Instruction 106-6415

S&S Cycle, Inc

®

07-10-13 .
Copyright © 2009–2013 14025 Cty Hwy G PO Box 215
Viola, Wisconsin 54664
by S&S® Cycle, Inc.
Phone: 608-627-1497 • Fax: 608-627-1488
Technical Service Phone: 608-627-TECH (8324)
All rights reserved. Technical Service Email: [email protected]
Printed in the U.S.A. Website: www.sscycle.com

Installation Instructions: S&S Standard and Easy Start

Chain Drive Camshafts for Harley-Davidson® Twin Cam 88® Engines
1999–2006 Big Twin, except 2006 Dyna® models

DISCLAIMER: IMPORTANT NOTICE:

S&S parts are designed for high performance, closed course, racing
Statements in this instruction sheet preceded by the following words are of
applications and are intended for the very experienced rider only. The
special significance.
installation of S&S parts may void or adversely affect your factory warranty.
In addition such installation and use may violate certain federal, state, and WARNING
local laws, rules and ordinances as well as other laws when used on motor Means there is the possibility of injury to yourself or others.
vehicles used on public highways, especially in states where pollution laws
may apply. Always check federal, state, and local laws before modifying your CAUTION
motorcycle. It is the sole and exclusive responsibility of the user to determine Means there is the possibility of damage to the part or motorcycle.
the suitability of the product for his or her use, and the user shall assume all
NOTE
legal, personal injury risk and liability and all other obligations, duties, and
risks associated therewith. Other information of particular importance has been placed in italic type.
S&S recommends you take special notice of these items.
The words Harley®, Harley-Davidson®, H-D®, Sportster®, Evolution®, and all
H-D part numbers and model designations are used in reference only. S&S
Cycle is not associated with Harley-Davidson, Inc.
WARRANTY:
SAFE INSTALLATION AND OPERATION RULES: All S&S parts are guaranteed to the original purchaser to be free of
manufacturing defects in materials and workmanship for a period of twelve
Before installing your new S&S part it is your responsibility to read and follow (12) months from the date of purchase. Merchandise that fails to conform to
the installation and maintenance procedures in these instructions and follow these conditions will be repaired or replaced at S&S’s option if the parts are
the basic rules below for your personal safety. returned to us by the purchaser within the 12 month warranty period or within
••Gasoline is extremely flammable and explosive under certain conditions 10 days thereafter.
In the event warranty service is required, the original purchaser must call or
and toxic when breathed. Do not smoke. Perform installation in a well
ventilated area away from open flames or sparks. write S&S immediately with the problem. Some problems can be rectified by a
••If motorcycle has been running, wait until engine and exhaust pipes telephone call and need no further course of action.
have cooled down to avoid getting burned before performing any A part that is suspect of being defective must not be replaced by a Dealer
installation steps. without prior authorization from S&S. If it is deemed necessary for S&S to
••Before performing any installation steps disconnect battery to eliminate make an evaluation to determine whether the part was defective, a return
potential sparks and inadvertent engagement of starter while working authorization number must be obtained from S&S. The parts must be packaged
on electrical components.
••Read instructions thoroughly and carefully so all procedures are
properly so as to not cause further damage and be returned prepaid to S&S
with a copy of the original invoice of purchase and a detailed letter outlining
completely understood before performing any installation steps. the nature of the problem, how the part was used and the circumstances at
Contact S&S with any questions you may have if any steps are unclear or the time of failure. If after an evaluation has been made by S&S and the part
any abnormalities occur during installation or operation of motorcycle
was found to be defective, repair, replacement or refund will be granted.
with a S&S part on it.
••Consult an appropriate service manual for your motorcycle for correct ADDITIONAL WARRANTY PROVISIONS:
disassembly and reassembly procedures for any parts that need to be (1) S&S shall have no obligation in the event an S&S part is modified by any
removed to facilitate installation.
••Use good judgment when performing installation and operating
other person or organization.
(2) S&S shall have no obligation if an S&S part becomes defective in whole or in
motorcycle. Good judgment begins with a clear head. Don’t let alcohol,
part as a result of improper installation, improper maintenance, improper use,
drugs or fatigue impair your judgment. Start installation when you are
abnormal operation, or any other misuse or mistreatment of the S&S part.
fresh.
••Be sure all federal, state and local laws are obeyed with the installation. (3) S&S shall not be liable for any consequential or incidental damages
••For optimum performance and safety and to minimize potential resulting from the failure of an S&S part, the breach of any warranties, the
failure to deliver, delay in delivery, delivery in non-conforming condition, or
damage to carb or other components, use all mounting hardware that is
provided and follow all installation instructions. for any other breach of contract or duty between S&S and a customer.
••Motorcycle exhaust fumes are toxic and poisonous and must not be (4) S&S parts are designed exclusively for use in Harley-Davidson® and other
American v-twin motorcycles. S&S shall have no warranty or liability obligation
breathed. Run motorcycle in a well ventilated area where fumes can
dissipate. if an S&S part is used in any other application.
CONTENTS OF CHAIN DRIVE CAMSHAFT KIT INSTRUCTION CONTENTS:
• Chain drive cams front and rear A. Introduction & Specifications
• Inner cam bearings B. Securing Motorcycle
• Retaining ring C. Disassembly
• Cam cover gasket D. Installing New Cams and Reassembly
• Oil pump scavenge o-ring E. Pushrod Adjustment
• 5ml tube of Loctite® 262
• 5ml tube of Loctite 243

A. Introduction & Specifications

The S&S® chain drive cams outlined in this instruction sheet are intended for 1999-2006 Harley-Davidson® Twin Cam 88® models.
Timing 99-04 05-UP
Models Models Works
Cam
Lobe Duration Lift Centerline TDC Lift Works with Works with with stock
Name Open Close stock valve stock valve pushrods
springs springs
Int 2° 34° 216° 106° .060"
475 0.475" X X X
Exh 36° 4° 220° 106° .060"
Int 18° 18° 216° 90° .0174"
509C 0.509" X X X
Exh 46° 11° 237° 107.5° 0.140"
Int 20° 38° 238° 99° 0.187"
510C 0.510" X X X
Exh 52° 20° 252° 106° 0.179"
Int 17° 19° 216° 91° 0.178"
551C (E) 0.550" X
Exh 41° 17° 238° 102° 0.170"
Int 20° 40° 240° 100° 0.187"
570C (E) 0.570" X
Exh 55° 20° 255° 107.5° 0.179"
Int 5° 18° 203° 96.5° 0.113"
583C (E) 0.583" X
Exh 58° 24° 262° 107° 0.206"
Int 20° 45° 245° 102.5° 0.186"
585C (E) 0.585" X
Exh 60° 20° 260° 110° 0.179"
Int 20° 55° 255° 107.5° 0.189"
625C (E) 0.625"
Exh 60° 20° 260° 110° 0.184"

Int 25° 60° 265° 107.5° 0.228"

640C (E) 0.640"
Exh 65° 25° 270° 110° 0.214"
Int 25° 60° 269° 109.5° 0.235''
675C (E) 0.675"
Exh 74° 25° 275° 112.5° 0.205"

NOTES
• 1 999–2004 stock springs will handle camshafts with lift up to 0.510". If a camshaft with higher lift is installed, high performance valve springs capable
of handling a greater lift must be used.
• 2 005–up stock valve springs will handle camshafts with lift up to 0.585". If a camshaft with higher lift is installed, high performance valve springs
capable of handling a greater lift must be used. Cams with over 0.585" of lift will cause interference between the valve spring top collar and the valve
seal with stock cylinder heads.
• P
 iston to valve clearance will need to be confirmed when using a cam with over 0.585" of lift. Clearance should be at least 0.060" intake and .080"
exhaust.
• Valve to valve clearance will need to be confirmed when using a cam over 0.585" lift. Clearance should be a minimum of 0.060"
• I nstallation of S&S chain drive cams requires special tools. See Picture 1 on page 3 for the required tools. Attempting the cam change operation
without these tools will be difficult. Damage can result which will not be covered under warranty.
• P
 ossible failure may result if thread locking compound is not applied to the cam drive sprocket flange bolts. Always prepare threads according to the
instructions on the container.
• S &S® chain drivecams are compatible with the stock splined chain sprocket used in 2000–up Twin Cam 88 engines, but may be used in 1999 engines if
the Harley-Davidson 2000–up splined rear cam sprocket and appropriate 2000-up sprocket spacer are used.
• C
 hanging camshafts in the Twin Cam 88® engine requires use of hydraulic press and special tools. This installation should be undertaken only by
experienced mechanic with access to Harley-Davidson® service manual and all required tools or equivalent. Tightening fasteners to correct specifications
with accurate torque wrench is mandatory.
• F or lifts over .510" S&S strongly recommends that the stock chain drive cam be upgraded to the S&S gear drive or to the H-D® part number 25284-08. This
kit upgrades the problematic spring loaded chain tensioners to more reliable hydraulic tensioners, and also upgrades the oil pump.
• T he S&S® chain drive cams outlined in this instruction sheet are intended for 1999-2006 Harley-Davdison Twin Cam 88 models, except 2006 Dyna®
models.

OVERVIEW OF EASY START CAMSHAFTS (IF EQUIPPED): General Notes On Cam Installation
S&S® has developed Easy Start cams to assist starting with a built in • Whenever new camshafts are installed, it is highly recommended
centrifugally operated compression release. The operation is simple: that new tappets be installed. If tappets are reused, they must be
at cranking speeds a spring loaded decompression lever holds the reinstalled in the same position they were removed from.
exhaust valve open slightly. Once the engine fires and exceeds 750 RPM,
centrifugal force move the lever to a retracted position, allowing the
engine to run normally. Cam Intended Displacement Intended Compression Ratio

Important Notes Regarding Easy Start Camshafts: 551 88–106 9.0–10.0

• Stock EFI engines require a minimum of 80 PSI cranking compression, 570 88–106 9.0–10.0
checked with the throttle open, for the ECU to fire the spark plugs. 583 88–106 9.0–10.0
• S&S easy start cams were designed to work with specific compression 585 88–106 9.2–10.5
ratio and displacement combinations. If an Easy Start cam set is used
625 95+ 10.0–10.75
in an application other than what it was designed for occasionally an
engine may not build the required compression to start the bike. 640 95+ 10.5–11.5
• Cranking compression numbers are no longer a valid health check of 675 120+ 11+
the engine. We recommend performing a leak down test.
• If the lifters have been disassembled or bled down for any purpose,
the starter may have difficulty with the initial start. Although the • Attempting the cam change operation without the required tools
decompression lobe lifts the lifter body, the lifter is not pumped up will be difficult and can easily result in damage to the components
and it will not lift the exhaust valve. You may need to remove the spark not covered under warranty.
plugs and crank the engine to get oil pressure to the lifters. • 1999 models used interchangeable ball bearings on the outer end
• Easy Start cams require no special service. If they are ever removed for of both cams. For 2000 and up, the rear bearing is a roller type and
any reason however, inspect the mechanism for wear and verify that the front bearing is a ball bearing type. It is highly recommended
the lever operates smoothly. to update 1999 models to the 2000 and up bearing set, which is
included in the S&S Cam Installation Kit. These instructions are for
• If your bike is carbureted, the starting routine may be slightly different, 2000–up installation. See Picture 2, next page.
allow yourself time to experiment to find the best method.
• Possible failure may result if Loctite® is not applied to cam drive
• When the engine is turned off, you may hear a slight click as the sprocket flange bolts. Always prepare threads for Loctite according
decompression lever resets. This is normal and does no harm. to instructions on container.
• If engine speed drops below 900 RPM, you may hear clicking as the
decompression lever starts engaging. Idle speed should be adjusted CAUTION
higher. The engine idle should be set at 1000-1100 RPM. Failure of fasteners or parts caused by incorrect installation can
cause extensive damage not covered under warranty.
Special Tools Required: See Picture 1, below
H-D #42314 Crankshaft/Camshaft Sprocket Locking Tool
WARNING
H-D #42325 Camshaft Needle Bearing Remover/Installer Failure of camshaft related parts caused by incorrect installation
H-D #43644 Camshaft Remover/Installer can cause immediate seizure of engine. Engine seizure can result in
H-D #42313 Cam Chain Tensioner Unloader serious injury to motorcycle operator, passenger, or others.
• Original cam bearings will likely be damaged during removal. S&S
strongly recommends installing new bearings at same time as
cam change. S&S camshaft installation kit 33-5175 provides parts
needed to install S&S chain drive camshaft sets. The installation
kit also includes a new oil pump scavenge o-ring. The oil pump
scavenge o-ring should never be reused since it can become stiff
from heat and exposure to oils. This often results in poor sealing
and inadequate oil scavenging.
H-D #43644 CAUTION
For 2000 models and up, the front and rear cam bearings are not
H-D #42325 interchangeable! Ball bearing in front, roller bearing in rear.
B. Securing Motorcycle
CAUTION
H-D #42313 Motorcycle must be adequately secured to avoid falling over during
the cam change operation! Use of tie down straps on both sides of
motorcycle is recommended.
H-D #42314 1. Place motorcycle on a suitable repair stand so that motorcycle is
stable and secure with the rear tire elevated. Shift transmission in
Picture 1
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.
3
 Roller Bearing Ball Bearing

Picture 2

4th or 5th 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.
Picture 3
2. Disconnect negative terminal of battery to eliminate potential
sparks and inadvertent engagement of starter while working on
motorcycle. CAUTION
NOTE: S&S® 475, 509, and 510 cams are compatible with stock pushrods. Do not pull the retention pins from the primary or secondary cam
However, replacing stock pushrods with S&S adjustable pushrods 93-5096 chain tensioners when the chain and sprockets are removed! The
will simplify cam set installation. 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
C. Disassembly for Early (99–06 excluding 06 Dyna) full travel, damaging it, and/or the tensioner shoe. The tensioner
1. Removing pushrods can also injure hands and fingers in its path.

a. If stock pushrods are to be reused, remove motorcycle gas tank NOTE: If cam chain tensioner retaining pins interfere with cleaning or
service procedures when the cam support plate is removed, use cam chain
and top rocker covers. Remove rocker assemblies and pushrods
tensioner unloader tool (H-D #42313) to hold against spring pressure, then
according to procedure described in the Harley-Davidson®
remove retaining pin and ease spring assembly into the unloaded position.
Service Manual.
7. Working gradually around edge of sprocket, carefully pry
b. To remove stock pushrods which will not be reused, remove
sprockets off cams until loose on shaft. Remove sprocket/chain
pushrod cover clips, collapse pushrod covers, place motorcycle
assembly and mark chain with magic marker to indicate direction
in gear, and rotate rear tire (see Step B securing motorcycle) to
of travel. Chain should be reinstalled in same direction.
place lifters and pushrods for either cylinder at lowest point on
camshaft. Piston for same cylinder will be at TDC on Compression 8. Remove chain guide. See Picture 6, next page.
stroke and pushrods will spin with light finger pressure. Use bolt 9. Gradually loosen and remove four oil pump bolts according to
cutters to cut pushrods. sequence shown in Figure 1, next page.
WARNING 10. Gradually loosen and remove six support plate bolts according to
Cutting pushrods when they are under spring pressure can result in sequence shown in Figure 2, next page.
pushrod parts being ejected with considerable force, and can cause NOTE: Failure to remove or install bolts according to correct procedure may
bodily injury. result in parts damage not covered under warranty.
CAUTION 11. Carefully remove cam support plate assembly from crankcase. Use
Cutting pushrods with saw may result in metal chips entering unloading tool H-D #42313 to swing secondary cam tensioner
engine and causing extensive engine damage not covered under away from chain. Secure tensioner with second retention pin
warranty. inserted through front of support plate. Do not remove pin until
support plate assembly has been reinstalled in engine.
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.

Picture 4
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
 Picture 5 Picture 6

NOTE: Before reinstalling cam support plate, replace oil pump scavenge further steps require use of 2000 and up splined rear sprocket and
o-ring (supplied in kit) even if the original appears to be in good condition. spacer. Spacer style used with keyed cams is not compatible with
The stock o-ring can become brittle and provide a poor seal if reused. This splined cams. Spacers are available in five different thickness.
can cause poor oil scavenging, oil carry-over and loss of power.. Prepare cam for installation:
12. Remove screws that secure bearing retainer to support plate and NOTE: When using 551C, 583C, 585C, 625C, or 640C camshafts clearance
remove retainer from plate. between pinion bearing boss and rear cam lobe must be checked. See
13. Support cam support plate on table of hydraulic press. Using Pictures 9 & 10 next page. Remove just enough material to provide .030"
camshaft remover/installer tool H-D® #43644, remove stock cams clearance between top of cam lobe and pinion bearing boss when camshaft
and bearings from plate. Mark chain with magic marker to indicate is rotated in inner needle bearing. Also check clearance between all cam
direction of travel. See Picture 7, next page. lobes and tappet guide bosses. To avoid contamination of engine with
chips, we recommend that all holes in the gear case be taped off with duct
tape and that gear case be thoroughly cleaned with parts cleaner or solvent
Do not attempt to remove camsCAUTION
from bearings while bearings are after clearancing is performed.
in bearing plate. Cams and bearings must be removed from plate
together. See Picture 7, next page. D. Replacing Cams ONLY — Early (99–06 excluding 06 Dyna)

Cam and bearings may press out easily. Use care to support cams so NOTE: Not recommended for cams above .510 lift. If replacing cams and
they don’t unexpectedly fall to the floor. upgrading cam plate (recommended), follow instructions included with
H-D® Kit #25284-08. After cam plate and cams have been installed, go
to Section E for pushrod adjustments and special notes on compression
NOTES: Bearings are usually damaged during removal and should not be releases.
reused. If S&S® Cam Installation Kit (33-5175) is not used, new cam bearings NOTE: Before reinstalling cam support plate, replace oil pump scavenge
should be obtained from other source and installed with new cams. o-ring (supplied in kit) even if the original appears to be in good condition.
• Check primary and secondary cam shoes for wear and/or damage. The stock o-ring can become brittle and provide a poor seal if reused.
Do not re-use either shoe if more than 1⁄2 the shoe thickness is worn, or 1. Test fit front and rear bearings into bearing bores. If either bearing
if there is any evidence of melting, burning, or cracking. will slip into the bore, use red Loctite® 271 on bearing outer race
• Replacement shoes are installed per appropriate Harley-Davidson® during installation. If either bearing will not slip into bearing
service manual. bore, use assembly lube on bearing outer race during installation.
Using tool H-D #43644 and hydraulic press, install cam bearings in
• If upgrading from keyed rear camshaft to splined rear camshaft,
support plate, roller bearing in rear location, and ball bearing in
front location. See Picture 11 next page.

3 6

5 2

4 2
4
1

1 3

Figure 1 Figure 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.
5
 6. Remove cam needle bearings from crankcase with tool H-D #42325
and replace with new bearings provided in S&S installation kit 33-
5175 or obtained from other source. Lubricate with clean engine
oil.
7. Apply thin layer of assembly lube to cam journals and lobe
surfaces. Align cams with needle bearings and carefully slide
support plate assembly over crankcase dowels. See Picture 14
below right.
8. Apply Loctite® 243 (blue) to six support plate screws, install
screws, and gradually tighten to 95 in-lbs. in sequence illustrated
in Figure 2 on page 7.
NOTE: Support plate assembly should slide into place without resistance. If
resistance is encountered, determine cause before proceeding. Do not force
plate assembly!

Picture 7 CAUTION
S&S® has stripped holes for support plate screws when using
2. Using Loctite® 243 (blue) on screw threads, reinstall bearing maximum 120 in-lb. maximum torque spec recommended by
retainer and tighten screws to 20-30 in-lbs. Harley-Davidson®. Holes stripped are those which pass through
alignment dowels, Positions #1 & #2 in Harley-Davidson diagram of
.055” Thrust Washer
2000-Up Style Cam Support Plate/Oil Pump Torque Sequence.
OEM Sprocket Spacer 9. Apply Loctite® #243 (blue) to threads and reinstall four oil pump
bolts according to following procedure:
a. Gently bottom screws, then back out 1⁄4 turn.
Inner b. Center pump by rotating engine while snugging screws.
Bearing Race
c. Rotate engine by turning rear wheel (see Section B securing
motorcycle).
d. Tighten bolts to 90-120 in-lbs. in sequence illustrated in Figure
1 on page 5.

CAUTION
Do not use primary cam sprocket or crank sprocket bolt heads to
rotate engine.
“O”-ring Bearing Assembly
10. Carefully remove secondary cam tensioner retaining pin.
Figure 3 - Rear Cam Detail 11. Check front to back alignment of outer drive sprockets.
3. Align cam timing marks and install secondary cam chain in original a. Place rear cam sprocket spacer next to rear bearing race.
direction of travel. See Picture 12 next page.
b. Install rear camshaft and crankshaft sprockets.
4. Apply thin film of assembly lube to bearing surface of S&S®
camshafts and inner race of cam bearings in cam plate. Support c. Temporarily install crankshaft and camshaft sprocket bolts.
bearings by inner race. Using tool H-D® #43644, align both cams Temporarily use a smaller diameter washer under the head of
with bearings, install into cam bearings by pressing on front cam the crankshaft bolt. (This will allow a straightedge to fit on the
only, guide slip-fit rear cam into bearing. See Picture 13 next sprocket face for Steps 13 d and e.)
page. d. Torque crankshaft and rear camshaft sprockets to 25 ft-lb. Do not
5. Install new retaining ring in groove at end of front cam. use Loctite® at this time.
e. Push on rear camshaft to remove end play.

clearance
clearance

Picture 9 Picture 10

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.
6
 Timing Marks

Picture 11 Picture 12

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

Picture 13 Picture 14
7
 7
6
1
4

9
10

5
8

3 2

Picture 15
Picture 16
b. Insert the pushrods into the collapsed pushrod tubes. Make sure position, you can rotate the engine in the forward direction and
the proper o-rings are installed in the tappet covers, and on the feel for the exhaust tappet to slightly lift (about .030”) and set
cylinder head end of the pushrod covers. back down on base circle. This is the proper point to adjust the
c. Verify the correct locations for the pushrods that were removed. pushrods.
The longer pushrods go in the exhaust locations and the shorter b. Loosen locknuts on adjustable pushrods and turn adjusters to
pushrods are for the intakes. make all rods as short as possible. Z. When installing pushrods,
d. Insert the top of the pushrod into the hole in the head, then drop note that longer S&S® pushrods are for exhaust valves, and shorter
the bottom into the tappet cover. ones are for intake. Pass one long and one short pushrod through
assembled pushrod covers.
e. Apply assembly lube or suitable clean engine oil to the pushrod
tips where they will contact the rocker arms. c. Place pushrod and cover assemblies through lifter cover. Inner
tappet hole is for intake pushrod, and outer tappet hole is for
f. Insert the rocker arm support assembly into the rocker box. exhaust pushrod. If using S&S standard adjustable pushrods, hold
g. Ensure that the pushrod tips are fully engaged in the rocker arms. a new gasket under lifter cover and install push rod, pushrod cover,
lifter cover, and gasket as an assembly on crankcase. Tighten lifter
h. Apply Loctite® 243, then evenly snug the four 5/16" bolts which
cover screws to 95 in-lbs. torque. Stock pushrods or S&S Quickee
hold the rocker arms in place just finger tight at this time.
pushrods, can be installed without removing tappet cover.
i. Start the two breather cover bolts at this time, but do not tighten
d. While holding the top of the pushrod into the cup of the rocker
them.
arm, extend the bottom end into the tappet until the pushrod is
j. Begin tightening the rocker arm bolts. Following the sequence of just making contact with the cup of the tappet. From this point,
lowest bolt on spark plug side, highest bolt on intake side, lowest extend the pushrod 24 flats (4 full turns). Move the jam nut on
bolt on intake side, then highest bolt on spark plug side. Tighten the threaded portion of the pushrod to lock the end in place and
each bolt ¼ turn at a time following this sequence until they have tighten.
reached a torque of 18-22 ft-lbs.
NOTE: S&S® adjustable pushrods have 32 threads per inch, and 24 flats
k. Tighten the two breather cover bolts to 90-120 ft-lbs. will place the pushrod in the optimal position of the stock style tappet. If
l. Allow lifters to bleed down, then check to ensure both pushrods pushrods other than S&S adjustable or quickee’s are used, refer to the
rotate freely by hand. manufacturer’s instruction sheets to find the number of flats needed.
m. Install pushrod cover keepers. e. Allow the tappet to bleed down until you are able to rotate the
pushrod freely by hand, before adjusting the next pushrod.
n. Install new rocker box gasket, and rocker box top cover.
f. Repeat steps 5 and 6 for the other pushrod on the same cylinder.
o. Apply blue threadlocker to the six rocker cover bolts and tighten
in a star pattern to 15-18 ft-lbs. g. Ensure both pushrods rotate freely, then repeat steps 1 through 6
for the other cylinder.
p. Repeat for the other cylinder, following steps 1 through 15.
h. Install pushrod clips.
q. Install the gas tank.
i. Shift transmission into neutral.
r. Shift transmission into neutral.
j. Lower motorcycle onto lift and remove jack.
s. Lower motorcycle onto lift and remove jack.
k. Install spark plugs and plug wires.
t. Install spark plugs and plug wires.
l. Reconnect negative battery cable.
u. Reconnect negative battery cable.
NOTE: The tappets may be noisy upon initial start-up after installing cams.
2. Using Adjustable Pushrods This is normal after the tappets have all been bled down, and will go away
a. Place transmission in high gear and turn rear wheel to rotate shortly as long as the proper oil pressure is available.
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 CAUTION
equipped with S&S Easy Start cams, you must use extra care when If the engine is rotated before the tappets have bled down and the
adjusting pushrods. Because the decompression lobe is near TDC, pushrods can be rotated by hand, valve to valve or valve to piston
you must make sure that the tappet is not on the lobe. This will contact may occur. Serious engine damage could result.
cause incorrect exhaust pushrod adjustment. To verify correct