S&S 97ci Big Bore Part 2

In Depth Last issue we got into the first part of a S&S hop-up install by giving an overview of some of the parts that were going to be installed. The main component of the hop-up was S&S' new 97ci Big Bore kit ($725) which includes pistons, cylinders, rings and gaskets with black or silver powdercoated cylinders for '99-06 Big Twins, a kit is also available for '07-later Big Twins to bump them up to 106ci. With a 3.927-inch bore this is a pretty economical way to increase displacement and performance because it's a direct bolt-on kit, which you can use your stock heads with, and it requires no machining.

1 Drifty made quick work of removing the tanks, disconnecting the battery, removing the exhaust and tearing into the engine.

1 Drifty made quick work of removing the tanks, disconnecting the battery, removing the e

Aside from the bolting on the Big Bore kit, the bike the kit was being installed onto, a carbureted '02 Softail with more than 60,000 miles, had extremely worn out cam chain tensioner shoes, which led to the decision to replace the stock cam chain setup for gear drive cams. And since gear drive was in order, an upgrade to more performance oriented cams seemed like a smart move, so a set of S&S' new 583 Easy-Start cams ($795) were ordered. To add to the hop-up portion of the install, the owner decided to replace his stock carb for an S&S Super E Shorty carb kit: carb, backing plate, a hi-flow air filter, breather kit, and tear drop air cleaner cover ($527.80). He also got some S&S Shotgun Slash-Cut Slip-on Performance mufflers ($403.60), Hi-Performance Hydraulic Tappet set ($248.35), Quickie Pushrods ($196.60), and Push Rod Covers ($127.80).

We caught up with Anaheim-Fullerton Harley-Davidson tech Drifty as he was tearing into the engine. Follow along as this old Softie gets its heart freshened up.

2 With the cam plate/cams out you can get a look at how bad of shape the tensioner shoes were in. This is the upper shoe on the backside of the cam plate, you can see that not only is the shoe completely worn, but the metal arm has been torn up as well.
2 With the cam plate/cams out you can get a look at how bad of shape the tensioner shoes
3 Using a bearing puller, Drifty removed the stock INA inner cam bearings...
3 Using a bearing puller, Drifty removed the stock INA inner cam bearings...
4... and replaced them with a set of Torrington Inner Cam bearings from S&S. These new bearings have more rollers to them, which mean more bearing contact surface and more support. Before installing the bearings Drifty applied a liberal amount of Crane Cams Engine Assembly Lube.
4 ... and replaced them with a set of Torrington Inner Cam bearings from S&S. These new be

5 Here's a look at one of the 585 Easy Start cams. Each of the exhaust cam lobes have a spring-loaded compression release lobe in the heal of the cam where the valve would normally be closed. The lobe holds the exhaust valve slightly open at cranking speed, releasing some compression making it easier for the engine to crank. When the engine starts and the rpm increases the compression release lobe is centrifugally retracted and the engine runs normally with full compression.
5 Here's a look at one of the 585 Easy Start cams. Each of the exhaust cam lobes have a s
6 Using a press, Drifty pushed out the stock cams and cam bearings and pressed in new bearings and the 583 cams. For easy identification of the timing marks and to ensure proper alignment, Drifty marked the timing marks on the inner cam gears with a red line. S&S offers the Easy Start cams in three performance grinds: 551 Torque, 585 Horsepower, and these 583s, which are a mid-range cam for good overall performance with strong low-end torque.
6 Using a press, Drifty pushed out the stock cams and cam bearings and pressed in new bea
7 The S&S cam retaining plate was then bolted in place. Before installing the cams/support plate, Drifty disassembled and inspected the old oil pump and noticed that there was some grooves/scarring. Therefore he replaced it with a new oil pump. The new pump was thoroughly packed with grease then slid into position.
7 The S&S cam retaining plate was then bolted in place. Before installing the cams/suppor

8 The cams were coated with some Crane Cams Engine Assembly Lube then the cam plate was bolted in place and torqued to spec.
8 The cams were coated with some Crane Cams Engine Assembly Lube then the cam plate was b
9 The S&S High Performance Hydraulic Tappets (lifters) were oiled and then set in place.
9 The S&S High Performance Hydraulic Tappets (lifters) were oiled and then set in place.
10 Next the outer drive gears were aligned and installed.

By Eric Ellis

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