INSTRUCTIONS - Harley
Contents
1. HARLEY DAVIDSON J02268 INSTRUCTIONS REV 8 16 01 Kit Number 18088 02 CHROME BILLET LIFTER COVER KIT General This kit fits all 1999 and later Twin Cam 88 engines Kit contents QTY DESCRIPTION PART NO 1 Front chrome billet lifter cover 18089 02 1 Rear chrome billet lifter cover 18091 02 2 Lifter cover gaskets 18635 99A 8 Socket head cap screws chrome 94314 91T WARNING A Service Manual is required to install this kit The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have your Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury NOTE A Service Manual for your model motorcycle is available from your Harley Davidson Dealer This kit installs in one of two ways depending upon the kind of pushrods to be installed with the chrome billet lifter cover kit If you are installing e stock pushrods with the chrome billet lifter cover kit refer to the service manual for your motorcycle model e Screamin Eagle adjustable pushrods with the chrome billet lifter cover kit refer to Installation with Adjustable Pushrods in this instruction sheet NOTE Harley Davidson recommends replacing the pushrod cover O rings with O ring part numbers 11293 top 11132 mid dle and 11145 bottom during lifter cover installation and assemb2. 2268 i il i F 3 Front cylinder intake 4 Front cylinder exhaust 1 Rear cylinder exhaust 2 Rear cylinder intake Figure 5 Pushrod Locations and Functions NOTE Check for contact between the pushrods and upper pushrod covers Rotate the engine slowly until both valves are closed on the cylinder you are checking If contact occurs shift the rocker arm supports toward the engine s cam side 14 Install the pushrod spring cap retainers on the pushrod covers 15 Install the spark plugs and plug wires and shift the transmission to neutral WARNING Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 16 Connect the battery cables Setting the Lifters to the Base Circle This procedure positions both lifters of a cylinder to their lowest position on the cam reducing valve spring pressure to a minimum This procedure is required for removing and installing a rocker arm support plate on a cylinder 1 Remove the spark plugs from the engine 2 Elevate the motorcycle on a center stand until the rear wheel is elevated from the ground 3 Shift the transmission into 5th gear 4 From the left side of the motorcycle put a left hand finger over the spark plug hole on a cylinder e Turn the rear wheel counterclockwise with your right hand unt
3. il you feel the compression stroke of the piston forcing air out of the spark plug hole e When air pressure through the spark plug hole stops the piston is at top dead center TDC Stop turning the rear wheel and check TDC with a flashlight beam directed into the spark plug hole e f the piston is at TDC on the compression stroke and the lifters are in their lowest position on the cam then the intake and exhaust valves are closed and the pushrods are unloaded and the rocker arm support plate can be safely removed or installed 3of3
4. lation 1 See Figure 3 Verify that the lifter anti rotation pin is in position 04188 Figure 3 Lifter Anti Rotation Pin CAUTION Installing or removing the pushrods with the valve train loaded can result in engine damage On the cylinder being serviced always set the lifters to the base circle on the cam before servicing pushrods lifters rocker arms and valves 2 Verify that the cylinder lifters are set to their lowest point or base circle on the cam Refer to Setting the Lifters to the Base Circle in this instruction sheet 3 Fasten the new lifter cover gasket and chrome billet lifter cover to the engine using the chrome screws from this kit In a cross pattern torque the lifter cover screws to 90 120 in Ibs 10 2 13 6 Nm 4 See Figure 4 Loosen the jam nut on all of the pushrods and adjust the pushrods to their shortest length NOTE See Figures 4 and 5 Install the narrow band pushrods in the cylinder intake location Install the wide band pushrods in the cylinder exhaust location Assemble the O rings purchased separately and pushrod covers 6 Install the pushrods with the pushrod covers The adjustment end of the pushrod must be on the lifter NOTE Do not install the spring cap retainers on the pushrod covers at this time 7 To adjust pushrods on hydraulic lifters go to step 8 To adjust pushrods on solid lifters go to step 11 NOTE Pushrod adjustment must be made with the engine c
5. ly NOTE Installing an adjustable pushrod kit may void the Harley Davidson limited warranty CAUTION Solid lifters must not be installed with the stock camshaft Severe engine damage may result WARNING To protect against shock and accidental start up of the vehicle disconnect the negative battery cable before proceeding Inadequate safety precautions could result in death or serious injury WARNING Always disconnect the negative battery cable first If the positive battery cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or seri ous personal injury Installation with Stock Pushrods Refer to the service manual for your motorcycle model Installation with Adjustable Pushrods Lifter Cover Removal CAUTION Installing or removing the pushrods with the valve train loaded can result in engine damage On the cylinder being serviced always set the lifters to the base circle on the cam before servicing pushrods lifters rocker arms and valves 1 Set the lifters of the rear cylinder to their lowest point or base circle on the cam Refer to Setting the Lifters to the Base Circle in this instruction sheet N See Figure 1 Insert a screwdriver into the slot on the side of the spring cap retainer on the pushrod cover Figure 1 Pushrod Cover Removal 3 Press the spring cap and retainer down while pulling o
6. old 8 See Figure 4 Adjust each pushrod length to zero clearance e Use a wrench to keep the pushrod from rotating 2 of 3 e Slowly turn the adjusting screw 2 1 2 complete turns lengthening the pushrod 9 Hold the adjusting screw and tighten the jam nut against the pushrod If the pushrod turns with the jam nut use three wrenches one to hold the pushrod one to hold the adjusting screw and one to turn the jam nut i02097 Intake Exhaust Pushrod is Pushrod is shorter has longer has narrow band wide band Adjusting screw flats Jam nut Adjusting screw Figure 4 Adjustable Push Rod CAUTION Wait ten minutes before turning engine over after adjusting front or rear cylinder pushrods This allows lifters to bleed down and prevents bending the pushrods and valves Pushrods should turn freely and valves must be seated before turning over the engine 10 Wait ten minutes Go to step 13 11 See Figure 4 Adjust each pushrod length to zero clearance The pushrod must turn with no drag and no vertical play 12 Hold the adjusting screw and tighten the jam nut against the pushrod If the pushrod turns with the jam nut use three wrenches one to hold the pushrod one to hold the adjusting screw and one to turn the jam nut 13 Repeat Lifter Cover Removal steps 1 11 and Lifter Cover Installation steps 1 7 for the front cylinder When both cylinders pushrods are installed go to step 14 J0
7. utward to remove the spring cap retainer 4 See Figure 2 Lift the lower pushrod cover to reveal the lower third of the pushrod 5 Ifthe engine has stock pushrods installed and you are installing adjustable pushrods with this lifter cover installation go to step 6 If the engine already has adjustable pushrods installed and you are installing adjustable pushrods with this lifter cover installation go to step 7 1of3 104187 Description O ring Pushrod upper cover Spring cap pin Description O ring Lifter cover Lifter anti rotation Gasket Lifter Screw Pushrod retainer Spring cap Spring Washer O ring Pushrod lower cover Figure 2 Pushrod Pushrod Cover and Lifter Cover 6 Use a bolt cutter or similar tool to cut the stock pushrod Avoid cutting the pushrods with a saw grinder or other method that may allow metal debris into the engine Go to step 8 7 Loosen the jam nut on each adjustable pushrod and resize each rod to its shortest length 8 Remove the pushrod covers and pushrods from the engine 9 Remove the O rings from the seats in the engine at the top and bottom of the pushrod cover 10 Remove the four screws fastening the lifter cover to the engine to remove the cover and gasket 11 Remove old lifter cover gasket material from the engine taking care not to allow material to fall into the engine Continue to Lifter Cover Installation in this Sheet J02268 Lifter Cover Instal
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