101 Harley-Davidson Performance Projects: For Evolution Big Twins and Sportsters

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Motorbooks International, 1998 - Transportation - 256 pages
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Put a veteran mechanic on your bookshelf. From simple 15-minute jobs such as lubing cables and bolting on new air cleaners to more advanced tasks such as cam changes and swapping heads, this how-to guide offers carefully selected projects you can do in a weekend. Color photographs guide you step-by-step through each performance project. Explains why each project should be done and what performance gains you can expect.
 

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Contents

ACKNOWLEDGMENTS
8
INTRODUCTION
9
Understanding the Information Boxes
10
SECTION ONE BASICS
11
The Lowdown on Replacement Parts
12
Vehicle Identification Numbers VIN
16
SECTION TWO SIMPLE MAINTENANCE
20
Performing the 10000Mile Service
21
Installing an Aftermarket Camshaft
138
Replacing 1992 and Later Big Twin Cam Bearings
145
Balancing Your Engine
147
Crank Assembly Repair
148
Replacing Defective Crankcases
149
Aftermarket XL Crankcases
151
Replacing Noisy Pinion Gears on Big Twins
153
Replacing the Timer Cover
155

Lubing Cables
28
Changing Engine Oil
30
Changing Transmission and Primary Fluid
32
Servicing Air Cleaners
36
Choosing Reading and Replacing Spark Plugs
38
Checking and Tensioning Your Drive Belt
40
Replacing Brake Pads
42
Timing Your Engine
44
Adjusting Your Clutch
47
SECTION THREE FUEL AND EXHAUST
49
Installing a Screamin Eagle Air Cleaner
50
Rejetting for Altitude
52
Tuning Your Stock CV Carb
54
Choosing a Jet Kit
56
Installing a Jet Kit
57
Swapping Carbs
62
Choosing a HighPerformance Exhaust
65
Replacing VacuumOperated Petcocks
70
Installing a Fuel Stat
72
Troubleshooting Fuel Injection
73
HotRodding Fuel Injection
74
SECTION FOUR SUSPENSION AND CHASSIS
76
Fixing Clunking Wide Glide Forks
77
Installing a CartridgeFork Emulator Valve
78
Retrofitting 1200S Cartridge Forks and Shocks
82
Lowering Forks
86
Lowering the Softail Rear
89
Lowering TwinShock Rear Ends
90
Installing a TorsionBar Suspension on a Soflail
91
Taming VibrationServicing Rubber Engine Mounts
93
Installing a Torque Arm or Race Brace
95
SECTION FIVE TIRES WHEELS AND BRAKES
96
Installing Wide Tires and Thin Belts
97
Building and Maintaining Wire Wheels
98
Servicing Your Brakes
100
Upgrading Brake Discs
103
Installing MultiPiston Brake Calipers
105
Upgrading Softoil Brakes
107
SECTION SIX ENGINE
108
Rnding Your Build Date
109
Keeping Excess Oil Out of Your Air Cleaner
110
Blueprinting Your Engine
112
Breaking in a New Engine
114
Setting Cam and Ignition Timing
115
Increasing Compression Ratio
116
Fixing Base Gasket Leaks
118
Checking Cylinders
121
Choosing HighPerformance Heads for Your Sportster
123
Choosing HighPerformance Heads for Your Big Twin
126
Sealing Your Rocker Boxes
128
Installing Roller Rocker Arms and Adjustable Pushrods
130
Converting Sportster 883s to 1200s
132
Choosing Aftermarket Camshafts
135
Dyno Tuning Your Engine
157
Using Desk Top Dynos
159
SECTION SEVEN LUBRICATION
160
Installing an Oil Cooler
161
Fixing Your Sportsters Oil Tank
162
Upgrading Your Sportsters Oil Pump
164
Upgrading Your Big Twins Oil Pump
165
Keeping Your Oil ParticleFree
167
SECTION EIGHT DRIVETRAIN
168
Updating the 19841989 Big Twin Clutch
169
Updating the 19841986 Big Twin Main Drive Gear
171
Installing a Big Twin ProClutch
172
Improving the FourSpeed Sportster Clutch
176
Improving the FiveSpeed Sportster Clutch
178
Fitting a Primary Chain Tensioner
179
Installing Fluid Balance Masters
180
Updating RveSpeed Big Twin Belts and Pulleys
181
Installing a Belt Primary Drive
184
SECTION NINE TRANSMISSION
187
Fixing HardShifting Sportster Four Speeds
188
Altering Final Gearing
190
Fixing Sloppy Sportster FiveSpeed Shifting
192
Fixing Tranny Mainshaft Leaks on Your FourSpeed Big Twin
193
SECTION TEN ELECTRICAL SYSTEM
194
The Truth about Gauges
195
Choosing HighPerformance Plug Wires
197
Servicing Your Battery
200
Installing a HighPerformance Starter on Big Twins
203
Upgrading Your Charging System
205
Selecting a HighPerformance Factory Ignition Module
207
Choosing and Installing an Aftermarket Ignition
210
Optimizing Your VOES
212
Upgrading Your Horn
213
Troubleshooting Electrics
214
Mapping Your Ignition Curve
215
SECTION ELEVEN PERSONAL TOUCHES
217
Clean and Shine
218
Swapping Turn Signals
220
Swapping Taillights
221
Choosing Sissybars and Racks
223
Decoding Harley Paint Colors
224
Paint Repair
230
Installing Chrome Handlebar Controls
232
Changing Handlebars
234
Hiding Handlebar Wiring
236
Mounting Forward Controls on Your Big Twin
238
Installing Rearsets and Forward Controls on Your Sportster
239
Applying Coatings
241
APPENDIX CAMSHAFT SPECIFICATIONS
243
SOURCES
249
INDEX
255
Copyright

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About the author (1998)

Kip Woodring, the author of the Harley-Davidson Sportster/Buell Engine Hop-Up Guide, has been writing for Harley-Davidson publications for more than 20 years. A certified mechanic, he lives in Scotts Valley, CA.

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