101 Harley-Davidson Twin Cam Performance Projects

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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.

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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.

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Product Details

  • ISBN-13: 9780760316399
  • Publisher: Motorbooks
  • Publication date: 2/28/2005
  • Series: Motorbooks Workshop Series
  • Edition description: First
  • Pages: 256
  • Sales rank: 963,044
  • Product dimensions: 8.50 (w) x 11.12 (h) x 0.75 (d)

Meet the Author

Mark Zimmerman is the Technical Editor of Motorcycle Cruiser magazine, and a contributor to Classic Bike Guide magazine. He lives in Danbury, Connecticut.

Jeff Hackett has been photographing motorcycles for magazines, books, and calendars for 19 years. He lives outside New Haven, Connecticut.

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Table of Contents

Preface and Acknowledgments 7
Section 1 Work and Tools 8
Prep 1 The Work Area 9
Prep 2 Work Practices 10
Prep 3 Tools 12
Section 2 Simple Maintenance 17
Project 1 VINs and Engine Case Numbers 18
Project 2 Performing the 10,000-Mile Service 21
Project 3 Lubricating Cables 23
Project 4 Changing the Engine Oil and Filter 25
Project 5 Changing Transmission and Primary Oil 27
Project 6 Servicing the Air Cleaner 29
Project 7 Choosing, Reading, and Replacing Spark Plugs 30
Project 8 Inspecting and Adjusting the Rear-Drive Belt 33
Project 9 Checking and Adjusting the Primary Chain 35
Project 10 Replacing Brake Pads 37
Project 11 Adjusting the Clutch 39
Section 3 Intake and Exhaust 41
Project 12 Installing a Screamin' Eagle Air Cleaner 42
Project 13 Installing an S&S Air Cleaner 44
Project 14 Rejetting the Stock CV Carb 46
Project 15 Installing a Dynojet Thunderslide Kit 49
Project 16 Installing an S&S Super E/G Carburetor 52
Project 17 Installing a Performance Intake Manifold 55
Project 18 Replacing the OEM Vacuum-Operated Petcock 57
Project 19 Understanding the Twin Cam EFI System 59
Project 20 Installing a Screamin' Eagle EFI Race Tuner 62
Project 21 Installing and Adjusting the Power Commander IIIr 65
Project 22 Installing a Performance Exhaust System 68
Section 4 Suspension and Chassis 72
Project 23 How to Fix Clunking Forks 73
Project 24 Installing a Cartridge Fork Emulator 75
Project 25 Lowering Front Forks 78
Project 26 Installing New Fork Springs 81
Project 27 Swapping the Shock on a Springer 83
Project 28 Adjusting Front and Rear Preload (Sag) 85
Project 29 Lowering the Rear of a Softail and Installing New Rear Shocks 87
Project 30 Lowering a Twin Shock Rear End 89
Project 31 Servicing Rubber Engine Transmission Mounts 91
Project 32 Installing Rear Air Shocks 92
Section 5 Tires, Wheels, and Brakes 94
Project 33 Balancing Wheels 95
Project 34 Building and Maintaining Wire Wheels 97
Project 35 Servicing the Brakes-Changing the Brake Fluid 100
Project 36 Installing Braided Brake Lines 102
Project 37 Upgrading Your Brake Discs 105
Project 38 Upgrading Calipers 107
Project 39 Changing Wheels 109
Project 40 Checking and Replacing Wheel Bearings 112
Section 6 The Engine 113
Project 41 Breaking in a New Engine 114
Project 42 Dyno Tuning an Engine 116
Project 43 Installing Adjustable Pushrods 119
Project 44 Installing Custom Lifter Covers 121
Project 45 Installing Roller Rocker Arms 123
Project 46 Installing High-Performance Valve Springs 125
Project 47 Installing TP Pro-Vent Rocker Boxes 128
Project 48 Installing High-Performance Heads 130
Project 49 Checking Combustion Chamber Size 133
Project 50 Claying High-Compression Pistons 136
Project 51 Installing a 95-Cubic-Inch Kit 140
Project 52 Installing a Custom Cam Cover 143
Project 53 Installing an Andrews Camshaft Sprocket 145
Project 54 Replacing the Rear Camshaft Ball Bearing 147
Project 55 Replacing the Inner Camshaft Bearings 150
Project 56 Installing High-Performance Cams 152
Project 57 Installing S&S Gear-Driven Cams 156
Project 58 Installing a Delkron Camshaft Support Plate 159
Project 59 Blueprinting the Engine 161
Project 60 Balancing the Engine 163
Project 61 Installing a Stroker Kit 165
Project 62 Servicing the Breather Assembly 169
Section 7 The Engine Oil System 172
Project 63 Installing an Oil Cooler 173
Project 64 Installing an S&S Crankcase Breather Valve 175
Project 65 Aligning a Twin Cam Oil Pump 177
Project 66 Installing a Feuling Oil Pump 179
Section 8 The Drivetrain 181
Project 67 Installing a Hydraulic Clutch Actuator 182
Project 68 Installing a Rivera Pro Clutch 184
Project 69 Installing a Barnett Scorpion Clutch Spring Conversion Kit 187
Project 70 Installing a Primary Chain Tensioner 190
Project 71 Installing a Balance Masters Kit 192
Project 72 Installing a Primary Belt Drive 194
Project 73 Installing a Transmission Pulley 197
Project 74 Replacing the Drive Belt 199
Project 75 Swapping to a Custom Sprocket 200
Project 76 Installing a Rear Drive Chain 201
Project 77 Installing a Custom Tranny Side Cover 203
Project 78 Installing a BAKER Reverse Shifter Assembly 205
Project 79 Installing a Six-Speed Gear Set Kit 208
Section 9 The Electrical System 212
Project 80 Installing Aftermarket Digital Gauges 213
Project 81 Choosing High-Performance Ignition Wires 215
Project 82 Installing a High-Performance Starter 216
Project 83 Maintaining Your Charging System 217
Project 84 Installing a Screamin' Eagle Adjustable Map Ignition System 219
Project 85 Installing an Aftermarket Ignition 222
Project 86 Replacing the Thermometer with an Oil Temperature Gauge 224
Project 87 Upgrading the Horn 225
Project 88 Troubleshooting the Electrical System 226
Project 89 Upgrading Your Headlight 228
Project 90 Hiding Wiring in the Handlebar 229
Section 10 Personal Touches 231
Project 91 Detailing Your Bike 232
Project 92 Custom Turn Signals 234
Project 93 Swapping Taillights 236
Project 94 Fiberglass Repair 238
Project 95 A Primer on Paint 241
Project 96 Paint Repair 242
Project 97 Installing Chrome Handlebar Control Pods 244
Project 98 Selecting and Changing Handlebars 246
Project 99 Installing Forward Controls 248
Project 100 Selecting and Changing Seats 249
Project 101 Applying Coatings 251
Sources 254
Index 255
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Customer Reviews

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Sort by: Showing all of 2 Customer Reviews
  • Posted December 4, 2009


    I purchased this because I wanted to start doing the service maintenance on my 2009 Road Glide. When I went to B & N I looked up the oil change section as well as primary and tranny oil change. It had pictures and since I had never done this before, I didn't know better. When I looked at my bike, nothing matched the pictures. The illustrations in the book seem to be from 30 year old Harleys. To top it off, on most of the other "projects" they refer you to the Harley Davidson shop and service manuals any way. I cannot believe Mark Zimmerman would sell out to put his name on this piece of garbage.

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  • Anonymous

    Posted December 11, 2009

    No text was provided for this review.

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