Instruction Sheet For Tool #1409
Contents
1. No 1409 1IS REv N C 4 05 UJ INSTRUCTION SHEET FOR TOOL 1409 PARTS LIST o TITLE OR DESCRIPTION PART NUMBER 1 1 MOUNTING PLATE 1177 1 2 1 BASE PLATE 1177 2 3 1 ALIGNMENT PLATE CASE BORING TOOL EVO 1409 1 4 1 BORING HEAD BORING ASSEMBLY 1177 4 5 1 LOCATING PLATE CASE BORING EVO 1409 2 6 1 SUPPORT PLATE BORING ASSEMBLY 1177 6 7 1 SHIELDED BEARING 7 8 x 2 x 9 16 1640 2RS 8149 8 1 PULL OUT DOWEL 1 2 x 3 1 2 1685 6 3 8 16 x 1 SHCS 1686 2 1 4 20 x 1 SHCS 2133 4 DOWEL PIN 1 4 x 3 4 8093 2 BUSHING 502 I D x 75 O D x 75 LONG 1681 3 5 16 18 x 1 SHCS 2405 2 TOOL BIT AL CEMENTED CARBIDE 3 8 1688 6 1 4 28 x 1 2 SET SCREW 1689 2 WASHER 1 4 SAE 1683 1 1 4 20 X 1 3 4 SET SCREW 1679 1 1 4 20 JAM NUT 1682 1 1 4 20 x1 2 BHCS 8090 1 DOWEL PIN 1 2 x 3 1 2 1680 3 3 8 AN WASHER 1265 3 3 8 16 x 1 1 4 SHCS 1036 23 1 INSTRUCTION SHEET 1409 IS 1409 2 is not covered under warranty if locating plate displays cutter marks from improper adjustment 1688 Non serviceable wear item no warranty WARRANTY All JIMS parts are guaranteed fo the original purchaser to be free of manufacturing defects in material and workmanship for a period of six 6 months from the date of purchase Merchandise that fails to conform to these conditions will be repaired or replaced at JIMS option the parts are returned within2. Mount the boring assembly onto the engine case with 2 lubed 3 8 16 SHCS No 9 Make sure the boring assembly is sitting flush on the engine case Using a 5 16 allen wrench torque the mounting bolts to 18 20 ft Ibs Place the case boring fixture onto a drill press or milling machine table Center the shaft of boring head No 4 in chuck or collet NOTE If using a chuck be sure that the chuck jaws locate on the flats of the boring head shaft Tighten the chuck or collet depending on the machine being used and remove the wood block used to seperate the boring assembly Clamp the base No 2 to the drill press table using the provided holes if possible If you are unable to use the provided holes be sure to clamp the fix ture using C Clamps or comparible clamps Before running the machine lube the two guide dowels with a light oil and run the quill up and down to make sure the boring assem bly is not binding CAUTION DO NOT STRIKE CUTTERS AGAINST CRANKCASE When checking to make sure the tool action is correct be aware not to strike the cutters against the crankcase while the machine is not running Damage may result to the tool and crankcase NOTE If the cradle assembly is not sitting flat to the machine table adjust the table or head flat before clamping down the assembly Set the machines speed to approximately 600 800 RPM s Before running the machine make sure that the quill is at the top of it s travel S
3. case so either the Front or Rear cylinder deck is hori zontal and facing up Fig 3 Install 2 lubed 1 4 20 SHCS No 10 into the appro priate holes depending on the spigot bore you are modifying in the alignment plate No 3 as shown in Fig 2 Do not tighten Install 3 lubed 5 16 18 SHCS No 7 3 into the mounting plate No 7 holes marked with letter of the spigot bore you are modifying Using a 1 4 allen wrench snug all three 5 16 18 bolts then torque to 13 15 ft Ibs Once you have tightened the 5 16 18 bolts torque the 1 4 20 bolts to 90 120 ft Ibs using a 3 16 allen wrench 5 Installing cutters NOTE Boring head set up shown is for reference only Your set up will vary depending on cylinder bore diameter and cylinder manufacturer Instruction sheet is written for bor ing 3 5 8 bore cylinders Again if your cylinders are made from a different manufacturer or you are machining for other than a 3 5 8 bore you will need to calculate your cutter dimensions see set up sheet page 5 NOTE JIMS recommends removing no more than 125 on the diameter of material at a time Case machining may require more than one pass and set up of cutters to obtain the desired bore Once you have determined the cutter dimensions install the cutters in the boring head as shown in FIG 5 FIG 6 amp FIG 7 Using a 1 8 Allen wrench adjust the adjust ment screws No 1689 to set the cutters dimensions
4. rate will yield a cleaner finish until the boring assembly stop bottoms Note Place a 1 1 2 to 2 wood block out Shut down the machine and wait until it comes between boring assembly plates to to a complete stop Slowly retract the boring assem keep top plate from dropping bly until the cutters clear the case Hold the quill up and replace the wood block Remove the boring assembly from the case CAUTION DO NOT PUSH IN OR LIFT OUT CUTTER TOO FAST OR ABRUPTLY WHILE BORING DOING SO COULD RESULT IN DAMAGE TO YOUR WORK OR INJURY TO YOURSELF CAUTION BEFORE RE ASSEMBLY OF YOUR ENGINE MAKE SURE THE INSIDE OF THE CASE SPIGOT BORE AND ALL INTERIOR AND EXTERIOR POCKETS AND HOLES ARE FREE OF ANY CONTAMINANTS AND DE BURRED STOP DOUBLE CHECK AND THEN TRIPLE CHECK YOU DO NOT WANT ANY CONTAMINANTS LEFT INSIDE DOING SO CAN AND WILL CAUSE PPRE MATURE WEAR AND DAMAGE NOTE When re assembling cases tighten case bolts to factory specs except top center case bolt between cylin ders Install this bolt last after you have cylinders and heads installed and torqued to H D specs Apply Hylomar or equivalent sealer to shoulder of top center case bolt and torque to 50 90 in lbs maximum JIMS IS NOT RESPONSIBLE FOR YOUR WORK SO PLEASE USE YOUR BEST JUDGEMENT AND ALWAYS DOUBLE AND EVEN TRIPLE CHECK YOUR WORK DOING SO WILL HELP ENSURE A POSITIVE EXPERIENCE AND OUTCOME CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 5
5. 55 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 REV N C 4 05 No 1409 IS SET UP SHEET FOR 3 5 8 BORE A 220 I Rouen Er LD 155 B P oS BORING HEAD DIAMETER CYLINDER SPIGOT DIAMETER 3 45 03 87 Step 1 Measure your cylinder spigot diameter S and add 02 Step 2 Measure the boring head diameter T D OVERALL CLEARANCE as shown above Subtract boring head diameter S CYLINDER SPIGOT DIAM ETER from answer obtained in step 1 this is your 7 overall clearance D T BORING HEAD DIAMETER Step 3 Divide your overall clearance by 2 This C CASE BORING DIAMETER is your A dimension Step 4 Subtract 065 from your A dimension This is you B dimension Step 1 S 02 C 3 87 02 3 89 Step 2 C T D 3 89 3 45 44 Step 3 D 2 A 44 B 22 Step 4 A 065 B 22 065 155 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422
6. No 1409 IS REV N C 4 05 Evo EVOLUTION CASE BORING TOOL The JIMS EVO Case Boring Tool takes all the guess work out of boring EVO engine cases to accept up to 3 13 16 bore cylinders This tool is designed to be used in a heavy duty 15 drill press or milling machine Note Please read all instructions completely and thoroughly before performing any work IF YOU DO NOT KNOW WHAT YOU ARE DOING DO NOT DO IT No information in this instruction sheet pertaining to motorcycle repair is represented as foolproof or even altogether safe Some people can ruin a mechanic s vise with a tack hammer Even something safe done incorrectly or incompletely can and will backfire You and only you are responsible for the safety of your repair work and for your understanding and application with the use of repair equipment components methods and concepts Each and every step that this tool is designed to do must be carefully and systematically performed safely by you All information listed in this instruction sheet has been tested re tested and used daily in JIMS Research and Developement Department JIMS IS NOT RESPONSIBLE FOR THE QUALITY AND SAFETY OF YOUR WORK Follow instructions in H D Service Manual for removal of engine for your year and model With the engine removed from the frame and safely mounted in one of JIMS No 1006T motor stands follow the engine dissasembly instructions in the service manual includ ing re
7. from your calculations FIG 7 Use a caliper for accurate measurements Ensure that the cutters are held snug against the adjusting screws as the lock down screws are CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 2 No 1409 IS REV N C 4 05 SL INSTRUCTION SHEET FOR TOOL 1409 inish Cut Side Rough Cut Side 03 Step 2 PLC No 1689 Tighten these screws first Tighten these screws second LOCK DOWN SCREWS tightened Torque the lock down screws in order shown FIG 7 to 90 in lbs to secure the cutters in place WARNING If cutters are set beyond 4 09 the cutters may come in contact with the I D of the locating plate 1409 2 voiding the warranty of the 1409 2 Evo Case Boring Tool Setting Spigot depth Measure the length of your cylinders spigot and add 03 06 This will be the depth you need to bore your cases to Example If your spigot is 1 600 add 03 06 and your bore depth will be 1 630 03 00 Using a 1 8 allen wrench and a 7 16 wrench set the boring depth to the dimension as calculated above as shown in Fig 8 Be sure to measure from the finish tool cutter to the bottom of the locating plate No 5 Place a 1 1 2 2 wood black between the boring assem bly plates
8. moval of the cylinder studs Mask off all bearings and oil holes to prevent chips from contaminating those areas Bolt cases togeth er with H D hardware using sequence and torque specs stated in H D service manual except top center case bolt between cylinders Install this bolt last and torque to 50 90 in lbs maximum Read Step 1 Tools required for boring 1 8 3 16 1 4 amp 5 16 Allen wrenches 7 16 Wrench Calipers Torque wrench 1 2 socket Cutting Fluid Drill press or Milling machine 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422 1 REV N C 4 05 No 1409 IS SL INSTRUCTION SHEET FOR TOOL 1409 INSTRUCTIONS Prior to boring your cases you will need to determine the Rockwell hardness your case hardware is If your hardware is under 30 RC you may bore your cases with your case bolts installed If your hardware is harder than 30 RC you will need to clearance the top center and top rear case bolts See Fig 4 Damage may occur to the tool cutters if the above instructions are not followed JIMS is not liable for damaged tool cutters When you bore your cases for larger bore sizes you may break out the tappet machining oil hole See Fig 1 You may need to re plug and seal as required if disturbed Assemble Engine Cradle No 7 No 2 No 3 as shown in Fig 2 Make sure all mating surfaces are clean Place the Engine Case in the Cradle and rotate the
9. tart the machine to make sure that the head and or table are not vibrating If no vibrations occur the RPM s may be increased If vibrations occur the RPM s will need to be reduced JIMS has found that 600 800 RPM s is CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422 3 REv N C 4 05 SOW 4 INSTRUCTION SHEET FOR TOOL 1409 the best when using a drill press although results can vary from your set up and machine Not all drill press Depth adjustment es and milling machines are made the same No 1177 1S screw CAUTION It is recommended that you use a well maintained and dependable machine for this type of work Ifyou use a drill press or milling machine that is not up to normal standards you risk the chance of damage to your work and injury to yourself This is why we recommend you use a safe and well main taned drill press or milling machine Make sure your machine is in good working order before starting any project ALWAYS WEAR SAFETY GLASSES OR OTHER FACE AND EYE PROTECTION SUCH AS FULL FACE SHIELD JIMS is not responsible for damage injury or your work 10 Make sure your eye and or face protection is on Double check to make sure you followed the proce dures correctly and your work is properly clamped to the table Start boring with slow even pressure while applying cutting fluid slower feed
10. the six 6 months warranty period or within ten 10 Days thereafter In the event warranty service is required the original purchaser must call or write JIMS immediately with the problem Some problems can be rectified by a telephone call and need no further course of action A part suspected of being defected must not be replaced by a dealer without prior authorization by JIMS If it is deemed necessary for JIMS fo make an evaluation to determine whether the part is defective it must be packaged properly to prevent further damage and be returned prepaid to JIMS with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem 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 person or organization JIMS shall have no obligation if a JIMS part becomes defective in whole or in part as a result of improper installation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the part JIMS shall not be liable for any consequential or incidental damages resulting in the failure of a JIMS part the breach of any warranties the failure to deliver delay in delivery delivery in nonconforming condition or for any o
11. ther breach of contract or duty between JIMS and a customer JIMS parts are designed exclusively for use in HarleyDavidson motorcycles JIMS shall have no warranty or liability obligation if JIMS part is used in any other application Any parts or tool replaced by JIMS becomes the property of JIMS and will not be returned under any circumstance 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 6
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