[Jonny Bravo]

@luky13 : I have seen so many bike building progs on Discovery Turbo but its a delight to see one such making in my own country ! Go baby Go ... you will surely inspire a lot more to follow your footsetps to accomplish their dream buildoffs !

[luky_13]

Originally Posted by Jonny Bravo

@luky13 : I have seen so many bike building progs on Discovery Turbo but its a delight to see one such making in my own country ! Go baby Go ... you will surely inspire a lot more to follow your footsetps to accomplish their dream buildoffs !

Thanks bud, i think this forum is full of motivation to pull off something like this

[Slick]

Wo! Lucky what effort dude, All the best for the bike, I sincerely think that it turns out to be one amazing machine.
And a very well documented thread with great pictures. You deserve 5 *s

[Latheesh]

How did I miss this thread?

Luky - We know the difficulty in doing such project where no detailed information available. Wish all the best and hope to spot you soon on Bangalore roads with a valid licence plate.

You deserve a special for that frame, most critical part in the project according to me.

[luky_13]

The installation of the timken bearing went on smoothly, i must admit that it was almost an embarrassment ... designed a TOOL for installation, checked, re-checked, tested and after putting in all that effort Mr. Timken just slipped over the crankshaft without applying any force or use of tool. On close inspection we realized that the bearing was not sitting on the crank shoulder, we finally got the opportunity to use our tool to guide it to the designated spot.

Bearing heated to approx. 210 C


Placement


Job done


Video of the act :-

YouTube - Harley Twin cam - Timken bearing install

Timken conversion is done. Next episode - End play setting on the left half of the crank case.

[luky_13]

With the flywheel transformed to generate some heavy duty power, time to move on.

A bit of harley history before that... Till 2002 all twin cam engines were factory fitted with a timken setup. The MoCo was facing productivity issues during the engine assembly because timken's specifically required end play adjustment which was time consuming and non-productive for a power train division that had to churn out huge numbers of units each day. A rather tough call was taken to move over to a cylindrical roller bearing as it did not require any end play adjustment during assembly saving valuable time, an inferior trade-off. Stock motors were offered with a timken setup only on purchase of a CVO bike (Custom vehicle operations) or Screamin' Eagle motor at a premium.

End play specification - .001" or 25 µm

Placed a washer of required thickness over the timken bearing then carefully guided the Left half of the crankcase over the flywheel and slide the other bearing cone over it and tightened to check end play


During our first check found out that the end play was over 100 µm ... off target


Stripped the setup again and replaced the washer with a slightly thinner one and assembled the setup back again. End play check - 60 µm ... still off. Using the bearing assembly tool tightened the bearing to the required torque specification and checked the end play again ... this time right on target 27 µm




A final check to see if everything was okay, rotating freely


Some snaps after putting the two halves of the case together, trial fitting

[luky_13]

Trying to get my weird mind to plan the complete engine assembly, following the standard bottom up approach in typical harley tradition, bottom end followed by top end:-

1. BOTTOM END

   • Put together two halves of the crankcase
   • Install breather and oil pump
   • Install cams
   • Install cam plate
   • Install gasket and chrome cover

2. TOP END

   • Install cylinders and pistons
   • Install heads
   • Install rocker arm assy
   • Install lifters, push rods and covers
   • Install chrome rocker covers

   .. and on completion plug a few sensors here and there

[luky_13]

Assembly of the two crank halves, the components and tool spread

• RHS crank half
• Piston jets
• O-rings
• Tools
• 3bond Liquid gasket

Piston Jets
Twin cam piston jets have a bit of history. Earlier Twin cam prototypes had considerable cooling problems which delayed its launch way back in 1997, the reason sited was the oil scavenging system. An acoustic phenomenon that caused pressurization of the scavenge passageway when the pistons were moving down. A more serious problem was that of overheating. Piston temperatures in particular were troubling. This was solved by installing oil jets in the crankcase, aimed so that they sprayed the piston crown from underneath.




To be honest, i don't think harley's would have existed on this planet without Loctite. Harley's are addicted to Loctite, here is one example




Baffle Plate
The virtual oil sump


Dowels


Gasket
Dispensing the liquid gasket over the narrow crank terrain was a very tricky task, my hand was shaking like a leaf. After a couple of trials and heavy breathing I was able to sputter the slimy liquid. The gasket track resembles my ECG at that point in time.

[luky_13]

Next, the two long lost brothers meet. I mean the two halves. Carefully placing them over each other such that it does not disturb the gasket.



I suddenly realized that the bolts enter from the other half of the case, had to flip the complete assembly




Remember what i said about loctite and harley's, once again




All bolts in ready to bolt-in


Torque the bolts to 14nm and then 24 nm in the specified pattern



Case assembly done.

[luky_13]

Before we moved over to further assembly we needed a few specialized but pricey tools

1. Oil pump alignment pins, $ 28.00
2. Chain pre tensioner, $ 42.00
3. Gear locking tool, $ 49.00
4. Cam holder, $ 155.00
--------------------------------------------------------------
Total, $ 274 + $ 150 (shipping) + $ 115 (customs duty)
Finally = Rs. 24,770.00
--------------------------------------------------------------

A unanimous decision taken to make them in house, God help us!

OIL PUMP ALIGNMENT PINS
Turned out of some spare EN-8 leftover


Sweet! Time taken 90 mins, cost Rs. 200 (considering the cost of the material + labour)


CHAIN PRE TENSIONER
Made out of locally procured plumbing hardware. First extra portion chopped


Faced


Slotted


Done. Time taken 25 mins, cost Rs 82.00


GEAR LOCKING TOOL
This was done by my partner Ajay, cutting gears without a gear hobber can be a nightmare but this is art ! I wont go into detail, we cut these gears over a milling machine using an indexer attachment. Time taken 6 hours, cost priceless !


CAM HOLDER
This was the simplest, took the centre distance between the cams along with the diameter. Just machined out.


Done. Time taken 50 mins, cost Rs. 350.00


Total time = approx 9 hrs, Total cost = Rs. 632.00. At the end of the day it was totally worth putting in all the effort, the savings were mind boggling.

[aargee]

Beautiful!!! Probably my first comment now from a silent observer. Using Locite was a good piece of information that I didn't know. Any idea why?

I did a hand made RX at home & that made me realize the pains you're undergoing, which is atleast 1000 times more than what I experienced. Wish you a great success in your endeavour.

[luky_13]

Originally Posted by aargee

Beautiful!!! Probably my first comment now from a silent observer. Using Locite was a good piece of information that I didn't know. Any idea why?

I did a hand made RX at home & that made me realize the pains you're undergoing, which is atleast 1000 times more than what I experienced. Wish you a great success in your endeavour.

Thanks.

Loctite is a very commonly used THREAD-LOCKER, prevents the bolts from getting loose when subjected to severe vibrations something that harleys are famous for.

[aargee]

Originally Posted by luky_13

Loctite is a very commonly used THREAD-LOCKER, prevents the bolts from getting loose when subjected to severe vibrations something that harleys are famous for.

Thanks. I feel like stupid; I should've spoken to you before I carried out my work to take some good inputs. Thanks for the education.

[_raVan_]

Oh my God! What a thread! Please do keep updating the thread as always.

Am not much of a machine head, hence couldnt get most of the technical terms used but tried to keep up with some of it. But yes, a biker at heart. Wish you all the best in completing your project.

[desideep]

Locktite also helps with the bullet i have used it on my new engine build