101 Harley-Davidson Twin Cam Performance

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.

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.

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

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101 Harley-Davidson Twin Cam Performance Projects

Summary

Author Biography

Table of Contents

Supplemental Materials