S&S Cycle Adjustable Pushrods - Manual (Page 3)

3
CAUTION
Failure to allow hydraulic unit to bleed down before rotating en-
gine 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.
8. Repeat above procedures for rear cylinder, this time bringing rear
cylinder to TDCC (top dead center compression).
9. Replace spark plugs and pushrod tube clips. Start motorcycle and
check for leaks.
1986–UP SPORTSTER® & BUELL® MODELS SPECIFIC INFORMATION
NOTES:
In order to access the pushrod adjustor screws in 1991 and later Harley-
Davidson® Sportster® and Buell® models, it will be necessary to use push-
rod cover assembly kit for 1986–'90 Sportster® models, S&S part 93-4038,
and the appropriate length pushrod cover keepers. 1991-'03 models will
also require pushrod cover adapter kit, S&S part 33-5355.
On 1991 and later models, it is necessary to disassemble the rocker arm/
rocker box to remove the stock one piece pushrod cover.
HARLEY-DAVIDSON® TWIN CAM 88® AND TWIN CAM 96™
SPECIFIC INFORMATION
NOTES:
•
S&S pushrod kits for the Twin Cam 88®, Twin Cam 96™, and Twin Cam
103™ engines are available as a kit containing pushrods only, however,
it will be necessary to use S&S pushrod covers, or similar aftermarket
product, in order to be able to access the adjuster units on the pushrods.
S&S has a kit available, part number 106-6051, for stock height 1999–up
big twin engines that contains the four adjustable pushrods, pushrod
tube set, gaskets and o-rings for a complete assembly.
•
If equipped with S&S Easy Start compression release cams, you must use
extra care when adjusting pushrods. Because the decompression lobe is
near TDC, it is possible to adjust the pushrod while the tappet is on the
lobe if it is not exactly at TDC. 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 the base circle. This is the proper point to
adjust the pushrods.
•
Remove lifter cover from crankcase to install regular adjustable push-
rods.
•
Reinstall rocker assembly if removed in above step, following procedures
& torque specifications recommended in appropriate service manual.
•
Insert pushrods through pushrod cover assemblies. Install intake and ex-
haust pushrod assemblies, along with the tappet cover and new gasket,
into position in front cylinder. See Picture 2, above.
S&S® HYDRAULIC LIFTER LIMITED TRAVEL KIT (HL2T)
NOTES:
The S&S HL2T kit is designed to limit the travel of the hydraulic lifter
making it impossible for the lifter to collapse. Stronger valve springs are
often used to avoid valve float at high rpm. The HL2T kit prevents high
valve spring pressure from collapsing lifters. With the HL2T kit installed,
stock hydraulic lifters work like solid lifters at high rpm, while retaining
normal hydraulic function for minimal noise and maintenance under
normal conditions. Another advantage of the HL2T kit is that if a valve is
held open when the engine is not running, valve spring pressure will not
cause lifters to bleed down and collapse. Collapsed lifters can cause hard
starting and excessive valve train noise when engine is restarted. Adjust-
able pushrods must be used with the HL2T kit.
NOTES:
•&S Limited Travel Kit 33-5338 fits all S&S tappets and all Harley-Davidson®
replacement tappets for 1999-'14 big twins (18538-99C & 18572-13) and
1991-'14 Sportster® models (18526-89A & 18538-99C).
•S&S Limited Travel kit does not fit Harley-Davidson® replacement tappets
(18523-86B) for 1984-'99 big twins and 1986-'90) Sportster® models.
•If using aftermarket tappets, consult the manufacturer to determine
compatibility. See Limited Travel washer dimensions below.
INSTALLATION
1. If tappets are installed in the engine, it is recommended that they
be removed. Be sure that each tappet is kept with its original
tappet block and bore.
NOTE: This procedure is the preferred method of installation. However,
kit can be installed without removing lifters from engine.
2. Remove hydraulic piston retaining wire clip from one assembly at
a time.
CAUTION
Be careful not to bend wire clip during disassembly.
3. Completely disassemble tappet removing all parts.
KIT OD ID
33-5338 .605 OD .440 ID
Picture 2
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.