101 Harley-Davidson Twin Cam Performance Projects

by Zimmerman, Mark

• ISBN13: 9780760316399
• ISBN10: 0760316392
• Format: Paperback
• Copyright: 2005-03-28
• Publisher: Motorbooks

Summary

The Harley-Davidson Twin Cam engine is powering many of the most popular modern Harley-Davidson motorcycles on the road today. And like most Harleys, Twin Cams receive special attention from their owners in the form of cosmetic customization and performance enhancements. If you're a Twin Cam owner, chances are you've modified, or thought about modifying, your bike on your own. Whether you want to swap in some dazzling aftermarket taillights, or increase your engine output with some high-performance cams, this is your information source.

Author Biography

Mark Zimmerman is the Technical Editor of Motorcycle Cruiser magazine, and a contributor to Classic Bike Guide magazine. He lives in Danbury, Connecticut. Jeff Hackett has been photographing motorcycles for magazines, books, and calendars for 19 years. He lives outside New Haven, Connecticut.

Table of Contents

Preface and Acknowledgments	7	(1)
SECTION ONE WORK AND TOOLS	8	(9)
The Work Area	9	(1)
Work Practices	10	(2)
Tools	12	(5)
SECTION TWO SIMPLE MAINTENANCE	17	(24)
VINs and Engine Case Numbers	18	(3)
Performing the 10,000-Mile Service	21	(2)
Lubricating Cables	23	(2)
Changing the Engine Oil and Filter	25	(2)
Changing Transmission and Primary Oil	27	(2)
Servicing the Air Cleaner	29	(1)
Choosing, Reading, and Replacing Spark Plugs	30	(3)
Inspecting and Adjusting the Rear-Drive Belt	33	(2)
Checking and Adjusting the Primary Chain	35	(2)
Replacing Brake Pads	37	(2)
Adjusting the Clutch	39	(2)
SECTION THREE INTAKE AND EXHAUST	41	(31)
Installing a Screamin' Eagle Air Cleaner	42	(2)
Installing an S&S Air Cleaner	44	(2)
Rejetting the Stock CV Carb	46	(3)
Installing a Dynojet Thunderslide Kit	49	(3)
Installing an S&S Super E/G Carburetor	52	(3)
Installing a Performance Intake Manifold	55	(2)
Replacing the OEM Vacuum-Operated Petcock	57	(2)
Understanding the Twin Cam EFI System	59	(3)
Installing a Screamin' Eagle EFI Race Tuner	62	(3)
Installing and Adjusting the Power Commander IIIr	65	(3)
Installing a Performance Exhaust System	68	(4)
SECTION FOUR SUSPENSION AND CHASSIS	72	(22)
How to Fix Clunking Forks	73	(2)
Installing a Cartridge Fork Emulator	75	(3)
Lowering Front Forks	78	(3)
Installing New Fork Springs	81	(2)
Swapping the Shock on a Springer	83	(2)
Adjusting Front and Rear Preload (Sag)	85	(2)
Lowering the Rear of a Softail and Installing New Rear Shocks	87	(2)
Lowering a Twin Shock Rear End	89	(2)
Servicing Rubber Engine Transmission Mounts	91	(1)
Installing Rear Air Shocks	92	(2)
SECTION FIVE TIRES, WHEELS, AND BRAKES	94	(19)
Balancing Wheels	95	(2)
Building and Maintaining Wire Wheels	97	(3)
Servicing the Brakes---Changing the Brake Fluid	100	(2)
Installing Braided Brake Lines	102	(3)
Upgrading Your Brake Discs	105	(2)
Upgrading Calipers	107	(2)
Changing Wheels	109	(3)
Checking and Replacing Wheel Bearings	112	(1)
SECTION SIX THE ENGINE	113	(59)
Breaking in a New Engine	114	(2)
Dyno Tuning an Engine	116	(3)
Installing Adjustable Pushrods	119	(2)
Installing Custom Lifter Covers	121	(2)
Installing Roller Rocker Arms	123	(2)
Installing High-Performance Valve Springs	125	(3)
Installing TP Pro-Vent Rocker Boxes	128	(2)
Installing High-Performance Heads	130	(3)
Checking Combustion Chamber Size	133	(3)
Claying High-Compression Pistons	136	(4)
Installing a 95-Cubic-Inch Kit	140	(3)
Installing a Custom Cam Cover	143	(2)
Installing an Andrews Camshaft Sprocket	145	(2)
Replacing the Rear Camshaft Ball Bearing	147	(3)
Replacing the Inner Camshaft Bearings	150	(2)
Installing High-Performance Cams	152	(4)
Installing S&S Gear-Driven Cams	156	(3)
Installing a Delkron Camshaft Support Plate	159	(2)
Blueprinting the Engine	161	(2)
Balancing the Engine	163	(2)
Installing a Stroker Kit	165	(4)
Servicing the Breather Assembly	169	(3)
SECTION SEVEN: THE ENGINE OIL SYSTEM	172	(9)
Installing an Oil Cooler	173	(2)
Installing an S&S Crankcase Breather Valve	175	(2)
Aligning a Twin Cam Oil Pump	177	(2)
Installing a Feuling Oil Pump	179	(2)
SECTION EIGHT: THE DRIVETRAIN	181	(50)
Installing a Hydraulic Clutch Actuator	182	(2)
Installing a Rivera Pro Clutch	184	(3)
Installing a Barnett Scorpion Clutch Spring Conversion Kit	187	(3)
Installing a Primary Chain Tensioner	190	(2)
Installing a Balance Masters Kit	192	(2)
Installing a Primary Belt Drive	194	(3)
Installing a Transmission Pulley	197	(2)
Replacing the Drive Belt	199	(1)
Swapping to a Custom Sprocket	200	(1)
Installing a Rear Drive Chain	201	(2)
Installing a Custom Tranny Side Cover	203	(2)
Installing a BAKER Reverse Shifter Assembly	205	(3)
Installing a Six-Speed Gear Set Kit	208	(5)
Installing Aftermarket Digital Gauges	213	(2)
Choosing High-Performance Ignition Wires	215	(1)
Installing a High-Performance Starter	216	(1)
Maintaining Your Charging System	217	(2)
Installing a Screamin' Eagle Adjustable Map Ignition System	219	(3)
Installing an Aftermarket Ignition	222	(2)
Replacing the Thermometer with an Oil Temperature Gauge	224	(1)
Upgrading the Horn	225	(1)
Troubleshooting the Electrical System	226	(2)
Upgrading Your Headlight	228	(1)
Hiding Wiring in the Handlebar	229	(2)
SECTION TEN: PERSONAL TOUCHES	231	(23)
Detailing Your Bike	232	(2)
Custom Turn Signals	234	(2)
Swapping Taillights	236	(2)
Fiberglass Repair	238	(3)
A Primer on Paint	241	(1)
Paint Repair	242	(2)
Installing Chrome Handlebar Control Pods	244	(2)
Selecting and Changing Handlebars	246	(2)
Installing Forward Controls	248	(1)
Selecting and Changing Seats	249	(2)
Applying Coatings	251	(3)
Sources	254	(1)
Index	255