continuing Under sized or over sized cam gears are available at Wood Performance If gear clearance is OK remove cam support plate and oil gears now STEP 16 Inspect and clean oil pump thoroughly Replace with new Harley Davidson pump if necessary Install O ring in case cavity Install cam support plate assembly and torque to Harley Davison service manual procedures 90 120 inch Ibs STEP 16a Note 06 DYNA and 2007 gear drive models only Lubricate both sides of furnished 075 thrust washer and install on rear cam STEP 17 Install KNIGHT PROWLER base plate cover with the 10 new 4 20 x 1 stainless steel bolts and new gasket supplied in the kit Torque to Harley Davison service manual procedure 90 120 inch lbs Note USE EXACT TIGHTENING AND SEQUENCE STEPS STEP 18 Install KNIGHT PROWLER BELT DRIVE crank gear with outer flange as a unit Place transmission in 4
11. ure and tools Continue to the next page for special instructions concerning this step with 06 DYNA amp CHAIN DRIVE MODELS and also with 1999 THRU 2006 CHAIN DRIVE MODELS STEP 6a 06 DYNA amp CHAIN DRIVE MODELS If you are going to use the stock or camshafts that are already installed in your engine you may install the belt drive crank pulley and tighten with supplied 5 16 18 X 1 4 12 point bolt There is no need to torque at this time Install camshaft timing gear and spider gear Next check for alignment see step 20 Remove crank and cam pulleys and install 1 pin into cam support plate See pictures 1 amp 2 Install block off plate and torque to Harley Davidson specifications and tightening sequence Proceed to step 17 You may now install crank gear and cam gear Then proceed to steps 21 thru 25 STEP 6b 1999 THRU 2006 CHAIN DRIVE MODELS EXCEPT 06 DYNA On these models regardless of the chain drive cams you are going to use you must proceed to steps 7 thru 12 Now proceed to steps 17 amp 18 Install supplied cam spacer and cam spider gear Tighten snug with supplied 3 8 24 x 1 3 12 point bolt and hardened 1 washer If you are using an after market camshaft that has the 050 hardened washer against the roller cam bearing remove it at this time You will only need the spacer supplied with this kit Proceed to steps 20 thru 25 STEP 7 Hemove cam support plate Remove oil pump and set aside at this time In
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