Caution – S&S Cycle Pushrod Kits and Travel Limiters (all) User Manual

Page 6

1984-'99 big twin and S&S

⁄

" bore engines.

NOTE 1: Replacement of the stock pushrods will require either
rocker arm disassembly, or cutting of the original pushrods if
Quickee Pushrods are used. If the original pushrods are to be cut,
S&S recommends that a bolt cutter be used.

CAUTION 1 – If pushrods are cut with a saw, metal chips
may enter engine and cause extensive damage not covered
by warranty.

Remove pushrod cover clips and lift cover
assemblies to view lifters.

Remove spark plugs 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).

Remove front pushrods by disassembling the
rocker cover assembly, as per the appropriate
service manual. See NOTE 1 and CAUTION 1 for
Quickee Pushrods.

Clean & inspect pushrod tubes. Replace all O-rings.
Apply a light coat of engine oil to O-rings.

Fully collapse Quickee Pushrod and insert new
pushrods through tube assemblies and install
in appropriate positions. Skip step f for
Quickee Pushrods.

Reinstall rocker assemblies according to
appropriate service manual procedures.

Extend adjusting screws to remove lash in
pushrods. Compress hydraulic piston assembly in
exhaust lifter 4 complete turns (24 flats) and
tighten locknut. Allow sufficient time for piston
assembly to bleed down (at least 10 minutes)
before adjusting intake pushrod.

NOTE: Typically, S&S

engines are supplied with the HL

Hydraulic Lifter Limited Travel Kit installed in the lifters. If the
piston assembly is compressed 4 complete turns of the pushrod,
and will not bleed down after 10 minutes, the HL

T kit is installed

in the lifters and the adjustment procedure for this kit must be
followed. Detailed instructions for the HL

T kit are listed below.

Failure to allow hydraulic unit to bleed down before
rotating engine 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.

Repeat above procedures for rear cylinder.

Replace spark plugs and pushrod tube clips. Start
motorcycle and check for leaks.

Pushrod kits for Harley-Davidson

Twin Cam 88

engines.

NOTES:
●

S&S pushrod kits for the Twin Cam 88

engine 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 93-5095,
for stock height Twin Cam 88

engine, 88", 95", that contains

the four adjustable pushrods, pushrod tube set, gaskets and
O-rings for a complete assembly.

●

The following instructions are for installing S&S adjustable
pushrods with the stock-style hydraulic lifters. If the S&S HL

kit is to be used, refer to that section of this instruction sheet
for installation of the kit, and pushrod adjustment.

CAUTION 1 – If pushrods are cut with a saw, metal chips
may enter engine and cause extensive damage not covered
by warranty.

1. Remove pushrod cover clips and lift cover assemblies

to view lifters.

2. Remove spark plugs 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).

3. Remove front pushrods, either by cutting the pushrods

as described in the note above, or by disassembling the
rocker arms, as per the appropriate service manual.

4. Remove lifter cover from crankcase.
5. Reinstall rocker assembly if removed in above step,

following procedures & torque specifications
recommended in appropriate service manual.

Apply a light coat of oil to O-rings and assemble
pushrod covers.

7. Insert pushrods through pushrod cover assemblies.

Install intake and exhaust pushrod assemblies, along
with the tappet cover and new gasket, into position in
front cylinder.

8. Install and tighten lifter cover screws to 90-110 in-lbs.
9. Extend adjusting screws to remove lash in pushrods.

Compress hydraulic unit in exhaust lifter 4 complete
turns (24 flats) and tighten locknut. Allow sufficient
time for lifter to bleed down (5 to 10 minutes) before
adjusting intake pushrod.

CAUTION