S&S Cycle Pushrod Kits and Travel Limiters (all) - Manual (Page 2)

NOTES:
●
If pushrod kit contains four different length pushrods, the
longest pushrod is for the front exhaust, next longest is
the rear exhaust. Of the two shorter pushrods, the longer
one is the front intake, the shortest pushrod is the rear
intake. The pushrod kits for the Twin Cam 88
® engine
have two different lengths – short for the intakes, long
for the exhausts.
● All installation and adjustments must be made when engine
is cold. Read instructions thoroughly and follow all
recommended steps and procedures.
Failure to follow recommended steps and procedures may
result in damage to engine components.
Installing or adjusting pushrods while engine is hot could
result in burns from contact with hot engine parts.
NOTE: 1 ⁄
2
" diameter alloy pushrod kits, for ironhead
Sportster ® models & knucklehead engines, may contact the
pushrod tubes. It is advisable to chamfer the lower, inside
diameter of the top pushrod cover tube when installing
these pushrod kits. See Figure 1.
A. Pushrod kits for Harley-Davidson ® ironhead
Sportster ® models
(Part 93-5030 and 93-5035.)
1.
Remove pushrod cover clips and lift cover assemblies to
view lifters.
2. Remove sparkplugs and rotate engine until the rear
exhaust lifter is at its highest point.
3. Loosen front exhaust adjuster and remove pushrod and
tube assembly.
4. Clean & inspect pushrod tubes. Prepare top cover as per
above note. Replace all cork and/or O-ring seals. Apply a
light coat of engine oil to O-rings.
5. Insert new pushrod through tube assembly and install in
front exhaust position.
6. Extend lifter to remove lash in pushrod. Adjust lifter to
be able to spin pushrod with fingertips with a slight
drag, and tighten locknut.
7. Rotate engine until front exhaust lifter is at its
highest point, and repeat above procedure for rear
exhaust pushrod.
8. Rotate engine until rear intake lifter is at its highest
point and replace front intake pushrod as per above
procedure. Repeat for rear intake pushrod.
9. Replace sparkplugs and pushrod tube clips. Start
motorcycle and check for leaks.
B. Pushrod kits for knucklehead & panhead engines.
1.
1936-'47 knucklehead, 61" & 74"
(Part 93-5041, 93-5044, and 93-5045)
NOTE: The knucklehead solid lifter pushrod kit requires stock-
style adjustable tappets.
a. Remove pushrod cover clips and lift cover
assemblies to view lifters.
b. Remove sparkplugs and rotate engine until front
piston is at the top of its stroke, with both front
lifters at their lowest position (TDCC – top dead
center, compression).
c. Loosen front lifter adjusters and remove pushrod
and tube assemblies.
d. Clean and inspect pushrod tubes. Prepare top
covers as per above note. Replace all cork
and/or O-ring seals. Apply a light coat of engine
oil to O-rings.
e. Insert new pushrods through tube assemblies and
install in appropriate positions.
f. Extend lifters to remove lash in pushrods. Adjust
lifters to be able to spin pushrods with fingertips
with a slight drag, and tighten locknuts.
g. Repeat above procedures for rear cylinder.
h. Replace sparkplugs and pushrod tube clips. Start
motorcycle and check for leaks.
2. 1948-'65 panhead 61" & 74"
(Part 93-5029, 93-5059, and 93-5027.)
NOTE: These kits are intended to replace the stock pushrods
found in 1948-'52 engines that contain a hydraulic unit built into
the pushrods. These kits require the stock 1948-'52 style
adjustable lifters.
a. Remove pushrod cover clips and lift cover
assemblies to view lifters.
b. Remove sparkplugs and rotate engine until front
piston is at the top of its stroke, with both front
lifters at their lowest position (TDCC – top dead
center, compression).
c. Loosen front lifter adjusters and remove pushrod
and tube assemblies.
d. Clean & inspect pushrod tubes. Replace all cork
and/or O-ring seals. Apply a light coat of engine
oil to O-rings.
e. Insert new pushrods through tube assemblies and
install in appropriate positions.
f. Extend lifters to remove lash in pushrods. Adjust
lifters to be able to spin pushrods with fingertips
with a slight drag, and tighten locknuts.
g. Repeat above procedures for rear cylinder.
h. Replace sparkplugs and pushrod tube clips. Start
motorcycle and check for leaks.
2
CAUTION
WARNING
Figure 1
Check top pushrod cover tube inside diameters for sharp
corners. Bevel corners with file or hand grinder. In
instances where pushrods are made with
1 ⁄
2
" diameter
tubing, sharp edges lift on covers and may rub pushrods.