INSTRUCTIONS - Revolution Performance

1 INSTRUCTIONS2 Table of Contents4 NSC Characteristics and Nuances Initial Break-In Guidelines5 Cylinder Head Torque INSTRUCTIONS Cylinder/Piston Preparation6 Cylinder/Piston Installation7 Piston Ring Installation8 Checking Piston Deck Height9 Twin Cam /Evo /XL/Buell Case Boring Instructions10 Adjustable Push rod Installation Instructions11 Valve to Valve Tolerances12 Preventing Gasket Seepage Around Cylinder/Case Locating Dowels13 Intake Manifold Fitment Issues and Remedies14 How to Clearance Rocker Boxes for Roller Rockers and Larger Diameter Springs15 Determining Case Clearance for Larger Cams3 Revolution Performance was founded with two major goals in mind to go that extra mile and provide a superior level of customer service and support in the V-Twin Performance industry and to provide an outlet for a complete line of Performance components and services for Harley-Davidson Evo Big Twin and Twin Cam 88 as well as Buell American Motorcycles.

2 Revolution Performance carries a full line of aerospace aluminum alloy cylinders for Harley-Davidson and Buell American motorcycles as well as a complete inventory of Performance components to make your package work together. The staff at Revolution Performance brings a great deal of engine development experience to the table not only in several disciplines of professional racing but in street applications as well. From the individual who wants a one stop shop for all his Performance component needs to the shop owner seeking a reliable supplier of parts and services we are here to help. We also have a long history in professional race team support so not only can we assist in your R&D efforts, but, with our manufacturing capabilities, we can make your ideas reality with the utmost in security.

3 We use our expertise to help OEMs produce better racing components as well as parts that make it to the street. We work closely with premier engineers at both Harley-Davidson and Buell on many of their projects and our customers receive that same level of dedication. Our commitment to providing the best components and customer service in the industry is a basis for everything we do so that the customer can meet any realistic Performance goal that they set for Characteristics and NuancesSome concerns regarding the nature of plated bores has recently come to our attention. This article is meant to quell some of the concerns regarding the appearance of the bores immediately post initial start-up. There is a chance upon initial start up that cylinder streaking can occur due to ring to cylinder wall contact.

4 This will manifest itself as dark gray or even black longitudinal striping in the bore. It can even feel like it has texture to it. This can be anywhere in the circumference of the bore and run from the top of the stroke to the bottom. This is not detrimental to the engine and has no influence on long term reliability of the engine. If measured with a dial bore indicator the depth of this will not exceed 1/10,000th of an inch and in no way affects ring seal. We have done extensive testing to not only determine the effects of the streaking, but also the long term viability of the bores after it occurs. After performing a battery of tests following a purposeful inducing of streaks in the bore including, but not limited to, leak down and measuring plating thickness it was determined that not only was this inconsequential but that eventually the markings wore away to only a light haze.

5 Make no mistake, when this phenomenon occurs the plating is NOT coming off the cylinder wall. Should this condition arise please perform leak down testing prior to calling. Initial Break-In GuidelinesNow that you have your engine assembled and ready to fire, there are a few initial start up guidelines that we encourage you to follow to insure proper break in and long life for your engine. Our research has determined that at least three initial heat cycles produces the best all around results for initial break in and ring seal. A heat cycle consists of starting the engine and bringing it up to normal operating temperature then killing it and allowing it to cool to ambient temperature. This allows the material to stabilize without insult and promotes a much smoother overall break in the heat cycle procedure is performed the engine is not broken in but is ready to be ridden.

6 We highly recommend that you ensure that your machine is in an adequate state of tune before riding. A trip to your local dealer or service shop is recommended for confirmation if you have any doubts. Again, through extensive research, we have determined that the first fifty miles are the most crucial with the next four hundred fifty miles following a close second. Unless you have completely rebuilt the lower end with new bearings and components five hundred miles are sufficient. Our recommended behavior for break in is to not exceed 2500 to 3000 rpm for the first fifty miles with varying throttle input and no prolonged idling of the engine. A nice twisty back road works great to encourage this technique. At the end of the first fifty miles change your oil and filter to insure that all initial break in particles and fluids are removed.

7 For the next four hundred fifty miles 3000 to 3500 rpm is a good limit and varying throttle input, especially on long highway trips, is encouraged. After five hundred miles of riding you should change your oil and filter again using a synthetic lubricant and a quality should note the level of oil in your tank to insure that oil consumption during break-in has not been excessive. A small amount of oil consumption during this time is normal but should stabilize following break in. At 2500 miles oil and filter should be changed again and this routine can be followed for the life of your Head Torque InstructionsThe first step in any engine assembly process is the assurance that all components are cleaned thoroughly and laid out in an organized assembly pattern.

8 Once this is done the case deck area should be cleaned of any debris or preexisting gasket material. It is best to wipe the case deck surface with a shop towel soaked with brake or contact cleaner so as to ensure a clean and dry gasket surface. After the cylinders and pistons have been installed onto the engine, the cylinder deck surfaces must be wiped with brake or contact cleaner. Be certain that the supplied cylinder locating dowels have been installed before installing the head gasket. The enclosed head gasket is composed of the finest materials available and by design does not require the use of O-rings around the locating dowels. Install the cylinder heads as per your service manual. Place a small amount of machinist s oil or synthetic lubricant on the head bolt threads and on the underside of the head bolt flanges to ensure accurate torque.

9 Torque in manufacturer s sequence starting at 15 ft/lbs and increase by increments of 5 ft/lbs in to a final torque of 42 ft/lbs. Once final torque is achieved, go around in sequence at 42 ft/lbs at least three rotations to ensure all stud stretch is removed. At this point you are ready to finish your reassembly as per your factory service manual guidelines. Any time you feel that you need support or assistance before or during the installation of any components please don t hesitate to call our technical department and we will stay with you until you are comfortable! Cylinder/Piston PreparationCleaning your cylinder properly is a critical part of engine assembly. Any dirt or foreign material in the bore can cause serious damage to the plating or at the very least inhibit piston ring break-in.

10 This can and probably will result in loss of compression, increased blow-by and a drop in horsepower and torque. We recommend that you use HOT soapy water for the initial cleaning of the bore and brake cleaner or a good contact cleaner for the bore area. Spray the bore liberally with the solvent and wipe clean. Repeat this until you see no visible dirt or material on your rag (preferably a white terry cloth or a blue disposable shop towel). Install the supplied locating dowels in their respective receptacles by lightly tapping them into place with a plastic or rubber mallet. DO NOT force them as cylinder spigot damage can occur. Clean rings with brake cleaner or contact cleaner before installation. Wipe the entire bore as well as the piston skirts and rings lightly with quality synthetic oil and assemble per our piston and cylinder assembly INSTRUCTIONS .