101 Harley-Davidson Twin Cam Performance Projects

by Mark Zimmerman, Jeff Hackett (Photographer), Mark Zimmerman (With)

Overview

If you're looking for ways to keep up with the pack - or blow right past them - this book has 101 of them. Boost the performance of your Harley-Davidson's Twin-Cam engine with 101 projects broken out by each specific aspect of the motorcycle, including engine, suspension, transmission, exhaust, brakes, and body. Hundreds of photos and diagrams take you step-by-step through each project making it a breeze to keep other riders in your rearview mirror.

Product Details

ISBN-13:	9780760316399
Publisher:	Motorbooks
Publication date:	02/01/2005
Series:	Motorbooks Workshop Series
Edition description:	First
Pages:	256
Product dimensions:	8.25(w) x 10.75(h) x 0.70(d)

About the Author

Mark Zimmerman is the Technical Editor of Motorcycle Cruiser magazine, and a contributor to Classic Bike Guide magazine. He lives in Danbury, Connecticut. Jeff Hackett has been photographing motorcycles for magazines, books, and calendars for 19 years. He lives outside New Haven, Connecticut.

Table of Contents

	Preface and Acknowledgments	7
Section 1	Work and Tools	8
Prep 1	The Work Area	9
Prep 2	Work Practices	10
Prep 3	Tools	12
Section 2	Simple Maintenance	17
Project 1	VINs and Engine Case Numbers	18
Project 2	Performing the 10,000-Mile Service	21
Project 3	Lubricating Cables	23
Project 4	Changing the Engine Oil and Filter	25
Project 5	Changing Transmission and Primary Oil	27
Project 6	Servicing the Air Cleaner	29
Project 7	Choosing, Reading, and Replacing Spark Plugs	30
Project 8	Inspecting and Adjusting the Rear-Drive Belt	33
Project 9	Checking and Adjusting the Primary Chain	35
Project 10	Replacing Brake Pads	37
Project 11	Adjusting the Clutch	39
Section 3	Intake and Exhaust	41
Project 12	Installing a Screamin' Eagle Air Cleaner	42
Project 13	Installing an S&S Air Cleaner	44
Project 14	Rejetting the Stock CV Carb	46
Project 15	Installing a Dynojet Thunderslide Kit	49
Project 16	Installing an S&S Super E/G Carburetor	52
Project 17	Installing a Performance Intake Manifold	55
Project 18	Replacing the OEM Vacuum-Operated Petcock	57
Project 19	Understanding the Twin Cam EFI System	59
Project 20	Installing a Screamin' Eagle EFI Race Tuner	62
Project 21	Installing and Adjusting the Power Commander IIIr	65
Project 22	Installing a Performance Exhaust System	68
Section 4	Suspension and Chassis	72
Project 23	How to Fix Clunking Forks	73
Project 24	Installing a Cartridge Fork Emulator	75
Project 25	Lowering Front Forks	78
Project 26	Installing New Fork Springs	81
Project 27	Swapping the Shock on a Springer	83
Project 28	Adjusting Front and Rear Preload (Sag)	85
Project 29	Lowering the Rear of a Softail and Installing New Rear Shocks	87
Project 30	Lowering a Twin Shock Rear End	89
Project 31	Servicing Rubber Engine Transmission Mounts	91
Project 32	Installing Rear Air Shocks	92
Section 5	Tires, Wheels, and Brakes	94
Project 33	Balancing Wheels	95
Project 34	Building and Maintaining Wire Wheels	97
Project 35	Servicing the Brakes-Changing the Brake Fluid	100
Project 36	Installing Braided Brake Lines	102
Project 37	Upgrading Your Brake Discs	105
Project 38	Upgrading Calipers	107
Project 39	Changing Wheels	109
Project 40	Checking and Replacing Wheel Bearings	112
Section 6	The Engine	113
Project 41	Breaking in a New Engine	114
Project 42	Dyno Tuning an Engine	116
Project 43	Installing Adjustable Pushrods	119
Project 44	Installing Custom Lifter Covers	121
Project 45	Installing Roller Rocker Arms	123
Project 46	Installing High-Performance Valve Springs	125
Project 47	Installing TP Pro-Vent Rocker Boxes	128
Project 48	Installing High-Performance Heads	130
Project 49	Checking Combustion Chamber Size	133
Project 50	Claying High-Compression Pistons	136
Project 51	Installing a 95-Cubic-Inch Kit	140
Project 52	Installing a Custom Cam Cover	143
Project 53	Installing an Andrews Camshaft Sprocket	145
Project 54	Replacing the Rear Camshaft Ball Bearing	147
Project 55	Replacing the Inner Camshaft Bearings	150
Project 56	Installing High-Performance Cams	152
Project 57	Installing S&S Gear-Driven Cams	156
Project 58	Installing a Delkron Camshaft Support Plate	159
Project 59	Blueprinting the Engine	161
Project 60	Balancing the Engine	163
Project 61	Installing a Stroker Kit	165
Project 62	Servicing the Breather Assembly	169
Section 7	The Engine Oil System	172
Project 63	Installing an Oil Cooler	173
Project 64	Installing an S&S Crankcase Breather Valve	175
Project 65	Aligning a Twin Cam Oil Pump	177
Project 66	Installing a Feuling Oil Pump	179
Section 8	The Drivetrain	181
Project 67	Installing a Hydraulic Clutch Actuator	182
Project 68	Installing a Rivera Pro Clutch	184
Project 69	Installing a Barnett Scorpion Clutch Spring Conversion Kit	187
Project 70	Installing a Primary Chain Tensioner	190
Project 71	Installing a Balance Masters Kit	192
Project 72	Installing a Primary Belt Drive	194
Project 73	Installing a Transmission Pulley	197
Project 74	Replacing the Drive Belt	199
Project 75	Swapping to a Custom Sprocket	200
Project 76	Installing a Rear Drive Chain	201
Project 77	Installing a Custom Tranny Side Cover	203
Project 78	Installing a BAKER Reverse Shifter Assembly	205
Project 79	Installing a Six-Speed Gear Set Kit	208
Section 9	The Electrical System	212
Project 80	Installing Aftermarket Digital Gauges	213
Project 81	Choosing High-Performance Ignition Wires	215
Project 82	Installing a High-Performance Starter	216
Project 83	Maintaining Your Charging System	217
Project 84	Installing a Screamin' Eagle Adjustable Map Ignition System	219
Project 85	Installing an Aftermarket Ignition	222
Project 86	Replacing the Thermometer with an Oil Temperature Gauge	224
Project 87	Upgrading the Horn	225
Project 88	Troubleshooting the Electrical System	226
Project 89	Upgrading Your Headlight	228
Project 90	Hiding Wiring in the Handlebar	229
Section 10	Personal Touches	231
Project 91	Detailing Your Bike	232
Project 92	Custom Turn Signals	234
Project 93	Swapping Taillights	236
Project 94	Fiberglass Repair	238
Project 95	A Primer on Paint	241
Project 96	Paint Repair	242
Project 97	Installing Chrome Handlebar Control Pods	244
Project 98	Selecting and Changing Handlebars	246
Project 99	Installing Forward Controls	248
Project 100	Selecting and Changing Seats	249
Project 101	Applying Coatings	251
	Sources	254
	Index	255