101 Harley-Davidson Twin Cam Performance Projects

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MotorBooks International
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Great book! Do the service yourself and save $$$$!!!

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Contents

The Work Area
9
Work Practices
10
Tools
12
SIMPLE MAINTENANCE
17
VINs and Engine Case Numbers
18
Performing the 10000Mile Service
21
Lubricating Cables
23
Changing the Engine Oil and Filter
25
Installing a 95CubicInch Kit
140
Installing a Custom Cam Cover
143
Installing an Andrews Camshaft Sprocket
145
Replacing the Rear Camshaft Ball Bearing
147
Replacing the Inner Camshaft Bearings
150
Installing HighPerformance Cams
152
Installing SS GearDriven Cams
156
Installing a Delkron Camshaft Support Plate
159

Changing Transmission and Primary Oil
27
Servicing the Air Cleaner
29
Choosing Reading and Replacing Spark Plugs
30
Inspecting and Adjusting the RearDrive Belt
33
Checking and Adjusting the Primary Chain
35
Replacing Brake Pads
37
Adjusting the Clutch
39
INTAKE AND EXHAUST
41
Installing a Screamin Eagle Air Cleaner
42
Installing an SS Air Cleaner
44
Rejetting the Stock CV Carb
46
Installing a Dynojet Thunderslide Kit
49
Installing an SS Super EG Carburetor
52
Installing a Performance Intake Manifold
55
Replacing the OEM VacuumOperated Petcock
57
Understandmg the Twin Cam EFI System
59
Installing a Screamin Eagle EFI Race Tuner
62
Installing and Adjusting the Power Commander IIIr
65
Installing a Performance Exhaust System
68
SUSPENSION AND CHASSIS
72
How to Fix Clunking Forks
73
Installing a Cartridge Fork Emulator
75
Lowering Front Forks
78
Installing New Fork Springs
81
Swapping the Shock on a Springer
83
Adjusting Front and Rear Preload Sag
85
Lowering the Rear of a Softail and Installing New Rear Shocks
87
Lowering a Twin Shock Rear End
89
Servicing Rubber Engine Transmission Mounts
91
Installing Rear Air Shocks
92
TIRES WHEELS AND BRAKES
94
Balancing Wheels
95
Building and Maintaining Wire Wheels
97
Servicing the Brakes Changing the Brake Fluid
100
Installing Braided Brake Lines
102
Upgrading Your Brake Discs
105
Upgrading Calipers
107
Changing Wheels
109
Checking and Replacing Wheel Bearings
112
THE ENGINE
113
Breaking in a New Engine
114
Dyno Tuning an Engine
116
Installing Adjustable Pushrods
119
Installing Custom Lifter Covers
121
Installing Roller Rocker Arms
123
Installing HighPerformance Valve Springs
125
Installing TP ProVent Rocker Boxes
128
Installing HighPerformance Heads
130
Checking Combustion Chamber Size
133
Claying HighCompression Pistons
136
Blueprinting the Engine
161
Balancing the Engine
163
Installing a Stroker Kit
165
Servicing the Breather Assembly
169
THE ENGINE OIL SYSTEM
172
Installing an Oil Cooler
173
Installing an SS Crankcase Breather Valve
175
Aligning a Twin Cam Oil Pump
177
Installing a Feuling Oil Pump
179
THE DRIVETRAIN
181
Installing a Hydraulic Clutch Actuator
182
Installing a Rivera Pro Clutch
184
Installing a Barnett Scorpion Clutch Spring Conversion Kit
187
Installing a Primary Chain Tensioner
190
Installing a Balance Masters Kit
192
Installing a Primary Belt Drive
194
Installing a Transmission Pulley
197
Replacing the Drive Belt
199
Swapping to a Custom Sprocket Pulley
200
Installing a Rear Drive Chain
201
Installing a Custom Tranny Side Cover
203
Installing a BAKER Reverse Shifter Assembly
205
Installing a SixSpeed Gear Set Kit
208
THE ELECTRICAL SYSTEM
212
Installing Aftermarket Digital Gauges
213
Choosing HighPerformance Ignition Wires
215
Installing a HighPerformance Starter
216
Maintaining Your Charging System
217
Installing a Screamin Eagle Adjustable Map Ignition System
219
Installing an Aftermarket Ignition
222
Replacing the Thermometer with an Oil Temperature Gauge
224
Upgrading the Horn
225
Troubleshooting the Electrical Syste
226
Upgrading Your Headlight
228
Hiding Wiring in the Handlebar
229
PERSONAL TOUCHES
231
Detailing Your Bike
232
Custom Turn Signals
234
Swapping Taillights
236
Fiberglass Repair
238
A Primer on Paint
241
Paint Repair
242
Installing Chrome Handlebar Control Pods
244
Selecting and Changing Handlebars
246
Installing Forward Controls
248
Selecting and Changing Seats
249
Applying Coatings
251
SOURCES
254
INDEX
255
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