Jims USA Twin Cam Racekit Box 1 1208-1351 User's Manual
Contents
1. caliper O A TC Engine Stand JIMS No 1022 O B TC Engine Stand JIMS No 902 O Small brass punch JIMS No 1081 O Small brass hammer JIMS No 1080 O 20W 50 clean H D engine oil Recommended Tools amp Supplies 0 O O O The following are required to install the cylinder studs 0 0 0 0O 0 Follow all manufacturer s instructions and heed all warnings specific to A small tooth brush Several lint free cloths A flashlight com One quart 20W 50 H D Motor Oil Fe nae The furnished six long and two short studs The furnished Loctite compound 620 Fig 4 Tools Required One 1 furnished cylinder dowel pin tool 1 4 x 1 2 One 1 furnished Short Head bolt A solvent to degrease the threads of each stud Use Loctite primer ace tone denatured alcohol rubbing alcohol or other non residue solvent fo this purpose each chemical used 0 0 0 A small tooth brush recommended Beta Engine Stand A lint free cloth JIMS No 902 Use on all Betas A flashlight recommended 5 S55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REV F 6 08 No 1208 1351 STEP 1 Preparation e Inspect the entire surface of the studs for damage See Fig 5 e Minor scratches are okay in the body of the stud e The threaded portion of the studs must not have deformities that stud would cause binding between the cases or head bolts e Set aside and cover STEP 2 Inspect the o2. Fig 3 Box 1 components See Pages 9 e Refer to the manufacturer s instructions included with your engine stand for proper installation e Replace the blue foam rod protectors into cylinder spigot bore prevents rod from knocking in case e Remove masking intended for cleanliness as indicated e Check case finish for scratches may have resulted from shipping e Cover lower end assembly with the supplied clean clear plastic bag Note Touch up paint is included in box 2 for your convenience Please see directions for proper application and curing Cylinder Studs You will find eight 8 cylinder studs Two 2 short studs and six 6 long studs Verify presence of green loctite 620 for use when installing the cylinder studs 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 i No 1208 1351 REV F 6 08 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 1 120 OR 131 ENGINE ASSEMBLIES OR ENGINE RACE KITS Oil Filter Mount for Engine A 99 06 FL 99 05 FXD Remove from package and inspect for debris and imperfections Verify the package includes three 3 bolts with washers and one 1 locking flange Check that there are two o rings present Tools necessary for box 1 installation See Fig 4 O 3 8 drive torque wrench 5 75 ft lbs O 3 8 drive torque wrench 40 200 In Ibs O 3 8 drive ratchet O 7 8 deep socket O 1 2 12 point socket O 7 16 socket O 6
3. Sliver 06 Pres FXD 07 to Pres FLH z C Spacer Sprocket shaft B 2001 2006 FXST E O Oil Filler Mount Kit Black A 99 07 FL 99 05 FXD a1 O Oil Filler Mount Kit Silver A 99 06 FL 99 05 FXD O Adapter Oil Filler B 2000 Pres FXST 06 Pres FXD 07 Pres FL L 1286 1360 Cylinder Stud Long A amp B 6 C 1286 1361 Cylinder Stud Short A amp B L 1286 1362 Retaining Compound 620 020z A amp B L 1286 1387 Stud Installer Tool A amp B L 1286 1395 Bag 24X24 To Cover Engine B 1286 1394 Zip Tie Motor Bagging A amp B LJ 1208 1302 Red Tag Shipping A amp B rifi2a6 1330 Molly Lube Package A B x Z 1208 1304 Warranty Card A amp B C 1208 1351 Instruction Sheet A amp B 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422
4. Rev F 6 08 i ASSEMBLY _ INSTRUCTIONS wae 1208 1351 These instructions are for all models of 120 or 131 Alpha Beta Engines Including Kits j in ath W i Le h ks 7 ih i j k Se 2 i h na a No 1208 1351 REV F 6 08 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 1 120 OR 131 ENGINE ASSEMBLIES OR ENGINE RACE KITS The following instructions are for both 120 or 131 Engine Assemblies and Engine Kits top end not assembled These instructions will have information not only for assembly of the engine but will have helpful info in other areas such as the drive line area electrical tuning oiling and frame info etc Read thoroughly before starting any assembly Note Throughout the following text we will make motor application reference as shown A for Alpha engines B for Beta engines and 06 FXD for 2006 to present DYNA and 07 FLH for 2007 to present FLH s If you ordered and received an assembled engine assembly we recommend you read all three instruction booklets to become familiar with your new engine Note that if your engine assembly does not come with a carburetor or ignition You can order carburetor and ignition separately Call JIMS sales depart ment for ordering JIMS 120 Or 131 Kit Engine General Instructions Check Box Contents Verify you have received three 3 of th
5. e in the stock TWIN CAM engine The 120 s or 131 s cylinder spigot notches are necessary to get the big bore cylinders to clear one another These notches make the front and rear cylinders different from one another The rear piston s skirt notch intake side is necessary to clear the front piston when both are at the bot tom of their stroke BDC See Fig 2 All gasket surfaces must be perfectly smooth and clean to properly seal the special high performance head and base gaskets Cleanliness Your work area must be as clean as possible From the point of view of engine building almost all motorcycle shops and private garages are very dirty places Your JIMS 120 or 131 Race Kit engine is going to have some of its most highly S55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 5 REV F 6 08 No 1208 1351 A Division of Thiessen Products INC INSTRUCTION SHEET FOR Box 1 120 OR 131 ENGINE ASSEMBLIES OR ENGINE RACE KITS loaded parts separated by an oil film only a millionth of an inch thick If a particle of dirt larger than the oil film gets between those parts they will be damaged A particle of sandpaper in the wrong place may start a chain of events that can either shorten the wear life of your new engine or cause it to fail complete ly This is not an exaggeration The greatest single threat to engine life is hard particle contamination dirt Modern engines can
6. gle Race Tuner Ignition JIMS No 1286 1376 or H D No 32124 04 These are for carbu retor models only and these must be ordered separately Recommended Carburetor It is recommended you use a 51mm CV Screamin Eagle carberator JIMS No 1286 1378 or H D No 27926 02 You will need to use 2 JIMS No 1286 1400 or H D No 26993 06 flanges and 2 No 27035 05 seals All these parts need to be ordered seperately See our sales staff for more detailed information Assembly Sequence all Models There is nothing particularly difficult about assembly of the JIMS 120 or 131 Race Kit engine With some differences assembly is very much the same as if it were a standard TWIN CAM However because those differences are important we request you closely follow our assembly instructions The JIMS 120 or 131 Race Kit instructions are arranged in a Step By Step sequence Each step builds upon and is dependent upon the previous one If you follow our instructions Step By Step you shall assemble your JIMS 120 or 131 Race Kit engine quickly and correctly The details of each step are also important Please study and follow these step details closely NOTE JIMS Engines are not equipped for a cam sensor because it is not needed with the recommend ed ignition module Disconnect as necessary per bike model shop manual The pistons and cylinders of the JIMS 120 or 131 Race Kit are not interchangeable front to rear as they ar
7. il filter o ring sealing surface e Sealing surface should be smooth and flat e If necessary clean thoroughly set aside and cover See Fig 8 for Engine A e Inspect both threads for any burrs or dents on oil filter adapter No 1486 Fig 5 Clean surfaces 1835 STEP 3 Base Gasket Surface Preparation OUIET ACARI for Engine B and A 06 Pres FXD amp 07 Pres FL No 1486 e Clean base gasket surface case deck with a clean lint free cloth and denatured alcohol isopropyl alcohol e Make certain the cylinder seating surfaces of the cases are smooth clean and dry See Fig 9 e Confirm the eight stud holes in the cases are empty clean and dry STEP 4 Stud Installation See Fig 7 amp Fig 8 Fig 6 Oil filter unit Note These studs are not designed to be an interference fit however there may be slight drag on some studs as they are installed into the case e Each stud is installed with two 2 small drops of Loctite 620 on the first four 4 threads and 2 small drops in each cylinder stud case Fig 7 3 8 Head bolt end hole Fig 8 7 16 Case stud end Note Dirt is an engine s worst enemy S55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 j REV F 6 08 No 1208 1351 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 1 120 OR 131 ENGINE ASSEMBLIES OR ENGINE RACE KITS IMPORTANT NOTE Use a head bolt and the furnished cy
8. irt is into your engine Do not use it Follow all manufacturer s instructions and heed all warnings specific to each chemical used The Boxes The exterior of the three boxes are going to be contaminated Keep them away from your work area Carry the individual sealed packages to your bench before opening them Do not unseal the packages until you are ready to install or use their contents Cover with clean plastic or return all parts to their original pack aging when you are not working with them S55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REV F 6 08 No 1208 1351 Box ONE ENGINE RACE KIT INSTALLATION INSTRUCTIONS Inspection of parts for box 1 For A Engine 99 06 FL For B Engine 06 FXD 99 05 FXD lt amp 07 FL to Pres Part No 1286 1346 Black Fig 3 Box 1 components See Page 9 Part No 1486 1835 Part No 1286 1345 Silver Note Please verify contents of box 1 and complete inspection of these parts prior to proceeding with installation as listed on page 9 Please contact JIMS Tech Support 805 482 6913 if there are any issues with the parts enclosed See Fig 3 and page 4 D e ee ee Lower End Assembly Inspection e Read and remove Red Tag attached to the plas tic bag containing the lower end e Cut open the protective plastic bag and with the help of a friend carefully remove the lower end from the box and place it into your engine stand
9. last a very long time This is partly due to superior materials more accurate machin ing and better lubricants Still the most important single factor is cleanliness Truck engines routinely trav el 600 000 miles and many reach a million before they are worn out There are many EVO and TWIN CAM Harley motors having approached or exceeded 200 000 miles of service None of this could happen if these engines were dirty inside Wash and Cover Everything Wash your tools It is not enough to drag a rag through a box end wrench wash it inside as well Soap water and scrub brushes are not too extreme When in doubt clean it Don t forget your hands Pictured at right is our cleanliness block This block is designed as a reminder to take special care not to introduce dirt or other con tamination into your JIMS 120 or 131 Race Kit You will find this block located next to the most dirt sensitive assembly instructions Wash or cover every surface the engine parts may contact Consider using thin plastic drop cloth material to cover the rest of the bench and surrounding area especially things like bench grinders In fact do not assemble your JIMS 120 or 131 Race Kit in the same room any grinding is performed Close the door Turn the fan off if you can stand to Do not use air pressure to clean anything Cleaning with air is like blowing leaves it just moves the stuff around One of the places an air nozzle moves d
10. linder dowel pin to drive the studs CAUTION Loctite 620 sets extremely quick do not stop until the stud has been installed to the correct height Apply a small amount of moly lube about 1 16 diameter drop to the 1 4 dowel pin this will help stop the pin from falling out when removing the head bolt from the stud Install the lubed dowel pin into a short head bolt Set the longer studs out of easy reach while you install the short ones Screw a short stud into the head bolt until stopped by the dowel pin Use this assembly to drive the short studs into the right cam side of the engine case See Fig 9 Apply one 1 small drop of Loctite 620 to the first four 4 threads of one side of the 7 16 case stud threads and then apply one more drop 180 degrees on the other side of the stud s first four 4 threads See Fig 10 ona AoD sade Apply one 1 small drop of Loctite 620 to the threads of the center stud holes fen P E a al on the right cam side of the case Then apply a second drop 180 degrees on the other side of the same case stud hole See Fig 11 Drive both short studs as pictured until the distance measured with your calipers between the case and the bottom of the head bolt is 4 650 030 above the case deck gasket surface of the short block See Fig 12 Verify the top of each stud without the head bolt attached should protrude 5 250 030 from the case deck See Fig 13 Repeat proced
11. ree 3 boxes After inspecting the exterior of the three boxes for damage proceed to open and examine the contents of each box Make sure there is no damage and you received the correct version of the JIMS 120 or 131 Race Kit Resist the temptation to open the sealed plastic bags or the Short Block wrapper This is to keep the parts as clean as possible Read red tag Start with Box One Verify the engine case color matches with the checked color on the box or labels See Fig 1 Use the checklist on page 9 and confirm you received everything on the list Close the box Fig 1 BLACK O Box Two SILVER O Verify that the color of the cylinders and heads match with the checked color on the UNCOATED O box label Use the checklist in box 2 instructions on page 19 Do not unwrap the ECT i heads Do not unwrap the pistons or rings unless you suspect damage Close the box Box Three See box label Use the check list to confirm the contents on page 19 Close the Box S55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REV F 6 08 No 1208 1351 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 1 120 OR 131 ENGINE ASSEMBLIES OR ENGINE RACE KITS Recommended Ignition 1999 03 A and 2000 03 B models we recommend the Screamin Eagle adjustable ignition JIMS No 1286 1379 or H D No 32704 01 On 2004 2006 A and B models we recommend the Screamin Ea
12. tly coat outside diameter of sprocket shaft spacer and the inside of the sprocket shaft seal with clean 20w 50 H D motor oil Slide sprocket shaft spacer onto sprocket shaft see illustration until it is seated on the sprocket shaft bearing See Fig 15 If you pur p chased a complete engine assy go to page 11 step 11 of the Box 3 Instructions 1208 1353 Fig 15 Install spacer NOTES 8 S55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REV F 6 08 No 1208 1351 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 1 120 OR 131 ENGINE ASSEMBLIES OR ENGINE RACE KITS BOX 1 Materials Check Off Sheet i UGUEN H D No Description Qty 1 1290 1309 120 Lower End Assembly Black A 1999 Pres FL 99 05 FXD L 1290 1315 120 Lower End Assembly Sliver A 1999 Pres FL 99 05 FXD O h1390 1309 131 Lower End Assembly Black A 1999 Pres FL 99 05 FXD L 1390 1315 131 Lower End Assembly Sliver A 1999 Pres FL 99 05 FXD 11490 1309 120 Lower End Assembly Black B 2000 2006 FXST o h1490 1315 120 Lower End Assembly Sliver B 2000 2006 FXST C f1690 1309 120 Lower End Assembly Black 06 Pres FXD 07 to Pres FLH 1 C 1690 1315 120 Lower End Assembly Sliver 06 Pres FXD 07 to Pres FLH f1708 1309 131 Lower End Assembly Black 06 Pres FXD 07 to Pres FLH C 1708 1315 131 Lower End Assembly
13. ure for the remaining 6 long studs Remove any visible Loctite with a clean cloth from gasket surface Fig 9 Install short studs here Fig 12 Measure stud height 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 1208 1351 REV F 6 08 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 1 120 OR 131 ENGINE ASSEMBLIES OR ENGINE RACE KITS STEP 5 Oil filter mount installation Remove stickers located over 2 holes located where filter mounts to case Refer to the instructions included with your oil filter mount kit for Engine A 99 05 FXD and 99 06 FLH For Engine B and 06 Pres FXD remove 1 7 8 sticker from case where filter mounts Thread in adapter with lock patch into case with a 7 8 hex socket torque to 120 168 inch lbs STEP 6 Sprocket shaft spacer installation You now have a completed Short Block Cover and seal this assembly with the supplied clear plastic bags When ready proceed to Box 2 installation instructions An D nd 9 Inspect the engine sprocket shaft seal and bearing cavities for any packaging debris before continuing See Fig 14 ae ay Locate spacer specific to your application a O 4 Dyna Models 24038 99A A for 1999 to 2005 Fa Softail Models 24038 99A B for 2000 FL Models 24008 99A A amp 2006 Dyna Models Softail Models 24039 01A B for 2001 2006 Inspect spacer for nicks and dents Ligh
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