S&S Cycle Pushrod Kits 1936-84 BT & 1957-85 XL - Manual (Page 2)

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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
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pushrods, the longer one is the front intake, the shortest pushrod is the rear intake. The pushrod kits for the big twin 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.
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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.
A- PUSHROD ADJUSTMENTS FOR HARLEY-DAVIDSON® IRONHEAD SPORTSTER®, KNUCKLEHEAD AND PANHEAD ENGINES
1- 1936-'47 Knucklehead, 61" & 74" (Part 93-5041, 93-5044, and 93-5045)
1948-'52 Panhead 61" & 74" (Part 93-5029, 93-5059, and 93-5027)
1957-'85 Ironhead Sportster® Models (Part93-5030 and 93-5035)
a- Remove pushrod cover clips and lift cover assemblies to view lifters.
b- Remove sparkplugs and rotate engine until the 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 adjusters and remove pushrods and tube assemblies.
d- Clean & inspect pushrod tubes. Prepare top cover as per Figure 1, if alloy pushrods are used. Replace all cork and/or o-ring seals.
Apply a light coat of engine oil to o-rings.
e- Insert new pushrods through tube assembly and install in appropriate position.
f- Extend lifter to remove lash in pushrod. Adjust lifter to be able to spin pushrod with fingertips with a slight drag, and tighten locknut.
Recheck after tightening.
g- Repeat the above procedure for rear cylinder, this time bringing the rear cylinder to TDCC (top dead center compression).
h- Replace sparkplugs and pushrod tube clips. Start motorcycle and check for leaks.
NOTES:
1⁄2" diameter alloy pushrod kits, for ironhead Sportster® models & knucklehead engines, may contact the pushrod tubes. It is advisable to chamfer the
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lower, inside diameter of the top pushrod cover tube when installing these pushrod kits. See Figure 1 below.
The knucklehead solid lifter pushrod kit requires stock-style adjustable tappets.
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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
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the stock 1948-'52 style adjustable lifters.
CAUTION
WARNING
Figure 1