Donny’s Unauthorized Technical Guide to Harley-Davidson, 1936 to Present

Winner of the 2012 International Book Awards. Chapter I: March 1998: Introduction of the Twin Cam The Secrecy Agreement Ya’ll Ain’t Gitten in der Boy! Dats were da secret stuff is. The Fathead Name 1919 to 1929: The First Twin Cam H-D Technical Heaven An Overview of the Twin Cam 88 Fathead Twin Cam Heads The Barrels (Cylinders) Twin Cam Hypereutectic Pistons Twin Cam Engine Cases The TC88 Flywheel (Crank) Assembly Curiosity didn’t Kill this Cat: the Hollow Crank Pin Connecting Rods Dual Cams and Timing Drive Chains Valve Train Tappet Hydraulic Lifters and Pushrods Oil Filtration The TC88 Oil Pump Twin Cam Engine Oil Feed and Return The Twin Cam Breather Vent Twin Cam Engine Covers and Gasketing Engine Compartmentalization Defeating Noise The Transmission Housing: Structural Strength Heat Treating Primary Gear Ratios Single Fire Ignition Spark Map CV Kehein Carbureted Ignition Magneti-Marelli Fuel Injected Ignition Delphi Fuel Injected Ignition Electronic Control Module Fuel is Pressure Delivered Evolution and Twin Cam Engine Shared Parts Designing the Twin Cam 88 Building the 1999 Twin Cam 88 Screamin’ Eagle is Flying High Milwaukee’s Secret Race Facility The $1,000 Lunch The Buell The Harley Fantasy Trip 1999 The Year 2000 Twin Cam 88B Chapter II: 1999 to 2000 Teething Problems Donny, What Went Wrong? Service Recalls Pinion Shaft Noise Whistling Pinion Bearing Cam Bolt Problems Cam Sprocket Keyway Cam Support Plate Bearings Rear Cam Ball Bearing Breakdown Cam Chain Tensioner Stress H-D Corrected the Ball-Bearing Debacle Quickly The Engine Build Date Determines the Rear Cam Bearing Defect Reading the Oil Filter for Engine Damage Fixing the Rear Cam Bearing Problem at the Factory Identifying Carbureted and EFI Camshafts What causes the Engine to Stop? Bearing Damage Cleanup Timing Compartment Debris The Mystery of Traveling Debris Unwinds Researching Service Recalls for all Years Chapter III: Timing Chest Breakdowns and Solutions Where Does the Noise Come From? Pushrod Engines 101 The Belt Drive Color-Coded Cam Gear Sizing H-D Engine Design Forces Valve Train Inertia and Momentum The S&S Gear Drive Solution The Harley-Davidson Solution Moment Arm Force Creates a Problem The Spintron Dynamometer Laser Video of Internal Engine Running 1999-2006 Cam Gear Drive Installation Gear Drive Specifications Chapter IV: Harley Oil Leaks: Marking its Spot The Shovelhead Blues Life Inside an Engine The Rotary Breather Gear Puking Gravity Feed Oil Tanks Twin Cam Pinion Bearing Twin Cam Sprocket Shaft Bearing(s) The Hollow Crank Pin Twin Cam Oil Pump Seepage at Rest Defining Blowby, Oil Carryover, and Venting Enlarging the Drain Hole The Real Problem: Disrupted Oil Return Digital Signal Processing Dynamometer The S&S “Reed Valve” SolutionThe TP “ProVent” Solution The Flathead 80: A Study in Pollution The Twin Cam 3-Stage Venting SystemThe Doherty “Myst” Free Fix The 2007 Harley Oil Pump Scavenging Fix Softail Oil Tank can be Blowby Cause Chapter V: Twin Cam Lubrication Grease Crude Oil Fractionalization Creates Many Products Oil has Four Jobs Fossil, Synthetic, and Semi-Synthetic Oil Syn 3 Oil vs. using Gear Oil in H-D Transmissions Synthetic Oil Disadvantages Advantages of Synthetic Oil The Mythological Bearing Skid Oil Change Intervals Oil Additives Airplane Oil in a Harley-Davidson Heat is the Enemy Two Modifications for Cooler Twin Cams Oil Coolers Reading the Oil Can Engine Oil Ratings The Law on Voiding Warranty Oil Recommendations for the Twin Cam Oil Pressure Filtering the Oil The Twin Cam Oil Pump Comparison: 1992 to 2000 Evolution Oil Flow Twin Cam Engine Oil Feed Twin Cam Engine Oil Return The Twin Cam Breather System Chapter VI: Twin Cam Heads: Deficient Air Flow Mom-and-Pop Dealerships The Big-Bore Kit Massaging Stock Twin Cam Heads Performance and Efficiency 101: Cutting the Valve Seat Performance and Efficiency 102: Valve Seat Fitment Polishing Head Ports Lighter Valve Train TC96, TC103, CVO 110 Head Flow Chapter VII: Retrofitting the Twin Cam Engine into Old Style Frames The Offset Twin Cam Engine TC88A Engine Installation in an Evolution Frame Wiring and Electrical Chapter VIII: Twin Cam Fuel Delivery Gasoline for the Twin Cam Octane Gasoline Additive Effects on a Harley-Davidson Fuel Tank Cleaning, Sealing, and Storage Primer for Gas Cap(s) History Evaporate Gas California (CARB) Vapor Re-burning The Vapor Valve Continuous Venting: 1992 to Present Diagnostic Skills: Gas Overflow Vacuum Operated Gas Valve (Petcock) Fuel Tank Venting Air Filtration Carburetion Types and Principles Basic Carburetor Tuning Screamin’ Eagle 40mm Carburetor The CV Kehein Carburetor: 1989 to 2006 Front View: CV Kehein Carburetor: 1989 to 2006 Rear View: CV Kehein Carburetor: 1989 to 2006 Left-side View: CV Kehein Carburetor: 1989-2006 Tuning the CV Kehein Carburetor Troubleshooting the CV Kehein CV Kehein Jet Sizing CV Kehein 1989 to 2006 Jet Part Numbers CV Kehein Carburetors: 1989 to 2006 Spark Plug Color Tuning the CV Kehein Managing the engine The ECM: Electronic Control Module EFI Components Pressurized Fuel Delivery EFI Specialty Tools EFI Cylinder Synchronization EPA Perfection: Stoichiometric Air Fuel Mixture Early CVO Problem is Oil Seepage not a Compression Leak Controlling Stoichiometric Heat Chapter IX: Synchronizing Ignition and Fuel Delivery A Brief History of Modern Harley-Davidson Ignitions Mechanical Points/Condenser Ignition: 1970 to Early 1978 The First Electronic Ignition: 1978 to Early 1979 V-Fire II Electronic Ignition: 1980 to 1983 V-Fire III Electronic Ignition: Evolution 1984 to 2000 The V-Fire III Engine Management System The Beginning: ECM Fuel-Spark Map for EFI The (EMS) Engine Management System (2009) 2006 Dyna: Stoichiometric Heat Management 2009 Heat Management System: Engine Idle Temperature System Chapter X: The Controversial Harley 6-speed Transmission Horsepower and Torque Mismanagement Primary Gear Reduction Ratio The Secret Comparing 6-Speeds The BAKER 7-Speed TC96 Transmission Sprocket Change Limitations Secondary Drive Gear Ratios Final Drive Gear Ratios Breaking in my 2007 Street Glide Internal Transmission Ratios Connecting the Powertrain 6-Speed Noise Clutch Cable Ease Helical and Spur Gears Engine Lugging The Throwaway Harley Shift Clutches, Dog Rings & Gear Dogs The S&S 6-Speed The BAKER Solution The IDS Fix or is that an Enhancement? Chapter XI: Twin Cam Electrics Troubleshooting Shortcut: Check the Grounds The Evolution of Circuit Breakers and Fuses Boosting (Jump Starting) a Dead Battery Battery Care Maintenance Free Battery (VRLA or AGM) Wet (Conventional) Battery Replacement Specific Gravity Battery Recharging Sulphation Battery Storage Amp-hour Rating Testing a Maintenance Free Battery The Ultimate Check: Load Testing Battery Life Expectancy Twin Cam Charging System Troubleshooting the Twin Cam Charging System Twin Cam Starter System The Starter Motor Calculating Starter Motor Power Starter Solenoid Troubleshooting the Evolution/Twin Cam Starting System Starter Clutch & Solenoid Repair Kits Electrical Future Begins in 2011 2011 Digital Technician: Modern Diagnostics Chapter XII: The 2007-to-present TC96 Chapter XIII: 2008 Model Changes Chapter X: 2009 Model Changes Chapter XV: 2010 Model Changes Chapter XVI: 2011 Model Changes Chapter XVII: Why is the Twin Cam Superior? Chapter XVIII: Riding the Post WWII Baby Boom Crash Chapter XIX: Deciphering the Twin Cam Serial Numbers