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 User Manual

Page 8

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b. Insert the pushrods into the collapsed pushrod tubes. Make sure

the proper o-rings are installed in the tappet covers, and on the

cylinder head end of the pushrod covers.

c. Verify the correct locations for the pushrods that were removed.

The longer pushrods go in the exhaust locations and the shorter

pushrods are for the intakes.

d. Insert the top of the pushrod into the hole in the head, then drop

the bottom into the tappet cover.

e. Apply assembly lube or suitable clean engine oil to the pushrod

tips where they will contact the rocker arms.

f. Insert the rocker arm support assembly into the rocker box.
g. Ensure that the pushrod tips are fully engaged in the rocker arms.
h. Apply Loctite® 243, then evenly snug the four 5/16" bolts which

hold the rocker arms in place just finger tight at this time.

i. Start the two breather cover bolts at this time, but do not tighten

them.

j. Begin tightening the rocker arm bolts. Following the sequence of

lowest bolt on spark plug side, highest bolt on intake side, lowest

bolt on intake side, then highest bolt on spark plug side. Tighten

each bolt 1⁄4 turn at a time following this sequence until they have

reached a torque of 18-22 ft-lbs.

k. Tighten the two breather cover bolts to 90-120 ft-lbs.
l. Allow lifters to bleed down, then check to ensure both pushrods

rotate freely by hand.

m. Install pushrod cover keepers.
n. Install new rocker box gasket, and rocker box top cover.
o. Apply blue threadlocker to the six rocker cover bolts and tighten

in a star pattern to 15-18 ft-lbs.

p. Repeat for the other cylinder, following steps 1 through 15.
q. Install the gas tank.
r. Shift transmission into neutral.
s. Lower motorcycle onto lift and remove jack.
t. Install spark plugs and plug wires.
u. Reconnect negative battery cable.

2. Using Adjustable Pushrods

a. Place transmission in high gear and turn rear wheel to rotate

engine until both lifters for front cylinder are at lowest point in

their travel. The front piston is now at TDC of compression stroke. If

equipped with S&S Easy Start cams, you must use extra care when

adjusting pushrods. Because the decompression lobe is near TDC,

you must make sure that the tappet is not on the lobe. This will

cause incorrect exhaust pushrod adjustment. To verify correct

position, you can rotate the engine in the forward direction and

feel for the exhaust tappet to slightly lift (about .030”) and set

back down on base circle. This is the proper point to adjust the

pushrods.

b. Loosen locknuts on adjustable pushrods and turn adjusters to

make all rods as short as possible. Z. When installing pushrods,

note that longer S&S® pushrods are for exhaust valves, and shorter

ones are for intake. Pass one long and one short pushrod through

assembled pushrod covers.

c. Place pushrod and cover assemblies through lifter cover. Inner

tappet hole is for intake pushrod, and outer tappet hole is for

exhaust pushrod. If using S&S standard adjustable pushrods, hold

a new gasket under lifter cover and install push rod, pushrod cover,

lifter cover, and gasket as an assembly on crankcase. Tighten lifter

cover screws to 95 in-lbs. torque. Stock pushrods or S&S Quickee

pushrods, can be installed without removing tappet cover.

d. While holding the top of the pushrod into the cup of the rocker

arm, extend the bottom end into the tappet until the pushrod is

just making contact with the cup of the tappet. From this point,

extend the pushrod 24 flats (4 full turns). Move the jam nut on

the threaded portion of the pushrod to lock the end in place and

tighten.

NOTE: S&S® adjustable pushrods have 32 threads per inch, and 24 flats

will place the pushrod in the optimal position of the stock style tappet. If

pushrods other than S&S adjustable or quickee’s are used, refer to the

manufacturer’s instruction sheets to find the number of flats needed.

e. Allow the tappet to bleed down until you are able to rotate the

pushrod freely by hand, before adjusting the next pushrod.

f. Repeat steps 5 and 6 for the other pushrod on the same cylinder.
g. Ensure both pushrods rotate freely, then repeat steps 1 through 6

for the other cylinder.

h. Install pushrod clips.
i. Shift transmission into neutral.
j. Lower motorcycle onto lift and remove jack.
k. Install spark plugs and plug wires.
l. Reconnect negative battery cable.

NOTE: The tappets may be noisy upon initial start-up after installing cams.

This is normal after the tappets have all been bled down, and will go away

shortly as long as the proper oil pressure is available.

If the engine is rotated before the tappets have bled down and the
pushrods can be rotated by hand, valve to valve or valve to piston
contact may occur. Serious engine damage could result.

Picture 15

Picture 16

CAUTION

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