TECH: S&S 107″ Cam & Cylinder Kit (Intro)

Our opening shot shows our 2012  Heritage Softail up on Kenny’s lift with the exhaust and top end removed. The gas tank is lifted, and the gearcase section is emptied, except for the oil pump. The pinion shaft runout has also been checked and is below the required 0.003" maximum

Our opening shot shows our 2012
Heritage Softail up on Kenny’s lift with the exhaust and top end removed. The gas tank is lifted, and the gearcase section is emptied, except for the oil pump. The pinion shaft runout has also been checked and is below the required 0.003″ maximum

Our Heritage gained 28 hp and 27 ft-lbs. of torque!

Captions and photos by Chris Maida

Harleys are built to cover some serious mileage. But even the most babied engine is going to need a top end rebuild at some point, although readers of this magazine probably don’t fall into that category. When it comes to the world of Harley-Davidson, anything you want to do has a bunch of different options. So when our high-mileage 2012 TC 103 Heritage Softail started hinting at a new top end, we examined a few of the options. The first, of course, is to rebuild it back to stock specs. Option B is to increase the engine’s displacement and throw in a hotter set of cams. Okay, so our only real options were how big and how hot.

Since the still-young Heritage sees lots of time out on the road, reliability and manners are just as important as power output. For that reason, we turned to the legendary S&S Cycle in Viola, Wisconsin, for a 107″ cylinder kit (#910-0479/$929.95) and its gear-driven HP103GE Easy Start camshafts (#330-0354/$824.95). The wrinkle black, 11-fin cylinder kit fits 2007 and later Big Twins. (No worries Twin-Cooled model owners! S&S has a kit for you, too.) The 3.937″-bore cylinders are the largest size that can fit in stock, unmodified engine cases. That means no machining is necessary, and you can achieve the maximum bore size with minimal effort. The S&S cylinders are also the same height as stock, which, again, makes this an easy install. The centrifugal-cast, gray iron liner and the included 4.937″, 4-3/8″ stroke CP pistons provide excellent wear and noise characteristics and performance. The fin area is increased for better cooling performance over stock cylinders. The cylinders are also available in a silver powdercoated finish, which also matches stock H-D engine finishes. The kit includes gaskets and piston rings, wristpins, and wristpin clips.

With the Heritage Softail’s new displacement, a set of performance cams is necessary to get the most out of the Beta motor. The HP103GE Easy Start camshaft is what S&S calls a “horsepower cam.” However, different intake and exhaust systems can turn the engine into more of a torque monster with a bit less top end. These are actually bolt-in cams, so no modifying of the cam compartment is necessary, a recurring theme with this S&S project. Since the heads and rocker boxes were off the bike when we installed the cams, there was no need to even order a set of pushrods; the stock ones slid right back into place! Of course, besides their high-performance profile, these are gear-driven cams. This means no more chain tensioners (great news for this high-mileage rider), but it also means a longer lifespan for the parts, and a more secure connection inside the engine’s bottom end.

For a tuner, we went with TechnoResearch’s Harley-Davidson (Delphi) 2 (#TR200053-M01-U/$638) tuner. We’ve worked with the TR quite a bit on a handful of different bikes, and it delivers flawless tuning every time. The USB port key allows for multiple reflashes on a single motor­cycle. Our choice for this build is a TechnoResearch DirectLink Flash Tuner. This module allows you to alter the fuel table, spark advance table, and other calibration table values. You can also get real-time fuel table and spark table cell tracing. The DirectLink (Flash-Tuner) communicates directly to the stock EFI module, so there’s no wiring changes or additional modules to install.

As reliable and easy to install as the S&S Cycle cylinder and cam kits are, they provide some majorly impressive numbers on the dyno. The 103″ Softail’s baseline runs yielded 68.9 hp and 87.6 ft-lbs. of torque. After tuning, the Twin Cam puts out 97 hp and 114.9 ft-lbs. of torque! That’s a 40 percent increase in horsepower and a 31 percent increase in torque. What’s really cool is that the same S&S kits also work on 96″ Twin Cams, delivering the same final output numbers. So if you’ve got a 96-incher, you can expect those percentages to be even higher, which makes your dollar-to-power ratio even higher as well!

When it comes to high-performance Harleys in the New York area, Rosa’s Cycle is the place to go. Andrew Rosa lent his skill and expertise to our S&S-equipped Heritage Softail, and the power numbers speak for themselves. Follow along as he takes us step by step in the accompanying photos and captions to see exactly how the experts do it. AIM

……….

Sources

Rosa’s Cycle Shop
631/424-4955
RosasCycle.com

S&S Cycle Inc.
866/244-2673
SSCycle.com

TechnoResearch Inc.
248/658-1800
TechnoResearch.com

Like what you see? The full article with all 25 steps, dyno chart, Tips & Tricks, and tools needed, is in American Iron Magazine issue # 324, NOW ON NEWSSTANDS! To order a back issue of this or any other issue of American Iron Magazine, visit Greaserag.com.
 
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AI Garage Install: Daymakers (Intro)

01 Opener_7633

The washers that come with the Daymaker headlight are only used with the Road Glide installation.

The washers that come with the Daymaker headlight are only used with the Road Glide installation.

Night And Day

Harley-Davidson Daymaker LEDs

text and photos by Tricia Szulewski

Dave Buerk isn’t just a fan of motorcycle safety; he’s actually a chief instructor for the Connecticut Rider Education Program (CONREP). To say that he does everything possible to make his ride a safe one is a monumental understatement. So when Harley came out with its vastly improved LED lighting for its Project RUSHMORE 2014 baggers, Daymaker, Dave read the reviews and promptly ordered a replacement headlight and fog lights for his 2009 Harley-Davidson FLHTCU Ultra Classic Electra Glide. Specifically, he purchased the Daymaker Reflector LED headlight (#67700173/$424.95) and Daymaker Reflector LED auxiliary lights (#68000075/$359.95).

Step 1: Dave removes the accessory chrome headlight trim ring with a Phillips screwdriver and puts it aside for reuse.

Step 1: Dave removes the accessory chrome headlight trim ring with a Phillips screwdriver and puts it aside for reuse.

Dave is an exceptional rider, admirable coach, and all-around good guy. But a handy wrench, he is not. That said, he tackled the installation of the Daymakers like a pro. Armed with only the few tools needed and a well-lit garage, Dave had the new plug-n-play lighting installed and running in about an hour and a half. And that includes time spent cleaning all the exposed nasty dirt when taking parts off the bike, pausing for pictures, and documenting each step.

The Daymaker LEDs imitate natural daylight by producing a bright-white color. Comparing them to the stock halogens, it’s a no brainer how much cleaner the light is. The headlight works by distributing two separate rays of light through two D-shaped lenses. The low beam shines light directly in front of the bike while the other projects a super-bright, focused high beam.

01 before-after

Before (left) with Daymakers (right)

 

To read the full 21 steps on how Dave Buerk installs Harley-Davidson Daymaker LEDs, the issue is on newsstands NOW!

 

For a digital delivery, click here.

 

AI Garage 1930s Harley VL and Sidecar Sneak peak (Video)

AI-Garage logo 1The crew at American Iron Magazine recently rescued this 1930s Harley VL and sidecar, which had been sitting in a basement for 10 years, and brought it over to Retrocycle to get her all back up to snuff for a story in a future issue of American Iron Garage, the all-tech, all-DIY Harley magazine special.

“It’s over painted, over chromed, and has wrong year parts,” says American Iron Magazine/Motorcycle Editor-in-Chief Buzz Kanter about the VL. “It hasn’t been started in years. We do know the motor is a 1930, but there are questions about what the other parts are.”

The bike will be featured in the Summer issue of Garage. The article will show readers how to get an old bike back on the road by noting what the crew at Retrocycle do to make this classic motorcycle ridable again. The Summer issue, the second of three Garage installments for 2015, hits newsstands 6/15.

The Spring issue is currently on newsstands and is also available via digital delivery on Zinio.com.

Watch the video below as Buzz shows us the current state of the bike.

Retrocycle is located at 1 Mars Ct. Unit 3, Boonton, NJ 07005.

Burly Slammer Install Video

(Click the Headline to watch)

Keep checking back to www.aimag.com – we’re going to be posting more tech and how to – everything from motor work to washing your bike!

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