Caution – S&S Cycle Pushrod Kits and Travel Limiters (all) User Manual

Page 5

Advertising

Pushrod kits for 1984-1999 big twin, Harley-Davidson

Sportster

and Buell

models, and S&S

⁄

" bore

engines and Quickee Pushrods.

NOTES:
●

The following instructions are for installing S&S adjustable
pushrods with the stock-style hydraulic lifters. If the S&S HL

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 HL

T kit is installed in the lifters of an

assembled engine, take note of the following: After the
hydraulic piston assembly is compressed 4 complete turns of
the pushrod, and after 10 minutes the pushrod is unable to
be spun with fingers, the HL

T kit is installed in the lifters and

the adjustment procedure for this kit must be followed.
Detailed instructions for the HL

T kit are listed below.

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.

NOTES:

S&S Quickee Pushrods for all big twin engines contain two
long and two short pushrods. All Sportster

model and Twin

Cam 88

pushrods are the same length.

1966-’84 big twin engines require the use of S&S tappets
and tappet guides.

1986-'90 Sportster

& Buell

models

NOTE 1: Replacement of the stock pushrods will require either
rocker arm disassembly, or cutting of the original pushrods if
Quickee Pushrods are used. If the original pushrods are to be cut,
S&S recommends that a bolt cutter be used.

If pushrods are cut with a saw, metal chips may enter engine and
cause extensive damage not covered by warranty.

Remove pushrod cover clips and lift cover
assemblies to view lifters.

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).

Remove front pushrods, disassembling the rocker
arms, as per the appropriate service manual. See
NOTE 1 and CAUTION 1 for Quickee Pushrods.

Clean and inspect the pushrod tubes. Replace
all O-rings. Apply a light coat of engine oil to
the O-rings.

Insert new pushrods through tube assemblies
and install in appropriate positions. Skip step f
for Quickee Pushrods.

NOTE: Make certain that new upper pushrod cover O-rings have
been installed into the cylinder head before proceeding further.

Reinstall rocker assemblies according to
appropriate service manual procedures.

Extend adjusting screws to remove lash in pushrods.
Compress hydraulic unit in exhaust lifter 4 complete
turns (24 flats) and tighten locknut. Allow sufficient
time for lifter to bleed down (5 to 10 minutes)
before adjusting intake pushrod.

Failure to allow hydraulic unit to bleed down before rotating
engine or adjusting the other pushrod could result in valve-
to-valve contact and serious valve train damage. Lifters are
bled down when pushrod can be turned with fingertips.

Repeat above procedures for rear cylinder.

Replace spark plugs and pushrod tube clips. Start
motorcycle and check for leaks.

1991 & later Sportster

& Buell

models.

NOTE: In order to be able to adjust the pushrods in 1991 & later
Sportster

and Buell

models, it will be necessary to use the

pushrod cover adapter, S&S part 33-5360, the pushrod cover
assembly for 1986-'90 Sportster

models, S&S part 93-4028, and

the appropriate length pushrod cover keepers.

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).

Refer to the appropriate service manual and
remove the rocker assemblies from the front
cylinder. Remove the two front pushrods, the
pushrod cover retainers, and the one-piece
pushrod covers.

Assemble the new pushrod covers. Install the
pushrod cover adapters in the cover retainers.

Install the pushrods through the cylinder head
and the pushrod cover assembly in the
appropriate positions.

NOTE: Make certain that new upper pushrod cover O-rings have
been installed into the cylinder head before proceeding further.

Reinstall rocker assemblies according to
appropriate service manual procedures.

Repeat above procedures for rear cylinder.

Replace sparkplugs and install pushrod tube clips.
Start motorcycle and check for leaks.

CAUTION

Advertising