Installing flywheels into engine cases can be a painful experience on ’03 and earlier twin cams, all EVOs, Shovels and Pans back to ’55. 1955 was the year harley changed the left side bearing to a timken tapered bearing. This is the same bearing that is used as front wheel bearings on most automobiles. This set-up is just about bullet proof, if timken bearings can support a car for 100-thousand miles, engine duty is a piece of cake. to install these flywheels correctly requires setting end-play. This is how much side-to-side clearance the flywheels have inside the engine cases.
There’s a really old specialty tool from h-D for checking end-play. it attaches to the left side shaft, the flywheels are shoved to the right, and the locating pin is pushed against the engine case. The flywheels are then shoved back to the left and a feeler gauge is used to measure the distance between the pin and engine cases. Not very high tech but it works. Problem is the cases and flywheels have to be assembled. if the clearance is incorrect you have to disassemble the cases, measure the spacer, select a new one, and do it all over again until it’s done right. During the eVo days, the factory manual suggested mak- ing a tool out of an old left side powershaft to make the process easier. There are a few companies that sell them. but, our philosophy is: if you buy it, you can’t make it, and where is the fun in that? Follow along as we build one. if you install flywheels often or only occasionally you’ll find this tool to be a big time saver.