A.   STRAP MOTORCYCLE ON LIFT  1) Refer to EMC Torque Multiplier Diagram dated 10 DEC. 1998 and Technical Drawing Package. 2) Clamp front wheel  3) Strap forks down.  

       B.   OUTER PRIMARY COVER REMOVAL   1) Drain primary case oil   2) Remove primary cover (see H-D Manual)  3) Remove compensator nut.

       C.    CUT OUTER PRIMARY See Dwg# BLWNT25-A  1) Install compensator nut with 1/2" dowel pin pilot shaft (TL92).  2) Tighten to approximately. 50 ft. pounds.  3) Drill 1/4" pilot in approximately at center of outer primary cover. 4. Use 5/8" drill through 1/4" pilot.  5) Assemble cover with four bolts 6)  Use chrome scratching tool no. (TL93) over the 1/2" pilot shaft. 7)   Put tap in 1.5 dia. hole and firmly press the tool and scratch a groove in the chrome.  Repeat for 1.4", 1.3" and1.2diameter.  Press firmly and turn to insure removal of nickel and copper.   8)   Use tool no. (TL92) as a broach to cut a 1.5" diameter hole.   9) Use a 1/2" three-jaw variable speed drill with a T-bar handle for stability.  Install the broach in the drill.  10) Lube the inside of the broach with light oil. 11)Apply steady pressure to insure a uniform diameter hole.  12)Caution: as you cut deeper into the casing there will be aluminum ribs that will grab and spin your drill.  13) After the hole is cut de-bur the outside edge.  14)Use a 3/16 or 1/4 rat tail file and file a deeper groove to the bottom of the hole.  This allows for better oil drainage back into the primary case.  The bottom hole of the alum oil seal must line up with this drain. 15)Remove the primary cover and clean all chips in the primary case and from the cover.  16) Remove the compensator guide pin. 

        D.    INSTALL DRIVE SHAFT ( Dwg#  BLWNT64-A   V-TWIN DRIVE NUT )   1)Install the compensator nut/drive shaft (SH10).   This nut may be marked with a 2, 4, 6, 8, 10  which represents the extension of .2 .4 .6 .8 & 1.0 inch of the sprocket beyond the primary cover.  2)Put a new primary gasket on and use the original shim washer behind the compensator/drive shaft.   Tighten to (150 ft. lbs.). 3 ) Oil the large red seal (SL10) disk and put it on the drive shaft (SH10) in the groove closest to the hex.  This seal should just touch the end of the aluminum cup (SL12) and prevent splashing of oil into the cup. 4)Oil the smaller red seal (SL11) disk and put it inside the outer groove of (SH10).   This spins inside the cup and forces any oil leakage into the hole at the bottom of the seal cup (SL12).

        E.      INSTALL SEAL ASSEMBLY 1) See Dwg# BLWNT33-A  DRIVE SEAL SHIMMING , Clean the hole in the primary cover free from oil and mark the area where the drain hole should be placed on the front cover with a dot.    2) Mark the seal cup (SL12) face with a hole location is.  This hole must line up with the filed deeper groove.   3) Put a thin layer of RTV on the outside wall of the seal cup. Match the hole of the seal cup with the drain location in the outer primary and press into primary cover.   4)      Use a large socket that would fit over the flange of the seal cup and tap the seal cup until it seats into the primary cover.   Wipe off any excess RTV and make sure the alignment marks matches with the drain area of the primary cover.

        F.       CHECK SEAL GAP  1) See Dwg#  BLWNT33-A   Drive Seal Shimming, Temporarily press outer primary cover into position with the gasket.  As you are pressing the cover on check to see the seal cup (SL12) just touches the red silicon seal (SL11).   2) Note:  the silicon seal should barely touch the metal seal.  If there is a gap of .005-.010 in. this gap will be reduced by the installation of your primary bolts after they are torque down.   3) However, if before torque down the outer primary cover, the seal (SL12) is already pressing on the silicon seal (SL11) then you must reduce the thickness of the compensator nut spacer washer (SP10) appropriately to its required thickness.   4)If necessary use the appropriate shims (SP10) supplied to adjust the compensator/drive shaft nut in or out. 

        G.      FINAL OUTER PRIMARY COVER ASSEMBLY      1)  Torque the drive shaft down to H-D Spec (150 ft.lbs.)    2) Install bolts to outer primary cover and torque 25/20 bolts to H-D Spec. 3)  Recheck the red seal to make sure the seal cover does not compress into it.  The red seal should rotate freely in the seal cup and acts as a centrifugal disk.   4)  However if you observe a compression of the red seal that you   must reduce the shim behind the compensator nut by the amount of compression.  

  5) Remove what shims are necessary so that the red seal spins freely.  6) however, if the shaft is too far inboard, then oil will enter into the seal cup and spray through the outer seal, therefore, it is important to have this portion done correctly.   7)  Install bolts to outer primary cover and torque 25/20 bolts to H-D Spec.   8) Put oil back into the compensator case to the level required by your H-D Manual.   

            H.   LOWER DRIVE SPROCKET   1) Install the 38 tooth drive sprocket (SK38) with the 3/16" woodruff key (KY10) in the taper.  2)  Bolt on the stainless steel sprocket face (CV38) plate and torque the hex bolt to 18 ft. lbs. 

             I.       REMOVAL FO TANK AND OTHER COMPONENTS   1) Drain gas and remove gas tank according to H-D Manual.    2)  Remove air filter carburetor intake manifold, carburetor cables VOES vacuum hose and other breather  tubes.   3) Motor Mount  (BK12) Remove mounting hardware and other accessories from other including the VOES switch.  There should be three 3/8" holes exposed.  (The horn can be relocated later.) 

          J.      Installing Manifold. 1) See DWG#  BLWMN41-E Intake Manifold Dimensions, 1) Clean the intake surfaces of the heads and lightly grease the surface.   Then install the new manifold (MN20) with the blue seals (GK10).    2) Replace the bottom left side Allen screws with grade 8 hex head bolts (HW15) with no washers.     3) Carefully install the manifold clamp assembly to insure that no seals are pinched.  4) Make sure the manifold is mounted level so that the tubes align with other components.   5)   Tighten the four screws according to H-D spec.

            K.      CONNECTING THE VACUUM TUBES TO THE VOES  1)  Connect a “T” to the VOES and the intake manifold pressure tap.      2) Connect a tubing from the T and route it over the engine to the handlebars for later installation of a boost gage.

3)   Bolt the boost gage onto the 5/16" bolts on the handlebar clamps and connect the manifold vacuum pressure hose.

            L.           AIR BOX CLAMPS  1) See Dwg#  BLWCB34-1   Plenum Mtg Plate,   Use TB11 with clamps HW17.   2)   Mount the accumulator (MN40) and 2" hose and two hose clamps.      

           M.          BREATHER TUBE   1)  Use (TB20) breather tube and bolt to air box using three stainless steel washers.   1)      Loc-tight the 1/2-13 breather bolts and torque to 30 ft.lbs.  

            N.       CRANKCASE MOUNTING BRACKET  See  drawing BLWBK12-A BLOWER TO CRANKCASE BKT,    1) Locate the two cylinder head blots next to the fwd cylinder.  Remove only one head bolt and replace with the 13/16 440 SS head bolts supplied.  Tighten to 40 ft lb torque.  Proceed to the second head bolt.  On the 113 S&S engines longer head bolts are used, 2.375 in.      2)  Below the front cylinder locate the front 5/16" hex bolt and remove.  Locate the 5/16" bolt at the “V” of the cylinder and remove.   3) These bolts will be supplied with two other grade 8 bolts (HW20) and spacers (SP11).   4)   Install the blower bracket (BK13) and the appropriate spacers (SP11).    5)  Use the two new bolts with medium loctite (HW20) and install and torque to 18-20 ft. lbs.   6)   For Vertical stiffening the blower lower mount has two 5/16-18 x 2.5" long studs installed.  Belt tensioning is attained by moving these studs up and down on the 1" long slots. (BLWBK12-A) .   7)  Install the 1.75 dia hose but do not tighten the hose clamps yet.   Mount the blower assembly by using these two 5/16-18 lower studs. Use the white belts tensioning wedge (tool # 18) and install between the primary and the blower bottom.  8)     Install the belt and tighten the wedge until the belt is tight.  9)   Now your are ready to intall the upper horizontal brace.  

            O.      HORIZONTAL BLOWER UPPER BRACKET INSTALL  1) See drawing  BLWBK29-C Blower To Head Assembly,  Locate the two 13/16 cylinder head blots you just installed.    2)  Locate the engine Cylinder Head type labeled on the horizontal brace.   The basic cylinder head type are, Twin Cam 88-95 cu in =(88TW), 80 cu in EVO =(80EVO), 883 or 1200 Sportster =(SP), 3.5" bore S&S =(3SS), 4" bore S&S =(4SS), And the Merch engine =(MR ).   3)  Various cylinder heights exist. Install the horizontal brace by shimming with washers or spacers provided.  The correct shim height and tighten the hex 5/16-18 x 1" bolts.    4)  For Horizontal stiffening the blower upper mount has two 5/16-18 x 2" long studs installed (BLWBK29-C).    5)  Spacers and washers are necessary to shim the top and bottom of the blower until the sprocket is parallel to the crank drive sprocket. The belt must running true.   6)   Install the 1 OZ. SS overflow tube using the 1/4-24 nut. Make sure the breather hole is pointing up.   7)  Tighten the 1.75 ID hose clamps.

            P.       BLOWER ALIGNMENT TOOL 1) See tool TL-17 ,  Mount the special alignment plate tool (TL17).   Install (4) 1/4-20 and bolt on to the belt bracket.  2)   (BK11) and use a 5/16-18 hex and bolt to the drive shaft with (SK38) and (CV38) installed.  This ties the blower to the drive shaft and allows freedom of rotational movement of the blower assembly.  3)  Typically a 30/38 sprocket combination is used. Tighten the drive shaft sprocket nut.  5)  Use the necessary spacers and washer combination at the lower Vertical crankcase bracket.  6)  Use the necessary spacers and washer combination at the upper Horizontal bracket.   7)   Check the alignment of blower and ensure the proper spacers are installed.    8)  Remove the alignment tool (TL17) and install the belt and belt cover.   9)  Adjust the blower up/down using the white wedge (TL18) that +- 3/16 ( cold engine ) inch movement is available at the center of the belt.   10)  Proper belt tension will prevent excessive wear on the blower bearing

            Q.       BLOWER ALIGNMENT WITHOUT SPECIAL TOOLS    1) Use a straight edge and place on the bottom of (CV38) 38 tooth drive sprocket cover(CV38).   2)       The edge of this ruler must touch the blower upper sprocket face (CV30).  3)  Shim upper and lower mounting bkt until the blower sprocket (CV30) is parallel to the edge of the ruler.  Now the blower shaft is parallel to the crank drive shaft.   4) Now you can add or remove thickness shim washers (two on top and two on the bottom) to move the blower inboard or outboard. This will make sure the sprockets are not only parallel but one above the other.  5) Now tighten the two blower bottom 9/16 hex nuts and the two blow top hex 9/16 nuts.  6)  Again check the belt tension to ensure that +/- 3/16 travel is available at the middle of the belt.  As the engine warms up the cylinder will grow in height and cause more tension in the belt.  7) If the engine is hot after 1/2 hr ride and the belt is too tight then the crankcase bkt nuts must be loosened and by pulling on the belt the blower will be lowered so that the belts is reasonably tight +- 1/16 in.   8)  Proper belt tension will prevent excessive wear on the blower shaft and seal bearing.

          R.      BELT GUARD INSTALL.  1)  Install belt guard bracket (BK11) using hardware (HW18) and (SP20).   2)  Install belt guard (BG10) using shim washers if necessary.   3)  Align belt guard and tighten.

           S.      INSTALL CARBURETOR   1) Use two stainless steel set screws (HW19).  Finger tighten into back of carburetor using medium strength loc-tight.

2)   Install throttle cable or modify as necessary.   3)  Use 5/16" gas line hose.  

            T.      INSTALL BOOST GAUGE & RE-FLOW TUBE    1)  Use 3/16" i.d. rubber hose and connect to (MN30).   2)  Connect the other end of the hose to the bottom of the boost gauge which should be mounted on your handle bar bracket.  3) The left side of the gauge reads vacuum in “Hg vacuum.  Approximately 2” vacuum equals 1 psi of vacuum.  The right hand side of the gauge reads pressure in units of psi.   4)  At the bottom of the plenum box (MN40) connect a rubber tube (TB20) to the tube fitting and bring it between the “V” of the cylinders and behind the blower and connect the needle valve (VL10) behind the carburetor.  The needle valve should be unscrewed two turns.   5) This needle valve allows minimal suction of condensed fuel from your plenum box (MN40) and directs it into the intake of the blower for recirculation.

            U.      GEAR SHIFT LINKAGE AND FRAME SPACERS   1) The Dyna Wideglide models require a (2) hole x 1.75 spacer block (SP30)for the left forward controls.  Remove the gear shift shaft and bend the arm to clear the bottom of the blower.   Install parts and ensure proper shifting.   2)  The Dyne Lowrider models require a (2) hole x 1.75 spacer block (SP30) for the left mid peg.  The shift lever need to be offset by 1.5 inches to clear the lower drive sprocket (BK22).  Install parts and ensure proper shifting.  3)  The Softail models require a (3) hole x 1.75 thick spacer (SP40) for the forward controls.  Remove the gear shift shaft and bend the lever to clear the bottom of the blower. Install parts and ensure proper shifting.   4)  The Fatboy models require a (3) hole x 1.75 thick spacer block (SP40) for the forward controls and the foot board.  Remove the gear shift shaft and bend the arm to clear the bottom of the blower.  Install parts and ensure proper shifting.   5)  The FXR models require a (3) hole x 1.75 thick spacer block (SP40) for the forward controls and the foot board.  Remove the gear shift shaft and bend the arm to clear the bottom of the blower.  Install parts and ensure proper shifting.