RevTech Engine Installation Guide (2)

Engine Installation Guide& Owner’s Manual

125" • 115" • 110" • 100" • 88"including EPA-Certified Engines

Engine Installation Guide and Owner's ManualDocument number 608000

edition 05.29.09

Table Of ContentsCongratulations on Making a Powerful Choice! .......................................................................iEmissions Compliance Statement .............................................................................................ii

SECTION 1 - The RevTech® Engine 1-11.1 Limited Engine Warranty ......................................................................................................1-21.2 Emissions Control System Warranty Statement ................................................................1-61.3 Engine Components .............................................................................................................1-91.4 Engine Specifications ...........................................................................................................1-10

SECTION 2 - Installation in Chassis 2-12.1 Pre-Installation Notice .........................................................................................................2-22.2 Emissions-Related Installation Instructions ......................................................................2-32.3 Engine Installation ................................................................................................................2-52.4 Ignition System Installation .................................................................................................2-92.5 Installation Diagrams ...........................................................................................................2-14

SECTION 3 - Owner's Manual 3-13.1 Engine Break-In Procedure .................................................................................................3-23.2 Maintenance Schedule .........................................................................................................3-33.3 Maintenance Procedures .....................................................................................................3-43.4 Troubleshooting Guide .........................................................................................................3-6

SECTION 4 - Parts Catalog 4-14.1 Parts Catalog ........................................................................................................................4-2

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Congratulations on Making a Powerful Choice!April, 2009

Thank you for purchasing a RevTech engine. We know that you have numerous options available to you when choosing an engine for your motorcycle, and by selecting RevTech, you have shown that you are part of a growing number of enthusiasts who demand quality. Quality in design, in function, and in performance is what makes the RevTech engine the right choice for your motorcycle.

As governmental regulations evolve, RevTech has kept pace with current EPA requirements to allow even more flexibility to you, the rider. Now, the 88, 100 and 110 cubic inch RevTech engines are available in EPA certified configurations, which means you get the best of what our engines have to offer in a package that meets current federal emissions regulations (California not included - see next page). Therefore, as long as you install your new engine in a motorcycle chassis following the instruction procedures outlined in this manual, the resulting motorcycle will be emissions compliant without the need to perform any form of testing.

For the builder and the rider, we believe few other engines on the market today have the level of design, engineering and testing that is built into every RevTech engine. With our commitment to the constant improvement of our engines, and to maintaining full compliance with emissions standards, you can rest assured that your RevTech engine will take you the distance.

High performance and great style in an EPA certified package…You’ve made a great choice – RevTech!

Sincerely,

Holger MohrCEOCustom ChromeA Division of DAE-IL USA, Inc.dba Global Motorsport GroupMorgan Hill, California

Emissions Compliance StatementCongratulations! You have purchased a RevTech EPA-certified motorcycle engine. This manual contains instructions for the installation of your engine and other important information for the ultimate owner of the motorcycle built with this engine, including break-in, routine maintenance, and warranty.

ATTENTION CALIFORNIA PURCHASERS: The engine-certification procedure described below, authorized under a July 25, 2006 Guidance letter issued by the federal Environmental Protection Agency, applies in all states except California. In California, the Air Resources Board has not adopted the same procedure set forth in the EPA’s July 25, 2006 Guidance letter. Accordingly, if you use this engine to build a motorcycle in California, you must comply with all state regulations, unless another exception applies.

IMPORTANT NOTICE: A small volume manufacturer of highway motorcycles, a producer, seller, or assembler of highway motorcycle kits, or an individual is not required to apply for, or receive EPA certification to install this engine provided such person ensures the following criteria are met. The resulting motorcycle may be operated and re-sold without restriction, as long as the vehicle also complies with all other applicable federal, state and local regulations, including licensing, registration, EPA noise and Federal Motor Vehicle Safety Standards (FMVSS).

Installation.1. The certified engine and emissions related components must be installed following the installation instructions provided in this manual (SECTION 2 - Installation in Chassis)

N/V Ratio.2. Your motorcycle’s highest engine speed-to-vehicle speed ratio (the “N/V ratio”) may not exceed 86.5. Use this formula to calculate your motorcycle’s N/V ratio:

N/V Ratio = 208.9 x (Overall Gear Ratio ÷ Rear Tire Diameter)

Determine the “Overall Gear Ratio” using the following formula:

Overall Gear Ratio =

C = The number of teeth on the clutch sprocket or pulley R = The number of teeth on the rear wheel sprocket or pulley A = The transmission’s highest gear ratio (0.89 for most 6-speed transmissions, and 1.00 for most 5-speed transmissions) E = The number of teeth on the engine sprocket or pulley K = The number of teeth on the transmission mainshaft sprocket or pulley Note: The rear tire diameter is measured when the tire is on the wheel and properly inflated. Tire manufacturers often post this value on their websites. When entering the rear tire diameter into the formula described above, the units must be in inches.

Weight.3. Your fully assembled motorcycle may not weigh more than 387 kg (851 pounds), with full fuel, oil, and other fluids, but without rider or cargo.

No Tampering.4. You may not make any change to the engine that could reasonably be expected to increase its exhaust emissions for any pollutant, including changes to the fuel metering system, ignition system, or camshaft. In addition, you may not modify, recalibrate, remove, or fail to install properly the carburetor, air cleaner cover, air cleaner housing, or air cleaner supplied with the engine.

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C x R x A

E x K

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Emissions Compliance StatementPermeation Equipment.5. In order to meet EPA evaporative emissions requirements, the fuel tank and fuel lines installed on the motorcycle must meet the specifications outlined in SECTION 2.2 - Emissions-Related Installation Instructions.

Emissions Control Information Label.6. The provided emissions control information label must be permanently affixed to the vehicle in a readily accessible location on the vehicle, as described in SECTION 2.2 - Emissions-Related Installation Instructions.

Owner's Manual.7. If you have used this engine to build a motorcycle for resale, you must provide this manual to the ultimate purchaser.

Exhaust.8. You must install this engine with an exhaust system so that, with the engine running at 1800 rpm, the exhaust backpressure is at least 0.1 psi but not more than 1.5 psi, measured within 12 inches of the engine’s exhaust port. Most aftermarket exhaust systems that comply with federal and state noise and emission regulations will satisfy this requirement.

WARNING - If you fail to meet any of the above requirements:

Your motorcycle will be deemed non-compliant with federal emissions regulations.•

You may be liable for violation of various federal laws, including laws relating to engine and •motorcycle certification, introduction into commerce, and anti-tampering laws, as provided under the federal Clear Air Act and federal EPA regulations.

You may be subject to monetary fines and other penalties.•

If you have any questions regarding this certified engine or any of the above requirements or prohibitions, please contact Global Motorsport Group (GMG) Customer Service and Technical Support at:

Global Motorsport GroupCustomer Service and Technical Support18225 Serene Drive, Suite 150Morgan Hill, CA 95037866-888-5980408-778-6190 [email protected]

WARNING - Tampering is Prohibited!

Any act by you, or any other person, that renders inoperable or reduces the effectiveness of any part or component of the engine that effects vehicle emissions is “tampering.” The federal Clean Air Act specifically prohibits tampering. Tampering may result in penalties imposed by the federal government.

SECTION 1 The RevTech® Engine 1.1 Limited Engine Warranty 1.2 Emissions Control System Warranty Statement 1.3 Engine Components 1.4 Engine Specifications

1.1 Limited Engine Warranty

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LIMITED ENGINE WARRANTY (Non-Emission)1

Please detach, complete and return the warranty card in this manual.

Who does the limited RevTech® engine warranty cover?

Only the original retail customer of this RevTech 88, 100, 110, 115 and 125 inch engine is entitled to warranty service. Coverage terminates if you sell or otherwise transfer the engine to another user.

What does the warranty cover?

Custom Chrome warrants that the engine is free from defects in workmanship and material. If a warranty claim occurs, Custom Chrome will repair or replace all parts necessary to restore the engine to accepted factory specifications. All warranty work must be performed by a Custom Chrome RevTech Repair Center.

How long is the warranty coverage?

The warranty extends for two years from the date of the original retail customer’s purchase of the engine or 20,000 miles, whichever comes first. For valid warranty claims arising during the first 18 months of coverage, Custom Chrome will reimburse a dealer, with a merchandise credit, for its labor charges in removing and reinstalling the engine. [Dealer: Please contact Custom Chrome for details.] After the first 18 months, this warranty covers only parts and labor provided by a RevTech Repair Center. Any other parts, labor charges (including removal and reinstallation of the engine), and freight costs are the sole responsibility of the retail customer.

What is not covered under your warranty?

Your warranty does not cover any of the following:

Any work performed in the field, unless specifically authorized and directed in writing by a 1. RevTech Repair Center. Any such work will void your warranty.

Piston failure caused by excessive heat, fuel in the oil due to a non-vacuum petcock being left 2. in the 'ON' position when the vehicle is not being operated, or incorrect tuning (as determined by a RevTech Repair Center Technical Support Specialist).

Any sign of owner abuse or negligence (as determined by a RevTech Repair Center Technical 3. Support Specialist).

A failure caused by improper or incorrectly performed maintenance (as determined by a 4. RevTech Repair Center Technical Support Specialist).

Oil weeps and seeps (as determined by a RevTech Repair Center Technical Support Specialist).5.

A failure due to non-compliance with recommended break-in procedures 6. (page 3-2 of this manual).

1 A separate warranty covers your engine’s emission systems. The emission warranty’s terms and condi-tions are on pages 1-6 through 1-8.

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Incidental and consequential damages, including loss of time, inconvenience, or loss of use of 7. your motorcycle during warranty repair.

Incidental damage to any other component of your motorcycle or to the paint on your 8. motorcycle, as the result of the removal or reinstallation of the engine.

Any charges for towing, hauling, or storing your motorcycle or any accommodation costs.9.

Damages resulting from improper crating or packaging of the engine.10.

Additional notes: Disassembly of any part or any physical modification to the engine without prior approval of a RevTech Repair Center voids the entire warranty.

Custom Chrome will make the arrangements to have the engine picked up for warranty service via truck (ground freight only). Freight charges will not be covered if Custom Chrome determines that the warranty claim is invalid.

Troubleshooting, diagnosis, and technical issues:

The biggest enemy of an air-cooled engine is heat. Sufficient airflow must be present at all times. 1. To ensure sufficient airflow, avoid slow-moving traffic and do not allow the engine to idle for extended periods of time. This is owner abuse (see 3 above). YOUR WARRANTY DOES NOT COVER PISTON SEIZURE CAUSED BY OVERHEATING.

If the engine begins making strange or unusual noises, turn off the engine as soon as it is safe to 2. do so and take the engine to an authorized Custom Chrome dealer for service. Continued use of an engine making noise can create a serious safety risk and could lead to an engine failure that is not covered under your warranty.

Turn off the motorcycle’s fuel supply valve (petcock) when the engine is not operating. Failure 3. to do so may result in fuel draining into the engine, causing pollution of the engine oil or engine damage not covered by your warranty.

If you discover an oil leak, please provide photographs (preferably digital) clearly showing where the 4. leak is coming from and the volume of the leak. Do not assume that the engine is leaking – check the primary transmission, oil tank, and all related hoses and connectors first.

If, after careful cleaning and checking, you determine that the leak is coming from the engine 5. (that is, if there are oil spots on the horizontal floor directly under the engine during a 24-hour period), contact an authorized Custom Chrome dealer for warranty service.

Our technicians will perform an extensive bench test, including running the engine at full 6. operating temperature. If the leak cannot be duplicated, the warranty claim will be denied, and we will return the engine, freight collect, as received. No credit for labor will be given.

Weeps and seeps may occur. They are not considered warranty issues and we will not reimburse 7. labor charges to repair them.


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How to obtain warranty service:

To obtain warranty consideration, the original retail customer must contact an authorized Custom 1. Chrome dealer, preferably the dealer where you purchased the engine.

The dealer must contact RevTech Customer Service and Technical Support. Together, they 2. will make an initial determination if the problem is covered by the warranty. The dealer, not the customer, must make this contact.

Custom Chrome and RevTech Customer Service and Technical Support will not accept calls from 3. retail customers relating to warranty claims.

If Custom Chrome and the dealer determine that the problem may be covered by warranty, they 4. will arrange to have the engine shipped to a RevTech Repair Center. For the first 18 months after original retail purchase, Custom Chrome will cover the freight charges for valid warranty claims.

Only a RevTech Repair Center can perform warranty service. Custom Chrome will not 5. reimburse the cost of parts or labor for warranty service performed anywhere other than a RevTech Repair Center.

What you must do to maintain the RevTech engine warranty:

Adhere to the break-in procedure prescribed in this manual (1. page 3-2).

Do not abuse or misuse your engine in any way.2.

Use premium unleaded fuel, with an octane rating of 91 or higher.3.

Wash and oil air filter element as needed.4.

Perform oil and oil filter changes according to the maintenance schedule in this manual (5. page 3-3).

Do not remove or modify any engine component, including those listed below. Altering these or 6. any other emission-related component will make your engine illegal to use in the U.S.

Carburetor•Ignition Module•Camshaft•Heads•

FAILURE TO FOLLOW ANY OF THE THESE PROCEDURES MAY RESULT IN THE DENIAL OF YOUR WARRANTY CLAIM OR CANCELLATION OF YOUR WARRANTY, OR BOTH.

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1.1 Limited Engine WarrantyYour rights under state law: This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Any implied warranty, including any warranty of merchantability or fitness for a particular purpose, is limited to the express terms of this Limited Engine Warranty. Some states do no permit limitations on the duration of an implied warranty, so this limitation may not apply to you.

Custom Chrome cannot accept warranty claims directly from retail customers. To make a warranty claim, you must return the engine to an authorized Custom Chrome dealer. For the location of the nearest authorized Custom Chrome dealer and RevTech Repair Center, call the number listed below.

Warranty card:

Please detach, complete and mail the warranty card, together with a clear, legible copy of your receipt, showing the dealer name, date of purchase and engine serial number, to:

Custom ChromeCustomer Service and Technical Support18225 Serene Drive, Suite 150Morgan Hill, CA 95037866-888-5980408-778-6190 [email protected]

The Warranty Card is for product registration and to ensure that we have a record of your purchase and that we are able to contact you, if necessary, with any important information regarding your engine.

1.2 Emissions Control System Warranty Statement

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The U.S. Environmental Protection Agency and Global Motorsport Group, Inc. (GMG), are pleased to explain the emission control system warranty on your 2007 and later engine. New motor vehicles must be designed, built and equipped to meet U.S. EPA Federal anti-smog standards. GMG must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition system, hoses and other emission-related assemblies.

Where a warrantable condition exists, GMG will repair your engine at no cost to you, including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE

Class I motorcycles (50 to 169 cc): for a period of use of five (5) years or 12,000 kilometers •(7,456 miles), whichever first occurs.

Class II motorcycles (170 to 279 cc): for a period of use of five (5) years or 18,000 kilometers •(11,185) miles, whichever first occurs.

Class III motorcycles (280 cc and larger): for a period of use of five (5) years or 30,000 •kilometers (18,641 miles), whichever first occurs.

If an emission-related part on your engine is defective, the part will be repaired or replaced by GMG. This is your emission control system DEFECTS WARRANTY.

OWNER’S WARRANTY RESPONSIBILITIES

As the engine owner, you are responsible for the performance of the required maintenance •listed in your owner’s manual. GMG recommends that you retain all receipts covering maintenance on your engine, but GMG cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

You are responsible for presenting your engine to a GMG dealer as soon as a problem exists. The •warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

As the engine owner, you should be aware that GMG may deny your warranty coverage •if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

If you have any questions regarding your warranty rights and responsibilities, you should contact GMG Customer Service and Technical Support (see page 1-8 for contact details).

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Global Motorsport Group, Inc. warrants that each new 2007 and later RevTech® motorcycle engine:

is designed, built and equipped so as to conform at the time of initial retail purchase with all A. applicable regulations of the United States Environmental Protection Agency, and;

is free from defects in material and workmanship which cause such engine to fail to conform B. with applicable regulations of the United States Environmental Protection Agency for a period of use, depending on the engine displacement, of 12,000 kilometers (7,456 miles), if the engine’s displacement is less than 170 cubic centimeters; of 18,000 kilometers (11,185 miles), if the engine’s displacement is equal to or greater than 170 cubic centimeters but less than 280 cubic centimeters; or of 30,000 kilometers (18,641 miles), if the engine’s displacement is 280 cubic centimeters or greater; or 5 (five) years from the date of initial retail delivery, whichever first occurs.

COVERAGEI. . Warranty defects shall be remedied during customary business hours at any authorized GMG dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency. Any part or parts replaced under this warranty shall become the property of GMG.

II. LIMITATIONS. This Emissions Control System Warranty shall not cover any of the following:

Repair or replacement required as a result of:A. (1) accident, (2) misuse, (3) repairs improperly performed or replacements improperly installed, (4) use of replacement parts or accessories not conforming to GMG specifications which adversely affect performance and/or (5) use in competitive racing or related events

Inspections, replacement of parts and other services and adjustments necessary for B. required maintenance.

Any engine from a motorcycle on which the odometer mileage has been changed so that actual C. mileage cannot be readily determined.

III. LIMITED LIABILITY

The liability of GMG under this Emission Control System Warranty is limited solely to the A. remedying of defects in material workmanship by an authorized GMG dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the engine or transportation of the engine to or from the GMG dealer. GMG IS NOT LIABLE FOR ANY OTHER EXPENSES, LOSS OR DAMAGE, WHETHER DIRECT, INCIDENTAL, CONSEQUENTIAL OR EXEMPLARY, ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE REVTECH ENGINE FOR ANY PURPOSE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.


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NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY GMG EXCEPT B. AS SPECIFICALLY SET FORTH HEREIN. ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY. THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.

No dealer is authorized to modify this Limited Emission Control System Warranty.C.

LEGAL RIGHTSIV. . THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

THIS WARRANTY IS IN ADDITION TO THE CUSTOM CHROME/GLOBAL MOTORSPORT V. GROUP, INC. LIMITED WARRANTY (pages 1-2 through 1-5).

ADDITIONAL INFORMATIONVI. . Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. However, GMG is not liable for these parts. The owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service establishment or by any individual. The warranty period begins on the date the engine is delivered to an ultimate purchaser.

Custom ChromeCustomer Service and Technical Support18225 Serene Drive, Suite 150Morgan Hill, CA 95037866-888-5980408-778-6190 [email protected]


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1.3 Engine Components

RIGHT/CAM SIDE VIEW

Air cleaner cover1. Cam cover2. Ignition cover3. Oil pump4. Oil pressure sender5. Oil filter mount6. Oil filter7. Front engine mount8. Rear engine mount9. Carburetor10. Rocker box11. Front exhaust port12. Rear exhaust port13. Ignition wiring14.

1

3

4

5

2

6

7

8

9

1011

1213

14

11

LEFT/PRIMARY SIDE VIEW

15. Front spark plug16. Rear spark plug17. Compression Release18. Top engine mount pads19. Timing plug20. Alternator location21. Alternator wiring port22. Sprocket shaft23. Bottom inspection plate24. Intake manifold

15 16

1818

19

20

21

22

23

24

Listed below are callouts of basic engine components to help you install and maintain your RevTech engine. For further information on these and other components, see SECTION 2 - Installation in Chassis and SECTION 3 - Owner's Manual.

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1.4 RevTech Engine Specifications

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RevTech Engine Specifications

Generation Gen 2 88"

Gen 3 100"

Gen 3 110"

Gen 4 115"

Gen 4 125"

Engine Type 4-cycle, 45-deg. V 4-cycle, 45-deg. V 4-cycle, 45-deg. V 4-cycle, 45-deg. V 4-cycle, 45-deg. V

Number of Cylinders 2 2 2 2 2

Bore and Stroke 3.623" x 4.25" 4" x 4" 4" x 4.375" 4.125" x 4.30" 4.25" x 4.41"

Displacement 88 cu-in / 1440cc 100 cu-in / 1636cc 110 cu-in / 1800cc 115 cu-in / 1880cc 125 cu-in / 2050cc

Compression Ratio 9.5:1 10:01 10:01 9.5:1 9.5:1

Connecting Rod Length 7.440 in 7.440 in 7.440 in 7.667 in 7.667 in

Horsepower 82 hp @ 5700 96 hp @ 5000 106 hp @ 5500 108 hp @ 5700 115 hp @ 5500

Torque 88 ft/lbs @ 4500 109 ft/lbs @ 4250 112 ft/lbs @ 4100 115 ft/lbs @ 3750 135 ft @ 3700

Rocker Box Assembly

Item Standard Fit Wear Limits

Rocker arm to bushing (press fit) 0.002~0.004 Less then 0.002

Rocker arm shaft to bushing 0.0005~0.002 Exceeds 0.0035

Rocker arm end play 0.005~0.015 Exceeds 0.020

Cylinder Head


Valve Guide fit into head 0.002~0.0035 Less then 0.002

Valve Seat fit into head 0.004~0.006 Less then 0.004

Intake Valve fit in guide 0.0012~0.0020 0.0035

Exhaust Valve fit in guide 0.0015~0.0025 0.0040

Valve seat width 0.040~0.060 0.090

Valve stem protrusion, Gen 2 engines

1.800~1.900 1.900

Valve stem protrusion, Gen 3&4 engines

1.900~2.025 2.035

Valve face runout 0.002 0.002

Piston


Fit into cylinder 0.0025~0.0030 0.0050

Wrist pin to piston 0.0004~0.0007 0.0010

Wrist pin to rod bushing 0.0005~0.0010 0.0015

Compression ring end gap 0.015~0.025 0.030

Oil control ring end gap 0.010~0.040 0.050

Flywheels


Runout at shafts 0.000~0.002 0.004

Connecting rod side play, Gen 2&3 engines

0.030~0.045 0.050

Connecting rod side play, Gen 4 engines

0.010~0.030 0.040

Timken endplay, Gen 2&4 engines 0.001~0.005 0.006

Timken endplay, Gen 3 engines 0.002~0.006 0.007

Crank pin running clearance 0.0008~0.0012 0.0020

Pinion bearing running clearance 0.0004~0.0010 0.0015

Gearcase


Breather gear endplay 0.005~0.015 0.016

Camshaft endplay 0.005~0.020 0.021

Camshaft in bushing 0.0007~0.0020 0.0030

Pinion shaft in bushing 0.001~0.0025 0.0035

Bushing fit into cover 0.0007~0.0025 Less then 0.0006

Lifter fit in guide 0.0008~0.0020 0.0030

Torque Specifications

Rocker box 1/4" hardware 90-120 in/lbs

5/16" hardware 18 ft/lbs

Rocker arm support 18 ft/lbs

Head bolts 8ft/lbs, 16ft/lbs, 90deg

Cylinder studs 90-120 in/lbs

Crankcase 1/4" hardware 12 ft/lbs

5/16" hardware 18 ft/lbs

Cam cover 90-120 in/lbs

Oil pump 90-120 in/lbs

Plugs, oil pump, tappet screen, timing hole

90-120 in/lbs

Tappet guide 90-120 in/lbs

Ignition cup, sensor plate 20-30 in/lbs

Intake manifold flanges 16 ft/lbs

Pinion nut 35-45 ft.lbs

Spark plug 18 ft/lbs

Air cleaner mount to head 120-150 in/lbs

SECTION 2 Installation In Chassis 2.1 Pre-Installation Notice 2.2 Emissions-Related Installation Instructions 2.3 Engine Installation 2.4 Ignition System Installation 2.5 Installation Diagrams

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2.1 Pre-Installation Notice

2.2 Emissions-Related Installation Instructions

Installation in OEM Harley-Davidson® models:This section covers the installation techniques necessary to install the RevTech engine. For installations in OEM Harley-Davidson® models, a service manual for the year and model of the motorcycle is required. Different models and production years have seen many changes that are impossible to catalog here. Therefore, using this guide in conjunction with an OEM service manual will provide all the information necessary to allow for a seamless installation of the RevTech engine.

Installation in aftermarket custom manufactured models:Installation of the RevTech engine in aftermarket custom motorcycles can be completed, in most cases, by using an OEM Harley-Davidson® service manual relevant to the chassis style of the motorcycle. Most aftermarket custom motorcycles are built around chassis designs similar to many popular Harley-Davidson® models, so using the OEM manual in conjunction with this guide should provide enough information to assist with the installation. Specific information about your aftermarket custom motorcycle can be obtained by contacting the manufacturer directly and by consulting the owner's manual provided with the motorcycle.

Essential warnings:WARNING: Health disorders can arise from contact with oil. Although it is extremely unlikely, repeated contact on your skin can cause serious health problems, including cancer. Avoid contact to the extent possible and wear latex or nitrile gloves whenever handling oil or oily parts.

WARNING: Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the motorcycle. Do not smoke or allow open flames or sparks near the work site. Inadequate safety precautions could result in death or serious injury.

WARNING: Never start the engine in a closed area. Always operate your motorcycle in an area with adequate ventilation as poisonous exhaust fumes may cause lose of consciousness or death.

WARNING: You may be seriously injured if you attempt to service your engine or motorcycle with improper tools, do not properly know how to use the required tools, or if you do not use appropriate protective equipment. Always follow the instructions in this manual and do not attempt operations you are not competent to undertake.

PLEASE READ! VERY IMPORTANT!WARNING: Failure to follow these instructions when installing a certified engine in an on-road motorcycle violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.WARNING: Your RevTech engine is only intended for use in a motorcycle chassis. Do not install the engine in any other form of vehicle.WARNING: If you install the engine in a way that makes the engine’s emissions control information label hard to read during normal engine maintenance, you must place a duplicate label on the vehicle, as described in 40 CFR 1068.105.

Evaporative Emissions Equipment Requirements:The motorcycle you are building or assembling is covered by what the EPA refers to as “Permeation” requirements. The EPA has determined that gasoline vapors can seep through plastic fuel tanks and rubber hose lines and has deemed that excessive levels of this vapor are unacceptable. As a result, you must comply with the following requirements to ensure this does not occur:

Install the engine only in a motorcycle equipped with an all-metal fuel tank.1. Be sure that all of the gaskets in the fuel tank represent an area exposed to the fuel of 1,000 millimeters 2. squared or less. This area is determined by analyzing the inside diameter of the gasket, that is, the portion of the gasket that is wetted by the fuel. On most fuel tanks, there are only two or three gaskets, one for the fuel filler cap, and one or two for the petcock or petcocks. If you use a filler neck with a diameter or 3 inches or less, this requirement should be met. Call the GMG Customer Service and Tech Support Line at 866-888-5980 if you have questions.

Utilize fuel lines that meet Category 1 permeation specifications of SAE J2260 or R11-A or R12 permeation 3. specifications of SAE J30. Hoses from reputable manufacturers (Goodyear hose SAE J30R9) which meet these specifications will be marked, showing that the requirements are met.

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2.2 General Requirements for Builders and Assemblers

The elements described below are intended as examples of some techniques that can be used by the engine manu-factures and others to prevent new motorcycles (those with less than 7,500 odometer miles) in uncertified configura-tions from being acquired, sold or offered for sale in California. Other compliance and quality assurance procedures not listed here can and should be used to prevent these violation from occurring. A chassis builder, kit builder, seller, or assembler of HMC kits, or an individual who assembles a HMC kit not intended for resale, is not required to apply for or receive EPA/CARB certification for its newly built HMC, provided such person follow the steps below. However, if violations occur (i.e. if motorcycles in uncertified configurations with less than 7,500 odometer miles are acquired, sold or offered for sale) , the EPA/CARB retains authority to seek penalties from all persons involved in the violations, including manufacturers.

Installs a certified engine and emission related components (exhaust and evaporative ECS) following the installation instructions provided by engine manufacturer. a. Does not install the engine in a vehicle that exceeds the weight or N/V limits used to certify the engine. b. Does not modify the engine and emission related components.Permanently affixes the required engine manufacturers VECI label in a readily accessible location on the vehicle as specified by the engine manufacturer.

Ensures that the owners manual and warranty booklet are provided to the ultimate purchaser.Maintains, for a period of not less than two years, written and photographic records documenting (1) the N/V ratio; (2) weight; (3) evaporative canister installation (photograph required); (4) installation of the label meeting the requirements of paragraph G above (photograph required); (5) the appearance of the finished motorcycle from both right and left sides (photograph required); and (6) foe emission control systems using one or more oxygen sensors, photographic evidence that the oxygen sensors were installed in the proper location.

Notifies EPA/CARB within 10 days of producing the first motorcycle using an engine certified under the procedure specified in this Mail-out of the location where inspections can be performed and where records will be kept.

Provides for immediate inspection of records documenting the proper assembly of each motorcycle upon the request of the EPA/CARB. The Photographic requirements of subparagraph 6. above shall not apply to a business regis-tered as a vehicle manufacturer by the California Department of Motor Vehicles. The requirements of subparagraphs 6.-8. shall not apply to HMC assembled by the registered owner for personal use that is to be registered as a spe-cially constructed vehicle per California Vehicle Code Section 580. Any dealer selling a complete motorcycle kit that includes a Vehicle Identification Number shall be responsible for the requirements of subparagraphs 6-8 and shall not provide the Vehicle Emission Control Information label, described under paragraph G. above, to the purchaser of the kit until the records required by subparagraph 6. have been completed.

Reports the Vehicle Identification Numbers (VIN) of the newly built vehicle(s) to the engine manufacturer.The MSO is used by the engine manufacturer to identify a vehicle that it (manufacturer) believes has been built in conformance with the descriptions and specifications in its application for certification with EPA/CARB. Under EPA/CARB certification of engines for use to build new motorcycles, only bikes with an MSO issued by the certified engine manufacturer is deemed legal for sale and registration in California. Therefore, the MSO should be obtained promptly from the engine manufacturer upon completion of the vehicles construction in order to prevent the vehicle from being found by EPA/CARB to be in violation of the certification requirements while on commercial display or being offered for sale to the public.In the special case of authorized dealer-builders, i.e., dealers that have a close business relationship with the engine manufacturer and build bikes for retail sale under agreement with and/or factory support ( e.g., up to date factory ser-vice information bulletins for latest design changes) and factory recognition (e.g., authorized display of engine manu-facturers brand and logo on vehicle) from the engine manufacturer, the EPA/CARB considers these authorized dealer-builders as an extension of an engine manufacturers vehicle assembly process. The engine manufacturer should have a procedure to assure that HMC newly built by authorized dealer-builders can be reasonably expected to be in com-pliance with all certification requirements. Any contractual agreements between authorized dealers-builders and the engine manufacturer can be required by the engine manufacturer to assure compliance of vehicles built by authorized dealer-builders. The engine manufacturer shall maintain such agreements and make them available to EPA/CARB upon request. An authorized dealer-builder may follow the procedures described in paragraph 1. through 9. above, or any other procedures stipulated by the engine manufacturer. However, if violations occur (i.e., if motorcycles in uncer-tified configurations with less than 7,500 odometer miles are acquired, sold or offered for sale), the EPA/CARB retains authority to seek penalties from all persons involved in the violations, including manufacturers.

2-4

2.2 Emissions-Related Installation Instructions

WARNING: Failure to properly install the emissions control information label will make the vehicle manufacturer, kit manufacturer, or motorcycle assembler, as applicable, liable for violation of federal laws, and subject to monetary fines and other penalties.

Label Construction: The label provided is constructed in such a way that it will be destroyed if removed after initial application. As a result, please take care to ensure the label is applied properly on the first attempt.

Installation Instructions:

1) Peel the emissions label from its plastic backing.

2) Install the label on the frame of the motorcycle or on a plate permanently attached to the frame of the motorcycle in a location that is visible when the seat of the motorcycle has been removed.

Suggested Installation Location:

It is recommended that the emissions label be located on the front down tube of the motorcycle frame in a clearly visible location as shown.

Note: An EPA emissions control information label has been supplied along with your new engine and this owner’s manual. Please locate the label, which can be found in a plastic bag, and carefully follow the instructions provided. Your emissions label will appear similar to one of these samples shown here.

Place emissions label on frame

downtube

EMISSIONS CONTROL INFORMATION LABEL REQUIREMENTS

ENGINE EMISSION CONTROL INFORMATIONCUSTOM CHROME18225 SERENE DR. STE. 150 • MORGAN HILL, CA 95037

ENGINE DISPLACEMENT:ENGINE FAMILY:ENGINE ECS: EM

ENGINE TUNEUP SPECIFICATIONS:IDLE MIXTURE: NON ADJUSTABLEVALVE CLEARANCE: HYDRAULIC (ZERO LASH)SPARK PLUG: AUTOLITE 4265SPARK PLUG GAP: .038 - .043 INCHESIGNITION TIMING: NON ADJUSTABLEIDLE SPEED: 900-1000 RPM IN NEUTRALFUEL: UNLEADED GASOLINE ONLY - 91 (R+M)/2 OCTANE OR HIGHEROIL: SAE 20 W 50

THIS ENGINE CONFORMS TOUS EPA REGULATIONS APPLICABLE TO MODEL YEAR NEW ENGINES

MANUFACTURED ON (MM/YY)

ENGINE SERIAL NO.


ENGINE DISPLACEMENT: 125 ciENGINE FAMILY: 9GMGC2048TDCThis vehicle conforms to EPA regulations applicable to 2009 model year new motorcycles and is certified to 1.4g/km HC+Nox, 12g/km CO exhaust emission standard.ENGINE ECS: EM

ENGINE TUNEUP SPECIFICATIONS:IGNITION TIMING: 32 BTDCIDLE SPEED: 900-1000 RPM IN NEUTRALFUEL: UNLEADED GASOLINE ONLY - 91 (R+M)/2 OCTANE OR HIGHEROIL: SAE 20 W 50

Made in USADate of Manufacture:


ENGINE SERIAL NO.


ENGINE DISPLACEMENT: 115 ciENGINE FAMILY: 9GMGC2048TDCThis vehicle conforms to EPA regulations applicable to 2009 model year new motorcycles and is certified to 1.4g/km HC+Nox, 12g/km CO exhaust emission standard.ENGINE ECS: EM

ENGINE TUNEUP SPECIFICATIONS:IGNITION TIMING: 32 BTDCIDLE SPEED: 900-1000 RPM IN NEUTRALFUEL: UNLEADED GASOLINE ONLY - 91 (R+M)/2 OCTANE OR HIGHEROIL: SAE 20 W 50

Made in USADate of Manufacture:


ENGINE SERIAL NO.

2-5

2.3 Engine InstallationBEFORE YOU BEGIN:

The RevTech engine is designed as a replacement for the Harley-Davidson® Evolution® engine. Any Harley-Davidson® model built with the Evolution® engine can accept the installation of the RevTech engine. Furthermore, any aftermarket chassis designed to accept Evolution® engines can also accept the RevTech engine.

The installation procedures shown in this section are based on the Harley-Davidson® Softail® chassis. Other solid-mount frames such as pre-Softail® FX® 4-speed frames and various rigid (no rear suspension) frames designed to use Evolution® engines will follow the same installation procedures as with the Softail® chassis. Rubbermount chassis such as those found on FXR®, FLT® and Dyna® models require some procedures for engine removal and installation that differ from those of the Softail® chassis. Therefore, it is imperative that the installer/owner use this manual in conjunction with an OEM service manual for the year and model of motorcycle in which the RevTech engine is to be installed. Other than the engine mount and oil line differences between Softail® and rubbermount chassis, the remainder of the engine installation instructions in this section are valid for all chassis types.

For custom motorcycles built from scratch, and for complete custom motorcycles (either production-custom or one-off individual custom motorcycles), consult the frame manufacturer or the manufacturer of the complete motorcycle for any specific installation questions not covered in this manual or an OEM service manual.

This section:

The installation procedure that follows in the subsequent pages begins with the existing engine and all other relevant components already removed from the motorcycle, as outlined by the manufacturer.

2-6

2.3 Engine Installation

Before installing the engine, remove the oil filter to avoid damage. Thoroughly clean the front and rear engine mounting surfaces and all other parts of the frame that are dirty. Set the engine in place by installing it from the right side of the motorcycle. Next, follow the OEM service manual’s procedures for installing and torquing the front and rear engine mount bolts and also the inner primary mounting bolts.

Install and adjust the compensating sprocket, primary chain, and outer primary following the OEM service manual’s instructions. Torque all hardware to the values specified.

A vacuum fitting is located on the back side of the carburetor (INSET, ARROW) to which the vacuum line for the VOES (Vacuum Operated Electric Switch) must be attached (MAIN IMAGE, ARROW). As this is a vacuum line, no clamp is necessary. Simply push the line over the fitting until it bottoms against the carburetor body.

Before installing the engine in the chassis, ensure that the engine-to-primary o-ring is in place (A). Next, the alternator stator must be installed. The set screw (B) holds the stator plug in place, preventing it from slipping back into the engine case. DO NOT over-tighten this set screw, or damage to the stator plug may result. Before installing the magnet/rotor, make sure that the appropriate spacer is installed over the sprocket shaft first (INSET).

As mentioned, you must have an OEM service manual for the year and model of the motorcycle on which the work is to be performed. Use of the service manual in conjunction with this guide is required for correct installation of the RevTech engine.

To begin, follow the OEM service manual’s procedures for ‘Stripping Motorcycle for Engine Repair’ and ‘Removing Complete Engine.’ This will leave the motorcycle stripped and ready for installation of the RevTech engine.

INSTALLING ENGINE IN CHASSIS

2-7


Follow the OEM service manual’s procedures for installation and adjustment of the throttle and idle cables to the carburetor. Ensure that the throttle opens the carburetor slide completely, or poor performance may result. This can be checked by removing the air cleaner and watching the slide travel as you open the throttle.

SEE DIAGRAM 1 (Page 2-14)

Before installing the oil lines, completely flush out the oil tank and lines to ensure they are clean and free of debris (it is recommended to use new 3/8” oil line when making an engine change). Use either worm-style or squeeze-type hose clamps to secure the lines to the fittings.

To oil tank vent

Feed fromoil tank

To oil tankreturn

To Oil Filter

The fuel-in fitting is located on the rearward-facing side of the carburetor (INSET). When hooking up the fuel system, it is recommended to use a new piece of fuel line. Selecting the correct grade of fuel line is important to ensure that your engine installation meets all regulations. Attach a long piece of 5/16” fuel line to the fitting on the carburetor and attach with a worm-style or squeeze-type hose clamp.

The VOES should be attached to the underside of the top engine mount (INSET). Follow the OEM service manual's procedures for proper wiring of the VOES. Continue following the OEM service manual’s procedures for installing and torquing the top engine mount hardware. At this point, the engine is now securely bolted into the frame and attached to the primary drive.

FUEL LINES, THROTTLE CABLES AND OIL LINES

2-8


Verify that the engine idle speed is 1,000rpm by use of the tachometer. If your motorcycle is not so equipped, it is recommended to obtain a tachometer for periodically checking idle speed if you choose not to install one on your motorcycle. Adjust the idle screw (ARROW) to achieve the correct idle speed. If further adjustments are necessary, follow the procedures listed in the OEM service manual regarding correct adjustment of the throttle and idle cables.

Complete the installation of the remaining vehicle components by following the OEM service manual’s procedures for 'Engine Installation'.

Install the oil pressure switch wire, re-install the oil filter that was included with the engine, and fill the oil tank to the specified level as noted in your service manual.

Follow the instructions in SECTION 3 - Owner's Manual for the proper engine break-in procedure and recommended maintenance schedule.

SEE DIAGRAM 2 (Page 2-14)

To comply with regulations, an appropriate exhaust system must be used with your RevTech engine. See DIAGRAM 2 on Page 2-14 for details. Following the OEM service manual’s procedures, install the exhaust system to the motorcycle. Torque all fasteners as recommended in the OEM manual.

SEE IGNITION SYSTEM INSTALLATION (Pages 2-9 - 2-13)

Follow the detailed instructions in Ignition System Installation, Pages 2-9 through 2-13, regarding the installation and wiring of the ignition system into your motorcycle. Using the wiring diagram in your OEM service manual, connect the ignition system to the wiring harness in the motorcycle. The ignition system provided with your RevTech engine is capable of running in Single-Fire or Dual-Fire mode.

MODESELECT

ADJUST

STATUS

VOES

IGNITION SYSTEM, EXHAUST SYSTEM AND IDLE SPEED ADJUSTMENT

2-9

2.4 Ignition System InstallationThe 658183 ignition unit offers switch selectable single or dual fire modes. Single fire mode improves starting, reduces the occurrence of backfiring at low RPM, and improves power at high RPM. A red status LED flashes when the engine reaches top dead center (TDC) and allows easy static timing. The status LED also provides diagnostic information. A green VOES LED illuminates when the VOES input is active.

Installation:

1. Route the wire harness along the frame tubing to the ignition coil. Make sure that the harness is clear of hot exhaust areas and cannot chafe against sharp edges. Secure the harness with nylon cable ties.

2. Refer to the appropriate wiring diagrams on page 2-11 for dual fire and page 2-12 for single fire. Use appropriate crimp terminals for coil and VOES hookup. With the exception of the tachometer and rear coil section (single fire only), standard H-D® wire color codes are used. Tape up any unused wires.

3. Install the supplied connector set on the brown tachometer wire as shown. If a tachometer is not used, seal the end of the mating plug with silicone RTV and use it as a protective cover. Use a proper crimping tool or solder the terminals.

4. Reconnect the battery ground cable.

NOTE: The unit is grounded by means of the gear case housing. The mounting surface must not be anodized or painted.

WARNING: Do not adjust the ignition timing. RevTech engines are delivered from the factory with the ignition timing set. Any attempt to adjust the ignition timing will be considered 'tampering' and may result in penalties imposed by the federal government.

Operating Modes:

A single 10 position rotary switch is used to select the operating mode. Switch settings are as follows:0 Dual fire, multi-spark disabled1 Dual fire, multi-spark enabled2 Single fire, multi-spark disabled3 Single fire, multi-spark enabled4-9 Reserved

CAUTION: Engine damage from excessive timing advance may result if the purple/white VOES wire is inadvertently shorted to ground.

The engine will not run if the mode switch setting does not match the wiring hookup (that is, you cannot select single fire mode with a dual fire coil hookup). We recommend that you enable multi-spark. When multi-spark is enabled, a continuous series of sparks is fired from the advanced timing point until TDC. Most air-cooled engines require relatively cold spark plugs to prevent detonation under high load. Multi-spark reduces the consequent tendency for plug fouling at idle.

2-10

2.4 Ignition System InstallationRPM Limiter:

The 658183 unit has preprogrammed RPM limits. A lower 4,500 RPM break-in limit is used during the first 10 hours of operation. After the break-in period has elapsed, the limit increases to 5,700 RPM. The unit uses a newly developed RPM limiting algorithm that has been highly optimized for odd firing V-twin engines. When the engine is held against the RPM limit, cylinder firing is always paired. This results in very smooth operation compared to random or sequence type RPM limiters.

General Recommendations:

Coil primary resistance must not be less than 3 ohms. Most OE style dual fire and aftermarket single fire coils meet this requirement. Coils for Twin Cam® engines have low primary resistance and are not compatible.

Due to the short lengths involved on motorcycle applications, energy losses in spark plug wires are insignificant. OE carbon core suppression cables will deteriorate after several years. For a more durable replacement, we suggest spiral core spark plug cables.

CAUTION: Do not use solid copper spark plug cables or non-resistor type spark plugs. If used, the unit may misfire.

The 658183 module is compatible with all modern "ground sensing" type tachometers including H-D® OE and Autometer units. The red status LED is internally connected to the tachometer output. If the red status LED blinks, the tachometer output should be functional. Some early tachometers require a high voltage trigger pulse. In this case, you will require a commercially available tachometer adapter.

VOES Considerations:

The VOES is normally open. At low manifold pressure or manifold vacuum greater than about 5 inch-Hg, the VOES grounds the purple/white wire and causes the 658183 module to generate additional timing advance.

The green VOES LED illuminates whenever the vacuum switch input is active (timing advanced).

2-112-11

MODESELECT

ADJUST

STATUS

VOES

2.4 Ignition System InstallationFIGURE 1 - Dual-Fire Ignition Wiring Diagram

2.4 Ignition System InstallationFIGURE 1 - Dual-Fire Ignition Wiring Diagram

2.4 Ignition System Installation

2-12

MODESELECT

ADJUST

STATUS

VOES

FIGURE 2 - Single-Fire Ignition Wiring Diagram

IGNITION SYSTEM TROUBLESHOOTING FLOWCHART

Follow the troubleshooting flowchart shown below. Experience has shown that most units returned for warranty are okay and another problem, such as a defective coil, is later identified.

2.4 Ignition System Installation

2-13

2-14

2.5 Installation Diagrams

Federal law states that it must be possible to sample exhaust emissions after a vehicle has been placed in service. In order to comply with this requirement, all RevTech® engines must utilize an exhaust system with at least a two foot straight section before the pipe end (point where exhaust products enter the surrounding atmosphere). If necessary, exhaust sampling can be performed by placing a gas analyzer probe two feet into the exhaust pipe as shown here. If your exhaust system has dual outlets, it must be possible to sample emissions from both pipes.

In this diagram, all connections for the engine's oil lines are shown. As oil tank design will vary from model and manufacturer, it is important to refer to your OEM service manual to familiarize yourself with the correct function of all connections on the oil tank in your motorcycle. Improperly connecting oil lines from the oil tank to your RevTech engine could result in engine damage or failure.

Before installing the oil lines, the oil tank must be flushed out, cleaned and dried to ensure that no debris enters the engine. It is also highly recommended that new oil lines and clamps be used.

DIAGRAM 1 - Oil Line Routing

DIAGRAM 2 - Exhaust System Compliance

To oil tank vent

Feed fromoil tank

To oil tankreturn

To Oil Filter

SECTION 3 Owner’s Manual 3.1 Engine Break-In Procedure 3.2 Maintenance Schedule 3.3 Maintenance Procedures 3.4 Troubleshooting Guide

3-2

3.1 Engine Break-In ProcedureTo ensure long life and optimum performance from your new RevTech engine, the break-in procedures listed below must be strictly followed. Failure to adhere to these procedures may void your warranty, so please review these break-in procedures carefully.

CAUTION: Stop and go traffic, and excessive idling should be avoided during the break-in period (0-2,500 miles). Otherwise, overheating and engine damage could occur. The first 500 miles are the most important for your engine!

Note:During break-in, use a high quality, non-synthetic motorcycle oil such as RevTech or RevTech •Pure to ensure that all components seat properly. After break-in, change engine oil at least every 2500 miles.

We reccommend 20W50 motorcycle oil for RevTech engines under normal operating •conditions, and 25W60 motorcycle oil for use in temperatures above 80°F (27°C).

The ignition rev-limiter will restrict engine speed to 4500 rpm during the first 10 hours of use. •After the initial 10 hour break-in period, the rev-limiter setting will automatically change to 5700 rpm.

0-50 Miles:After starting the engine, check for oil and fuel leaks. If all is well and the engine is at operating temperature, proceed for the first 50 miles avoiding engine RPMs above 4000 and below 2500 so the piston rings have a chance to seat properly. Vary your speed as much as possible and do not “lug” the engine in higher gears.

Service Requirements (50 miles):Change engine oil and oil filter• Clean tappet screen•

50-500 Miles:Proceed for the next 450 miles avoiding RPMs above 4500. Always let the engine reach proper operating temperature before riding. Do not subject the engine to hard acceleration or “lug” the engine in higher gears.

Service Requirements (500 miles): Change engine oil and oil filter• Clean tappet screen• Check idle speed and adjust if necessary• Inspect spark plugs and replace if necessary•

500-2500 Miles:Your engine may now be operated normally. Avoid hard acceleration until you have 2000 miles and always avoid “lugging” the engine in higher gears.

Service Requirements (2500 miles): Change engine oil and oil filter• Inspect air cleaner - clean and re-oil if necessary•

3-3

3.2 Maintenance Schedule

500 Mile Required Maintenance1. Change engine oil and oil filter2. Clean tappet screen3. Check idle speed and adjust if necessary4. Inspect spark plugs and replace if necessary

2,500 Mile Required Maintenance1. Change engine oil and oil filter2. Inspect air filter - clean & re-oil if necessary

5,000 Mile Required Maintenance1. Change engine oil and oil filter2. Clean tappet screen3. Inspect air filter - clean & re-oil if necessary4. Check idle speed and adjust if necessary5. Inspect spark plugs and replace if necessary

7,500 Mile Required Maintenance1. Change engine oil and oil filter2. Inspect air filter - clean & re-oil if necessary

10,000 Mile Required Maintenance1. Change engine oil and oil filter2. Clean tappet screen3. Inspect air filter - clean & re-oil if necessary4. Check idle speed and adjust if necessary5. Inspect spark plugs and replace if necessary

12,500 Mile Required MaintenancePerform 2500 mile required maintenance








Your new RevTech engine was designed to provide a long life of service. To ensure that you get the most from your engine, strictly follow the maintenance schedule listed here, and use the recommended service parts whenever possible.

Item Description CCI Part #

Quantity

Engine Oil RevTech 20W50 or equivalent (under 80° F / 27° C) 35052 3-4 quarts*RevTech 25W60 or equivalent (above 80° F / 27° C) 35048 3-4 quarts*

Oil Filter Chrome RevTech 'Long' or equivalent 35078 1Spark Plugs Autolite 4265 (set gap to .040" / 1.02mm) 22185 2Air Filter RevTech High-Performance 58284 1

Recommended Service Parts and Fluids

Correct engine idle speed: 1000rpm

Recommended Maintenance Schedule

* Refer to OEM manual for correct oil requirements.

WARNING: Improper servicing of your engine can cause seizure or other equipment malfunction which can lead to injury or death. Never attempt a service operation which you do not thoroughly understand.

3-4

3.3 Maintenance Procedures

The oil should be changed only when the engine is at normal operating temperature. If the engine is not at normal operating temperature, the motorcycle should be ridden until the engine reaches that stage. When the engine is sufficiently warmed up, turn the engine off to change the oil.

Locate the engine oil tank and drain plug on your motorcycle. Following the procedures listed in the appropriate service manual for your year and model of motorcycle, drain the oil. Use the type and quantity of oil recommended in the MAINTENANCE SCHEDULE on Page 3-3.

Change engine oil and oil filter - SERVICE INTERVALS: ALL

All RevTech engines utilize a tappet screen as a preventative measure to keep large debris from entering the oiling system that feeds the lifters. Using a large, broad, flat-blade screwdriver, remove the tappet screen plug. Remove and inspect the tappet screen (INSET), then clean it and the tappet screen plug.

Lightly oil the o-ring on the tappet screen plug, place the tappet screen back into the engine case and tighten the plug securely.

Clean tappet screen - SERVICE INTERVALS: 500, 5K, 10K, 15K, 20K, 25K, 30K

The oil should be checked only when the engine is at normal operating temperature. If the engine is not at normal operating temperature, the motorcycle should be ridden until the engine reaches that stage. When the engine is sufficiently warmed up, turn the engine off to check the oil level.

Locate the engine oil tank and filler plug on your motorcycle. Following the procedures listed in the appropriate service manual for your year and model of motorcycle, check the oil level. Add oil as necessary, using oil recommended in the MAINTENANCE SCHEDULE on Page 3-3.

Check oil level - SERVICE INTERVALS: ALL, BEFORE EACH RIDE

The following six procedures provide a visual step for the five areas of maintenance covered in the Maintenance Schedule, and the most crucial 'every time you ride' step, checking the oil level.

3-5

3.3 Maintenance Procedures

Verify that the engine idle speed is 1,000rpm by use of the tachometer (if your motorcycle is so equipped), or with a suitable timing light. Adjust the idle screw (arrow) to achieve the correct idle speed. If further adjustments are necessary, follow the procedures listed in the appropriate service manual for your year and model of motorcycle to correctly adjust the throttle and idle cables.

Check idle speed - SERVICE INTERVALS: 500, 5K, 10K, 15K, 20K, 25K, 30K

To access the spark plugs, first disconnect the spark plug cables from the plugs by pulling on the molded connector caps. Using a spark plug wrench, remove the spark plugs. Following the procedures listed in the appropriate service manual for your year and model of motorcycle, inspect the spark plugs and replace as necessary.

Before installing new spark plugs, the gap should be checked and adjusted if necessary. Apply a small amount of anti-seize compound to the threads as shown (INSET). Once re-installed, the spark plugs must be tightened to the specified torque (11-18 lbs.-ft.) to ensure proper heat transfer. If a torque wrench is not available, tighten the plugs by hand, then tighten them another 1/4-turn with a

Inspect spark plugs - SERVICE INTERVALS: ALL

Remove the air cleaner cover and inspect the condition of the element. If the element has a red coloration, it is suitable for continued use. A darker brown color will indicate that the filter is dirty and in need of cleaning. For illustration, a new, clean air flter is placed atop a well-used, dirty filter. Use K&N's cleaning kit (CCI #5561123 or #5561125) for cleaning and re-oiling the air filter following the guidelines included with the kit.

Do not run the engine without the air filter element in place. Dust and debris could be drawn into the engine, thereby causing significant damage.

Inspect air filter - SERVICE INTERVALS: ALL EXCEPT 500

3-6

3.4 Troubleshooting GuideHard Starting

Check for: Remedy:

1. Fuel tank empty or fuel supply blocked 1. Check fuel tank, fuel valve and fuel lines

2. Fouled spark plugs or improper gaps 2. Replace spark plugs or adjust gaps

3. Battery discharged 3. Charge battery

4. Intake air leak 4. Check manifold seals

5. Engine flooded 5. Let engine sit for 10 minutes

6. Spark plug cables in poor condition 6. Replace cables

7. Water or dirt in carburetor 7. Clean carburetor

8. Choke not operating correctly 8. Adjust cable

9. Loose wire connection at coil, battery or ignition module 9. Check all connections

Poor Engine Idle

Check for: Remedy:

1. Fouled spark plugs or improper gaps 1. Replace spark plugs or adjust gaps

2. Spark plug cables in poor condition 2. Replace cables

3. Idle speed improperly adjusted 3. Adjust idle speed to 1000 RPM

4. Clogged pilot jet 4. Clean jet

5. Faulty ignition coil, module or sensor 5. Inspect and replace as necessary

6. Dirty air or fuel filter 6. Clean or replace as necessary

7. Water or dirt in carburetor 7. Clean carburetor

8. Fuel tank or carburetor vent clogged 8. Clear blockage

9. Choke still in “on” position 9. Turn choke “off”


11. Loose wire connection at coil, battery or ignition module 11. Check all connections

Poor Fuel Economy

Check for: Remedy:

1. Excessive choke use 1. Only use until engine is at operating temp.

2. Idle speed improperly adjusted 2. Adjust idle speed to 1000 RPM

3. Dirty air filter 3. Clean or replace as necessary

4. Loose jets 4. Tighten jets

5. Fuel level too high (overflows) 5. Adjust level

6. Worn or damaged needle or needle jet 6. Replace needle or needle jet

7. Plugged jets or air passages 7. Clean and clear

Poor Acceleration

Check for: Remedy:

1. Fuel tank vent clogged 1. Clear blockage


3. Accelerator system leaking or no output 3. Repair as necessary

4. Fuel supply restricted 4. Check fuel valve and fuel lines



Poor On-Road Performance

Check for: Remedy:


2. Fuel tank vent clogged 2. Clear blockage

3. Dirty air filter 3. Clean or replace as necessary

4. Accelerator pump inoperative 4. Repair as necessary

5. Fuel supply restricted 5. Check fuel valve and fuel lines



8. Loose or plugged main jets 8. Tighten or clean as necessary

SECTION 4 Parts Catalog 4.1 Parts Catalog

The components used to manufacture RevTech® engines are available for sale. This means that your RevTech® engine can be maintained with genuine RevTech® parts to provide extended service and perfor-mance.

RevTech® engine components are available only through authorized Custom Chrome dealers and are not directly available for sale from Custom Chrome to the general public. Use this parts catalog to determine the correct part and part number when ordering replacement components for your RevTech® engine.

4.1 Parts Catalog

4-2

ALWAYS INSIST ON GENUINE

REPLACEMENT PARTS

4.1 Parts Catalog

4-3

Engine Assembly, Complete – RevTech® 125" Motor

Part # Description

680272 49-State Natural aluminum finish680271 49-State Black wrinkle finish680270 49-State Polished finish


Part # Description



Part # Description



Part # Description



Part # Description

58500 Black wrinkle finish58501 Natural aluminum finish58503 Polished finish

NOTES: Regarding the RevTech® 115" & 125" Big Twin Engines:1. Size = Stroke and Bore (4.25" x 4.41" = 125 inch) (4.125" x 4.30" = 115 inch)

Regarding the RevTech® 110" & 100" 4x4 Big Twin Motors:1. Size = Stroke and Bore. (4 3/8" x 4" = 110 inch) (4" x 4" = 100 inch)2. Finish or color of cases, cylinders & heads all with chrome covers. a. Black Powder Coated paint, wrinkle finish, the cylinder fins machined. b. Natural (raw) aluminum finish with cylinder fins machined. c. Polished aluminum finish with cylinder fins machined.3. Engines are completely assembled

RevTech Gen 2 Complete Motor Assembly

SEE CHART A, B

88 Inch & 100 Inch Motors

SEE CHART C, D, E

31657

2135194065

9398759430

5415059431

58162

2385758265

9398732813

5828858289

2605426055

28081

28027

54440

54014

5827058271

58284

75400

59657

59628

54009

37064 35627

25300

59240

54006

2531120036

26048

32105

26173

659000659001659002

657055

2517714625

59654

59624

59622

5961359623

94053

94053

660350

660352

12328660370

99196

5964659660

58089-In659617-Ex

STD+.001”

5825058251

660358-F660351-R

659626

35623

94054-7

2009520091

28014

58076~7

69404094045~51

58072

20645 26011

659645

31700

3170132108

32812

692042 32813

692040

692041

9363732111

71014

659005

598975989859899

2133892236

54423

32104

20235

54250

2023920240

54058

20281

2023720238

20029

54000

20095

20243

19485

20244

54254

20233

2024319485

20241

20242

94034

75585

28013

1771432106

25335

32110

25403

25273

65803458125

5823058235

26010 93537

3211632813

20302

35078

32787

58630

658180

28555

5972659725

54442

54441

54085

54082

54414

54086

54227

93500

2540420213~7

94018

660360

20283660367

660365

4.1 Parts Catalog

4-4

CCI # Description12328 Ignition plate studs and washers. (repl. OEM 32601-78) Pack of 10.14625 Chrome 5/16"-18 nylon-inserted lock nuts. Pack of 10.17714 Oil pressure switch. (repl. OEM 26561-84)19482 O-Ring, tappet oil screen & oil pump plug. (repl. OEM 11105) Pack of 10.20029 Oil pump shaft. (repl. OEM 26346-70)20036 Spacer, engine sprocket shaft. (repl. OEM 24002-70)20091 Pinion shaft key, pinion gear.(repl. OEM 23985-54) Pack of 10.20095 Oil pump shaft key.(repl. OEM 26348-15) Pack of 10.20213 Cam shims .060" thick. (repl. OEM25552-36) Pack of 5.20214 Cam shims .065" thick. (repl. OEM25553-36) Pack of 5.20215 Cam shims .070" thick. (repl. OEM25554-36) Pack of 5.20216 Cam shims .075" thick. (repl. OEM25555-36) Pack of 5.20217 Cam shims .080" thick. (repl. OEM25556-79) Pack of 5.20233 Chrome plug, 1/8-27 NPT oil pump body. 20235 Chrome hose fitting, 3/8" hose. (repl. OEM 63533-41) Sold each.20237 Drive gear-oil return, case side. (repl. OEM 26315-68A)20238 Idler gear-oil return, case side. (repl. OEM 26317-68A)20239 Drive gear-oil supply, cover side (repl. OEM 26328-74)20240 Idler gear-oil supply, cover side (repl. OEM 26326-62A)20241 Spring, oil pump relief valve. (repl. OEM 26207-83) Sold each.20242 Plunger, oil pump relief valve. ( repl. OEM 26400-82) Sold each.20243 Chrome plug, tappet oil screen & oil pump. (repl. OEM 26263-80) Sold each.20244 Spring, oil pump check valve. (repl. OEM 26262-80) Sold each.20281 Revtech polish complete oil pump assembly. 20283 Polish Revtech oil pump cover.20302 Chrome oil filter housing. Includes fittings & mounting hardware.20645 Pinion shaft nut, left hand thread.(repl. OEM 24023-54) Sold each.21338 #10 flatwasher, stainless steel. Sold each.21351 Chrome banjo fitting, breather. Sold each. 23857 Rubber intake adapter flange with hose clamp for 42mm Mikuni carbs.25177 Chrome 5/16" flat washer. Pack of 100.25273 Bushing, upper piston rod +.002" oversize. (repl. OEM 24334-36) Sold each.25300 O-Ring, middle pushrod cover. (repl. OEM 11132) Pack of 10.25311 Oil seal, left engine case. (repl. OEM 12026B) Pack of 5.25335 Seal, cam cover. (repl. OEM 83162-51)25403 Cam needle bearing. (repl. OEM 9058) 25404 Thrush washer, cam gear. (repl. OEM 25550-57) Pack of 5.26010 Cam bushing, cam cover. (repl. OEM 25581-70)26011 Pinion bushing, cam cover.(repl. OEM 25582-73)26048 Left engine case Timken bearing set. (repl. OEM 9028)26054 Rocker arm, rear exhaust or front intake. (repl. OEM 17360-83)26055 Rocker arm, front exhaust or rear intake. (repl. OEM 17375-83)26173 Chrome Evo front & rear tappet block set. Includes hardware.28013 Oil pump driven gear 24 tooth. (repl. OEM 26345-73) 28014 Oil pump drive gear. (repl. OEM 26349-73) 28027 Rocker arm shaft. (repl. OEM 17611-83)28081 Bushing, rocker arms.(repl. OEM 17428-57) Sold each.28530 Chrome smooth profile rocker box cover set.31657 Chrome banjo bolt, breather. Sold each. 31700 Chrome oil pump cover with spacers & hardware.31701 Spacers, oil pump cover. Sold in pairs.32104 Chrome 1/4-20 x 3/4" sockethead bolt. Pack of 10.32105 Chrome 1/4-20 x 7/8" sockethead bolt. Pack of 10.32106 Chrome 1/4-20 x 1" sockethead bolt. Pack of 10.32108 Chrome 1/4-20 x 1-1/2" sockethead bolt. Pack of 10.32110 Chrome 1/4-20 x 2" sockethead bolt. Pack of 10.32111 Chrome 1/4-20 x 2-1/4" sockethead bolt. Pack of 10.32116 Chrome 5/16-18 x 1-1/4" sockethead bolt. Pack of 10. 32787 Chrome 8-32 x 1/2" flathead screws. Pack of 10.32812 Chrome 1/4" AN flatwasher. Pack of 50.32813 Chrome 5/16" AN flat washer. Pack of 50.35078 Revtech high performance spin-on oil filter.35623 Chrome timing hole plug.35627 Inner pushrod cover set. Set of 4.37064 Chrome complete pushrod cover kit. Set of 4.54000 Retaining ring, oil pump driven gear, (repl. OEM 11002) Pack of 10.54006 O-Ring, lower pushrod cover. (repl. OEM 11145) Pack of 10.54009 O-Ring, upper pushrod cover. (repl. OEM 11157) Pack of 10.54014 O-Ring, cylinder dowel. (repl. OEM 26432-76A) Pack of 1054058 Oil seal, oil pump shaft. (repl. OEM 2622-58) Pack of 10.54082 Gasket, silicone inner rocker box.(repl OEM 17358-84A) Pack of 10.54085 Gasket, silicone lower rocker box.(repl. OEM 17355-92) Pack of 1054086 Gasket, silicone upper rocker box. (repl. OEM 17356-92) Pack of 10.54150 Seal, intake manifold. Pack of 10.54250 Retaining ring, oil pump drive shaft. (repl. OEM 26348-36) Pack of 10.54254 Check ball, oil pump. (repl. OEM 8873) Pack of 10.54414 Umbrella valve. (repl. OEM 26856-89) Pack of 10.54423 O-Ring, oil pump end cap. (repl. OEM 11241) Pack of 10.54440 O-Ring, upper cylinder to head. Pack of 1054441 O-Ring, oil control jet. Pack of 1054442 O-Ring, lower cylinder to case. Pack of 1058072 Thrust washer, Revtech breather valve, Pack of 4 with 4 different thickness. 58076 Revtech breather valve, stock duration.58077 Revtech breather valve, +10° duration.58079 Revtech +.030" oversize breather valve, +10° duration.

58089 Revtech intake valve 1.94" dia. Sold each58125 Press-together flywheel assembly, 4-3/8" stroke for 100" Revtech motors.58162 Revtech intake manifold. 58230 Revtech EV-50 cam for 88" motor.58235 Revtech EV-100 cam for 100" motor.58250 Silver pushrods for 2 hole lifters. Set of 4. 58251 Black pushrods for 1 hole lifters. Set of 4.58265 HSR 42mm Mikuni carburetor with chrome top cover & choke cable.58270 Chrome Revtech 88" air cleaner insert.58271 Chrome Revtech 100" air cleaner insert.58284 Revtech replacement air filter element.58288 Chrome Revtech 88" complete air cleaner & breather assembly .58289 Chrome Revtech 100" complete air cleaner & breather assembly.58630 Chrome point cover with Revtech logo.59240 Revtech hydraulic tappets. (repl. OEM 18523-86A) Sold each.59430 Rear intake manifold flange. (repl. OEM 27010-86A) Sold each.59431 Front intake manifold flange. (repl. OEM 27009-86A) Sold each.59432 Intake manifold flange set. Sold in pairs.59613 Inner valve spring spacer, (.115" thick) 59622 Revtech valve springs. Sold as a set for one valve. 59623 Valve spring lower collar. Sold each.59624 Valve spring upper collar. Sold each.59628 Exhaust studs, Sold each.59646 Valve guide intake and exhaust standard size.59654 Valve keepers. Sold in pairs.59657 Chrome plated 12 point flanged outer head bolts.

(repl. OEM 16480-92A) Sold each.59660 Valve guide intake and exhaust +.001" oversize.59725 Ignition rotor. (repl. OEM 32402-83)59726 Screw and washer, ignition rotor. (repl. OEM 2611B) pack of 10.59897 Natural Gen II sump plate.59898 Black Gen II sump plate.59899 Polish Gen II sump plate.71014 Chrome 90° hose fitting, 1/8 NPT, 3/8" hose. (repl. OEM 63554-90) Pack of 10.75400 Zinc plated 12 point flanged inner head bolts. (repl. OEM 16478-85A) Sold each.75585 Tappet oil screen. (repl. OEM 24981-70) Pack of 5.92236 #10-24 x 5/8" hex screws, stainless steel. Pack of 10.93500 Chrome 12-point flange bolt, rocker box top cover. Pack of 1093501 Brass 1/4" washer, rocker box top bolts. Pack of 10.93537 Chrome 1/4" flatwasher with 7/16" o.d. Pack of 10.93637 Flat washer, Revtech oil pump. Pack of 6.93987 Black oxide 5/16-18 x 3/4" sockethead bolt. Pack of 10.94018 Retaing ring, pinion bearing. (repl. OEM 11177A) Pack of 10.94034 Spring, tappet oil screen. (repl. OEM 24982-70) Pack of 5.94045 Pinion gear, orange. (repl. OEM 24040-78)94046 Pinion gear, white. (repl. OEM 24041-78)94047 Pinion gear, yellow. (repl. OEM 24042-78)94048 Pinion gear, red. (repl. OEM 24043-78)94049 Pinion gear, blue. (repl. OEM 24044-78)94050 Pinion gear, green. (repl. OEM 24045-78)94051 Pinion gear, black. (repl. OEM 24046-78)94053 Complete Evo rocker box hardware kit.94054 Pinion bearing, green. (repl. OEM 24628-87A)94055 Pinion bearing, red. (repl. OEM 24641-87A)94056 Pinion bearing, blue. (repl. OEM 24643-87A)94057 Pinion bearing, white/gray. (repl. OEM 24626-87A)94065 Aluminum head breather washers. Pack of 10.99196 Valve guide seals. Set of 4657055 Outer pinion shaft plug .060" hole. Pack of 10658034 Press-together flywheel assembly, 4-1/4" stroke for 88" Revtech motors.658180 Revtech electronic ignition with break-in rev-limiter.658181 Revtech electronic ignition without break-in rev-limiter.659000 Natural Revtech Gen II cases with studs, sump plate & case hardware.659001 Black Revtech Gen II cases with studs, sump plate & case hardware.659002 Polish Revtech Gen II cases with studs, sump plate & case hardware.659005 Gasket, Gen II sump plate. Pack of 10.659617 Revtech exhaust valve 1.61" dia. Sold each.659626 Cylinder studs, 3/8" x 7/16" x 6.70". Set of 8.659645 Revtech chrome cam cover.660350 Gasket, lower rocker box cover to head, right side

(repl. OEM 16778-84A) Pack of 10660351 Gasket, rear tappet block.( repl. OEM 18633-48D) Pack of 10.660352 Gasket, lower rocker box cover to head, left side

(repl. OEM 16779-84A) Pack of 10660358 Gasket, front tappet block.( repl. OEM 18634-48C) Pack of 10.660360 Gasket, cam cover with silicon bead. (repl. OEM 25225-93) Pack of 10.660365 Gasket, oil pump body to case. (repl. OEM 26373-92) Pack of 10.660367 Gasket, oil pump outer cover to body. (repl. OEM 26276-92) Pack of 10.660370 Gasket, point cover. (repl. OEM 32591-80) Pack of 10.692040 Chrome 5/16-18 x 3-1/2" hex bolt. Pack of 10.692041 Chrome 5/16-18 x 3" hex bolt. Pack of 10.692042 Chrome 1/4-20 x 3-1/2" hex bolt. Pack of 10.694040 Spacer, between pinion & oil drive gear. Pack of 10.

RevTech Gen 2 — 88 & 100 Motor Parts List

4.1 Parts Catalog

4-5

4.1 Parts Catalog

4-6

RevTech Gen 3 Complete Motor Assembly110 Inch & 100 Inch 4x4 Motors

658167

2135194065

9398759430

65816459431

658163

58279

675003675011

675002675010

32352

3221332218

28311

28313

32116

32118

94003

28312

628314

9261292607

53895

92606

53947

92605

660328

660327

28310

9398732813

658165658168

28027

53891

92610

92609

92617

659636659637

28081

653994

65816658271

58284

75400

59657

59628

54009

63706537064

35627

25300

59240

54006

2531120036

26048

32105

658161

587205872358726

657055

2517714625

699296

699258

699206

699207

699234

12328660370

99196

659705659706

659616-In659617-Ex

STD+.001”

660358-F660351-R

659625

654403659621

659620659628

35623

94054-7

2009520091

658150694040

94045~51

660360

20645 26011

659645

31700

3170132108

32812692042

32813692040

692041

9363732111

71014

659624

599005990159902

2133892236

20233

54423

32104

20235

54250658197

658198658143

658140

658195658196

20029

54000

20095

20243

19485

20244

5425420233

2024319485

20241

20242

94034

75585

658151

1771432106

25335

32110

25403

25273

5812058130

24309658236

26010 93537

3211632813

20302

35078

32787

58630

65818059726

59725

653994654400

2540420213~7

94018

20283620299

658147

620298

SEE CHART C, D, E, F

SEE CHART G, H

SEE CHART A, B

4.1 Parts Catalog

4-7

CCI # Description12328 Ignition plate studs and washers. (repl. OEM 32601-78) Pack of 10.14625 Chrome 5/16"-18 nylon-inserted lock nuts. Pack of 10.17714 Oil pressure switch. (repl. OEM 26561-84)19482 O-Ring, tappet oil screen & oil pump plug. (repl. OEM 11105) Pack of 10.20029 Oil pump shaft. (repl. OEM 26346-70)20036 Spacer, engine sprocket shaft. (repl. OEM 24002-70)20091 Pinion shaft key, pinion gear.(repl. OEM 23985-54) Pack of 10.20095 Oil pump shaft key.(repl. OEM 26348-15) Pack of 10.20213 Cam shims .060" thick. (repl. OEM25552-36) Pack of 5.20214 Cam shims .065" thick. (repl. OEM25553-36) Pack of 5.20215 Cam shims .070" thick. (repl. OEM25554-36) Pack of 5.20216 Cam shims .075" thick. (repl. OEM25555-36) Pack of 5.20217 Cam shims .080" thick. (repl. OEM25556-79) Pack of 5.20233 Chrome plug, 1/8-27 NPT oil pump body & sump plate.20235 Chrome hose fitting, 3/8" hose. (repl. OEM 63533-41) Sold each.20241 Spring, oil pump relief valve. (repl. OEM 26207-83) Sold each.20242 Plunger, oil pump relief valve. ( repl. OEM 26400-82) Sold each.20243 Chrome plug, tappet oil screen & oil pump. (repl. OEM 26263-80) Sold each.20244 Spring, oil pump check valve. (repl. OEM 26262-80) Sold each.20283 Polish Revtech oil pump cover.20302 Chrome oil filter housing. Includes fittings & mounting hardware.20645 Pinion shaft nut, left hand thread.(repl. OEM 24023-54) Sold each.21338 #10 flatwasher, stainless steel. Sold each.21351 Chrome banjo fitting, breather. Sold each. 24309 Revtech EV-72 cam for 110" & 100" 4x4 motor.25177 Chrome 5/16" flat washer. Pack of 100.25273 Bushing, upper piston rod +.002" oversize. (repl. OEM 24334-36) Sold each.25300 O-Ring, middle pushrod cover. (repl. OEM 11132) Pack of 10.25311 Oil seal, left engine case. (repl. OEM 12026B) Pack of 5.25335 Seal, cam cover. (repl. OEM 83162-51)25403 Cam needle bearing. (repl. OEM 9058) 25404 Thrush washer, cam gear. (repl. OEM 25550-57) Pack of 5.26010 Cam bushing, cam cover. (repl. OEM 25581-70)26011 Pinion bushing, cam cover.(repl. OEM 25582-73)26048 Left engine case Timken bearing set. (repl. OEM 9028)28027 Rocker arm shaft. (repl. OEM 17611-83)28081 Bushing, rocker arms.(repl. OEM 17428-57) Sold each.28310 Chrome smooth 2-piece rocker box set, front & rear.28311 Chrome smooth rocker box top cover.28312 Chrome smooth rocker box front base.28313 Rubber gasket, Smooth rocker boxes. Pack of 1028317 Chrome smooth rocker box rear base.31700 Chrome oil pump cover with spacers & hardware.31701 Spacers, oil pump cover. Sold in pairs.32104 Chrome 1/4-20 x 3/4" sockethead bolt. Pack of 10.32105 Chrome 1/4-20 x 7/8" sockethead bolt. Pack of 10.32106 Chrome 1/4-20 x 1" sockethead bolt. Pack of 10.32108 Chrome 1/4-20 x 1-1/2" sockethead bolt. Pack of 10.32110 Chrome 1/4-20 x 2" sockethead bolt. Pack of 10.32111 Chrome 1/4-20 x 2-1/4" sockethead bolt. Pack of 10.32116 Chrome 5/16-18 x 1-1/4" sockethead bolt. Pack of 10. 32118 Chrome 5/16-18 x 1-3/4" sockethead bolt. Pack of 10.32213 Chrome 5/16-18 x 3/4" Smooth sockethead bolt. Pack of 10.32218 Chrome 5/16-18 x 1-3/4" Smooth sockethead bolt. Pack of 10.32352 Chrome 5/16" sockethead plugs. Pack of 10032787 Chrome 8-32 x 1/2" flathead screws. Pack of 10.32812 Chrome 1/4" AN flatwasher. Pack of 50.32813 Chrome 5/16" AN flat washer. Pack of 50.35078 Revtech high performance spin-on oil filter.35623 Chrome timing hole plug.35627 Inner pushrod cover set. Set of 4.37064 Chrome complete pushrod cover kit. Set of 4.53891 O-ring, underneath breather assembly. (repl. OEM 11270). Pack of 10.53895 Umbrella Valve, breather assembly. (repl OEM 26858-99). Pack of 10.53947 Breather assembly filter element. (repl. OEM 63815-99). Pack of 10.54000 Retaining ring, oil pump driven gear, (repl. OEM 11002) Pack of 10.54006 O-Ring, lower pushrod cover. (repl. OEM 11145) Pack of 10.54009 O-Ring, upper pushrod cover. (repl. OEM 11157) Pack of 10.54250 Retaining ring, oil pump drive shaft. (repl. OEM 26348-36) Pack of 10.54254 Check ball, oil pump. (repl. OEM 8873) Pack of 10.54423 O-Ring, oil pump end cap. (repl. OEM 11241) Pack of 10.58120 Press-together flywheel assembly, 4-3/8" stroke for 110" Revtech motors.58130 Press-together flywheel assembly, 4" stroke for 100" 4x4 Revtech motors.58271 Chrome Revtech 100" air cleaner insert.58284 Revtech replacement air filter element.58630 Chrome point cover with Revtech logo.58720 Natural Revtech Gen III cases with studs, sump plate & case hardware.58723 Black Revtech Gen III cases with studs, sump plate & case hardware.58726 Polish Revtech Gen III cases with studs, sump plate & case hardware.59240 Revtech hydraulic tappets. (repl. OEM 18523-86A) Sold each.59430 Rear intake manifold flange. (repl. OEM 27010-86A) Sold each.59431 Front intake manifold flange. (repl. OEM 27009-86A) Sold each.59432 Intake manifold flange set. Sold in pairs.59628 Exhaust studs, Sold each.59657 Chrome plated 12 point flanged outer head bolts.

(repl. OEM 16480-92A) Sold each.59725 Ignition rotor. (repl. OEM 32402-83)59726 Screw and washer, ignition rotor. (repl. OEM 2611B) pack of 10.59900 Natural Gen III sump plate.59901 Black Gen III sump plate.59902 Polish Gen III sump plate.

71014 Chrome 90° hose fitting, 1/8 NPT, 3/8" hose. (repl. OEM 63554-90) Pack of 10.75400 Zinc plated 12 point flanged inner head bolts. (repl. OEM 16478-85A) Sold each.75585 Tappet oil screen. (repl. OEM 24981-70) Pack of 5.92236 #10-24 x 5/8" hex screws, stainless steel. Pack of 10.92605 Breather assembly lower housing.92606 Breather assembly middle housing.92607 Breather assembly top cover. 92609 Black oxide 5/16-18 x 2-5/8" hex head flanged bolt. Pack of 10.92610 Black oxide 5/16-18 x 2-3/8" hex head flanged bolt. Pack of 10.92612 Black oxide 1/4-20 x 2-1/4" hex head flanged bolt, head breather assembly.

Pack of 10.92617 Support tower, rocker arms.93537 Chrome 1/4" flatwasher with 7/16" o.d. Pack of 10.93637 Flat washer, Revtech oil pump. Pack of 6.93987 Black oxide 5/16-18 x 3/4" sockethead bolt. Pack of 10.94018 Retaing ring, pinion bearing. (repl. OEM 11177A) Pack of 10.94034 Spring, tappet oil screen. (repl. OEM 24982-70) Pack of 5.94045 Pinion gear, orange. (repl. OEM 24040-78)94046 Pinion gear, white. (repl. OEM 24041-78)94047 Pinion gear, yellow. (repl. OEM 24042-78)94048 Pinion gear, red. (repl. OEM 24043-78)94049 Pinion gear, blue. (repl. OEM 24044-78)94050 Pinion gear, green. (repl. OEM 24045-78)94051 Pinion gear, black. (repl. OEM 24046-78)94054 Pinion bearing, green. (repl. OEM 24628-87A)94055 Pinion bearing, red. (repl. OEM 24641-87A)94056 Pinion bearing, blue. (repl. OEM 24643-87A)94057 Pinion bearing, white/gray. (repl. OEM 24626-87A)94065 Aluminum head breather washers. Pack of 10.99196 Valve guide seals. Set of 4620298 Gasket, oil pump body to case. Pack of 10.620299 Gasket, oil pump outer cover to body. Pack of 10.628314 Metal gasket, rocker box base to head. Pack of 10637065 Chrome complete pushrod cover kit for 100" 4x4 motors only. Set of 4.653994 O-Ring, cylinder dowel / drain. Sold each.654400 O-Ring, lower cylinder to case. Pack of 10654403 O-Ring, piston oil squirters. Pack of 10657055 Outer pinion shaft plug .060" hole. Pack of 10658140 Revtech polish complete hi-flow oil pump assembly. 658143 Revtech hi-flow oil pump body only.658147 Oil seal, oil pump shaft. Pack of 10.658150 Oil pump drive gear, 3:1 ratio.658151 Oil pump driven gear 21 tooth, 3:1 ratio. 658161 Chrome Evo front & rear tappet block set. Includes hardware.658163 Revtech intake manifold. 658164 Seal, intake manifold. Pack of 10.658165 Chrome Revtech 110" complete air cleaner & breather assembly .658166 Chrome Revtech 110" air cleaner insert.658167 Chrome banjo bolt, breather. Sold in pairs. 658168 Chrome Revtech 100" 4x4 complete air cleaner & breather assembly.658180 Revtech electronic ignition with break-in rev-limiter.658181 Revtech electronic ignition without break-in rev-limiter.658195 Drive gear-oil return, case side. (repl. OEM 26315-68A)658196 Idler gear-oil return, case side. (repl. OEM 26317-68A)658197 Drive gear-oil supply, cover side (repl. OEM 26328-74)658198 Idler gear-oil supply, cover side (repl. OEM 26326-62A)658236 Revtech EV-110/100 smog cam for EPA motors.659616 Revtech intake valve 2" dia. Sold each659617 Revtech exhaust valve 1.61" dia. Sold each.659620 Rear piston oil squirter. 659621 Front piston oil squirter.659624 Gasket, Gen III sump plate. Pack of 10.659625 Cylinder studs, 3/8" x 7/16" x 6.30". Set of 8.659628 Black oxide #8-32 x 3/8" button head screw. Pack of 10.659635 Revtech roller rocker arm complete set.659636 Revtech roller rocker arm, rear exhaust or front intake. 659637 Revtech roller rocker arm, front exhaust or rear intake. 659645 Revtech chrome cam cover.659705 Valve guide intake & exhaust standard size.659706 Valve guide intake & exhaust +.001" oversize.660327 Gasket, breather top cover. (repl. OEM 17591-99). Pack of 10.660328 Gasket, breather baffle. (repl. OEM 17592-99) Pack of 10.660351 Gasket, rear tappet block.( repl. OEM 18633-48D) Pack of 10.660358 Gasket, front tappet block.( repl. OEM 18634-48C) Pack of 10.660360 Gasket, cam cover with silicon bead. (repl. OEM 25225-93) Pack of 10.660370 Gasket, point cover. (repl. OEM 32591-80) Pack of 10.675002 HSR 45mm Mikuni carburetor with chrome top cover & choke cable.675003 Oval rubber intake adapter flange with hose clamp for 45mm Mikuni carbs.675010 HSR 42mm Mikuni carburetor with chrome top cover & choke cable.675011 Oval rubber intake adapter flange with hose clamp for 42mm Mikuni carbs.692040 Chrome 5/16-18 x 3-1/2" hex bolt. Pack of 10.692041 Chrome 5/16-18 x 3" hex bolt. Pack of 10.692042 Chrome 1/4-20 x 3-1/2" hex bolt. Pack of 10.694040 Spacer, between pinion & oil drive gear. Pack of 10.699206 Outer valve spring, 600 lift. Sold each. 699207 Inner valve spring, 600 lift. Sold each. 699234 Valve spring lower collar. Sold each.699258 Valve spring upper collar. Sold each.699296 Valve keepers. Sold in pairs.

RevTech Gen 3 – 110 & 100 4x4 Motor Parts List

4.1 Parts Catalog

4-8

SEE CHART

RevTech Gen 4 Complete Motor Assembly115 Inch & 125 Inch Motors

684674684675

684635684636

684629684630684631

658161

37064

684653

684639

684658

SEE CHART

SEE CHART

SEE CHART

21351

58287658167

5827614625

9406593987

658164

684673

58279

59431

684676684677684669

684670

684638

654403 659636659637

28027

280813221932813

684662

68467159725

684637

68465158072 660359

94055~7 28014694040

20645

657055

654403684649

695628

20321

33386684650

53893

684633684632

21253

93537684634

32813692040

692041

35623

94018658150

20091

26011

32107

32812684641

20233 62029932107

93637

2024319485

2024454254

2024319485

20241

20242

94034

28013

620298 20095684647

5400093637

684648 7101454250

684642684643

684640648157

684644684645

684646

75585

32108

684668

17714

94045~51

25403684652

20213~7 24309658236

26010

59726

684657658180

684655684656

92609

684667

684662

35078

3211632813

20302

94077

32107

25335

93537

684663

684660

684666

684659

684661

68466454227684665

32108

3210632812

675003675011

675002

58282

92277

9398732813

59430

58278

25177

58285

58284

699296699258

699206

699207

69923499196

659705

659616 - In659617 - Ex

684672

59628

54009

59240

32105

12076-F12077-R

695625

2531120036

26048

94008

9400035627

940079400525300

36050

5400694004

22183 5828327177

4.1 Parts Catalog

4-9

CCI# Description14625 Chrome 5/16"-18 nylon-inserted lock nuts. Pack of 10.17714 Oil pressure switch. (repl. OEM 26561-84)19482 O-Ring, tappet oil screen & oil pump plug. (repl. OEM 11105) Pack of 10.20036 Spacer, engine sprocket shaft. (repl. OEM 24002-70)20091 Pinion shaft key, pinion gear.(repl. OEM 23985-54) Pack of 10.20095 Oil pump shaft key.(repl. OEM 26348-15) Pack of 10.20213 Cam shims .060" thick. (repl. OEM25552-36) Pack of 5.20214 Cam shims .065" thick. (repl. OEM25553-36) Pack of 5.20215 Cam shims .070" thick. (repl. OEM25554-36) Pack of 5.20216 Cam shims .075" thick. (repl. OEM25555-36) Pack of 5.20217 Cam shims .080" thick. (repl. OEM25556-79) Pack of 5.20233 Chrome plug, 1/8-27 NPT oil pump body & sump plate.20235 Chrome hose fitting, 3/8" hose. (repl. OEM 63533-41) Sold each.20241 Spring, oil pump relief valve. (repl. OEM 26207-83) Sold each.20242 Plunger, oil pump relief valve. ( repl. OEM 26400-82) Sold each.20243 Chrome plug, tappet oil screen & oil pump. (repl. OEM 26263-80) Sold each.20244 Spring, oil pump check valve. (repl. OEM 26262-80) Sold each.20302 Chrome oil filter housing. Includes fittings & mounting hardware.20645 Pinion shaft nut, left hand thread.(repl. OEM 24023-54) Sold each.21351 Chrome banjo fitting, breather. Sold each. 24309 RevTech EV-72 cam for 115" & 125" 4x4 motor.25177 Chrome 5/16" flat washer. Pack of 100.25300 O-Ring, middle pushrod cover. (repl. OEM 11132) Pack of 10.25311 Oil seal, left engine case. (repl. OEM 12026B) Pack of 5.25335 Seal, cam cover. (repl. OEM 83162-51)25403 Cam needle bearing. (repl. OEM 9058) 26010 Cam bushing, cam cover. (repl. OEM 25581-70)26011 Pinion bushing, cam cover.(repl. OEM 25582-73)26048 Left engine case Timken bearing set. (repl. OEM 9028)28027 Rocker arm shaft. (repl. OEM 17611-83)28081 Bushing, rocker arms.(repl. OEM 17428-57) Sold each.32105 Chrome 1/4-20 x 7/8" sockethead bolt. Pack of 10.32106 Chrome 1/4-20 x 1" sockethead bolt. Pack of 10.32107 Chrome 1/4-20 x 1-1/4" sockethead bolt. Pack of 10.32108 Chrome 1/4-20 x 1-1/2" sockethead bolt. Pack of 10.32112 Chrome 1/4-20 x 2-1/2" sockethead bolt. Pack of 10.32812 Chrome 1/4" AN flatwasher. Pack of 50.32813 Chrome 5/16" AN flat washer. Pack of 50.35078 RevTech high performance spin-on oil filter.35623 Chrome timing hole plug.35627 Inner pushrod cover set. Set of 4.37064 Chrome complete pushrod cover kit. Set of 4.54000 Retaining ring, oil pump driven gear, (repl. OEM 11002) Pack of 10.54006 O-Ring, lower pushrod cover. (repl. OEM 11145) Pack of 10.54009 O-Ring, upper pushrod cover. (repl. OEM 11157) Pack of 10.54250 Retaining ring, oil pump drive shaft. (repl. OEM 26348-36) Pack of 10.54254 Check ball, oil pump. (repl. OEM 8873) Pack of 10.58284 RevTech replacement air filter element.59240 RevTech hydraulic tappets. (repl. OEM 18523-86A) Sold each.59430 Rear intake manifold flange. (repl. OEM 27010-86A) Sold each.59431 Front intake manifold flange. (repl. OEM 27009-86A) Sold each.59432 Intake manifold flange set. Sold in pairs.59628 Exhaust studs, Sold each.59725 Ignition rotor. (repl. OEM 32402-83)59726 Screw and washer, ignition rotor. (repl. OEM 2611B) pack of 10.71014 Chrome 90° hose fitting, 1/8 NPT, 3/8" hose. (repl. OEM 63554-90) Pack of 10.75585 Tappet oil screen. (repl. OEM 24981-70) Pack of 5.92609 Black oxide 5/16-18 x 2-5/8" hex head flanged bolt. Pack of 10.93537 Chrome 1/4" flatwasher with 7/16" o.d. Pack of 10.93637 Flat washer, RevTech oil pump. Pack of 6.93987 Black oxide 5/16-18 x 3/4" sockethead bolt. Pack of 10.94018 Retaing ring, pinion bearing. (repl. OEM 11177A) Pack of 10.94034 Spring, tappet oil screen. (repl. OEM 24982-70) Pack of 5.94045 Pinion gear, orange. (repl. OEM 24040-78)94046 Pinion gear, white. (repl. OEM 24041-78)94047 Pinion gear, yellow. (repl. OEM 24042-78)94048 Pinion gear, red. (repl. OEM 24043-78)94049 Pinion gear, blue. (repl. OEM 24044-78)94050 Pinion gear, green. (repl. OEM 24045-78)94051 Pinion gear, black. (repl. OEM 24046-78)94054 Pinion bearing, green. (repl. OEM 24628-87A)94055 Pinion bearing, red. (repl. OEM 24641-87A)94056 Pinion bearing, blue. (repl. OEM 24643-87A)94057 Pinion bearing, white/gray. (repl. OEM 24626-87A)94065 Aluminum head breather washers. Pack of 10.99196 Valve guide seals. Set of 4620298 Gasket, oil pump body to case. Pack of 10.620299 Gasket, oil pump outer cover to body. Pack of 10.654403 O-Ring, piston oil squirters. Pack of 10657055 Outer pinion shaft plug .060" hole. Pack of 10658147 Oil seal, oil pump shaft. Pack of 10.658161 Chrome Evo front & rear tappet block set. Includes hardware.658164 Seal, intake manifold. Pack of 10.658167 Chrome banjo bolt, breather. Sold in pairs. 658180 RevTech electronic ignition with break-in rev-limiter.658181 RevTech electronic ignition without break-in rev-limiter.658236 RevTech EV-110/100 smog cam for EPA motors.659616 RevTech intake valve 2" dia. Sold each659617 RevTech exhaust valve 1.61" dia. Sold each.

659625 Cylinder studs, 3/8" x 7/16" x 6.30". Set of 8.659628 #8-32 x 3/8" button head screw. Pack of 10.659636 RevTech roller rocker arm, rear exhaust or front intake. 659637 RevTech roller rocker arm, front exhaust or rear intake. 659705 Valve guide intake & exhaust standard size.659706 Valve guide intake & exhaust +.001" oversize.660351 Gasket, rear tappet block.( repl. OEM 18633-48D) Pack of 10.660358 Gasket, front tappet block.( repl. OEM 18634-48C) Pack of 10.675002 HSR 45mm Mikuni carburetor with chrome top cover & choke cable.675003 Oval rubber intake adapter flange with hose clamp for 45mm Mikuni carbs.692040 Chrome 5/16-18 x 3-1/2" hex bolt. Pack of 10.692041 Chrome 5/16-18 x 3" hex bolt. Pack of 10.694040 Spacer, between pinion & oil drive gear. Pack of 10.699206 Outer valve spring, 600 lift. Sold each. 699207 Inner valve spring, 600 lift. Sold each. 699234 Valve spring lower collar. Sold each.699258 Valve spring upper collar. Sold each.699296 Valve keepers. Sold in pairs. CCI# Description 684629 Natural RevTech Gen IV Cases with studs & case hardware.684630 Black RevTech Gen IV Cases with studs & case hardware.684631 Polish RevTech Gen IV Cases with studs & case hardware.684632 Drian Plug684633 O-Ring, drain plug684634 Chrome 1/4-20 x 3-1/4" cap screw684635 Press-together flywheel assembly, 4.300" stroke for 115" RevTech motors.684636 Press-together flywheel assembly, 4.410" stroke for 125" RevTech motors.684637 Bushing, upper piston rod 684638 Chrome plated 12 point flanged head bolts, long. (repl. OEM 16478-85A) Sold each.684639 Oil Pump Kit, High Flow Wide Body684640 Oil pump body684641 Oil Pump cover684642 Supply drive gear684643 Supply driven gear684644 Return drive gear684645 Return driven gear684646 Drive shaft, oil pump684647 Modified Key28014 Drive gear, oil pump28013 Driven gear, oil pump684648 1/4-20x2-1/2" screw684649 Squirter Unit660359 Gasket, cam cover with silicon bead. (repl. OEM 25225-70B) Pack of 10.684650 Sensor Block off53893 O-Ring, Sensor block off33386 Screw, 1/4-20x5/8", button head684651 Breather Valve58072 Shim, breather valve684652 Thrust Washer, Camshaft684653 Cam Cover Kit684654 Cam Cover684655 Ignition Cover684656 Screw, Ignition Cover684657 Screw, Ignition Unit, #10-32x1/2"684658 Rocker Box Kit684659 Rocker Box, top684660 Rocker Box, base684661 Rubber gasket, rocker box. Pack of 10684662 O-ring, support684663 Screw w/washer, 5/16-18x1684664 Screw w/washer, 1/4-20x3/4684665 Screw w/washer, 1/4-20x154227 Sealing washer, 1/4"684666 Metal Gasket, base684667 Rocker Support, Gen432219 5/16-18 x 2" sockethead bolt . Pack of 10.32106 1/4-20 x 1-1/2" sockethead bolt . Pack of 10.32108 1/4-20 x 1" sockethead bolt . Pack of 10.684668 Ignition Cable Holder684669 Head Gasket, 115"684670 Head Gasket, 125"654403 O-Ring, Cylinder Alignment Dowel684671 Base Gasket, Gen422183 Spark Plug668230 Compression Release **Use # for Motorway's part**684673 Intake Manifold, Gen4684674 Air Cleaner Kit, 125"684675 Air Cleaner Kit, 115"684676 Insert, Air Cleaner 125"684677 Insert, Air Cleaner 115"93918 Plug, 1/4"npt

RevTech Gen 4 – 115 & 125 Motor Parts List

4-22

Chart A Piston With Rings For Revtech 110" & 100" 4x4 Motors658840 Piston 4" bore front, standard size with rings, wrist pin & clips658841 Piston 4" bore front, +.005" oversize with rings, wrist pin & clips658842 Piston 4" bore front, +.010" oversize with rings, wrist pin & clips658843 Piston 4" bore front, +.020" oversize with rings, wrist pin & clips658890 Piston 4" bore rear, standard size with rings, wrist pin & clips658891 Piston 4" bore rear, +.005" oversize with rings, wrist pin & clips658892 Piston 4" bore rear, +.010" oversize with rings, wrist pin & clips658893 Piston 4" bore rear, +.020" oversize with rings, wrist pin & clips Chart B Ring Set For Revtech 110" & 100" 4x4 Motors658930 4" bore piston ring set, standard size. Sold in a set for 1 piston658931 4" bore piston ring set, +.005"oversize. Sold in a set for 1 piston658932 4" bore piston ring set, +.010" oversize. Sold in a set for 1 piston658933 4" bore piston ring set, +.020" oversize. Sold in a set for 1 piston

Chart C Cylinder for Revtech 110" Motors51161 110" Natural cylinder 4" bore, front51162 110" Black cylinder 4" bore, front51163 110" Polish cylinder 4" bore, front51164 110" Natural cylinder 4" bore, rear51165 110" Black cylinder 4" bore, rear51166 110" Polish cylinder 4" bore, rearChart D Cylinder for Revtech 100" 4x4 Motors651167 100" Natural cylinder 4" bore, front651168 100" Black cylinder 4" bore, front651169 100" Polish cylinder 4" bore, front651170 100" Natural cylinder 4" bore, rear651171 100" Black cylinder 4" bore, rear651172 100" Polish cylinder 4" bore, rearChart E Cylinder Heads for Revtech 110" Motors (Valve guides & valve seats installed)58471 Black front head for 110" motors58472 Black rear head for 110" motors58473 Natural front head for 110" motors58474 Natural rear head for 110" motors58475 Polish front head for 110" motors58476 Polish rear head for 110" motorsChart F Cylinder Heads for Revtech 100" 4x4 Motors (Valve guides & valve seats installed)658477 Natural front head for 100" 4x4 motors658478 Black front head for 100" 4x4 motors658479 Polish front head for 100" 4x4 motors658480 Natural rear head for 100" 4x4 motors658481 Black rear head for 100" 4x4 motors658482 Polish rear head for 100" 4x4 motorsChart G Push rods for Revtech 100" 4x4 Motors694070 Pushrod, rear exhaust. Sold each694071 Pushrod, rear intake. Sold each694072 Pushrod, front exhaust. Sold each694073 Pushrod, front intake. Sold eachChart H Push rods for Revtech 110" Motors694074 Pushrod, rear exhaust. Sold each694075 Pushrod, rear intake. Sold each694076 Pushrod, front exhaust. Sold each694077 Pushrod, rear intake. Sold each

Gaskets and Seals658512 Complete engine gasket, seal & O-ring kit for RevTech® 110" engines658513 Top end gasket, seal & O-ring kit for RevTech® 110" engines

Chart A Piston With Rings For Revtech 88" Motors58807 88" Piston 3-5/8" bore front & rear, std size with rings, wrist pin & clips58811 88" Piston 3-5/8" bore front & rear, +.005" os. with rings, wrist pin & clips58808 88" Piston 3-5/8" bore front & rear, +.010" os. with rings, wrist pin & clips58809 88" Piston 3-5/8" bore front & rear, +.020" os. with rings, wrist pin & clips58810 88" Piston 3-5/8" bore front & rear, +.030" os. with rings, wrist pin & clips

Chart A Piston With Rings For Revtech 100" Motors58813 100" Piston 3-13/16" bore front & rear, std size with rings, wrist pin & clips58814 100" Piston 3-13/16" bore front & rear, +.005" os with rings, wrist pin & clips58815 100" Piston 3-13/16" bore front & rear, +.010" os with rings, wrist pin & clips58816 100" Piston 3-13/16" bore front & rear, +.020" os with rings, wrist pin & clips58817 100" Piston 3-13/16" bore front & rear, +.030" os with rings, wrist pin & clips

Chart B Rings For Revtech 88" Motors58240 88" Piston ring set, 3-5/8" standard size. Sold in a set for 1 piston58241 88" Piston ring set, 3-5/8" +.005"oversize. Sold in a set for 1 piston58242 88" Piston ring set, 3-5/8" +.010" oversize. Sold in a set for 1 piston

58243 88" Piston ring set, 3-5/8" +.020" oversize. Sold in a set for 1 piston

58244 88" Piston ring set, 3-5/8" +.030" oversize. Sold in a set for 1 piston

Chart B Rings For Revtech 100" Motors 58245 100" Piston ring set, 3-13/16" standard size. Sold in a set for 1 piston58246 100" Piston ring set, 3-13/16" +.005"oversize. Sold in a set for 1 piston58247 100" Piston ring set, 3-13/16" +.010" oversize. Sold in a set for 1 piston58248 100" Piston ring set, 3-13/16" +.020" oversize. Sold in a set for 1 piston58249 100" Piston ring set, 3-13/16" +.030" oversize. Sold in a set for 1 piston

Chart C Cylinder for Revtech 88" Motors51122 88" Polish cylinder 3-5/8" bore, front51123 88" Polish cylinder 3-5/8" bore, rear51124 88" Natural cylinder 3-5/8" bore, front51125 88" Natural cylinder 3-5/8" bore, rear51126 88" Black cylinder 3-5/8" bore, front51127 88" Black cylinder 3-5/8" bore, rear

Chart D Cylinder for Revtech 100" Motors51128 100" Polish cylinder 3-13/16" bore, front51129 100" Polish cylinder 3-13/16" bore, rear51130 100" Natural cylinder 3-13/16" bore, front51131 100" Natural cylinder 3-13/16" bore, rear51132 100" Black cylinder 3-13/16" bore, front51133 100" Black cylinder 3-13/16" bore, rear

Chart E Cylinder Heads for Revtech 88" & 100" Motors (Valve guides & valve seats installed)59791 Black front head for 88" & 100" motors59792 Black rear head for 88" & 100" motors59793 Polish front head for 88" & 100" motors59794 Polish rear head, for 88" & 100" motors59795 Natural front head, for 88" & 100" motors59796 Natural rear head, for 88" & 100" motors

Gaskets and Seals658510 Complete engine gasket, seal & O-ring kit for RevTech® 100" and 88"

engines with 97/98 Casting Marked Rocker Boxes658511 Complete engine gasket, seal & O-ring kit for RevTech® 100" and 88"

engines with 99/00 Casting Marked Rocker Boxes59784 Sump-plate gasket54095 Rocker box cover rubber gasket set for rocker box covers with

casting marks of ‘97’ or ‘98’Note: Rocker box covers with other casting marks use rubber gaskets for late Sportster® models.


SEE CHART A, B

SEE CHART G, H

SEE CHART A, B

SEE CHART C, D, E

RevTech Gen 3 – 110 & 100 4x4 Motor Parts List Charts

RevTech Gen 2 – 88 & 100 Motor Parts List Charts

Chart A Piston With Rings For Revtech 125" Motors684678 Piston Set 4-1/4" bore, standard size with rings, wrist pin & clips.684679 Piston Set 4-1/4" bore, +.005" oversize with rings, wrist pin & clips.684680 Piston Set 4-1/4" bore, +.010" oversize with rings, wrist pin & clips.684681 Piston Set 4-1/4" bore, +.020" oversize with rings, wrist pin & clips.684686 Retaining clip, wrist pin. Sold in a pair.

Chart A Piston With Rings For Revtech 115" Motors684687 Piston Set 4-1/8" bore, standard size with rings, wrist pin & clips.684688 Piston 4-1/8" bore front, +.005" oversize with rings, wrist pin & clips.684689 Piston 4-1/8" bore front, +.010" oversize with rings, wrist pin & clips.684690 Piston 4-1/8" bore front, +.020" oversize with rings, wrist pin & clips.684686 Retaining clip, wrist pin. Sold in a pair.

Chart B Ring Set For Revtech 125" Motors684696 4-1/4" bore piston ring set, standard size. Sold in a set for 1 piston. 684697 4-1/4" bore piston ring set, +.005"oversize. Sold in a set for 1 piston. 684698 4-1/4" bore piston ring set, +.010" oversize. Sold in a set for 1 piston. 684699 4-1/4" bore piston ring set, +.020" oversize. Sold in a set for 1 piston.

Chart B Ring Set For Revtech 115" Motors684700 4-1/8" bore piston ring set, standard size. Sold in a set for 1 piston. 684701 4-1/8" bore piston ring set, +.005"oversize. Sold in a set for 1 piston. 684702 4-1/8" bore piston ring set, +.010" oversize. Sold in a set for 1 piston. 684703 4-1/8" bore piston ring set, +.020" oversize. Sold in a set for 1 piston.

Chart E Cylinder for Revtech 125" Motors684704 125" Natural cylinder 4-1/4" bore, front.684705 125" Natural cylinder 4-1/4" bore, rear.684706 125" Black cylinder 4-1/4" bore, front.684707 125" Black cylinder 4-1/4" bore, rear.684708 125" Polish cylinder 4-1/4" bore, front.684709 125" Polish cylinder 4-1/4" bore, rear.

Chart E Cylinder for Revtech 115" Motors684710 115" Natural cylinder 4-1/8" bore, front.684711 115" Natural cylinder 4-1/8" bore, rear.684712 115" Black cylinder 4-1/8" bore, front.684713 115" Black cylinder 4-1/8" bore, rear.684714 115" Polish cylinder 4-1/8" bore, front.684715 115" Polish cylinder 4-1/8" bore, rear.

Chart F Cylinder Heads for Revtech 125" & 115" 684716 Natural front head for Gen 4 motors. Valve guides & valve seats installed.684717 Natural rear head for Gen 4 motors. Valve guides & valve seats installed.684718 Black front head for Gen 4 motors. Valve guides & valve seats installed.684719 Black rear head for Gen 4 motors. Valve guides & valve seats installed.684720 Polish front head for Gen 4 motors. Valve guides & valve seats installed.684721 Polish rear head for Gen 4 motors. Valve guides & valve seats installed.

Chart H Push rods for Revtech 125" & 115"684722 Pushrod, rear exhaust. Sold each684723 Pushrod, rear intake. Sold each684724 Pushrod, front exhaust. Sold each684725 Pushrod, rear intake. Sold each

Gaskets and Seals684726 Complete engine gasket, seal & O-ring kit for RevTech 125" engines684727 Complete engine gasket, seal & O-ring kit for RevTech 115" engines684728 Tep End gasket, seal & O-ring kit for RevTech 125" engines684729 Tep End gasket, seal & O-ring kit for RevTech 115" engines


SEE CHART A, B

SEE CHART G, H

RevTech Gen 4 – 115 & 125 Motor Parts List Charts

4-23

RevTech Engine Installation Guide (2)

Documents

Transcript of RevTech Engine Installation Guide (2)