101 Harley-Davidson Twin Cam Performance Projects

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Item # MB-16392  ISBN: 0760316392




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The Harley-Davidson Twin Cam engine is powering many of the most popular modern Harley-Davidson motorcycles on the road today. And like most Harleys, Twin Cams receive special attention from their owners in the form of cosmetic customization and performance enhancements. If you're a Twin Cam owner, chances are you've modified, or thought about modifying, your bike on your own. Whether you want to swap in some dazzling aftermarket taillights, or increase your engine output with some high-performance cams, this is your information source.

In 101 Harley-Davidson Twin Cam Performance Projects, experienced mechanics and motorcycling journalists Chris Maida and Mark Zimmerman guide you through the important steps of upgrading the major components of your motorcycle, while adding some style in the process. From simple maintenance, like replacing chains to belts, to complex suspension or fuel injection modification, you'll be ready to take on any weekend project. They'll explain the tools, skills, and cost involved, as well as handy tips known by the pros. With over 100 projects, there's bound to be something for everyone.

If you've ever wanted to do it yourself, but were afraid of the cost, frustration, or simply didn't know where to begin. 101 Harley-Davidson Twin Cam Performance Projects is your one-stop resource, and the best tool in your garage.

Table of Contents

PREFACE and ACKNOWLEDGEMENTS

SECTION ONE: WORK and TOOLS
• The work area
• Work practices
• Tools
  
  SECTION TWO: SIMPLE MAINTENANCE
• VINs and engine case numbers
• Performing the 10,000-mile service
• Lubricating cables
• Changing the engine oil and filter
• Changing transmission and primary oil
• Servicing the air cleaner
• Choosing, reading, and replacing spark plugs
• Inspecting and adjusting the rear-drive belt
• Checking and adjusting the primary chain
• Replacing brake pads
• Adjusting the clutch
  
  SECTION THREE: INTAKE and EXHAUST
• Installing a Screamin' Eagle air cleaner
• Installing an S&S air cleaner
• Rejetting the stock CV carb
• Installing a Dynojet Thunderslide kit
• Installing an S&S Super E/G carburetor
• Installing a performance intake manifold
• Replacing the OEM vacuum-operated petcock
• Understanding the Twin Can EFI system
• Installing a Screamin' Eagle EFI race tuner
• Installing and adjusting the Power Commander IIIr
• Installing a performance exhaust system
  
  SECTION FOUR: SUSPENSION and CHASSIS
• How to fix clunking forks
• Installing a cartridge fork emulator
• Lowering front forks
• Installing new fork springs
• Swapping the shock on a Springer
• Adjusting front and rear preload (sag)
• Lowering the rear of a Softail and installing new rear shocks
• Lowering a twin shock rear end
• Servicing rubber engine transmission mounts
• Installing rear air shocks
  
  SECTION FIVE: TIRES, WHEELS, and BRAKES
• Balancing wheels
• Building and maintaining wire wheels
• Servicing the brakes—Changing the brake fluid
• Installing braided brake lines
• Upgrading your brake discs
• Upgrading calipers
• Changing wheels
• Checking and replacing wheel bearings
  
  SECTION SIX: THE ENGINE
• Breaking in a new engine
• Dyno tuning an engine
• Installing adjustable pushrods
• Installing custom lifter covers
• Installing roller rocker arms
• Installing high-performance valve springs
• Installing TP Pre-Vent rocker boxes
• Installing high-performance heads
• Checking combustion chamber size
• Claying high-compression pistons
• Installing a 95-cubic-inch kit
• Installing a custom cam cover
• Installing an Andrews camshaft sprocket
• Replacing the rear camshaft ball bearing
• Replacing the inner camshaft bearings
• Installing high-performance cams
• Installing S&S gear-driven cams
• Installing a Delkron camshaft support plate
• Blueprinting the engine
• Installing a stroker kit
• Servicing the breather assembly
  
  SECTION SEVEN: THE ENGINE OIL SYSTEM
• Installing an oil cooler
• Installing an S&S crankcase breather valve
• Aligning a twin cam oil pump
• Installing a Feuling oil pump
  
  SECTION EIGHT: THE DRIVETRAIN
• Installing a hydraulic clutch actuator
• Installing a Rivera pro clutch
• Installing a Barnett Scorpion clutch spring conversion kit
• Installing a primary chain tensioner
• Installing a Balance Masters kit
• Installing a primary belt drive
• Installing a transmission pulley
• Replacing the belt drive
• Swapping to a custom sprocket
• Installing a rear chain
• Installing a custom tranny side cover
• Installing a Baker reverse shifter assembly
• Installing a six-speed gear set kit
  
  SECTION NINE: THE ELECTRICAL SYSTEM
• Installing aftermarket digital gauges
• Choosing high-performance ignition wires
• Installing a high-performance starter
• Maintaining your charging system
• Installing a Screamin' Eagle adjustable map ignition system
• Installing an aftermarket ignition
• Replacing the thermometer with an oil temperature gauge
• Upgrading the horn
• Troubleshooting the electrical system
• Upgrading our headlight
• Hiding wiring in the handlebar
  
  SECTION TEN: PERSONAL TOUCHES
• Detailing your bike
• Custom turn signals
• Swapping taillights
• Fiberglass repair
• A primer on paint
• Paint repair
• Installing chrome handlebar control pods
• Selecting and changing handlebars
• Installing forward controls
• Selecting and changing seats
• Applying coatings

Plus, sources directory with website addresses.

101 Harley-Davidson Twin Cam Performance Projects