DIY Network

Rebuild Lifter Rollers, Install Tappet Blocks, Lifters and Push Rods From "Classic Rides" episode DCLR-102

In this final segment of the second episode, host Kevin Tetz and Harley-Davidson master mechanic Bill "Dunk" Dunkelberger finish the camshaft upgrade by rebuilding the lifter rollers and installing the tappet blocks, lifters and push rods.

When the camshaft was pulled apart in the earlier segments and there were problems, Dunk also noticed that the lobes on the cam weren't in good shape. They had scratch marks. And the rollers had a lot of wear on them, and since money was spent on the cam, he and Kevin decided to spend a few more dollars to install all new parts, including the lifter rollers.

Figure A

Rebuilding the Lifter Rollers

To remove the old lifter roller, Dunk puts the lifter in a vice with a jig in it (figure A) and drills the end of the roller pin down.
• Use a punch to knock the pin out.

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• When you take the assembly apart, inside are a whole bunch of rollers (figure B). Sometimes these will go bad because they get ground up and fall out. A new one will be installed for the project bike.

• Dunk installs the new roller and pin, using the jig on the vice. A little bit of tension is what you want, with free rolling.

  Note: When the lifters were removed in the last segment, they were put in a bag and labeled front intake, front exhaust, etc. -- and now they need to be installed back in the exact same location.

• Add some assembly lubrication to a lifter and then install the newly painted tappet block (figure C), which will sit in the way it's pictured here. The bottom hole will be the exhaust and the top hole will be the intake.

• The lifter (figure D) should be installed with the flat sides and the small oiling holes "facing" the middle of the tappet block. As a result the oiling holes will face each other.

Figure B

Figure C

Figure D

	Figure E
	Figure F
	Figure G

• Using clean hands, the gasket goes in and the first tappet block goes in (figure E).

• The back lifters and tappet block go in the exact same way.

• Install the newly painted bolts, adding a drop of Threadlocker to each.

• Snug the bolts with a ratchet wrench and then tighten them all the way down to specification using a torque wrench. Be sure to torque in a criss-cross pattern.

  Push-rod Tip: Make sure the cork washer is on the bottom of the metal washer (figure F) to create a good seal.

• Before installing the push rods, bleed each lifter by inserting a paper clip into the bottom to press the oil out. And then reinstall into the tappet block.

• A new gasket goes on top of each lifter and onto the push rod at the top, and then the push rod is installed. Holding the push rod across its flats, turn the adjuster nut until it reaches the bottom -- pushing the hydraulic unit down into the lifter.

  When it's all the way down and tight, it'll start to turn the whole push rod (figure G).

• Dunk comes up nine flats, which is actually 1-1/2 turns because there are six flats on the push rod. Holding the bottom adjuster nut in place, the middle lock nut is then adjusted back up to lock in the push rod.

  Note: What this establishes by turning down and bringing back up is approximately a 50 to 60 1/1000th oil cushion for the hydraulic unit. This is all the tension it will need.

• Do the same for the rest of the push rods.

Kevin and Dunk have installed the new camshaft, stripped and refinished the tappet blocks, replaced the rollers on the lifters and rebuilt the push-rod assemblies.

In the next episode of Classic Rides a new performance carburetor is installed to allow the engine to breathe better and produce more power.

RESOURCES :

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

RaceDeck Modular Flooring (SnapLock Industries)
SnapLock Industries
Website: www.racedeck.com

Ultimate Harley-Davidson
0789499746
Hugo Wilson
(October, 2003)
To order this title from Amazon, click here.
Dorling Kindersley / DK Publishing

Hugo Wilson's Hot Bikes
0751336947
Hugo Wilson
To order this title from Amazon, click here.
Penguin Books

The Harley-Davidson Century
0760311552
Darwin Holmstrom
(September, 2002)
To order this title from Amazon, click here.
Motorbooks International

Restoration Parts (Custom Chrome)
Custom Chrome
Website: www.customchrome.com

Performance Carburetor, Camshaft and Other Restoration Parts (S & S Cycle Inc.)
S & S Cycle Inc.
Website: www.sycycle.com

Ironclad Gloves

Manufacturers of work gloves for all types of work including automotive. Griptec™ Gloves with 3M gReptile™ gripping material.

Website: www.iclad.com

Motorcycle Restoration Parts (In the Wind Motorcycle Parts)
In Wind Motorcycle Parts
508 Lovell Rd.
Knoxville, TN 37932
Phone: 865-560-5650 or 865-777-0884
Fax: 865-777-0886

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com