No.1932-IS “From The Track... To The Street!” For the
Contents
1. i E threads CAUTION Keep all foreign material out of piston oiling Piston Clearance Information jets Install the new o rings in the groove on the piston oiling jets Minimum __ 002 Clearance and then apply a very thin film of clean 20 50 engine oil to the new Maximum 003 Clearance o rings Torque the new Allen screws to 20 30 inch Ibs NOTE These threads in the engine case are very delicate so be careful not to Direction _7 Valve cross thread these screws or over torque Oo ae NOTE For future service of JIMS piston oiling jets use O E M P N 26432 76A for o ring replacement 74 C H 6 Pistons and cylinders in these kits are clearanced for installment Below is the clearance information Always check fitment and clearance before final assembly See Picture No 5 NOTE Check H D service manual for ring positioning around each piston also read the instructions within your piston set box for installing rings yn astalling pictonepaation Hie pis on pistons ton so that the arrow marked on the top NOTE When installing JIMS flywheel into a 2003 or later case you must use 9f the piston points in the direction of crankshaft roller bearing kit H D No 24004 03 in the left side crank HSA Mane WANS peer gee De shaft bore Picture No 5 7 Assemble per H D Service Manual NOTE When assembling case halves together seal with High Performance Sealant H D No 99650 02 or equiv alent A Tighten case bolts to2. the risk of per sonal injury Refer to H D Service Manual for specifications and for removal and installation of the engine Read instructions com pletely so you understand before performing any steps Always disconnect battery cables to prevent injury Your work place should be clean and well lit wear safety glasses and protective clothing when working around power tools and compressed air Use authorized H D Service Manual for reference If you are not sure about the procedures in these instructions have a reputable H D repair shop perform those procedures for you From The Track To The Street 2 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422 No 1932 IS REV F 2 04 ATTENTION Please read all instructions completely and thoroughly before performing any work Follow instructions in H D Service Manual for removal of engine for your year and model With engine removed from frame and sitting on the workbench fol low the disassembly instructions in the service manual to disassemble engine Clean all parts thoroughly including gasket surfaces and inspect all parts for vis ible damage Measure all parts for wear using the service wear limit section in the H D Service Manual Replace any worn or damaged parts with JIMS engine parts or equivalent 2 On 4 bore kits 100 113 and 116 you will be required to machine cases to accept 4 bore cylinders use JIMS No 117
3. 7 Case Boring Fixture See Picture No 1 amp 2 Bore to 4 220 03 00 diameter at a depth of 1 645 03 00 for the 116 amp 113 kits and 1 330 03 00 for the 100 kit measuring from the gasket surface Before machining cases you must remove cylinder studs and H D piston oiling jets Note You will be using JIMS piston oiling jets for reassembly included with this kit Mask off all bearings and oil holes Bolt cases together with H D hardware Tighten case bolts to factory spec Check all cylin der studs and stud threaded holes Replace any damaged cylinder studs JIMS suggest using the latest cylinder studs from H D or Screamin Eagle f f Picture No 2 After machine work is done clean cases of all machine material Follow H D Service Manual for installation of studs 4 Checking Clearances connecting rod to case cylinder to cylinder piston to pis ton and piston to case below cylinder spigot both front and rear See Pic 3 To make the job easier use JIMS No 1745 Timken Bearing Simulator A With flywheel assembly simulated in left case install pistons without rings Pistons can be installed in either location front or rear Mount both cylinders and pistons to left case NOTE On 4 bore cylinders there is a relief area on the cylinder spigot Each 4 bore cylinder and piston must have the reliefs on the cylinder spigot facing each other when installed on cases See Picture N
4. JIMS No 1283 Cam chain tensioner tool A must JIMS No 1285 Cam crank sprocket lock tool A must JIMS No 1276 Wristpin remover A must JIMS No 1047TP Crank assembly removing tool A must JIMS No 1048 Hard cap A must JIMS No 39361 69 Motor sprocket seal installation tool A must JIMS No 1022 Engine stand or base 1145 w 1140 A motor 1142 B A must JIMS No 97225 55 Sprocket shaft bearing installation tool A must JIMS No 1745 Timken bearing simulator As needed JIMS No 1236 Piston ring compressor tool A must JIMS No 1235 Ring expander tool JIMS No 1169 Compression Release Valves JIMS No 1177 Case Boring Tool JIMS No 1163 Balancer Shaft Retention Pins Dial indicator For measuring endplay of crankshaft NOTE It is the engine builder s responsibility to check and confirm all operating clearances when installing any JIMS products From The Track To The Street 6 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422
5. REV F 2 04 No 1932 IS FOR THE FOLLOWING PART NUMBERS 1501 1501B 1937 1938 1941 1942 1957 1958 1959 1960 Alpha Stroker Kit FLH FXD Beta Stroker Kit FXST 100 Big Bore Kit A or B Twin Cam Motors Application Bore Compression Ratio Cylinder Finish Use on Alpha or Beta 99 Present 56 Silver Use on Alpha Beta 99 Present 56 Black Wrinkle 113 Twin Cam Alpha FLH FXD Stroker Kits with Cylinders Application Stroke Bore Compression Ratio Cylinder Finish Use on Alpha 99 Pres 4 1 2 4 9 94 1 Black Wrinkle Use on Alpha 99 Pres 4 1 2 4 9 94 1 Silver 116 Twin Cam Alpha FLH FXD Stroker Kits with Cylinders Part No Application Stroke Bore Compression Ratio Cylinder Finish 1941 Use on Alpha 99 Pres 4 5 8 4 10 19 1 Black Wrinkle 1942 Use on Alpha 99 Pres 4 5 8 4 10 19 1 Silver WARNING Beta Stroker kits must never be revved any higher than 6 200 RPM 113 Twin Cam Beta FXST Stroker Kits with Cylinders Stroke Bore Compression Ratio Cylinder Finish Use on Softails 2000 present Black Wrinkle Use on Softails 2000 present Silver 4 5 8 4 10 19 1 Silver NOTE 2003 Present Twin Cam Motor Cases will need H D No 24004 03 Crank Shaft Bearing Kit WARNING BETA STROKER USERS Your JIMS 116 amp 113 Balanced Stroker Kit ships with a pressed on balancer drive gear This gear was tested and proven to protect agai
6. VES G Carburetor Includes aluminum spacer Customer must use his bakelite spacer No 725 Head to Manifold Spacer Use on taller than stock motors 1984 pres ent Use to fill and seal the 0 080 gap between the head and mani fold after you have installed about 0 100 taller cylinders Comes with O Rings A must IMPORTANT STARTER NOTE for EFI manifolds Due to the higher compression ratio created by the 113 amp 116 stroker kits your starter system efficiency may be reduced and may become prematurely damaged JIMS rec ommends installing high output starter components High IMPORTANT CYLINDER PREPARATION heavy duty gauge cables heavy duty battery and high out Before installing cylinders on cases the inner bores and gasket put starter along with compression release valves to maintain area must be scrubbed and cleaned with hot soapy water your starter system efficiency Compression release valves are a must when building large displacement engines These valves will manually vent cylin der compression to the atmosphere at startup Install JIMS Compression Release Valves with JIMS installation tool No 1169 for Twin Cam or use JIMS tapping tool No 1169 1 for all other engines No 727K Use on all Big Twin Sportsters and Buells WARNING Note Read all instructions before performing work Prior to installation of this kit please read and follow the procedures and safety precautions to reduce
7. e guaranteed to the original purchaser to be free of manufacturing defects in materials and work manship for a period of 6 six months from the date of purchase Merchandise that fails to conform to these con ditions will be repaired or replaced at JIMS option if the parts are returned to us by the purchaser within the 6 six month warranty period or within 10 ten days thereafter In the event warranty service is required the orig inal purchaser must call or write JIMS immediately with the problem Some problems can be rectified by a tele phone call and need no further course of action A part suspected of being defective must not be replaced by a Dealer without prior authorization from JIMS If it is deemed necessary for JIMS to make an evaluation to deter mine whether the part is defective it must be packaged properly to prevent further damage and be returned pre paid to JIMS with a copy of the original invoice of purchase and a detailed letter outlining the nature of the prob lem how the part was used and the circumstances at the time of failure If after an evaluation has been made by JIMS and the part was found to be defective repair replacement or credit will be granted ADDITIONAL WARRANTY PROVISIONS JIMS shall have no obligation in the event a JIMS part is modified by any other person or organization 2 JIMS shall have no obligation if a JIMS part becomes defective in whole or in part as a result of improper instal
8. factory specs except top center case bolt between cylinders B Install top center bolt last after you have cylinders and heads installed and torqued to H D specs NOTE When installing 4 bore cylinders on cases they need to have the relief on bottom of skirt fac ing each other when installed as shown in picture No 4 z C Apply High Performance Sealant H D No 99650 02 to shoulder of Picture No 6 top center case bolt and torque to 50 90 inch Ibs maximum See Picture No 6 You can use your stock man ifold for 100 Big Bore Kit and 113 stroker kits For 116 kits you will need JIMS manifold JIMS No 700 or 702 or flange JIMS No 703 701 or 725 for your carburetor application See page 2 Note Before installing head gasket If you are using a 3 layer riveted EST style head gasket and you have aftermarket heads you may find that you have interference with the rivet in the head gasket If so use a smooth jaw vice to reduce the thickness of the rivet before installation Instructions continued on page 5 gt NOTE It is the engine builder s responsibility to check and confirm all operating clearances when installing any JIMS products From The Track To The Street 4 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 1932 IS REV F 2 04 INSTRUCTION SHEET FOR JIMS TWIN CAM FLYWHEEL ASSEMBLIES amp BIG BORE KITS BREAK IN PROCEDURE After final assembly the en
9. gine must be broken in Over revving or lugging engine could cause damage to pistons and or other engine components On the initial start up excessive heat build up can occur Do not over heat by revving engine or running at a fast idle too long To ensure proper head gasket seal upon first time engine start up idle engine 1000 1500 R P M until cylinder head temper ature reaches about 250 degrees Shut engine off and let cool This procedure is necessary to properly seal top end compo nents CAUTION Improper initial engine start up may cause head gaskets to fail prematurely Because most engine damage could occur during the first 50 miles keep the heat down by not exceeding 2800 R P M but do not lug engine Continue to vary speed for the next 500 miles and do not exceed 3800 R P M For the balance of the first 1000 miles avoid overheating engine Do not lug engine or idle for long periods of time No trailer towing racing etc Change oil and filter after the first 500 miles WARNING Beta Stroker kits must never be revved any higher than 6 200 RPM Compression Table Stock Head C R Screamin Eagle Head C R 96 2cc Swept Volume 86 3cc Swept Volume 040 Gasket 040 Gasket Stock Twin Cam Head 85 9cc Screamin Eagle Head 76 0cc Swept Volume Combustion 9 94 1 10 88 1 Chamber Volume Gasket Volume e e a _ 7 Valve Pocket Volume 10 19 1 11 2 1 WARRANTY All JIMS parts ar
10. lation improper maintenance improper use abnormal operation or any other misuse or mistreat ment of the part 3 JIMS shall not be liable for any consequential or incidental damages resulting from the failure of a JIMS part the breach of any warranties the failure to deliver delay in delivery delivery in nonconform ing condition or for any other breach of contract or duty between JIMS and a customer i 4 JIMS parts are designed exclusively for use in Harley Davidson motorcycles JIMS shall have no warranty or liability obligation if a JIMS part is used in any other application 5 Any parts which have been replaced for any reason become the property of JIMS and will not be returned under any circumstances CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS AND TOOL SEE JIMS CATALOG FOR OVER 200 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From The Track To The Street 5 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REV F 2 04 No 1932 IS INSTRUCTION SHEET FOR JIMS TWIN CAM FLYWHEEL ASSEMBLIES amp BIG BORE KITS Recommended Tools Part No Description JIMS No 2234 Primary drive locking tool A must JIMS No 1288 Crankshaft guide A must JIMS No 1287 Cylinder torque plates A must JIMS No 1726 3 Wristpin bushing reamer tool As needed JIMS No 1051 Connecting rod bushing tool As needed
11. nst potential damage caused by over revving the engine past 6 200 RPM THIS GEAR WILL MOVE DUE TO OVER REVVING Your flywheels will NOT be warranted against movement of this gear due to over rewing In addition to this the pressed on gear will NOT be available separately JIMS insists that a 6 200 MAX RPM rev limiting device be used at ALL times From The Track To The Street 1 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422 No 1932 IS REV F 2 04 IMPORTANT PRODUCT INFORMATION FOR BOTH ALPHA amp BETA STROKERS KITS The following components are recommend by JIMS for use with JIMS stroker kits GASKET KITS FOR JIMS TWIN CAM STROKER KITS MANIFOLD FOR JIMS TWIN CAM No 858 113 amp 116 Stroker Kits 100 Big CARBURETED STROKER KITS Bore Kits 4 bore Use on Twin Cam Se a ieee 88 Softail amp Dyna 040 Head No 700 Manifold Use with Mikuni Gasket 020 Base Gasket Carburetor Stock CV Carburetor p 7 are A gt or Screamin Eagle CV Carburetor No8525 1113 amp gi Stroker Kits 100 Big See adapter below Bore Kits 4 bore Use on Twin Cam A p 88 FL Models 040 Head 5 Gasket 020 Base Gasket No 703 Flange for use with Part No 700 40mm CV or a 42mm Mikuni No 701 Flange for use with Part No 700 44mm CV or a 45mm Mikuni No 702 Manifold Use with amp Super COMPRESSION RELEASE VAL
12. o 4 B Check and if necessary grind or file for a minimum clearance of 060 between rod and case See Picture No 3 NOTE Only remove material from the case and not the rods C Check and if necessary grind or file for a minimum clearance of 050 between cylinder spigots and a minimum clearance of 060 between piston skirts See Picture No 4 NOTE Clean all machine material from cases CAUTION Only remove enough material to maintain the minimum clear ance CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS AND TOOL SEE JIMS CATALOG FOR OVER 200 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From The Track To The Street 3 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 1932 IS REV F 2 04 INSTRUCTION SHEET FOR JIMS TWIN CAM FLYWHEEL ASSEMBLIES amp BIG BORE KITS lt Instructions continued from page 3 Ring End Gaps For Ductile 5 After checking all clearances for proper fitment install piston oiling moly rings TC 88 jets into right case half All kits are provided with new piston oiling Top compression ring _ 016 022 jets except the 100 Big Bore Kit This kit will use the original H D 2nd compression ring _ 016 022 piston oiling jets Before installing piston oiling jets clean threads in Oil control Ring rail 016 050 case Then apply a drop of loctite 222 purple to the last few
Download Pdf Manuals
Related Search