S&S Cycle Chain Drive Camshaft for 2007-Up Big Twin and 2006-Up Harley-Davidson Dyna - Manual (Page 7)

7
Adjustable Pushrod Installation And Adjustment
1- Rotate engine so one cylinder is at TDC compression, by rotating the rear tire while feeling the tappets. When both tappets are at the bottom
of their lift, and the cylinder is at TDC, the cylinder is at TDC compression.
2- Insert the adjustable pushrods into the collapsed pushrod tubes. Make sure the proper o-rings are installed in the tappet covers, and on the
cylinder head end of the pushrod covers.
3- If the pushrod kit contains different length pushrods, the longer pushrods go in the exhaust locations and the shorter pushrods are for the
intakes.
4- Insert the top of the pushrod into the hole in the head, then drop the bottom into the tappet cover.
5- While holding the top of the pushrod into the cup of the rocker arm, extend the bottom end into the tappet until the pushrod is just making
contact with the cup of the tappet. From this point, extend the pushrod 24 flats (4 full turns). Move the jam nut on the threaded portion of the
pushrod to lock the end in place and tighten.
NOTE: S&S® adjustable pushrods have 32 threads per inch, and 24 flats will place the pushrod in the optimal position of the stock style tappet. If pushrods
other than S&S adjustable or quickee's are used, refer to the manufacturer's instruction sheets to find the number of flats needed.
6- Allow the tappet to bleed down until you are able to rotate the pushrod freely by hand, before adjusting the next pushrod.
7- Repeat steps 5 and 6 for the other pushrod on the same cylinder.
8- Ensure both pushrods rotate freely, then repeat steps 1 through 6 for the other cylinder.
9- Install pushrod clips.
10- Shift motorcycle into neutral.
11- Lower motorcycle onto lift and remove jack.
12- Install spark plugs and plug wires.
13- Reconnect Negative battery cable.
If the engine is rotated before the tappets have bled down and the pushrods can be rotated by hand, valve to valve or valve to piston
contact may occur. Serious engine damage could result.
Stock Non-Adjustable Pushrod Installation
NOTE: Using stock pushrods is only possible if the camshafts installed have the same base circle as stock, and no more than .585" lift. S&S labels these
cams as "Bolt-In" for easy reference. Currently S&S 510 and 551 cams are bolt-in.
1- Rotate engine so one cylinder is at TDC compression, by rotating the rear tire while feeling the tappets. When both tappets are at the bottom
of their lift, and the cylinder is at TDC, the cylinder is at TDC compression.
2- Insert the pushrods into the collapsed pushrod tubes. Make sure the proper o-rings are installed in the tappet covers, and on the cylinder head
end of the pushrod covers.
3- Verify the correct locations for the pushrods that were removed. The longer pushrods go in the exhaust locations and the shorter pushrods are
for the intakes.
4- Insert the top of the pushrod into the hole in the head, then drop the bottom into the tappet cover.
5- Apply assembly lube or suitable clean engine oil to the pushrod tips where they will contact the rocker arms.
6- Insert the rocker arm support assembly into the rocker box.
7- Ensure that the pushrod tips are fully engaged in the rocker arms.
8- Apply Loctite® 243, then evenly snug the four 5/16” bolts which hold the rocker arms in place just finger tight at this time.
9- Start the two breather cover bolts at this time, but do not tighten them.
10- Begin tightening the rocker arm bolts. Following the sequence of lowest bolt on spark plug side, highest bolt on intake side, lowest bolt on
intake side, then highest bolt on spark plug side. Tighten each bolt ¼ turn at a time following this sequence until they have reached a torque
of 18-22 ft-lbs.
11- Tighten the two breather cover bolts to 90-120 ft-lbs.
12- Allow lifters to bleed down, then check to ensure both pushrods rotate freely by hand.
13- Install pushrod cover keepers.
14- Install new rocker box gasket, and rocker box top cover.
15- Apply blue threadlocker to the six rocker cover bolts and tighten in a star pattern to 15-18 ft-lbs.
16- Repeat for the other cylinder, following steps 1 through 15.
17- Install the gas tank.
18- Shift motorcycle into neutral.
19- Lower motorcycle onto lift and remove jack.
20- Install spark plugs and plug wires.
21- Reconnect negative battery cable.
NOTE: The tappets may be noisy upon initial start-up after installing cams and adjusting pushrods. This is normal after the tappets have all been bled
down, and will go away shortly as long as the proper oil pressure is available to the tappets.
CAUTION