Cam It Up! | Fuel Moto Hop-Up, Part 2

11. He then installed the rear cam sprocket, crank sprocket, and outer cam chain as an assembly with the sprocket timing marks aligned. Once the sprockets were torqued to spec, Jim installed the cam chain tensioner and torqued it down.

12. The Fuel Moto Quick Install pushrods make future cam changes or lower end work much easier and quicker. They fit ’99-11 Twin Cams, have a 0.095 chromoly taper design and have been engineered for maximum strength and durability. They can be used with stock pushrod tubes and come with a tool to hold the tubes in place for easy adjustment.

13. Jim installed the pushrods and tubes and tightened the pushrods by opening them until there was pressure against the lifter. He then opened the adjustment nut three full revolutions plus two flats. Once all the lifters had bled down, he opened the adjustment nut until the rod was tight against the lifter, then he tightened the locknut.

14. After finishing up the cam swap, Jim then began working on porting and polishing the throttle body and intake assembly. The throttle body was removed from the engine and Jim taped up all the plug openings to prevent metal debris from entering them.

15. With the backing plate still mounted to the throttle body, Jim took the assembly to the porting/polishing station. In this process he cleans up the backing plate and throttle body ports and makes sure their ports match up perfectly by cleaning up any drops or steps at the mating surfaces. He’ll also clean up the casting imperfections in the throttle body left by the casting process. It’s a three-step process that involves light grinding, sanding, and then polishing. Fuel Moto offers its throttle body porting service for $169.

16. Here’s what the surfaces look like once they are ported and polished. The finished results will allow the incoming airflow a smooth and even path into the engine.

17. At the backside of the throttle body, Jim cleaned up the runner ports as well. Often times the ports aren’t exactly the same size with one side of the port being thicker than the other, causing the port to not mate up with the intake port of the head perfectly. Jim cleans up the runners so that the air will rush into the cylinders unobstructed.

19. After bolting the throttle body back in place and buttoning up the rest of the bike, the install was complete. All that was left was for Jamie to flash the ECM with the new map he had created specifically for this setup via the Dynojet Power Vision EFI module. As we discussed last issue, Fuel Moto worked extensively with Dynojet as a technical partner on the development of the new Power Vision, and Jamie has spent many hours creating maps for a myriad of hop-ups/part combinations. With its easy-to-use touch screen surface, Jamie had the new map installed in about a minute.

20. Once again, even though the bike didn’t need to be dyno-tuned since Jamie installed one of his preconfigured maps, we wanted to see what kind of result this hop-up created. With the Fuel Moto pipes, air cleaner kit, throttle body porting/polishing service, and the Knight Prowler TW-555 cams, the bike churned out 94.99 hp and 103.15 lb-ft of torque. That’s a gain of 45 percent more horsepower and 32 percent more torque over stock. And the nice broad torque curve is well above 90 lb-ft from 3,000 rpm to nearly 5,000 rpm.

21. Overall the combination of parts between the two install articles really worked well with each other and delivered excellent results. Most importantly, Jason rode away one very satisfied customer who didn’t need a dyno sheet to tell him how well the hop-up went—he could feel it from the snap in his neck when hammering the throttle.