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1. No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS e These marks will be used as a guide to tighten all head bolts an addi tional 1 4 of a turn or 90 degrees See Fig 68 e After all 8 head bolts have been tightened an additional 1 4 turn or 90 degrees all 8 head bolts need to be loosened to allow seating in of the gaskets e Loosen the head bolts using the same sequence described in Fig 66 1 4 of a turn at a time until each is loose enough to turn with your fingers e After all 8 head bolts can be turned with your fingers start the torque Fig 68 1 4 turn sequence again e Torque each head bolt to 8 ft lbs following the sequence in Fig 66 e Continuing in the same sequence torque each bolt to 18 5 e Make a fresh mark on the head bolts as pictured in Fig 67 e Tighten all 8 head bolts in sequence an additional 1 4 turn or 90 degrees as pictured in Fig 68 JIMS 120 131 or 135 Race Kit torque sequence Year 6th 2003 4 A amp B 805 18005 1 4 turn 88 05 18ft lbs 1 4 turn STEP 10 Compression Release Installation Preparation e Unwrap and clean the threads of the compression releases See Fig 719 70 Thread spark plug 69 e Install the sealing washers e Lightly lubricate with copper anti seize lube the threads and sealing washers e Make sure the threaded holes in the heads are clean an
2. Important The torque value for the center case bolt is 135 155 in Ibs e Center case bolt torque specification During each case bolt re torquing sequence the H D prescribed torque specification for the 1 4 center case bolt 1 in the H D Service manu al diagram should be amended to 135 155 in lbs See Fig 71 for Engine A amp 72B for Engine B Pushrod Bores L LONG BOLT S SHORT BOLT LEFT SIDE RIGHT SIDE Pushrod Bores Fig 71 Case torque sequence Fig 72 Case torque sequence 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 17 REv I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS Instruction Appendices Appendix One Piston Ring Burr Removal Remove any burrs with a fine jeweler s file NOTES Do this work away from the engine assembly e Piston ring filings are extremely hard and dangerous to the fine internal surfaces of your 120 131 or 135 engine especially its roller and needle bearings Piston ring filings are often slightly magnetic and may be difficult to remove from the rings or steel tools like the jeweler s file you might use to adjust end gap Piston ring end gap filing creates very sharp corners on the rings These must be removed before inserting the rings into the cylinder bores It is not necessary or desirable to bevel or break t
3. s notch goes toward the rear of the engine toward the center of the V formed by the cylinders See Fig 32 e The rear cylinder s notch goes toward the front of the engine again toward the center of the V formed by the cylinders e When the front cylinder is correctly placed its shortened fins will be on the right and the spigot notch will be toward the rear of the engine e When the rear cylinder is in place its shortened fins will also be on the right but the spigot notch will be toward the front of the engine e Both cylinder notches go toward the center of the engine they face each other e Piston differences and orientation The front and rear pistons are dif ferent e The rear piston has a notch at the bottom of its skirt e The rear piston s notch goes toward the front of the engine See Fig e Toward the center of the V formed by the cylinders We e The front piston does not have a notched skirt See Fig 34 Fig 34 Rear piston notch e The front piston s larger valve pocket goes toward the rear of the engine the intake side of the cylinder e Toward the center of the V formed by the cylinders Installation Procedure e The JIMS 131 120 or 135 Race Kit piston installation procedure differs from that found in Harley Davidson s Twin Cam shop manuals e Our alternate procedure is commonly used and preferred by many engine builders e Assembly Rear Piston Cylinder w e
4. the oil drain hole in the cylinder Note The JIMS 120 131 or 135 Race Kit gaskets do not need or use O rings The gasket coating and embossment seals the surfaces and eliminates oil leaks Cylinder Head Installation e Clean the head gasket sealing surface with a lint free cloth and dena tured isopropyl alcohol and allow the surface to dry prior to installation e Lightly lubricate with the supplied moly lube the threads of the cylin der studs Fig 61 Note oil hole 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 ia No 1208 1352 REV 8 12 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS Note Do not allow any lube to contact the gasket or gasket surfaces e Select a head and place it over the locating dowels and onto the cylin der e Be sure the head gasket is properly placed See Fig 63 Head orientation See Fig 66 e The Screamin Eagle logo goes to the right of the engine The pushrod holes go to the right of the engine The intake port goes toward the center of the engine Make sure the head is fully seated on the cylinder Lay out the head bolts within easy reach two short and two long bolts are used for each head Lightly lubricate with copper anti seize lube the internal threads of each bolt e Lightly lubricate with copper anti seize lube the underside of each
5. 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS e Install the second rail with its gap roughly opposite the gap of the first i rail e Make sure the expander spring ends butt and do not overlap VS 7 Installation Compression Rings Identification e The top two rings are different and each have an up side and a down side They must be installed correctly e The first or top Fig 23 amp 24 ring has a light colored hard chrome plated sealing edge face It has a very small dot on its top about half an inch from one end Also one of its inside edges is beveled Both the dot and the bevel go up toward the top of the piston e The second ring is very dark almost black in color It is marked with dot or TOPC about 1 2 from one end This identifies the top side of the ring Bevel goes down See Fig 25 TOPC Up DOT 2ND RING Installation Second Ring See Fig 25 e Select a second ring Remember it is nearly black e Make sure the top of the ring is facing up Remember the top of the second ring has a dot or a TOPC about 1 2 from one end e Grasp the ring with your piston ring expander tool JIMS No 1235 See Fig 26 e With the piston supported on the clean pad gently expand and guide the ring over the top of the piston and into its groove Do not expand the ring any more than is needed to get it over the piston Top ring installation See Fig
6. 2 head bolt flange See Fig 64 Fig 63 Verify gasket alignment This is the flat area under the bolt head that contacts the cylinder head oO Thread the two short bolts into the stud holes on the left spark plug a Bee side of the head Thread the remaining longer bolts into the other two Gently snug all four bolts finger tight Repeat step on page 14 See Very Important Note to install the remaining head e Remember to align the hole in the gasket with the cylinder s oil drain hole Fig 64 Moly lube Cylinder Head Torque See Fig 65 Note Follow the tightening sequence exactly as it is described below Deviation from the procedure can result in gasket failure or severe damage to the heads and cylinders If you have any questions regarding the torque sequence please contact JIMS Tech Support at 805 482 6913 See Fig 66 Pg 17 e After all head bolts are finger tight follow the sequence in Fig 66 Pg 17 to torque the heads as described below with a 1 2 12 point deep socket e Torque each lubed head bolt to 8 ft lbs following the sequence in Fig 66 e Continuing in the same sequence torque each bolt to 18 5 e With a grease pencil or similar marker mark a line on the smooth surface of all 8 head bolts continuing this line down to the head casting surface as pictured in Fig 67 Fig 67 Mark bolt and head S55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 ta REv I 8 12
7. 27 e Select a 15 compression ring Remember it has a light colored hard chrome plated sealing edge face a smaller dimple and a beveled inside edge e With the dimple and bevel up grasp the ring with the piston ring expander tool Fig 27 Top ring install 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REV I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS e Expand the ring just enough to clear the piston and guide the ring into its groove See Fig 28 e Repeat the above procedure to install the remaining piston rings on the other piston e Check the fit between piston rings and piston ring grooves by sliding each ring around in its respective groove There should be no tight spots Clean pistons and proceed to the next step See Fig 29 Fig 28 Carefully expand rings STEP 6 Cylinder Inspection and Preparation e Inspection Inspect the fins and spigots of both cylinders for damage Closely inspect the cylinder bores There should be no scratches other than the normal hone cross hatch e Cleaning e Soak the non abrasive cleaning pad in hot water e Wearing your clean mechanics gloves thoroughly scrub the cylinder bores with the soapy pad and hot water See Fig 30 e Rinse the bores with clean hot water until you can wipe the bore with a clean white cloth a
8. 482 6913 FAX 805 482 7422 m A No 1208 1352 REV 8 12 A Division of Thiessen Products INC INSTRUCTION SHEET FOR Box 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS Of course the fins should also be straight and undamaged Any small chipped paint areas can be touched up later Inspect the head gaskets See Fig 60 They should be smooth and clean A small amount of curl is okay The surface coating should be intact You will find a small area of machined fins on the spark plug side of each head as pictured This is normal See Fig 59 Head Gasket Installation VERY IMPORTANT NOTES e The head gaskets can be installed either of two ways only one is cor rect e Incorrect installation will close off the oil drain hole from the head e Incorrect head gasket installation requires a partial engine tear down to fix Head Gasket Orientation e The gaskets have a seventh hole about 3 8 in diameter near one of the stud holes e Install each gasket so this hole is over the oil drain hole in its cylinder See Fig 60 The front cylinder s drain hole is located at the left front See Fig 1 The rear cylinder s drain hole is located at the left rear See Fig 62 Make sure each cylinder and gasket is clean and free of oil Place the gasket over the locating dowels Dry Note Do not apply sealant to gasket e Double check to make sure the oil drain hole in the gasket aligns with
9. IES OR ENGINE RACE KITS e The rear piston has a notch on the bottom of the intake side of its skirt See Fig 6 e The rear piston s notch goes toward the front or intake side of the engine gt The front piston s intake valve relief points toward the rear of the engine See Fig 7 STEP 2 Piston Pin Clip Insertion IMPORTANT NOTE Fig 6 Rear only piston notch e Piston pin clip insertion must be done carefully to avoid damaging the Rear ne gt corners of the piston pin hole e A crushed corner is a collection of cracks At the high stress levels this intake engine was designed to withstand one or more of those cracks could oe 24 grow and eventually result in piston failure and severe engine damage 8 e Use Harley Davidson tool No 42317 or JIMS Tool No 769 Piston Pin Circlip Remover Installer if you have one This is an excellent tool and makes the task simple and safe for the pistons This tool can only be used for left side of piston e Lock ring is to be installed on the left side at this time See Fig 7 e tis very important you do not scratch or gouge the piston pin bore e Place the piston on the clean pad If using the Harley tool follow the directions in your Harley shop manual to insert a piston pin clip into the left side of each piston See Fig 8 8 9 e Check to make sure the wrist pin clip is fully seated in its groove Fig 7 Front F Intake Marked STEP 3 Piston Ring Inspection and Preparation Preparatio
10. Place the rear cylinder on your bench Spigot or bottom end up gr See Fig 5 e Place the rear piston assembly on your bench e Top end up 566 Fig 36 Arrange the piston rings so that the end gaps do not line up stagger alignment Fig 35 Align correctly Fig 36 Piston up 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REv I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR Box 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS FRONT REAR e See Fig 37 for proper front and rear piston ring placement This placement is very critical to piston installation be cer tain you have duplicated ring position per the diagram or Bottom OCR Rail piston and ring damage can occur D Second Ring E Top Ring A Note If you find it useful take a magic marker and duplicate the numbers from the diagram onto your piston Be sure you have the rear cylinder with the rear piston e Fit the piston ring compressor with a light film of clean H D 20W 50 oil over the piston just far enough to capture all the rings See Fig 38 e Align the ring compressor s handle with the smaller exhaust valve relief See Fig 39 e Tighten the compressor e Confirm all rings are compressed See Fig 39 e Lube skirt with assembly lube and slide the piston into the bore of the cylinder See Fig 40 e Place the ring compressors h
11. REV I BOX 2 ASSEMBLY INSTRUCTIONS 1208 1352 These instructions are for all models of 120 131 or 135 Alpha Beta and Evo Mount Engines Sn 1 x A H k Fy hy j GYLINDER AND CYLINDER HEAD INSTALEATION INSTRUCTION fl ae NS No 1208 1352 REV 8 12 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS Box 2 Installation Instructions CONTENTS Note Use Fig 1 on this page and Fig 73 in conjunction with the check off list on page 18 amp 19 to verify contents prior to proceeding with any installation instructions TOOLS AND LUBRICANT See Fig 2 JIMS No 1235 Piston Ring Expander Tool Snap On PRS8 JIMS No 1236 Piston Ring Compressor Set JIMS No 769 or No HD 42317 Piston Pin Circlip Installer JIMS No 1255 Ring Gap Grinder Tool Feeler gage set including 0015 through 040 blades 3 8 drive torque wrench 0 25 ft Ibs 12 point 1 2 deep socket 3 8 drive 13mm deep socket 3 8 drive Non abrasive scouring pad amp dish soap for cleaning cylinder bores Clean pair of mechanic s gloves JIMS No 4507 Copper Anti Seize Lubricant Piston Inspection and Preparation GENERAL NOTES amp CAUTIONS e Obtain and use a Harley Davidson Twin Cam service manual s
12. andle opposite the larger cylinder spigot notch See Fig 40 e Be careful to avoid damaging the piston skirts e Carefully push the piston into the bore with the palm of your gloved hand The ring compressor will release when the piston is completely in the bore See Fig 41 e Turn each piston to the right and left approximately one 1 inch this movement should be smooth Assembly Front Piston Cylinder e Use the same assembly technique as the above steps Go back to step 7 and perform the same steps for other cylinder and piston e Be sure you have the Front piston with the Front cylinder 0080 Fig 38 Proper ring clamping Note If you are not going to install the cylinders on your lower end assem bly at this time you must bag the cylinders using one of the supplied clean plastic bags STEP 8 Cylinder Installation Note This step is best done by two people 4 Fig 41 Use hand to push 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 a No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS REV I 8 12 e Work from the right side of the short block e One person should hold and position each piston cylinder assembly See Fig 42 e The second can then align the connecting rod with the wrist pin and insert the pin into the rod See Fig 43 e Uncover the short block and position it wi
13. d empty Installation e Thread a compression release into its head e Using your 13mm deep socket torque to 12 to 18 5 e Repeat for other compression release Note Before proceeding apply a small amount of moly lube to the spark plug threads and the spark plug threads in the head and then thread the spark plugs a few turns into the heads e The purpose of this is to prevent anything from falling into the cylinders e Do not torque them at this time as they will be removed to make the engine easier to rotate during pushrod installation and adjustment See Fig 70 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 ue REv I 8 12 No 1208 1352 INSTRUCTION SHEET FOR Box 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS Please Note The following case bolt re torquing procedure contains a specification for the center case bolt that is unique to your new JIMS 120 131 or 135 Race Kit e The 1 4 center case bolt must be retorqued prior to initial start up and again after the engine has cooled OR e All case bolts must be re torqued once the engine has cooled after initial start up Retorquing must be continued after each heat cycle until the case bolts cannot be torqued any further e Refer to your Twin Cam A or 8 H D Service Manual for the proper tightening sequence and torque specifications for all case bolts with the following exception
14. e Piston ring gap tool e Determine how much material must be removed from the ends of the ring It will probably be only a few thousandths of an inch If say a 2nd compres sion ring s end gap was 013 then you would need to remove a total of 004 from the ends to meet the minimum gap standard of 017 s h e Remember JIMS No 1255 piston ring end gap tools file both ends of the Fig 14 Rotary ring cutter ring and material removal can be very rapid e Fit the ring into the tool according to the tool s instructions e Gently rotate the cutter and remove a very small amount of ring material See Fig 14 e Remove and clean the ring Deburr if needed Then re insert it into the bore Square it using the piston as before and measure the end gap e Check the end gap often as you work especially when you work with your first ring Fig 15 Square ring ends Flat jeweler s file e It is not necessary to remove material from both ends e t is important to get the filed end square When the two ends are brought together they should be as nearly parallel as possible 566 5 e Devise a method to clamp or control the piston ring as you file it You could use a clean smooth jawed vise with soft jaws or a machinist s vise See Fig 16 e An alternate method might be to use a flat hard sharp cornered object like Fig 16 Clamp securely a thick glass plate or even a piece of hard wood Place the ring end ove
15. e bore and positioned for end gap inspection e Use a feeler gage as pictured to measure the width of the gap You may stack two blades if necessary See Fig 11 e Remove each ring by hooking it with a finger on the side opposite the gap and pulling smoothly and gently out of the cylinder bore Front Piston Rear Piston Oil Control Rails Start measuring with all piston rings to one side of the cylinder e After each ring is checked Place rings having passed the end gap test on the opposite side of the cylin der Place each of those failing the end gap test on a piece of paper and write Fig 13 Press ring down their measured end gap on the paper e When you have finished separate and cover the piston rings not requiring additional fitting i Nin 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 1208 1352 REV 8 12 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS STEP 4 End Gap Adjustment e It is unlikely you will need to adjust the first and oil control ring end gaps However it is likely you will have to adjust the second ring end gap if you do the amount will be very small Please do not hurry the procedure and remove only a little material at a time e For the best result use a piston ring gap tool to remove metal from the ends of the rings e Do not work near the open engin
16. engine The large valve relief in the top of the piston goes toward the rear of the engine The front piston has no skirt notch See Fig 34 Installation Cylinder Dowel Pins No 1286 1387 Note Make sure the tappet block cover bores remain sealed so nothing can fall into them e Lightly lube the larger beveled side of the dowel pin with clean H D 20W 50 oil e Install 2 dowel pins per cylinder into cylinder gasket surface area as shown in Fig 7 Step 9 Cylinder Head Inspection and Assembly Important Note Any CNC ported heads used on JIMS 120 131 or 135 Twin Cam engines All of JIMS heads found on 120 131 or 135 engine s are powder painted either in black or silver prior to CNC porting When the CNC porting process is done some paint may remain inside the intake or exhaust ports Any paint that may be left inside ports will not affect airflow or performance in any way This is not a defect do not try to remove it e Inspection See Fig 58 gt All sealing surfaces must be free of dents deep scratches or foreign mate rial e Clean the cylinder gasket sealing surface with a lint free cloth and dena tured isopropyl alcohol and allow the surface to dry prior to installation This is particularly important with the JIMS 120 131 or 135 Race Kit as its special gaskets are hard and do not conform around deformities like the Fig 56 Front rod TD softer stock gaskets 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805
17. he corners formed by the piston pin hole and the sides of the pistons They should be smooth with no nicks or deformations If any burrs are noted please contact the JIMS Tech Department 805 482 691 3 e Inspect the piston ring grooves for any deformations e Clean the pistons and then proceed to the next step Piston and ring installation information e The 120 flat top piston is shown in Fig 4 and the 131 135 with a recessed top is shown in Fig 5 Both the 120 and 131 135 piston sets have a rear piston with a notch as shown in Fig 3 on the skirt In the following installations we show figure photos of 120 the ring sets The installation of the 131 or 135 ring sets is the same procedure for installation as 120 sets Note 120 131 or 135 Piston orientation There is a front and a rear piston They are not the same and must be installed correctly See Fig 3 e Both 120 131 and 135 pistons have valve reliefs machined into their tops The intake valve reliefs are clearly larger to clear the 2 080 diameter intake valves See Fig 4 and Fig 5 N87 135 rger Fig 5 Intake relief only ae aL 0 R Fig 4 Intake relief is la Fig 3 Inspect pistons 9 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 1208 1352 REV 8 12 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBL
18. he corners of a modified piston ring Merely remove the burrs 727 Compression Release Valve 1286 1332 1286 1331 T p 1286 1326 Spark Plug H 0 Cr 120 131 amp 135 1285 1332 SILVER Aa 1285 1 333 BLACK 1286 1354 1386 1354 l 120 Standard Ring Set 135 amp 131 Standard Ring Set for 2 Pistons for 2 Pistons 135 2208 1611 FRT BLK 2208 1612 REAR BLk 2208 1621 FRI SILVE 2208 1622 REAR SIL an 131 amp 135 i 120 ALPHA PISTON SETS aes 1308 1611 FRT BLK 77 1286 1357 AX MY 1308 1621 FRT SILVE PISTON SETS 20 KA 1286 1387 1308 1622 REAR SILV COMPLETE 120 BETA aN Le 120 1386 1357 PISTON SETS 1604 ae E 1208 1611 FRT BLK 131 BETA COMPLETE Set of 4 1208 1612 REAR BLK 131 BETA _ 1486 1357 1208 1621 FRT SILVER PISTON SETS 1208 1622 REAR SILVER COMPLETE Q 1586 1357 120 AAE FRT BLK 131 amp 135 1286 1361 E So 4308 1311 FRT BLK Fig 73 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 9 REV I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS 120 Cylinder Front 4 1 8 Black 120 Cylinder Rear 4 1 8 Black 131 Cylinder Rear 4 5 16 Silver 135 Cylinder Front 4 5 16 Black 135 Cylinder Rear 4 5 16 Black 135 Cylinder Fr
19. he ring end gaps be sure to deburr the ring ends prior e gt to installation Cover cylinder and set aside as you proceed to step 5 8 4 Fig 19 Ring set Wash all piston rings in warm water and dish soap prior to installation on EXPANDER SPRING the piston OIL CONTROL RAIL Wear safety glasses while installing all piston rings Install the rings from the top of the pistons Take care not to scratch the piston as you install the rings Place a piston top end up skirt end down on your clean pad Select one set of rings A set consists of two oil control rails one expander OIL CONTROL RAIL spring One second ring and one top ring See Fig 19 Fig 20 Oil control rings Installation Oil Control Ring Sets See Fig 20 The oil control rails can be installed either way there is no top or bottom Install the oil ring expander spring Make certain the ends of the expander spring butt against one another and do not overlap See Fig 21 Work one of the oil ring rails down over the piston with your fingers It is okay to slightly twist the ring as you do this Place the first rail on the lower side of the expander spring See Fig 22 Position its gap about 90 degrees from where the ends of the expander spring meet Fig 22 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 6 REv I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2
20. hin film of the supplied assembly lube to the front and back of the piston skirt e Inspect the mating surfaces of the base gasket and cylinder to be sure they are clean e Gently slide the cylinder down until it seats on the base gasket e The base gasket normally has a little curl so check that the gasket is gt located on the dowels as you lower the cylinder into position Fig 50 ingen ring clip Fig 51 Verify fully seated 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 i No 1208 1352 REV 8 12 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS e Clamp the cylinder down so it will not move as you rotate the crank shaft See Fig 52 e Slide a two inch length of stiff tubing or other spacer material over a short head bolt Note Use a short 1 2 I D oil or gas hose e Thread the bolt onto one of the cylinder studs until the spacer is finger tight against the cylinder See Fig 53 e Installation Front Cylinder See Fig 54 Note Prior to front cylinder installation pour 1 3 of a quart of clean 20W 50 H D oil over the crankpin area See Fig 55 Rotate the crankshaft until the front connecting rod is at TDC See Fig 56 Front cylinder installation is precisely similar to the rear s There are a couple of differences in the parts The notch on the front cylinder spigot goes toward the rear of the
21. n e Wipe excess oil from the piston rings e Run the rings through your fingers to feel for any burrs NOTE If burrs are discovered see Appendix 1 pg 18 for instructions on deburring You must Wash rings after deburring e Lightly lubricate with clean H D 20W 50 oil and slip one piston pin into a piston either piston will do Fig 9 Fully seat left clip 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REV I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR Box 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS e Place a cylinder on the bench top end up e The cylinder s bore should be clean to the touch and lightly oiled See Fig 10 End Gap Measurement See Fig 117 Piston Ring end gap range Top ring 017 to 022 Second ring 022 to 030 Oil control rails 015 to 030 Record your end gap measurements in the chart on page below Tilt and start a piston ring into the bore The most common and perhaps easiest way to do this is to first insert the side of the ring opposite the gap Then flex each ring end into the bore Use your fingers to control twist as you insert the ring See Fig 12 e When the ring is in the bore use the piston to force it down the bore until the piston pin is slightly below the top of the cylinder See Fig 13 e Remove the piston e The piston ring is now square with th
22. nd show no signs of dirt e Dry with a low lint cloth or towel e Immediately coat the cylinder bores with a light film of clean H D 20W 50 oil to prevent rust e Clean gasket surfaces base and head with a lint free cloth and dena tured or isopropyl alcohol make sure you clean all oil from the gas ket surfaces Fig 30 Cleaning pad soap amp water STEP 7 Piston Cylinder Assembly Note Please read the following notes carefully e Piston Ring Orientation IMPORTANT JIMS 120 131 or 135 Race Kit cylinders each have two cutaways in their skirts 566 e No piston ring end can be allowed to drop into either of these cut 7 aways e If a piston ring end gets into one of the cutaways and the piston KEEP moves upward during installation the end may catch and destroy the IT ring CLEAN 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REv I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR Box 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS e If you follow our piston installation directions the piston rings will be protected by keeping the ring gaps out of the cylinder spigot cut aways See Fig 37 e Cylinder differences and orientation The front and rear cylinders are different Both cylinders have reduced fin width on their right sides to allow for the pushrod tubes e Both cylinders have notched skirts e The front cylinder
23. of its travel TDC Fig 46 Lube wrist pin 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 11 REV I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR Box 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS e Lubricate the wrist pin bushing with assembly lube See Fig 47 e Carefully position the cylinder over the rear studs so the short fins are on the right toward you The spigot bevel will be toward the front of the engine See Fig 48 CAUTION Be careful not to scratch the base gasket sealing surface on the bottom with the cylinder studs during assembly Be careful not to bend the cylinder studs during cylinder installation e Lower the cylinder assembly over the studs while guiding the rod into the piston e Align the wrist pin with the wrist pin bushing e Slide the pin through the rod until it is stopped by the left far piston pin clip See Fig 49 e Install the remaining pin clip Start one end of the clip into the wrist pin hole Use a hard plastic rod or wooden dowel to work the clip fully into its groove Note Be sure to wear your safety glasses when installing wrist pin clips See Fig 50 e Verify the clip is fully seated in its groove See Fig 51 Important Be very careful not to gouge nick dent or otherwise deform the corners of the wrist pin hole e Remove the material protecting the case bore e Apply a t
24. ont 4 5 16 Silver 135 Cylinder Rear 4 5 16 Silver 135 131 amp 120 Head Set Frt amp Rear Black 135 131 amp 120 Head Set Frt amp Rear Silver 120 Piston Set Std Size with Rings All Alpha s 120 Piston Set Std Size with Rings All Beta s 135 amp 131 Piston Set Std Size with Rings All Alpha s Dowel Pin Cylinder Top 1 4 x1 2 1286 1326 131 amp 135 Gasket Set Head 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 7
25. pecific to your application for general assembly procedures e Unwrap and work with the pistons over a padded surface A half dozen new clean shop towels under a T shirt makes a reasonable low lint cushion S55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REv I 8 12 No 1208 1352 A Division of Thiessen Products INC INSTRUCTION SHEET FOR BOX 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS e Always handle pistons with great care While they are capable of withstanding extreme acceleration loads they can also be destroyed by a two foot fall onto a hard surface e Piston ring end gaps must be checked and adjusted if required use a ring gap tool and do the work away from the engine Piston ring particles are very hard and should not be allowed anywhere near the open engine Make sure you wash your hands after adjusting ring gaps or doing any other grinding e Avoid the use of sandpaper Keep all abrasives away from your work area and the internal compo nents of your new JIMS 120 131 or 135 Race Kit e Do not use pressurized air to clean anything Its use virtually guarantees damaging particles will get into your new engine If at all possible use liquid cleaners soft brushes and clean lint free towels instead STEP 1 Piston inspection e There should be no dents dings or gouges on any surface of the pistons Pay particular attention to edges and corners especially t
26. r the edge of this piece and hold it in place with the pressure of your hand as you gently remove a bit of material with the file e Do not be tempted to do the work in the air using your hand as the vise e As you start to file be sure the file is at right angles to the end of the ring Make the angle between file and ring square from both the top and side See Fig 17 Fig 17 Square ring end 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 1208 1352 REV I 8 12 A Division of Thiessen Products INC INSTRUCTION SHEET FOR Box 2 120 131 OR 135 ENGINE ASSEMBLIES OR ENGINE RACE KITS STEP 5 Piston Ring Installation See Fig 18 Note The expander spring can be installed either way there is no top or bottom Use light pressure as you file just enough to keep it cutting Let the file do the work Clean the ring and re check the end gap often as you work especially with your first ring Deburr the piston ring ends you have modified A light back stroke of the file across a burred corner should knock the burrs down See Appendix One Page 18 Do not be tempted to use abrasives Your fine file is good enough When you have finished all the rings put the file away and thoroughly clean and lightly oil the piston rings Be especially careful to remove any magnet ic steel particles that may be clinging to the rings A clean damp cloth works well 4 If you had to adjust t
27. th room to work comfortably e Make sure the cylinder base gaskets are properly positioned Note Do not apply any sealant to gasket Note Oil return hole position in case make sure it lines up with the base gasket as pictured See Fig 44 e f you are using the recommended JIMS No 1022 Alpha or No 902 Beta Twin Cam Engine Stand or a similar stand we recommend you bolt it down before proceeding The engine is going to get taller and heavier and needs to be secured e Carefully shield the crankcase so foreign objects like a dropped piston pin clip cannot fall into the engine e You can slit and re install the original foam shields JIMS used to hold and isolate the rods This technique centers the connecting rod and makes cylinder installation a bit easier See Fig 45 e Other materials such as clean lint free towels can also be used Installation Rear Cylinder e Lay the rear piston cylinder assembly on its side e With the small spigot cutaway up Rotate the piston so the wrist pin hole aligns with the cutaway See Fig 46 e Gently push the piston down the bore until the pin hole is exposed enough to receive the pin e Pre lubricate the piston s wrist pin hole by inserting a lubed wrist pin with assembly lube into the pin hole Slide the wrist pin in until it bot toms out on the left side wrist pin clip and then remove the wrist pin See Fig 46 e Rotate the crankshaft until the rear connecting rod is at the top

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