180+ HARLEY-DAVIDSON Service Manuals and Parts Catalogs

Donny’s Unauthorized Technical Guide to Harley-Davidson, 1936-Present Volume II: Performancing the Twin Cam Donny Petersen iUniverse, Inc. New York Bloomington

Donny’s Unauthorized Technical Guide to Harley Davidson 1936 to Present Volume II: Performancing the Twin Cam Copyright © 2008 by Donny Petersen All rights reserved. No part of this book may be used or reproduced by any means, graphic, electronic, or mechanical, including photocopying, recording, taping or by any information storage retrieval system without the written permission of the publisher except in the case of brief quotations embodied in critical articles and reviews. e views expressed in this work are solely those of the author and do not necessarily reﬂect the views of the publisher, and the publisher hereby disclaims any responsibility for them. iUniverse books may be ordered through booksellers or by contacting: iUniverse 1663 Liberty Drive Bloomington, IN 47403 www.iuniverse.com 1-800-Authors (1-800-288-4677) Because of the dynamic nature of the Internet, any Web addresses or links contained in this book may have changed since publication and may no longer be valid. e views expressed in this work are solely those of the author and do not necessarily reﬂect the views of the publisher, and the publisher hereby disclaims any responsibility for them. ISBN: 978-0-595-52745-8 (pbk) ISBN: 978-0-595-62797-4 (ebk) ISBN: 978-0-595-51516-5 (cloth) Printed in the United States of America iUniverse rev. date: 12/23/2008

Disclaimer This book expresses the views of I Petersen and Heavy Duty Cycles Limited (where mentioned) and are not intended in place of, or to diagnose or resolve any issue not assessed by a qualified technician. I Petersen and Heavy Duty Cycles Limited does not assume and expressly disclaims any liability with respect to the use of, or for damages resulting from the use of any information, advice, or recommendations within. We recognize that some words, model names, and designations mentioned herein are the property of the trademark holder. We use them for identification purposes only. This is not an official publication. Reference to any product, process, publication, service, or offering of any third party by trade name, manufacturer, or otherwise does not constitute or imply the endorsement or recommendation of such by I Petersen, Harley-Davidson Inc. or Harley-Davidson Motor Company or H-D Michigan, Inc. or Heavy Duty Cycles Limited. E. & O. E. (errors and omissions excepted) Use of the words, Andrews, Andrews Gears, Andrews Cams, Andrews Products, Aramid, ARP, Axtell, Axtell Sales, Axtell Dyno Master Performance Product’s, Band-Aid, Bendix, Brembo, Champion, Crane, Crane Cams, Crane Time Savers, Custom Chrome, Rev-Tech, Delphi, Derale, DFO, Dobeck, Doherty, Doherty Machine, MLS, Mystfree , Power Vent, Delkron, Dynojet, Edelbrock, Edelbrock Carb(s), Performer, Feuling, GESi Technology, Hayden, Hitachi, Hoover, Horsepower Inc., Ina, JIMS, JIMS Machining, JIMS Powerglide, JIMS Pro-Lite, Kehein, Kevlar, Knight Prowler, Kuryakin, Lexan, Lockhart, Loctite, Mace, Magneti Marelli, Manley, Max Flow, Mikuni, HSR Mikuni Smoothbore, Nachi, NASCAR, Pablum, Pingel, Plastocine, Procharger, Pro Vent, Prestolite, Rivera, Rivera Taper Lite, S&S, S&S Cycle, S&S Cycle, Inc., Super Stock, Spiro, STD, Sunnen, SuperFlow, SuperTrapp, Techlusion, Teflon, Thunder Jet, Tillotson, Timken, TP, TP Engineering, Trochoid, Uralite, Ultralite, VHR, Viton, Wood, Wood Carbs, various model names and designations, and OEM part numbers and derivatives of the foregoing along with trademarks and copyrights owned by the above companies or any companies owned or affiliated to the above companies whose names are listed wholly or partly are provided solely for reference, fitment, or partial fitment and application information, and there is no affiliation between the above companies or products whose names are listed wholly or partly and Heavy Duty Cycles Limited or I Petersen. E. & O. E. Use of the word Harley-Davidson, various model names and designations, and OEM part numbers along with trademarks and copyrights owned by Harley-Davidson, Inc. or Harley- Davidson Motor Company, H-D Michigan, Inc. or any companies owned or connected or affiliated to Harley-Davidson, Inc. or Harley-Davidson Motor Company, H-D Michigan, Inc. and derivatives of the foregoing are provided solely for reference, fitment or partial

fitment and application information and there is no affiliation between Harley-Davidson, Inc. or Harley-Davidson Motor Company and companies owned or connected to them and I Petersen or Heavy Duty Cycles Limited. The words Buell, Cruise Drive, Cyclone, CVO, Disc Glide, Dyna, Electra Glide, Evolution, Evo, Fatbob(s), Fatboy, HD, H-D, Harley, Harley- Davidson, Heritage Softail, Heritage Springer, HOG, Hog, Hawg, Hugger, Lightning, Low Rider, Night Train, Road Glide, Road King, Roadster, Screamin’ Eagle, Softail, Sport Glide, Sportster, Springer Softail, Streetglide, Sturgis, Super Glide, T-Sport, Tour Pak, Tour Glide, Twin Cam, Twin Cam 88, Twin Cam 88A, Twin Cam 88B, TC88, TC88A, TC88B, Twin Cam 96, Twin Cam 96A, Twin Cam 96B, TC96, TC96A, TC96B, Ultra Classic, and Wide Glide are registered trademarks of Harley-Davidson, Inc., Milwaukee, Wisconsin, USA or Harley-Davidson Motor Company. The words: Bad Boy, Blast, Convertible, Deuce, Duo- Glide, Firebolt, Hydra-Glide, Revolution, Thunderbolt, Tri Glide, V-Fire III and V-Rod are trademarks of Harley-Davidson, Inc., Milwaukee, Wisconsin, USA, or Harley-Davidson Motor Company. The following model designations and any derivatives thereof for Harley- Davidson motorcycles are used in this book for reference only: EL, FL, FLH, FLHC, FLHF, FLHR, FLHRI, FLHRCI, FLHS, FLHT, FLHTC, FLHTCI, FLHTCU, FLHTCUI, FLHTCUTG, FLHTC, FLHX, FLST, FLSTC, FLSTCI, FLSTF, FLSTFI, FLSTN, FLSTS, FLSTSI, FLT, FLTC, FLTCU, FLTCUI, FLTR, FLTRI, FX, FXB, FXD, FXDB, FXDC, FXDG, FXDL, FXDS, FXDS-Conv., FXDWG, FXDX, FXDXT, FXE, FXEF, FXLR, FXR, FXRC, FXRD, FXRDG, FXRP, FXRS, FXRSE, FXRS-Convertible, FXRS-SP, FXRT, FXS, FXSB, FXST, FXSTB, FXSTBI, FXSTC, FXSTD, FXSTDI, FXSTI, FXSTS, FXSTSB, FXSTSI, FXWG, GE, K, KH, VRSCA, VSRC, WL, WLA, XL, XL883C, XL883R, XL1200C, XL1200S, XLCH, XLCR, XLH, XLH883, XLH1100, XLH1200, XLR, XLS, XLT, XLX, XLX-61 and XR-1000. E. & O. E.

Contents Chapter I The Platform for Performance 1 Twin Cam Radical Design Change 8 The Weakness of Nostalgia 10 The Strength of the Twin Cam 12 The Platform 23 The Achilles’s Heel of the Twin Cam 24 Twin Cam Performance Obstruction 27 Stoichiometric Air-fuel Ratio Tendonitis 28 Chapter II Repairing the Achilles’ Heel 31 The Problem: Ovaling of Bearing Holes? 31 The S&S Solution 41 The Trick: Meet Emissions Dictates with More Power 42 The H-D Solution 42 The Andrews Solution 44 Moment Arm Torsional Bearing Wear 46 Knight Prowler (Silent) Advanced Belt Drive System 53 Which Cylinder Is the Boss? 61 The Advantage Summary of Gear Drives over Timing Chains 63 Gear Drive Installation Instructions 1999-2006 64 Knight Prowler Belt Drive Installation, 1999 to Present 69 Hydraulic Lifter Limiter Kits 72 Adjusting Performance Pushrods 72 Chapter III H-D 110 Cubic Inch CVO 75 The Symptom: Blowing Rear Head Gasket 79 Disassembling the CVO 110: What I Found 83 CVO 110-Cylinders and Liner Sleeves 94 Why is just the Rear Head Gasket Blowing? 107 EPA Perfection: Stoichiometric Air Fuel Mixture 108 The Problem is Oil Seepage not a Compression Leak 112 The Causes 118 The Band-Aids 119 Redesign the CVO 110-cylinders 122 Solving the Tendonitis of Lean Burning Air 125 Performance Bonus of a Cooler Air Fuel Ratio 127 CVO 110 Axtell Aftermarket Cylinders 129 Boring and Honing Cylinders 133 Axtell Cylinder Installation Instructions 139 Engine Tuning 142 Break-in 142 Conclusion 143 Chapter IV Cams, Cams, Cams 145 Cam Lift and Valve Lift 147

Potential High Lift Cam Lobe Interference 152 Cam Duration 160 Valve Overlap 162 Lobe Centerline Angle (LCA) 166 Degreeing Cams 170 Cam Lobe Separation Angle (LSA) 177 Choosing a Cam 181 Valve Springs 184 Radical Cam Profiles and Engine Longevity 187 Chapter V Twin Cam Vibration 191 The Primary Cause of Internal Vibration 191 Survival of the Fittest: A Brief History 207 External Causes of Twin Cam Vibration 209 Vibration Specific to Rubbermount Models 216 Vibration Specific to Counterbalanced Softails 220 Internal Cause of Vibration: Flywheel Runout 226 The Twin Cam Flywheel (Crank) Assembly 228 Twin Cam Flywheel Support Bearing(s) 230 Twin Cam Flywheel Misalignment 232 Truing Flywheels 244 Engine Balancing 254 Balancing: Reciprocating and Rotating Weight 257 Statically Balancing Flywheel Assemblies 264 Dynamic Balancing 268 External Aftermarket Vibration Dampeners 272 Conclusion and Summary 273 Chapter VI Oil Coolers 277 Detonation: The Great Engine Destroyer 278 Octane: Engine Salvation 278 Heat is the Savior 279 Heat is the Enemy 280 Lugging and Detonation 281 Air and Liquid Cooled Engines 284 Turbulation Balanced with Restriction is the Key 286 Stoichiometric Air Fuel Ratio for Gasoline 291 Oil Cooler Thermostats 291 Oil Cooler Pressure Drop 292 Practical Tips: Oil Cooler Installation 294 Negative Vacuum Principle 299 Oil Pressure Drop, Wind, and Bench Flow Analysis 300 Jagg Oil Cooler Installation Instructions 302 Chapter VII Torque and Horsepower 307 Torque and Horsepower Relationship 307 Calculating Torque and Horsepower 309 The Interrelationship between Torque, RPM, and Gearing 312 Performance Requires Increases to both Torque and RPM 313 Compression 313 Compression Equals Torque 315

Horsepower is a Multiple of Torque and rpm 316 Compression Ratio vs. Cam Duration 317 Cam Timing Events and Cylinder Fill 318 Overlap, Cam Lobe Centerline Angle and Valve Closing Delays 319 Cylinder Pressure and Intake Valve Closing 320 The Exhaust System, Cylinder Fill, and Torque 322 Connecting Rod Ratios 324 Why the TC96 is faster than the TC88 326 Why the Ironhead XL was faster than the Big Twin Shovel 330 Power-to-weight and Weight-to-power Ratios 333 Why the Sportster is faster than a TC96 335 Power Formulae 337 Lies, Lies, and Dynos 341 Some Different Types of Engine Horsepower 354 The Worldwide Diversity of Horsepower 356 Chapter VIII Eliminating the Performance Obstructions 361 Key to Power: Head Flow 361 Porting and Polishing 364 Cutting the Valve Seat 367 Valve Seat Fitment 368 The Flow Bench 369 Edelbrock Performer RPM Heads 372 S&S Super Stock Performance Heads 372 Screamin’ Eagle Heads 373 The Exhaust System 376 Performance Exhausts 377 Power Equals Breathing 380 The Catalytic Converter 381 Exhaust Pulses 381 Mufflers Silencing Noise 382 Backpressure 385 Exhaust Pipe Sizing 385 Exhaust Effect on Fuel Delivery 388 Cam Overlap, Torque, Cylinder Fill, and Exhaust 388 Chapter IX Fuel Delivery 393 Ethanol Fuel 396 Air Filtration and Power 397 Velocity Stacks 398 Cleaning Air Filters 400 Performance Filters and Air Breathers 404 Ram Flow Induction Systems 417 Flow Bench Manometer Test Pressure Conversions 423 Carburetion 425 Ignitions Coordinating with Carburetion 428 Intelligent Spark Technology 429 Tuning the CV Carburetor 429 Spark Plug Color Tuning 431 Tuning the S&S Super E and G Carburetor 434 Tuning the Mikuni Smoothbore Carburetor 439

The Engine Management System 443 Advance, Retard Ignition Timing 444 EFI: Ideal Fuel Delivery 448 EFI Cylinder Synchronization 453 Sensors 453 Performance EFI Ignition and Fuel Modifiers 460 Horsepower and Torque Bike-to-Bike Consistency 462 Modifying the Electronic Control Module 463 EFI Chips, Downloads, Burns 463 Piggyback EFI Modifiers 463 Output EFI Controllers 464 Engine Management Software 465 Power Commander 466 Screamin’ Eagle Race Tuner and Direct Link 467 EFI Modifier Technology Changes Fast 468 Changing EFI Fuel Delivery without a Modifier 470 Oxygen Sensors 471 Chapter X The Power Train 473 The Engine Compensating Sprocket 474 Is the TC96 Gearing Too High? 477 The Clutch 479 How to Wreck a Clutch 485 Finding a Difficult Neutral 486 Speed Shifting 486 Performance Clutches, Springs, and Pressure Plates 487 Gear Ratios 489 Secondary Drive Gear Ratios 491 Final Drive Gear Ratios 492 Internal Transmission Gear Ratios 495 Performance Transmissions 497 The BAKER 7-Speed TC96 Transmission 499 Comparing Six-speed Transmissions 500 Evolving Rear Belts 502 TC96 Primary Changes 504 6-Speed Transmission Noise 506 IDS: Power Train Harmonic Pulse Dampener 508 6-speed Increase in Torque Transfer Capabilities 513 Cruise Drive Shift Clutches, Gear & Ring Dogs 515 The Helical Gear S&S 6-Speed 518 The BAKER F6F Helical Gear Conversion 519 Chapter XI Performancing the TC88 and TC96 Twin Cams 523 Two Methods to Power Gain: Cubic Inches and Air Flow 526 Swept Volume 527 Air equals Power 528 Screamin’ Eagle Engines 532 Performance Basics 535 One Cubic Inch Should Deliver Minimum One Horsepower 536 Building an Engine the Wrong Way: The Saga of R’dR 548 1550 EFI Engine Using .585 Lift Cams and HTCC Heads 560

180+ HARLEY-DAVIDSON Service Manuals and Parts Catalogs

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