S&S Cycle Standard and Easy Start Chain Drive Camshafts for Harley-Davidson Twin Cam 88 Engines 1999–2006 Big Twin, except 2006 Dyna models - Manual (Page 4)

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All reference to Harley-Davidson part numbers is for identification purposes only. We in no way are implying that any of S&S Cycle’s products are original equipment parts
or that they are equivalent to the corresponding Harley-Davidson part number shown.
4 th or 5 th gear. Remove spark plugs. These steps are necessary so
that the rear tire can be used to rotate the engine to correctly align
the cam timing marks during installation, and align the oil pump
during reassembly.
2. Disconnect negative terminal of battery to eliminate potential
sparks and inadvertent engagement of starter while working on
motorcycle.
NOTE: S&S® 475, 509, and 510 cams are compatible with stock pushrods.
However, replacing stock pushrods with S&S adjustable pushrods 93-5096
will simplify cam set installation.
C. Disassembly for Early (99–06 excluding 06 Dyna)
1. Removing pushrods
a. If stock pushrods are to be reused, remove motorcycle gas tank
and top rocker covers. Remove rocker assemblies and pushrods
according to procedure described in the Harley-Davidson®
Service Manual.
b. To remove stock pushrods which will not be reused, remove
pushrod cover clips, collapse pushrod covers, place motorcycle
in gear, and rotate rear tire (see Step B securing motorcycle) to
place lifters and pushrods for either cylinder at lowest point on
camshaft. Piston for same cylinder will be at TDC on Compression
stroke and pushrods will spin with light finger pressure. Use bolt
cutters to cut pushrods.
Cutting pushrods when they are under spring pressure can result in
pushrod parts being ejected with considerable force, and can cause
bodily injury.
Cutting pushrods with saw may result in metal chips entering
engine and causing extensive engine damage not covered under
warranty.
2. Remove engine gear cover and gasket. It is not necessary to
remove ignition sensor from cover. Secure lifters with magnetic
tappet tool or one made from large binder clip spring. See Picture
3 above right.
3. Rotate rear tire (see Step B securing motorcycle) to align timing
marks on the pinion shaft sprocket and the rear cam sprocket.
NOTE: S&S recommends using Harley-Davidson Sprocket Locking Tool
H-D® #42314 to secure sprockets while bolts are removed or installed. See
Picture 4 right.
4. Remove bolt and washer from 17-tooth crankshaft sprocket.
5. Remove bolt and washer from 34-tooth rear camshaft sprocket.
6. Use tool H-D® #42313 (Cam Chain Tensioner Unloader) to swing
primary cam chain tensioner away from chain. Secure with
retention pin. See Picture 5, next page.
Do not pull the retention pins from the primary or secondary cam
chain tensioners when the chain and sprockets are removed! The
primary and secondary cam tensioner springs exert 35–40 pounds
of pressure when retained. Removing a retaining pin without
supporting the shoe will cause the spring to snap open through its
full travel, damaging it, and/or the tensioner shoe. The tensioner
can also injure hands and fingers in its path.
NOTE: If cam chain tensioner retaining pins interfere with cleaning or
service procedures when the cam support plate is removed, use cam chain
tensioner unloader tool (H-D #42313) to hold against spring pressure, then
remove retaining pin and ease spring assembly into the unloaded position.
7. Working gradually around edge of sprocket, carefully pry
sprockets off cams until loose on shaft. Remove sprocket/chain
assembly and mark chain with magic marker to indicate direction
of travel. Chain should be reinstalled in same direction.
8. Remove chain guide. See Picture 6, above left.
9. Gradually loosen and remove four oil pump bolts according to
sequence shown in Figure 1, below left .
10. Gradually loosen and remove six support plate bolts according to
sequence shown in Figure 2, below right.
NOTE: Failure to remove or install bolts according to correct procedure may
result in parts damage not covered under warranty.
11. Carefully remove cam support plate assembly from crankcase. Use
unloading tool H-D #42313 to swing secondary cam tensioner
away from chain. Secure tensioner with second retention pin
inserted through front of support plate. Do not remove pin until
support plate assembly has been reinstalled in engine.
Picture 3
Picture 4
Picture 2
Roller Bearing Ball Bearing
CAUTION
WARNING
CAUTION