S&S Cycle Adjustable Pushrods - Manual (Page 2)

2
NOTES:
•
S&S Quickee Pushrods for all big twin engines contain two
long and two short pushrods. All Sportster® model and 1999–up big
twin pushrods are the same length.
•
If S&S® adjustable pushrod kit contains four different length
pushrods, the longest pushrod is for the front exhaust, next longest
is the rear exhaust. Of the two shorter pushrods, the longer one is the
front intake, the shortest pushrod is the rear intake. The pushrod kits for
the 1999–up big twin engine have two different lengths—short for the
intakes, long for the exhausts.
•
All installation and adjustments must be made when engine
is cold. Read instructions thoroughly and follow all recommended steps
and procedures.
•
The following instructions are for installing S&S adjustable
pushrods with the stock-style hydraulic lifters. If the S&S HL2T (Hy-
draulic Lifter Limiter Travel) kit is to be used, refer to that section of this
instruction sheet for installation of the kit, and pushrod adjustment.
•
If unsure that the HL2T kit is installed in the lifters of an as-
sembled engine, take note of the following: After the hydraulic piston
assembly is compressed 4 complete turns of the pushrod, and after 20
minutes the pushrod is unable to be spun with fingers, the HL2T kit is
installed in the lifters and the adjustment procedure for this kit must be
followed. Detailed instructions for the HL2T kit are listed in Section C,
Page 3.
•
1966–’84 big twin engines with hydraulic conversion require
the use of S&S tappets and tappet guides.
•
Pushrods with oil holes are for use with S&S rocker arms.
•
Pushrods without oil holes are for stock rocker arms.
•
When adjusting Quickee Pushrods, count flats on the 6 sided
female adjuster, not the 4 sided male part.
•
S&S adjustable pushrods have a thread pitch of 32 threads
per inch. This means that one complete turn equals .031" of change in
pushrod length and one flat is .005".
•
S&S hydraulic lifters have .200" of hydraulic plunger travel.
•
When adjusting pushrods, the plunger should be moved near
the center of its travel. This would be 4 turns or 24 flats which is equal
to .125".
CAUTION
Failure to follow recommended steps and procedures may result
in damage to engine components.
WARNING
Installing or adjusting pushrods while engine is hot could result
in burns from contact with hot engine parts.
CAUTION
It is recommended that S&S Quickee Pushrods have a minimum
.500" thread engagement (adjuster to pushrod body) or failure
to maintain proper thread engagement may result in engine
damage.
PUSHROD KITS FOR HARLEY- DAVIDSON® 1984–'99 BIG TWIN,
1986–up SPORTSTER® AND BUELL® MODELS, S&S® P, SH, V
& T SERIES ENGINES, AND 1966–'84 BT w/S&S HYDRAULIC
CONVERSION AND QUICKEE PUSHRODS.
1. Remove pushrod cover clips and lift cover assemblies to view
lifters.
2. Remove spark plugs and rotate engine until front piston is at the
top of its stroke, with both front lifters at their lowest position
(TDCC—top dead center compression).
NOTE: To ensure that the cylinder is at the correct position to remove
pushrods, rotate the engine forward and watch the intake pushrod. The
intake pushrods are the two closest to the center of the engine. Watch
the intake pushrod rise and fall as the engine is rotated. When the intake
pushrod is at its lowest position, the cylinder is on its compression stroke.
Check to see if the piston is at TDC. If it isn't, rotate the engine a few more
degrees to bring the piston to the top of the cylinder.
3. Remove front pushrods. If installing standard adjustable pushrods,
disassemble the rocker cover and rocker arm assembly, as per the
appropriate service manual. If installing Quickee pushrods, stock
pushrods may be cut out with a bolt cutter to save time. See NOTE
and CAUTION below.
NOTE: Since S&S Quickee pushrods do not require rocker arm disassem-
bly for installation, stock pushrods may be cut out of the engine to save
time. S&S recommends that they be cut with a bolt cutter.
CAUTION
If pushrods are cut with a saw, metal chips may enter engine and
cause extensive damage not covered by warranty.
WARNING
Make sure tappet is at lowest point of travel and pushrod is not
under valve spring pressure before cutting pushrods. Sudden
release of valve spring pressure may cause cut pushrods to fly
out of motor, potentially causing serious injury.
4. Clean and inspect the pushrod tubes. Replace all o-rings. Apply a
light coat of engine oil to the o-rings.
5. Insert new pushrods through tube assemblies and install in
appropriate positions.
6. Reinstall rocker assemblies according to appropriate service
manual procedures if they were removed.
7. Holding pushrod so the top ball end is in the rocker arm cup,
extend adjusting screw until the bottom ball end just contacts the
tappet cup. Compress hydraulic unit in exhaust lifter an additional
4 complete turns (24 flats) and tighten locknut. Allow sufficient
time for lifter to bleed down (20 to 30 minutes) before adjusting
intake pushrod. Pushrods must spin freely with fingers.
NOTE: If pushrods can not be turned between fingers after 20 minutes,
tappets contains S&S HL2T spacers. Detailed instructions for the HL2T kit
are listed in Page 3.
Picture 1
Standard Adjustable Pushrod
Quickee Pushrod