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 7)

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f. Place a straightedge across the cam and crankshaft sprockets.
g. Try to slide a .010" thick feeler gauge between the straightedge
and each sprocket face. If the feeler gauge does not fit at either
location, the front to rear alignment of the sprockets is correct.
In most situations, re-using the original crankshaft and camshaft
sprockets, the alignment will be correct. Mis-alignment is
generally because a different camshaft sprocket is used at re-
assembly. In cases where the alignment front to back is not within
.010", spacing washers are available from the OEM or aftermarket
sprocket manufacturer to align the gears. Gear alignment must
be within .010" before proceeding.
h. After verifying correct sprocket spacing, remove camshaft and
crank sprocket bolts, remove both sprockets, and discard smaller
diameter washer used under head of crank sprocket during
alignment check.
12. Installing outer sprockets and drive chain.
a. While holding rear cam sprocket vertically in one hand, place
drive chain over sprocket with timing mark pointing down. Then,
with the other hand place the crank sprocket in the chain loop
with the timing mark pointing up. See Picture 15, next page.
b. Maintaining the position of the sprockets in the chain, rotate the
rear drive sprocket until it slides on the splines of the rear cam.
(The sprocket will only go onto the splines in one position.)
c. Continue to maintain the position of the sprockets on the
chain. Rotate the rear cam and sprocket until the flat on the
crank sprocket aligns with the flat on the crankshaft. Slide drive
sprocket onto crankshaft.
d. Rotate engine by turning rear wheel to align the timing marks as
close as possible. (See Section B Securing Motorcycle.)
e. Lay a straight edge across the centers of the crank and cam
sprockets and verify the timing marks are in alignment.
NOTE: If timing marks are not in alignment, the sprocket and chain
installation must be removed and reinstalled. Misaligned sprockets will
cause the engine to run erratically.
13. Replace cam chain guide. See Picture 6 on page 5.
14. Apply red Loctite® to threads of rear cam sprocket bolt and
crankshaft sprocket bolt and a drop of clean 20W-50 engine
oil beneath bolt heads. Place original large washer onto crank
sprocket bolt. Use sprocket tool H-D® #42314 to secure sprockets.
Tighten rear cam sprocket bolt to 34 ft./lbs. Tighten crank sprocket
bolt to 24 ft./lbs.
15. Using H-D #42313 (Cam Chain Tensioner Unloader) relieve spring
pressure on retaining pin and remove pin.
16. Install outer cover with new gasket and tighten bolts to 90-120
in-lbs. in sequence shown in Picture 16, next page.
17. Release lifters and slide them down the tappet bore to contact
cams. If using stock pushrods or S&S Quickee pushrods, tappet
covers may be left in place. If using S&S standard adjustable
pushrods, tappet covers must be removed.
E. Pushrod Installation And Adjustments
1. Using Stock Non-Adjustable Pushrods
NOTE: Using stock pushrods is only possible if the camshafts installed have
the same base circle as stock, and no more than .585" lift. S&S® labels these
cams as “Bolt-In” for easy reference. Currently S&S 475, 509, and 510 cams
are bolt-in.
a. Rotate engine so one piston is at TDC compression, by rotating
the rear tire while feeling the tappets. When both tappets are at
the bottom of their travel, and the cylinder is at TDC, the cylinder
is at TDC compression.
Picture 11 Picture 12
Timing Marks
Picture 13 Picture 14
clearance