101 Harley-Davidson Twin Cam Performance Projects Manual for Custom Harley Building and Maintenance

Motorbooks.
Author: Mark Zimmerman, Chris Maida
Photographer: Jeff Hackett
Paperback, 256 Pages

Easy to follow step-by-step instructions with hundreds of color illustrations.

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.

Cruisers such as Harley-Davidsons represent the fastest-growing segment in motorcycle sales and the Twin-Cam engine is used in many of the most popular Harleys on the road today. None of these bikes remains in stock condition. Owners personalize and customize them and most Twin-Cam models receive performance upgrades such as aftermarket pipes, brake and suspension upgrades and engine modifications. Respected motorcycle journalists Chris Maida and Mark Zimmerman present 101 projects an owner can consider or undertake to customize a bikes power, ride and styling. They cover basic regular maintenance and cosmetic customizing as well as more-complex performance projects such as suspension tuning and working on the electrical system. Color photos showing each project in step-by-step fashion make it easy for readers to undertake projects themselves.

CONTENTS

PREFACE AND ACKNOWLEDGMENTS

SECTION ONE WORK AND TOOLS
Prep 1 The Work Area
Prep 2 Work Practices
Prep 3 Tools

SECTION TWO SIMPLE MAINTENANCE
Project 1 VINs and Engine Case Numbers
Project 2 Performing the 10,000-Mile Service
Project 3 Lubricating Cables
Project 4 Changing the Engine Oil and Filter
Project 5 Changing Transmission and Primary Oil
Project 6 Servicing the Air Cleaner
Project 7 Choosing, Reading, and Replacing Spark Plugs
Project 8 Inspecting and Adjusting the Rear-Drive Belt
Project 9 Checking and Adjusting the Primary Chain
Project 10 Replacing Brake Pads
Project 11 Adjusting the Clutch

SECTION THREE INTAKE AND EXHAUST
Project 12 Installing a Screamin' Eagle Air Cleaner
Project 13 Installing an S&S Air Cleaner
Project 14 Rejetting the Stock CV Curb
Project 15 Installing a Dynojet Thunderslide Kit
Project 16 Installing an S&S Super E/G Carburetor
Project 17 Installing a Performance Intake Manifold
Project 18 Replacing the OEM Vacuum-Operated Petcock
Project 19 Understanding the Twin Cam EFI System
Project 20 Installing a Screamin' Eagle EFI Race Tuner
Project 21 Installing and Adjusting the Power Commander Illr
Project 22 Installing a Performance Exhaust System

SECTION FOUR SUSPENSION AND CHASSIS
Project 23 How to Fix Clunking Forks
Project 24 Installing a Cartridge Fork Emulator
Project 25 Lowering Front Forks
Project 26 Installing New Fork Springs
Project 27 Swapping the Shock on a Springer
Project 28 Adjusting Front and Rear Preload (Sag)
Project 29 Lowering the Rear of a Sottail and Installing New Rear Shocks
Project 30 Lowering a Twin Shock Rear End
Project 31 Servicing Rubber Engine Transmission Mounts
Project 32 Installing Rear Air Shocks

SECTION FIVE TIRES, WHEELS, AND BRAKES
Project 33 Balancing Wheels
Project 34 Building and Maintaining Wire Wheels
Project 35 Servicing the BrakesChanging the Brake Fluid
Project 36 Installing Braided Brake Lines
Project 37 Upgrading Your Brake Discs
Project 38 Upgrading Calipers
Project 39 Changing Wheels
Project 40 Checking and Replacing Wheel Bearings

SECTION SIX THE ENGINE
Project 41 Breaking in a New Engine
Project 42 Dyne Tuning an Engine
Project 43 Installing Adjustable Pushrods
Project 44 Installing Custom Lifter Covers
Project 45 Installing Roller Rocker Arms
Project 46 Installing High-Performance Valve Springs
Project 47 Installing TP Pro-Vent Rocker Boxes
Project 48 Installing High-Periormance Heads
Project 49 Checking Combustion Chamber Size
Project 50 Claying High-Compression Pistons
Project 51 Installing a 95-Cubic-Inch Kit
Project 52 Installing a Custom Cam Cover
Project 53 Installing an Andrews Camshaft Sprocket
Project 54 Replacing the Rear Camshaft Ball Bearing
Project 55 Replacing the Inner Camshaft Bearings
Project 56 Installing High-Performance Cams
Project 57 Installing S&S Gear-Driven Cams
Project 58 Installing a Delkron Camshaft Support Plate
Project 59 Blueprinting the Engine
Project 60 Balancing the Engine
Project 61 Installing a Stroker Kit
Project 62 Servicing the Breather Assembly

SECTION SEVEN: THE ENGINE OIL SYSTEM
Project 63 Installing an Oil Cooler
Project 64 Installing an S&S Crankcase Breather Valve
Project 65 Aligning a Twin Cam Oil Pump
Project 66 Installing a Feeling Oil Pump

SECTION EIGHT: THE DRIVETRAIN
Project 67 Installing a Hydraulic Clutch Actuator
Project 68 Installing a Rivera Pro Clutch
Project 69 Installing a Barnett Scorpion Clutch Spring Conversion Kit
Project 70 Installing a Primary Chain Tensioner
Project 71 Installing a Balance Masters Kit
Project 72 Installing a Primary Belt Drive
Project 73 Installing a Transmission Pulley
Project 74 Replacing the Drive Belt
Project 75 Swapping to a Custom Sprocket
Project 76 Installing a Rear Drive Chain
Project 77 Installing a Custom Tranny Side Cover
Project 78 Installing a BAKER Reverse Shifter Assembly
Project 79 Installing a Six-Speed Gear Set Kit

SECTION NINE: THE ELECTRICAL SYSTEM
Project 80 Installing Aftermarket Digital Gauges
Project 81 Choosing High-Performance Ignition Wires
Project 82 Installing a High-Performance Starter
Project 83 Maintaining Your Charging System
Project 84 Installing a Screamin' Eagle Adjustable Map Ignition System
Project 85 Installing an Aftermarket Ignition
Project 86 Replacing the Thermometer with an Oil Temperature Gauge
Project 87 Upgrading the Horn Project 88 Troubleshooting the Electrical System
Project 89 Upgrading Your Headlight
Project 90 Hiding Wiring in the Handlebar

SECTION TEN: PERSONAL TOUCHES
Project 91 Detailing Your Bike
Project 92 Custom Turn Signals
Project 93 Swapping Taillights
Project 94 Fiberglass Repair
Project 95 A Primer on Paint
Project 96 Paint Repair
Project 97 Installing Chrome Handlebar Control Pods
Project 98 Selecting and Changing Handlebars
Project 99 Installing Forward Controls
Project 100 Selecting and Changing Seats
Project 101 Applying Coatings

SOURCES

INDEX