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 Manual Document number 608000 edition 05.29.09 Table Of Contents Congratulations on Making a Powerful Choice! .......................................................................i Emissions Compliance Statement .............................................................................................ii SECTION 1 - The RevTech® Engine 1-1 1.1 Limited Engine Warranty ......................................................................................................1-2 1.2 Emissions Control System Warranty Statement................................................................1-6 1.3 Engine Components .............................................................................................................1-9 1.4 Engine Specifications...........................................................................................................1-10 SECTION 2 - Installation in Chassis 2-1 2.1 Pre-Installation Notice .........................................................................................................2-2 2.2 Emissions-Related Installation Instructions ......................................................................2-3 2.3 Engine Installation ................................................................................................................2-5 2.4 Ignition System Installation .................................................................................................2-9 2.5 Installation Diagrams ...........................................................................................................2-14 SECTION 3 - Owner's Manual 3-1 3.1 Engine Break-In Procedure .................................................................................................3-2 3.2 Maintenance Schedule .........................................................................................................3-3 3.3 Maintenance Procedures .....................................................................................................3-4 3.4 Troubleshooting Guide .........................................................................................................3-6 SECTION 4 - Parts Catalog 4-1 4.1 Parts Catalog ........................................................................................................................4-2 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 Mohr CEO Custom Chrome A Division of DAE-IL USA, Inc. dba Global Motorsport Group Morgan Hill, California i 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. including licensing. or camshaft. When entering the rear tire diameter into the formula described above. but without rider or cargo. IMPORTANT NOTICE: A small volume manufacturer of highway motorcycles. or fail to install properly the carburetor. Use this formula to calculate your motorcycle’s N/V ratio: N/V Ratio = 208. and other fluids.5. recalibrate. or assembler of highway motorcycle kits. or receive EPA certification to install this engine provided such person ensures the following criteria are met. 2006 Guidance letter issued by the federal Environmental Protection Agency. with full fuel. you must comply with all state regulations.Emissions Compliance Statement Congratulations! You have purchased a RevTech EPA-certified motorcycle engine. or an individual is not required to apply for. air cleaner housing. you may not modify. state and local regulations. Your fully assembled motorcycle may not weigh more than 387 kg (851 pounds). the Air Resources Board has not adopted the same procedure set forth in the EPA’s July 25. 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. routine maintenance. In California. as long as the vehicle also complies with all other applicable federal. Tire manufacturers often post this value on their websites. or air cleaner supplied with the engine. Your motorcycle’s highest engine speed-to-vehicle speed ratio (the “N/V ratio”) may not exceed 86. registration. EPA noise and Federal Motor Vehicle Safety Standards (FMVSS). including break-in. air cleaner cover. 3. including changes to the fuel metering system. Installation. You may not make any change to the engine that could reasonably be expected to increase its exhaust emissions for any pollutant. seller. a producer. 2006 Guidance letter.Installation in Chassis) 2. if you use this engine to build a motorcycle in California. The resulting motorcycle may be operated and re-sold without restriction. 4. and 1.89 for most 6-speed transmissions. ATTENTION CALIFORNIA PURCHASERS: The engine-certification procedure described below. No Tampering. the units must be in inches. Accordingly. ignition system. The certified engine and emissions related components must be installed following the installation instructions provided in this manual (SECTION 2 . ii . and warranty. N/V Ratio. In addition. remove. 1. authorized under a July 25. oil.9 x (Overall Gear Ratio ÷ Rear Tire Diameter) Determine the “Overall Gear Ratio” using the following formula: Overall Gear Ratio = CxRxA ExK 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. applies in all states except California. unless another exception applies. Weight. Emissions Control Information Label. and anti-tampering laws.Emissions Compliance Statement 5.5 psi. Exhaust. as described in SECTION 2. measured within 12 inches of the engine’s exhaust port.Emissions-Related Installation Instructions. iii . You must install this engine with an exhaust system so that.com WARNING . Owner's Manual. you must provide this manual to the ultimate purchaser.” The federal Clean Air Act specifically prohibits tampering. Tampering may result in penalties imposed by the federal government. • You may be subject to monetary fines and other penalties. Suite 150 Morgan Hill. The provided emissions control information label must be permanently affixed to the vehicle in a readily accessible location on the vehicle. 8. If you have any questions regarding this certified engine or any of the above requirements or prohibitions. • You may be liable for violation of various federal laws. 6. or any other person. the exhaust backpressure is at least 0. 7. WARNING .2 . that renders inoperable or reduces the effectiveness of any part or component of the engine that effects vehicle emissions is “tampering. If you have used this engine to build a motorcycle for resale. with the engine running at 1800 rpm. please contact Global Motorsport Group (GMG) Customer Service and Technical Support at: Global Motorsport Group Customer Service and Technical Support 18225 Serene Drive.Emissions-Related Installation Instructions. including laws relating to engine and motorcycle certification. Permeation Equipment.1 psi but not more than 1. as provided under the federal Clear Air Act and federal EPA regulations. In order to meet EPA evaporative emissions requirements. CA 95037 866-888-5980 408-778-6190 fax techservices@globalmotorsport. introduction into commerce. the fuel tank and fuel lines installed on the motorcycle must meet the specifications outlined in SECTION 2. Most aftermarket exhaust systems that comply with federal and state noise and emission regulations will satisfy this requirement.2 .Tampering is Prohibited! Any act by you.If you fail to meet any of the above requirements: • Your motorcycle will be deemed non-compliant with federal emissions regulations. 3 Engine Components 1.2 Emissions Control System Warranty Statement 1.4 Engine Specifications .SECTION 1 The RevTech Engine ® 1.1 Limited Engine Warranty 1. 4. Any such work will void your warranty. What is not covered under your warranty? Your warranty does not cover any of the following: 1. 6.] After the first 18 months. A failure due to non-compliance with recommended break-in procedures (page 3-2 of this manual). [Dealer: Please contact Custom Chrome for details. Oil weeps and seeps (as determined by a RevTech Repair Center Technical Support Specialist). Any work performed in the field. complete and return the warranty card in this manual. 5. Any other parts. 100. 110. Who does the limited RevTech® engine warranty cover? Only the original retail customer of this RevTech 88. 2. 1 A separate warranty covers your engine’s emission systems. A failure caused by improper or incorrectly performed maintenance (as determined by a RevTech Repair Center Technical Support Specialist). or incorrect tuning (as determined by a RevTech Repair Center Technical Support Specialist).000 miles. 1-2 .1 Limited Engine Warranty LIMITED ENGINE WARRANTY (Non-Emission)1 Please detach. fuel in the oil due to a non-vacuum petcock being left in the 'ON' position when the vehicle is not being operated. Piston failure caused by excessive heat. All warranty work must be performed by a Custom Chrome RevTech Repair Center. If a warranty claim occurs. For valid warranty claims arising during the first 18 months of coverage. What does the warranty cover? Custom Chrome warrants that the engine is free from defects in workmanship and material. Custom Chrome will repair or replace all parts necessary to restore the engine to accepted factory specifications. Custom Chrome will reimburse a dealer. for its labor charges in removing and reinstalling the engine. unless specifically authorized and directed in writing by a RevTech Repair Center. labor charges (including removal and reinstallation of the engine). 3. The emission warranty’s terms and conditions are on pages 1-6 through 1-8. Coverage terminates if you sell or otherwise transfer the engine to another user. and freight costs are the sole responsibility of the retail customer. with a merchandise credit. Any sign of owner abuse or negligence (as determined by a RevTech Repair Center Technical Support Specialist). whichever comes first. 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. 115 and 125 inch engine is entitled to warranty service. this warranty covers only parts and labor provided by a RevTech Repair Center.1. 1 Limited Engine Warranty 7. or storing your motorcycle or any accommodation costs. The biggest enemy of an air-cooled engine is heat. This is owner abuse (see 3 above). 7. If the engine begins making strange or unusual noises. 8. YOUR WARRANTY DOES NOT COVER PISTON SEIZURE CAUSED BY OVERHEATING. hauling. if there are oil spots on the horizontal floor directly under the engine during a 24-hour period). 5. diagnosis. turn off the engine as soon as it is safe to do so and take the engine to an authorized Custom Chrome dealer for service. 6. oil tank. contact an authorized Custom Chrome dealer for warranty service. Our technicians will perform an extensive bench test. They are not considered warranty issues and we will not reimburse labor charges to repair them. the warranty claim will be denied. If you discover an oil leak. Incidental and consequential damages. freight collect. 4. inconvenience. Do not assume that the engine is leaking – check the primary transmission. Damages resulting from improper crating or packaging of the engine. and we will return the engine. including loss of time. Sufficient airflow must be present at all times. If. as the result of the removal or reinstallation of the engine. If the leak cannot be duplicated. 10. 3. 9. 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). you determine that the leak is coming from the engine (that is. Freight charges will not be covered if Custom Chrome determines that the warranty claim is invalid. avoid slow-moving traffic and do not allow the engine to idle for extended periods of time. Any charges for towing. Weeps and seeps may occur. To ensure sufficient airflow. after careful cleaning and checking. 2.1. please provide photographs (preferably digital) clearly showing where the leak is coming from and the volume of the leak. and all related hoses and connectors first. 1-3 . No credit for labor will be given. Incidental damage to any other component of your motorcycle or to the paint on your motorcycle. causing pollution of the engine oil or engine damage not covered by your warranty. 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. and technical issues: 1. Failure to do so may result in fuel draining into the engine. including running the engine at full operating temperature. as received. or loss of use of your motorcycle during warranty repair. Troubleshooting. 1-4 . Only a RevTech Repair Center can perform warranty service. The dealer must contact RevTech Customer Service and Technical Support. Adhere to the break-in procedure prescribed in this manual (page 3-2). with an octane rating of 91 or higher. not the customer. For the first 18 months after original retail purchase. the original retail customer must contact an authorized Custom Chrome dealer. 5. If Custom Chrome and the dealer determine that the problem may be covered by warranty. they will make an initial determination if the problem is covered by the warranty. 3. OR BOTH. 3.1. including those listed below. Wash and oil air filter element as needed. must make this contact.1 Limited Engine Warranty How to obtain warranty service: 1. To obtain warranty consideration. Custom Chrome will not reimburse the cost of parts or labor for warranty service performed anywhere other than a RevTech Repair Center. Use premium unleaded fuel. 6. they will arrange to have the engine shipped to a RevTech Repair Center. preferably the dealer where you purchased the engine. Do not abuse or misuse your engine in any way. Do not remove or modify any engine component. What you must do to maintain the RevTech engine warranty: 1. The dealer. Together. Custom Chrome will cover the freight charges for valid warranty claims. 5. Custom Chrome and RevTech Customer Service and Technical Support will not accept calls from retail customers relating to warranty claims. 4. 4. 2. Perform oil and oil filter changes according to the maintenance schedule in this manual (page 3-3).S. Altering these or any other emission-related component will make your engine illegal to use in the U. • • • • 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. 2. so this limitation may not apply to you. date of purchase and engine serial number. with any important information regarding your engine. Suite 150 Morgan Hill. CA 95037 866-888-5980 408-778-6190 fax [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. and you may also have other rights which vary from state to state. including any warranty of merchantability or fitness for a particular purpose. Some states do no permit limitations on the duration of an implied warranty. together with a clear. Warranty card: Please detach. if necessary.1 Limited Engine Warranty Your rights under state law: This warranty gives you specific legal rights. To make a warranty claim. complete and mail the warranty card. For the location of the nearest authorized Custom Chrome dealer and RevTech Repair Center. showing the dealer name. legible copy of your receipt. you must return the engine to an authorized Custom Chrome dealer. Custom Chrome cannot accept warranty claims directly from retail customers. Any implied warranty.1. is limited to the express terms of this Limited Engine Warranty. to: Custom Chrome Customer Service and Technical Support 18225 Serene Drive. call the number listed below. 1-5 . built and equipped to meet U. Inc. If you have any questions regarding your warranty rights and responsibilities. whichever first occurs.2 Emissions Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The U. This is your emission control system DEFECTS WARRANTY. If an emission-related part on your engine is defective. including diagnosis. • Class II motorcycles (170 to 279 cc): for a period of use of five (5) years or 18. you should be aware that GMG may deny your warranty coverage if your engine or a part has failed due to abuse. The warranty repairs should be completed in a reasonable amount of time. Your emission control system may include parts such as the carburetor.S. (GMG).1. neglect. New motor vehicles must be designed.641 miles). improper maintenance or unapproved modifications.000 kilometers (18. 1-6 . OWNER’S WARRANTY RESPONSIBILITIES • As the engine owner. • Class III motorcycles (280 cc and larger): for a period of use of five (5) years or 30. Where a warrantable condition exists. EPA Federal anti-smog standards. MANUFACTURER’S WARRANTY COVERAGE • Class I motorcycles (50 to 169 cc): for a period of use of five (5) years or 12. Environmental Protection Agency and Global Motorsport Group. whichever first occurs. not to exceed 30 days. neglect or improper maintenance of your engine. • As the engine owner.456 miles). but GMG cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.000 kilometers (7. • You are responsible for presenting your engine to a GMG dealer as soon as a problem exists. you should contact GMG Customer Service and Technical Support (see page 1-8 for contact details). the part will be repaired or replaced by GMG. GMG must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse. GMG will repair your engine at no cost to you. hoses and other emission-related assemblies. you are responsible for the performance of the required maintenance listed in your owner’s manual.185) miles. ignition system. parts and labor.S.000 kilometers (11. whichever first occurs. GMG recommends that you retain all receipts covering maintenance on your engine. are pleased to explain the emission control system warranty on your 2007 and later engine. 1. The liability of GMG under this Emission Control System Warranty is limited solely to the remedying of defects in material workmanship by an authorized GMG dealer at its place of business during customary business hours. 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. I. Any engine from a motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined. SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. is designed. GMG IS NOT LIABLE FOR ANY OTHER EXPENSES. or of 30. LIMITATIONS.185 miles). This warranty does not cover inconvenience or loss of use of the engine or transportation of the engine to or from the GMG dealer. of 12. Inc.456 miles). whichever first occurs. if the engine’s displacement is equal to or greater than 170 cubic centimeters but less than 280 cubic centimeters. if the engine’s displacement is 280 cubic centimeters or greater. This Emissions Control System Warranty shall not cover any of the following: Repair (1) (2) (3) (4) or replacement required as a result of: accident. 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 II.000 kilometers (7. B. depending on the engine displacement.641 miles). LIMITED LIABILITY A. repairs improperly performed or replacements improperly installed. if the engine’s displacement is less than 170 cubic centimeters. WHETHER DIRECT. C. INCIDENTAL. is free from defects in material and workmanship which cause such engine to fail to conform with applicable regulations of the United States Environmental Protection Agency for a period of use. B.000 kilometers (11. 1-7 . warrants that each new 2007 and later RevTech® motorcycle engine: A. LOSS OR DAMAGE. ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE REVTECH ENGINE FOR ANY PURPOSE. Inspections. A. misuse. CONSEQUENTIAL OR EXEMPLARY. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. and. of 18.000 kilometers (18. or 5 (five) years from the date of initial retail delivery. replacement of parts and other services and adjustments necessary for required maintenance. Any part or parts replaced under this warranty shall become the property of GMG. COVERAGE. built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency. III.2 Emissions Control System Warranty Statement Global Motorsport Group. com 1-8 . LIMITED WARRANTY (pages 1-2 through 1-5).2 Emissions Control System Warranty Statement B. INC. CA 95037 866-888-5980 408-778-6190 fax techservices@globalmotorsport. LEGAL RIGHTS. Suite 150 Morgan Hill. 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. NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY GMG EXCEPT AS SPECIFICALLY SET FORTH HEREIN. No dealer is authorized to modify this Limited Emission Control System Warranty. C. IV.1. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. The owner is responsible for the performance of all required maintenance. 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. THIS WARRANTY IS IN ADDITION TO THE CUSTOM CHROME/GLOBAL MOTORSPORT GROUP. However. VI. AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. GMG is not liable for these parts. ADDITIONAL INFORMATION. Custom Chrome Customer Service and Technical Support 18225 Serene Drive. IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY. V. ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS. Oil filter 8. Oil pump 5. For further information on these and other components.Owner's Manual. Intake manifold 21 22 20 23 1-9 . Alternator wiring port 22. Front engine mount 9. Oil pressure sender 6. Timing plug 20. Front spark plug 16. Rear exhaust port 14. Cam cover 3.1. Carburetor 11. see SECTION 2 . Sprocket shaft 23. Rear spark plug 17. Air cleaner cover 2. Ignition wiring 11 10 11 13 1 5 9 6 12 7 4 3 2 8 14 18 15 18 16 24 19 17 LEFT/PRIMARY SIDE VIEW 15. Front exhaust port 13. RIGHT/CAM SIDE VIEW 1. Oil filter mount 7. Bottom inspection plate 24.Installation in Chassis and SECTION 3 . Ignition cover 4. Compression Release 18. Rocker box 12. Top engine mount pads 19.3 Engine Components Listed below are callouts of basic engine components to help you install and maintain your RevTech engine. Alternator location 21. Rear engine mount 10. sensor plate Intake manifold flanges Pinion nut Spark plug Air cleaner mount to head 90-120 in/lbs 18 ft/lbs 18 ft/lbs 8ft/lbs.0035 0.0025~0. Gen 2 engines Valve stem protrusion.0030 1-10 .005 0.0020 0.0010 Wear Limits 0. V 2 4" x 4.25" 88 cu-in / 1440cc 9.30" 115 cu-in / 1880cc 9.0004~0.0008~0.090 1. Gen 4 engines Timken endplay.0012~0.050 0.035 0.0020 0.4 RevTech Engine Specifications RevTech Engine Specifications Generation Engine Type Number of Cylinders Bore and Stroke Displacement Compression Ratio Connecting Rod Length Horsepower Torque Gen 2 88" 4-cycle.0030 0. Gen 2&3 engines Connecting rod side play.010~0.006 0.030~0.007 0.900 1.0005~0.1.002 Less then 0. V 2 4" x 4" 100 cu-in / 1636cc 10:01 7.0020 0.900~2.0025 0.050 Standard Fit 0.0007 0.000~0.002 0.900 2.0050 0.0007~0. V 2 4.015~0. 90deg 90-120 in/lbs 12 ft/lbs 18 ft/lbs 90-120 in/lbs 90-120 in/lbs 90-120 in/lbs 90-120 in/lbs 20-30 in/lbs 16 ft/lbs 35-45 ft.0015~0.0005~0.440 in 106 hp @ 5500 112 ft/lbs @ 4100 Gen 4 115" 4-cycle.002~0.0040 0.006 0. Gen 3&4 engines Valve face runout Piston Item Fit into cylinder Wrist pin to piston Wrist pin to rod bushing Compression ring end gap Oil control ring end gap Flywheels Item Runout at shafts Connecting rod side play.0035 Less then 0.375" 110 cu-in / 1800cc 10:01 7.030 0.0025 0.002 Wear Limits Less then 0.002 Exceeds 0.004 0. V 2 4.001~0.440 in 96 hp @ 5000 109 ft/lbs @ 4250 Gen 3 110" 4-cycle.0004~0.030 0.0006 0.004 0.015 Wear Limits Less then 0.005~0.440 in 82 hp @ 5700 88 ft/lbs @ 4500 Gen 3 100" 4-cycle.0007~0.800~1.021 0.060 1. timing hole Tappet guide Ignition cup.040~0.0012 0. 45-deg.025 0.002~0.125" x 4. oil pump. 45-deg.005~0. Gen 2&4 engines Timken endplay.002~0.006 0.040 0.667 in 108 hp @ 5700 115 ft/lbs @ 3750 Gen 4 125" 4-cycle.010~0. tappet screen.002 0.0035 Exceeds 0.0010 0. V 2 3.lbs 18 ft/lbs 120-150 in/lbs Standard Fit 0.020 Gearcase Item Breather gear endplay Camshaft endplay Camshaft in bushing Pinion shaft in bushing Bushing fit into cover Lifter fit in guide Torque Specifications Rocker box 1/4" hardware 5/16" hardware Rocker arm support Head bolts Cylinder studs Crankcase 1/4" hardware 5/16" hardware Cam cover Oil pump Plugs.0020 Wear Limits 0.667 in 115 hp @ 5500 135 ft @ 3700 Rocker Box Assembly Item Rocker arm to bushing (press fit) Rocker arm shaft to bushing Rocker arm end play Cylinder Head Item Valve Guide fit into head Valve Seat fit into head Intake Valve fit in guide Exhaust Valve fit in guide Valve seat width Valve stem protrusion. 45-deg.004~0.020 0.623" x 4.0015 Standard Fit 0.0030 0.015 0.004 0.005~0.0035 0. 45-deg.0025 0.001~0. 16ft/ lbs.040 Wear Limits 0. Gen 3 engines Crank pin running clearance Pinion bearing running clearance Standard Fit 0.41" 125 cu-in / 2050cc 9. 45-deg.5:1 7.016 0.0015 0.0010 0.002 Standard Fit 0.045 0.025 0.25" x 4.5:1 7.5:1 7.0008~0. 4 Ignition System Installation 2.2 Emissions-Related Installation Instructions 2.5 Installation Diagrams .SECTION 2 Installation In Chassis 2.3 Engine Installation 2.1 Pre-Installation Notice 2. 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. Essential warnings: WARNING: Health disorders can arise from contact with oil. Call the GMG Customer Service and Tech Support Line at 866-888-5980 if you have questions. the portion of the gasket that is wetted by the fuel. Different models and production years have seen many changes that are impossible to catalog here. or if you do not use appropriate protective equipment. a service manual for the year and model of the motorcycle is required. by using an OEM Harley-Davidson® service manual relevant to the chassis style of the motorcycle. so using the OEM manual in conjunction with this guide should provide enough information to assist with the installation. including cancer. 2-2 . WARNING: Gasoline is extremely flammable and highly explosive. subject to fines or other penalties as described in the Clean Air Act. you must place a duplicate label on the vehicle. Installation in aftermarket custom manufactured models: Installation of the RevTech engine in aftermarket custom motorcycles can be completed. 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. Avoid contact to the extent possible and wear latex or nitrile gloves whenever handling oil or oily parts. Hoses from reputable manufacturers (Goodyear hose SAE J30R9) which meet these specifications will be marked. WARNING: Never start the engine in a closed area. Do not smoke or allow open flames or sparks near the work site. For installations in OEM Harley-Davidson® models. 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. Always operate your motorcycle in an area with adequate ventilation as poisonous exhaust fumes may cause lose of consciousness or death. Most aftermarket custom motorcycles are built around chassis designs similar to many popular Harley-Davidson® models. 2. repeated contact on your skin can cause serious health problems. Be sure that all of the gaskets in the fuel tank represent an area exposed to the fuel of 1. 2. you must comply with the following requirements to ensure this does not occur: 1. and one or two for the petcock or petcocks.1 Pre-Installation Notice Installation in OEM Harley-Davidson® models: This section covers the installation techniques necessary to install the RevTech engine. Do not install the engine in any other form of vehicle. this requirement should be met.2. 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. in most cases. WARNING: You may be seriously injured if you attempt to service your engine or motorcycle with improper tools. Always stop the engine when refueling or servicing the motorcycle. If you use a filler neck with a diameter or 3 inches or less. Install the engine only in a motorcycle equipped with an all-metal fuel tank. This area is determined by analyzing the inside diameter of the gasket. WARNING: Your RevTech engine is only intended for use in a motorcycle chassis. do not properly know how to use the required tools. Utilize fuel lines that meet Category 1 permeation specifications of SAE J2260 or R11-A or R12 permeation specifications of SAE J30. On most fuel tanks.2 Emissions-Related Installation Instructions 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)). that is.000 millimeters squared or less. 3. As a result. Therefore. one for the fuel filler cap.105. showing that the requirements are met. Inadequate safety precautions could result in death or serious injury. as described in 40 CFR 1068. Always follow the instructions in this manual and do not attempt operations you are not competent to undertake. Evaporative Emissions Equipment Requirements: The motorcycle you are building or assembling is covered by what the EPA refers to as “Permeation” requirements. there are only two or three gaskets. Although it is extremely unlikely. provided such person follow the steps below. written and photographic records documenting (1) the N/V ratio.. through 9. Does not install the engine in a vehicle that exceeds the weight or N/V limits used to certify the engine. Under EPA/ CARB certification of engines for use to build new motorcycles. shall not apply to HMC assembled by the registered owner for personal use that is to be registered as a specially constructed vehicle per California Vehicle Code Section 580. to the purchaser of the kit until the records required by subparagraph 6. above. Therefore.-8. 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.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 manufactures and others to prevent new motorcycles (those with less than 7. However. is not required to apply for or receive EPA/CARB certification for its newly built HMC. if motorcycles in uncertified configurations with less than 7. or any other procedures stipulated by the engine manufacturer. The engine manufacturer shall maintain such agreements and make them available to EPA/CARB upon request. (5) the appearance of the finished motorcycle from both right and left sides (photograph required).2. authorized display of engine manufacturers brand and logo on vehicle) from the engine manufacturer. (3) evaporative canister installation (photograph required). if violations occur (i. and (6) foe emission control systems using one or more oxygen sensors.500 odometer miles) in uncertified configurations from being acquired. (4) installation of the label meeting the requirements of paragraph G above (photograph required). Ensures that the owners manual and warranty booklet are provided to the ultimate purchaser. the EPA/CARB retains authority to seek penalties from all persons involved in the violations. Does not modify the engine and emission related components. sold or offered for sale). the EPA/CARB retains authority to seek penalties from all persons involved in the violations. 2-3 ..e. only bikes with an MSO issued by the certified engine manufacturer is deemed legal for sale and registration in California. sold or offered for sale) . The engine manufacturer should have a procedure to assure that HMC newly built by authorized dealer-builders can be reasonably expected to be in compliance with all certification requirements. b. kit builder. including manufacturers. photographic evidence that the oxygen sensors were installed in the proper location.. the EPA/CARB considers these authorized dealerbuilders as an extension of an engine manufacturers vehicle assembly process. i. Provides for immediate inspection of records documenting the proper assembly of each motorcycle upon the request of the EPA/CARB. A chassis builder. 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. if motorcycles in uncertified configurations with less than 7. Installs a certified engine and emission related components (exhaust and evaporative ECS) following the installation instructions provided by engine manufacturer. 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. In the special case of authorized dealer-builders.500 odometer miles are acquired. However.e. have been completed. up to date factory service information bulletins for latest design changes) and factory recognition (e. above shall not apply to a business registered as a vehicle manufacturer by the California Department of Motor Vehicles. seller.g. Permanently affixes the required engine manufacturers VECI label in a readily accessible location on the vehicle as specified by the engine manufacturer. 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. sold or offered for sale in California. or assembler of HMC kits.500 odometer miles are acquired. Maintains.e. described under paragraph G. Other compliance and quality assurance procedures not listed here can and should be used to prevent these violation from occurring. (2) weight. An authorized dealer-builder may follow the procedures described in paragraph 1. if violations occur (i. 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.. including manufacturers. 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. The Photographic requirements of subparagraph 6.g. above. for a period of not less than two years. or an individual who assembles a HMC kit not intended for resale. a. The requirements of subparagraphs 6. as applicable.038 . STE. and carefully follow the instructions provided. 150 • MORGAN HILL. STE. As a result. CA 95037 MANUFACTURED ON (MM/YY) ENGINE SERIAL NO. liable for violation of federal laws. 2-4 . ENGINE DISPLACEMENT: 115 ci ENGINE FAMILY: 9GMGC2048TDC This vehicle conforms to EPA regulations applicable to 2009 model year new motorcycles and is certified to 1. ENGINE DISPLACEMENT: 125 ci ENGINE FAMILY: 9GMGC2048TDC This vehicle conforms to EPA regulations applicable to 2009 model year new motorcycles and is certified to 1.91 (R+M)/2 OCTANE OR HIGHER OIL: SAE 20 W 50 ENGINE EMISSION CONTROL INFORMATION CUSTOM CHROME 18225 SERENE DR. 150 • MORGAN HILL.4g/km HC+Nox. ENGINE EMISSION CONTROL INFORMATION CUSTOM CHROME 18225 SERENE DR. ENGINE ECS: EM ENGINE TUNEUP SPECIFICATIONS: IGNITION TIMING: 32 BTDC IDLE SPEED: 900-1000 RPM IN NEUTRAL FUEL: UNLEADED GASOLINE ONLY ..043 INCHES IGNITION TIMING: NON ADJUSTABLE IDLE SPEED: 900-1000 RPM IN NEUTRAL FUEL: UNLEADED GASOLINE ONLY . 12g/km CO exhaust emission standard. ENGINE DISPLACEMENT: ENGINE FAMILY: ENGINE ECS: EM THIS ENGINE CONFORMS TO US EPA REGULATIONS APPLICABLE TO MODEL YEAR NEW ENGINES ENGINE TUNEUP SPECIFICATIONS: IDLE MIXTURE: NON ADJUSTABLE VALVE CLEARANCE: HYDRAULIC (ZERO LASH) SPARK PLUG: AUTOLITE 4265 SPARK PLUG GAP: . CA 95037 MANUFACTURED ON (MM/YY) ENGINE SERIAL NO. Label Construction: The label provided is constructed in such a way that it will be destroyed if removed after initial application. STE. 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. kit manufacturer. Your emissions label will appear similar to one of these samples shown here.2.91 (R+M)/2 OCTANE OR HIGHER OIL: SAE 20 W 50 Made in USA Date of Manufacture: ENGINE EMISSION CONTROL INFORMATION CUSTOM CHROME 18225 SERENE DR. please take care to ensure the label is applied properly on the first attempt.91 (R+M)/2 OCTANE OR HIGHER OIL: SAE 20 W 50 Made in USA Date of Manufacture: Place emissions label on frame downtube WARNING: Failure to properly install the emissions control information label will make the vehicle manufacturer. which can be found in a plastic bag.2 Emissions-Related Installation Instructions EMISSIONS CONTROL INFORMATION LABEL REQUIREMENTS Note: An EPA emissions control information label has been supplied along with your new engine and this owner’s manual. 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. and subject to monetary fines and other penalties.4g/km HC+Nox. 150 • MORGAN HILL. CA 95037 MANUFACTURED ON (MM/YY) ENGINE SERIAL NO. Installation Instructions: 1) Peel the emissions label from its plastic backing. Please locate the label. or motorcycle assembler. 12g/km CO exhaust emission standard. ENGINE ECS: EM ENGINE TUNEUP SPECIFICATIONS: IGNITION TIMING: 32 BTDC IDLE SPEED: 900-1000 RPM IN NEUTRAL FUEL: UNLEADED GASOLINE ONLY . any aftermarket chassis designed to accept Evolution® engines can also accept the RevTech engine. Other than the engine mount and oil line differences between Softail® and rubbermount chassis. Therefore. FLT® and Dyna® models require some procedures for engine removal and installation that differ from those of the Softail® chassis. 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. Furthermore. Any Harley-Davidson® model built with the Evolution® engine can accept the installation of the RevTech engine. the remainder of the engine installation instructions in this section are valid for all chassis types. 2-5 . Rubbermount chassis such as those found on FXR®. For custom motorcycles built from scratch. The installation procedures shown in this section are based on the Harley-Davidson® Softail® chassis. and for complete custom motorcycles (either production-custom or one-off individual custom motorcycles). as outlined by the manufacturer. 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.2. 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 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.3 Engine Installation BEFORE YOU BEGIN: The RevTech engine is designed as a replacement for the Harley-Davidson® Evolution® engine. and outer primary following the OEM service manual’s instructions.’ This will leave the motorcycle stripped and ready for installation of the RevTech engine. no clamp is necessary. DO NOT over-tighten this set screw. Set the engine in place by installing it from the right side of the motorcycle. Next. you must have an OEM service manual for the year and model of the motorcycle on which the work is to be performed. Thoroughly clean the front and rear engine mounting surfaces and all other parts of the frame that are dirty. ARROW). follow the OEM service manual’s procedures for ‘Stripping Motorcycle for Engine Repair’ and ‘Removing Complete Engine. Install and adjust the compensating sprocket. Torque all hardware to the values specified.3 Engine Installation INSTALLING ENGINE IN CHASSIS As mentioned. A vacuum fitting is located on the back side of the carburetor (INSET. make sure that the appropriate spacer is installed over the sprocket shaft first (INSET). 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. Use of the service manual in conjunction with this guide is required for correct installation of the RevTech engine. the alternator stator must be installed. As this is a vacuum line.2. Simply push the line over the fitting until it bottoms against the carburetor body. preventing it from slipping back into the engine case. To begin. Next. Before installing the engine. 2-6 . remove the oil filter to avoid damage. ARROW) to which the vacuum line for the VOES (Vacuum Operated Electric Switch) must be attached (MAIN IMAGE. The set screw (B) holds the stator plug in place. Before installing the magnet/rotor. ensure that the engine-to-primary o-ring is in place (A). Before installing the engine in the chassis. or damage to the stator plug may result. primary chain. Feed from oil tank To oil tank return To Oil Filter 2-7 . the engine is now securely bolted into the frame and attached to the primary drive. Follow the OEM service manual's procedures for proper wiring of the VOES. Ensure that the throttle opens the carburetor slide completely.2. Use either worm-style or squeeze-type hose clamps to secure the lines to the fittings. This can be checked by removing the air cleaner and watching the slide travel as you open the throttle. At this point. When hooking up the fuel system.3 Engine Installation FUEL LINES. it is recommended to use a new piece of fuel line. The fuel-in fitting is located on the rearward-facing side of the carburetor (INSET). THROTTLE CABLES AND OIL LINES The VOES should be attached to the underside of the top engine mount (INSET). 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. SEE DIAGRAM 1 (Page 2-14) To oil tank vent Before installing the oil lines. Continue following the OEM service manual’s procedures for installing and torquing the top engine mount hardware. 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). Selecting the correct grade of fuel line is important to ensure that your engine installation meets all regulations. Follow the OEM service manual’s procedures for installation and adjustment of the throttle and idle cables to the carburetor. or poor performance may result. Verify that the engine idle speed is 1. The ignition system provided with your RevTech engine is capable of running in Single-Fire or Dual-Fire mode. re-install the oil filter that was included with the engine. If your motorcycle is not so equipped. Using the wiring diagram in your OEM service manual. ADJUST MODE SELECT STATUS VOES SEE DIAGRAM 2 (Page 2-14) To comply with regulations.000rpm by use of the tachometer. Complete the installation of the remaining vehicle components by following the OEM service manual’s procedures for 'Engine Installation'. Following the OEM service manual’s procedures. Torque all fasteners as recommended in the OEM manual.Owner's Manual for the proper engine break-in procedure and recommended maintenance schedule. follow the procedures listed in the OEM service manual regarding correct adjustment of the throttle and idle cables. connect the ignition system to the wiring harness in the motorcycle.3 Engine Installation IGNITION SYSTEM.2. 2-8 . install the exhaust system to the motorcycle. regarding the installation and wiring of the ignition system into your motorcycle. If further adjustments are necessary. Pages 2-9 through 2-13. Adjust the idle screw (ARROW) to achieve the correct idle speed. and fill the oil tank to the specified level as noted in your service manual. EXHAUST SYSTEM AND IDLE SPEED ADJUSTMENT SEE IGNITION SYSTEM INSTALLATION (Pages 2-9 . it is recommended to obtain a tachometer for periodically checking idle speed if you choose not to install one on your motorcycle. an appropriate exhaust system must be used with your RevTech engine. See DIAGRAM 2 on Page 2-14 for details. Follow the instructions in SECTION 3 .2-13) Follow the detailed instructions in Ignition System Installation. Install the oil pressure switch wire. multi-spark enabled 2 Single fire. We recommend that you enable multispark. Secure the harness with nylon cable ties. reduces the occurrence of backfiring at low RPM. A green VOES LED illuminates when the VOES input is active. Any attempt to adjust the ignition timing will be considered 'tampering' and may result in penalties imposed by the federal government. multi-spark disabled 3 Single fire. Operating Modes: A single 10 position rotary switch is used to select the operating mode. If a tachometer is not used.4 Ignition System Installation The 658183 ignition unit offers switch selectable single or dual fire modes. Switch settings are as follows: 0 Dual fire. The mounting surface must not be anodized or painted. a continuous series of sparks is fired from the advanced timing point until TDC. When multi-spark is enabled. 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.2. Refer to the appropriate wiring diagrams on page 2-11 for dual fire and page 2-12 for single fire. RevTech engines are delivered from the factory with the ignition timing set. and improves power at high RPM. Tape up any unused wires. Use appropriate crimp terminals for coil and VOES hookup. Install the supplied connector set on the brown tachometer wire as shown. Single fire mode improves starting. Reconnect the battery ground cable. WARNING: Do not adjust the ignition timing. The engine will not run if the mode switch setting does not match the wiring hookup (that is. seal the end of the mating plug with silicone RTV and use it as a protective cover. Make sure that the harness is clear of hot exhaust areas and cannot chafe against sharp edges. Use a proper crimping tool or solder the terminals. 3. 2. multi-spark enabled 4-9 Reserved CAUTION: Engine damage from excessive timing advance may result if the purple/white VOES wire is inadvertently shorted to ground. Multi-spark reduces the consequent tendency for plug fouling at idle. you cannot select single fire mode with a dual fire coil hookup). standard H-D® wire color codes are used. Route the wire harness along the frame tubing to the ignition coil. With the exception of the tachometer and rear coil section (single fire only). NOTE: The unit is grounded by means of the gear case housing. 2-9 . Installation: 1. Most air-cooled engines require relatively cold spark plugs to prevent detonation under high load. multi-spark disabled 1 Dual fire. 4. If used. 2-10 . Due to the short lengths involved on motorcycle applications. The red status LED is internally connected to the tachometer output. we suggest spiral core spark plug cables. Coils for Twin Cam® engines have low primary resistance and are not compatible. The 658183 module is compatible with all modern "ground sensing" type tachometers including H-D® OE and Autometer units.2. A lower 4. the VOES grounds the purple/white wire and causes the 658183 module to generate additional timing advance. VOES Considerations: The VOES is normally open. the tachometer output should be functional. The green VOES LED illuminates whenever the vacuum switch input is active (timing advanced). you will require a commercially available tachometer adapter. The unit uses a newly developed RPM limiting algorithm that has been highly optimized for odd firing V-twin engines. CAUTION: Do not use solid copper spark plug cables or non-resistor type spark plugs. If the red status LED blinks. the limit increases to 5. cylinder firing is always paired. In this case. This results in very smooth operation compared to random or sequence type RPM limiters. the unit may misfire. When the engine is held against the RPM limit. energy losses in spark plug wires are insignificant.500 RPM break-in limit is used during the first 10 hours of operation. Some early tachometers require a high voltage trigger pulse. Most OE style dual fire and aftermarket single fire coils meet this requirement. General Recommendations: Coil primary resistance must not be less than 3 ohms. At low manifold pressure or manifold vacuum greater than about 5 inch-Hg.700 RPM. For a more durable replacement. After the break-in period has elapsed. OE carbon core suppression cables will deteriorate after several years.4 Ignition System Installation RPM Limiter: The 658183 unit has preprogrammed RPM limits. 2.4 Ignition System Installation 2.Dual-Fire Ignition Wiring Diagram ADJUST MODE SELECT STATUS VOES 2-11 2-11 .Dual-Fire Ignition Wiring Diagram FIGURE 1 .4 Ignition System Installation FIGURE 1 . Single-Fire Ignition Wiring Diagram ADJUST MODE SELECT STATUS VOES 2-12 .4 Ignition System Installation FIGURE 2 .2. Experience has shown that most units returned for warranty are okay and another problem. is later identified. 2-13 . such as a defective coil.2.4 Ignition System Installation IGNITION SYSTEM TROUBLESHOOTING FLOWCHART Follow the troubleshooting flowchart shown below. 2-14 . 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. In order to comply with this requirement. Improperly connecting oil lines from the oil tank to your RevTech engine could result in engine damage or failure. it must be possible to sample emissions from both pipes. If your exhaust system has dual outlets. As oil tank design will vary from model and manufacturer. 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). the oil tank must be flushed out. cleaned and dried to ensure that no debris enters the engine.2.5 Installation Diagrams DIAGRAM 1 .Oil Line Routing In this diagram. It is also highly recommended that new oil lines and clamps be used. all connections for the engine's oil lines are shown. If necessary. Before installing the oil lines.Exhaust System Compliance Federal law states that it must be possible to sample exhaust emissions after a vehicle has been placed in service. To oil tank vent Feed from oil tank To oil tank return l To Oi Filter DIAGRAM 2 . exhaust sampling can be performed by placing a gas analyzer probe two feet into the exhaust pipe as shown here. 2 3.1 3.SECTION 3 Owner’s Manual 3.4 Engine Break-In Procedure Maintenance Schedule Maintenance Procedures Troubleshooting Guide .3 3. use a high quality. Failure to adhere to these procedures may void your warranty. the rev-limiter setting will automatically change to 5700 rpm. the break-in procedures listed below must be strictly followed. 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. • We reccommend 20W50 motorcycle oil for RevTech engines under normal operating conditions. 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.3. Do not subject the engine to hard acceleration or “lug” the engine in higher gears. change engine oil at least every 2500 miles. Always let the engine reach proper operating temperature before riding. After the initial 10 hour break-in period.clean and re-oil if necessary 3-2 . proceed for the first 50 miles avoiding engine RPMs above 4000 and below 2500 so the piston rings have a chance to seat properly. Service Requirements (2500 miles): • Change engine oil and oil filter • Inspect air cleaner . Otherwise. check for oil and fuel leaks. Vary your speed as much as possible and do not “lug” the engine in higher gears. The first 500 miles are the most important for your engine! Note: • During break-in. • The ignition rev-limiter will restrict engine speed to 4500 rpm during the first 10 hours of use. Avoid hard acceleration until you have 2000 miles and always avoid “lugging” the engine in higher gears. 0-50 Miles: After starting the engine.500 miles). CAUTION: Stop and go traffic.1 Engine Break-In Procedure To ensure long life and optimum performance from your new RevTech engine. and excessive idling should be avoided during the break-in period (0-2. overheating and engine damage could occur. If all is well and the engine is at operating temperature. non-synthetic motorcycle oil such as RevTech or RevTech Pure to ensure that all components seat properly. so please review these break-in procedures carefully. After break-in. and 25W60 motorcycle oil for use in temperatures above 80°F (27°C). 000 Mile Required Maintenance Perform 5000 mile required maintenance 17. Check idle speed and adjust if necessary 4. and use the recommended service parts whenever possible. To ensure that you get the most from your engine. strictly follow the maintenance schedule listed here. Clean tappet screen 3. Change engine oil and oil filter 2.500 Mile Required Maintenance Perform 2500 mile required maintenance 20. Inspect spark plugs and replace if necessary 12. Clean tappet screen 3. Check idle speed and adjust if necessary 5.500 Mile Required Maintenance Perform 2500 mile required maintenance 30. Clean tappet screen 3.clean & re-oil if necessary 5.000 Mile Required Maintenance Perform 5000 mile required maintenance 27. 3-3 .000 Mile Required Maintenance Perform 10000 mile required maintenance 22. Inspect spark plugs and replace if necessary 7.02mm) RevTech High-Performance Recommended Maintenance Schedule Correct engine idle speed: 1000rpm 500 Mile Required Maintenance 1. Change engine oil and oil filter 2.000 Mile Required Maintenance Perform 10000 mile required maintenance CCI Part # 35052 35048 35078 22185 58284 Quantity 3-4 quarts* 3-4 quarts* 1 2 1 * Refer to OEM manual for correct oil requirements. Change engine oil and oil filter 2. WARNING: Improper servicing of your engine can cause seizure or other equipment malfunction which can lead to injury or death. Change engine oil and oil filter 2. Inspect air filter .clean & re-oil if necessary 4. Never attempt a service operation which you do not thoroughly understand.040" / 1.500 Mile Required Maintenance Perform 2500 mile required maintenance 25. Inspect air filter .000 Mile Required Maintenance 1.500 Mile Required Maintenance 1. Inspect air filter . Change engine oil and oil filter 2. Recommended Service Parts and Fluids Item Engine Oil Oil Filter Spark Plugs Air Filter Description RevTech 20W50 or equivalent (under 80° F / 27° C) RevTech 25W60 or equivalent (above 80° F / 27° C) Chrome RevTech 'Long' or equivalent Autolite 4265 (set gap to . Inspect air filter .3.500 Mile Required Maintenance 1.clean & re-oil if necessary 10.000 Mile Required Maintenance 1.2 Maintenance Schedule Your new RevTech engine was designed to provide a long life of service.clean & re-oil if necessary 4. Inspect spark plugs and replace if necessary 2.500 Mile Required Maintenance Perform 2500 mile required maintenance 15. Check idle speed and adjust if necessary 5. then clean it and the tappet screen plug.SERVICE INTERVALS: ALL The oil should be changed only when the engine is at normal operating temperature. broad. Using a large.3. place the tappet screen back into the engine case and tighten the plug securely. If the engine is not at normal operating temperature.SERVICE INTERVALS: 500. Locate the engine oil tank and drain plug on your motorcycle. check the oil level. using oil recommended in the MAINTENANCE SCHEDULE on Page 3-3. Following the procedures listed in the appropriate service manual for your year and model of motorcycle. drain the oil. When the engine is sufficiently warmed up. turn the engine off to check the oil level. Use the type and quantity of oil recommended in the MAINTENANCE SCHEDULE on Page 3-3. Following the procedures listed in the appropriate service manual for your year and model of motorcycle. Check oil level . 25K. Lightly oil the o-ring on the tappet screen plug. Remove and inspect the tappet screen (INSET). the motorcycle should be ridden until the engine reaches that stage.3 Maintenance Procedures The following six procedures provide a visual step for the five areas of maintenance covered in the Maintenance Schedule. checking the oil level. 5K. If the engine is not at normal operating temperature. 10K. remove the tappet screen plug. Locate the engine oil tank and filler plug on your motorcycle. When the engine is sufficiently warmed up. Add oil as necessary. Change engine oil and oil filter . BEFORE EACH RIDE The oil should be checked only when the engine is at normal operating temperature. flat-blade screwdriver. 15K. and the most crucial 'every time you ride' step. 20K. 3-4 . 30K All RevTech engines utilize a tappet screen as a preventative measure to keep large debris from entering the oiling system that feeds the lifters. turn the engine off to change the oil. the motorcycle should be ridden until the engine reaches that stage.SERVICE INTERVALS: ALL. Clean tappet screen . If the element has a red coloration. 25K. 15K.SERVICE INTERVALS: 500.-ft. 30K Verify that the engine idle speed is 1. inspect the spark plugs and replace as necessary. If further adjustments are necessary. the spark plugs must be tightened to the specified torque (11-18 lbs. then tighten them another 1/ 4-turn with a Inspect air filter . remove the spark plugs. 3-5 . or with a suitable timing light. it is suitable for continued use.000rpm by use of the tachometer (if your motorcycle is so equipped). For illustration. 10K. If a torque wrench is not available. a new. Check idle speed . 5K. dirty filter. tighten the plugs by hand. Do not run the engine without the air filter element in place.3. 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.SERVICE INTERVALS: ALL To access the spark plugs. the gap should be checked and adjusted if necessary.SERVICE INTERVALS: ALL EXCEPT 500 Remove the air cleaner cover and inspect the condition of the element. clean air flter is placed atop a well-used. first disconnect the spark plug cables from the plugs by pulling on the molded connector caps. thereby causing significant damage. Following the procedures listed in the appropriate service manual for your year and model of motorcycle. Apply a small amount of anti-seize compound to the threads as shown (INSET). Once re-installed. Adjust the idle screw (arrow) to achieve the correct idle speed. A darker brown color will indicate that the filter is dirty and in need of cleaning. Using a spark plug wrench. 20K.) to ensure proper heat transfer. follow the procedures listed in the appropriate service manual for your year and model of motorcycle to correctly adjust the throttle and idle cables.3 Maintenance Procedures Inspect spark plugs . Dust and debris could be drawn into the engine. Before installing new spark plugs. Charge battery 4. Fouled spark plugs or improper gaps 2. Worn or damaged needle or needle jet 7. Let engine sit for 10 minutes 6. Check all connections 3-6 . Plugged jets or air passages Poor Acceleration Check for: 1. Intake air leak 11. Loose wire connection at coil. Choke still in “on” position 10. Repair as necessary 4. Clean and clear 8. Tighten or clean as necessary Remedy: 1. Clean or replace as necessary 4. Clean or replace as necessary 4. Fuel level too high (overflows) 6. Adjust idle speed to 1000 RPM 3. Check fuel valve and fuel lines 5. Loose wire connection at coil. Check manifold seals 2. Replace needle or needle jet 6. Excessive choke use 2. Worn or damaged needle or needle jet 6. Loose or plugged main jets Remedy: 1. Water or dirt in carburetor 8. Intake air leak 5. battery or ignition module Poor Engine Idle Check for: 1. Tighten jets 5. Replace needle or needle jet 7. Turn choke “off” 10. Battery discharged 4. Idle speed improperly adjusted 3. Spark plug cables in poor condition 7. Intake air leak 3. Clean or replace as necessary 7. Fuel supply restricted 6. Replace needle or needle jet 7. Fuel tank or carburetor vent clogged 9. Adjust idle speed to 1000 RPM 4. Spark plug cables in poor condition 3. Replace cables 3. Clean and clear Remedy: 1. Fouled spark plugs or improper gaps 3. Water or dirt in carburetor 8. module or sensor 6. Check fuel valve and fuel lines 6. Clear blockage 2. Adjust cable 9. Dirty air or fuel filter 7. Fuel tank vent clogged 2. fuel valve and fuel lines 2. Clear blockage 9. Worn or damaged needle or needle jet 7. Clogged pilot jet 5. Check manifold seals 5. Dirty air filter 4. Fuel tank vent clogged 3. Dirty air filter 4. Check manifold seals 11. Check all connections Remedy: 1. Check fuel tank. Faulty ignition coil. Clean and clear Remedy: 1. Check manifold seals 3. Clear blockage 3. Clean jet 5. Only use until engine is at operating temp.3. Choke not operating correctly 9. Idle speed improperly adjusted 4. Adjust level 6. Engine flooded 6.4 Troubleshooting Guide Hard Starting Check for: 1. Plugged jets or air passages 8. Accelerator pump inoperative 5. Replace spark plugs or adjust gaps 3. Repair as necessary 5. Clean carburetor 8. Accelerator system leaking or no output 4. Replace cables 7. Plugged jets or air passages Poor On-Road Performance Check for: 1. Clean carburetor 8. Replace spark plugs or adjust gaps 2. Fuel tank empty or fuel supply blocked 2. 2. battery or ignition module Poor Fuel Economy Check for: 1. Loose jets 5. Fuel supply restricted 5. Inspect and replace as necessary 6. Intake air leak 2. 1 Parts Catalog .SECTION 4 Parts Catalog 4. Use this parts catalog to determine the correct part and part number when ordering replacement components for your RevTech® engine. 4-2 .1 Parts Catalog ALWAYS INSIST ON GENUINE REPLACEMENT PARTS The components used to manufacture RevTech® engines are available for sale.4. 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. This means that your RevTech® engine can be maintained with genuine RevTech® parts to provide extended service and performance. 125" x 4. b. Black Powder Coated paint. wrinkle finish.1 Parts Catalog Engine Assembly. Natural (raw) aluminum finish with cylinder fins machined. Size = Stroke and Bore. a. Complete – RevTech® 125" Motor Part # 680272 680271 680270 Description 49-State Natural aluminum finish 49-State Black wrinkle finish 49-State Polished finish Engine Assembly. Polished aluminum finish with cylinder fins machined.41" = 125 inch) (4. Complete – RevTech® 110" Motor Part # 658526 658525 658527 Description 49-State Natural aluminum finish 49-State Black wrinkle finish 49-State Polished finish Engine Assembly. Complete – RevTech® 88" Motor Part # 58500 58501 58503 Description Black wrinkle finish Natural aluminum finish Polished finish NOTES: Regarding the RevTech® 115" & 125" Big Twin Engines: 1. Size = Stroke and Bore (4. cylinders & heads all with chrome covers.30" = 115 inch) Regarding the RevTech® 110" & 100" 4x4 Big Twin Motors: 1. 3.25" x 4. the cylinder fins machined. Engines are completely assembled 4-3 . c. (4 3/8" x 4" = 110 inch) (4" x 4" = 100 inch) 2.4. Complete – RevTech® 100" Motor Part # 658536 658535 658537 Description 49-State Natural aluminum finish 49-State Black wrinkle finish 49-State Polished finish Engine Assembly. Finish or color of cases. Complete – RevTech® 115" Motor Part # 680275 680274 680273 Description 49-State Natural aluminum finish 49-State Black wrinkle finish 49-State Polished finish Engine Assembly. D.001” 58089-In 659617-Ex 59628 54441 58250 58251 54442 54009 59725 59726 94053 94053 26054 26055 28081 54440 54014 28027 660350 660352 28555 SEE CHART A. B 658180 12328 660370 58630 32787 35078 37064 35627 20302 32813 32116 25300 59240 25273 54006 25311 32105 26173 659626 660358-F 660351-R 659000 659001 659002 94054-7 28014 58072 694040 94045~51 20645 20036 658034 58125 25403 25404 20213~7 58230 58235 660360 26010 93537 32110 26048 58076~7 25335 26011 659645 32106 17714 657055 94018 20095 20091 32108 31700 31701 20243 19485 20243 19485 20244 54254 20233 20241 20242 660365 20095 32812 692042 32813 35623 692040 94034 75585 28013 692041 659005 93637 32111 660367 20283 54000 20029 20238 59897 59898 59899 21338 92236 71014 54423 32104 54058 54250 20240 20235 20239 20237 20281 4-4 .1 Parts Catalog RevTech Gen 2 Complete Motor Assembly 88 Inch & 100 Inch Motors 21351 94065 93500 54227 93987 59430 54150 59431 23857 58265 54086 58162 31657 93987 32813 14625 25177 54082 54085 58288 58289 58270 58271 SEE CHART C.4. E 54414 59654 59624 58284 75400 59622 59657 59613 59623 99196 59646 STD 59660 +. Retaing ring. Exhaust studs. Bushing. Black pushrods for 1 hole lifters. Sold each. stock duration. OEM 24045-78) Pinion gear. (repl. Includes fittings & mounting hardware. silicone upper rocker box. Sold each. (repl. Spring. OEM 26328-74) Idler gear-oil supply. cam cover with silicon bead. (repl. oil pump outer cover to body. Pack of 10. Chrome 5/16-18 x 1-1/4" sockethead bolt. (repl.065" thick. O-Ring. Pack of 10. OEM 17360-83) Rocker arm. OEM 24002-70) Pinion shaft key. OEM 26315-68A) Idler gear-oil return.70". Sold in pairs. Revtech exhaust valve 1. Sold each. Pack of 10 Press-together flywheel assembly. OEM 24334-36) Sold each. Umbrella valve. OEM 24044-78) Pinion gear. Cam shims . Set of 4. Chrome Revtech 100" air cleaner insert. (repl. tappet oil screen & oil pump plug. Chrome 12-point flange bolt. OEM 18633-48D) Pack of 10. (repl. OEM 27010-86A) Sold each. OEM 24042-78) Pinion gear. Check ball. (repl. Chrome 5/16" AN flat washer. 4-5 . OEM 25581-70) Pinion bushing. Cam shims .( repl. oil control jet.94" dia. +10° duration. Cam shims . OEM 16778-84A) Pack of 10 Gasket. cam cover.(repl. green. Chrome Revtech 88" air cleaner insert. Revtech oil pump. Silver pushrods for 2 hole lifters. oil pump end cap. Black oxide 5/16-18 x 3/4" sockethead bolt. 4-1/4" stroke for 88" Revtech motors. rocker box top cover. Spacers. Revtech high performance spin-on oil filter. Gen II sump plate. (repl. between pinion & oil drive gear. (repl. Sold each. OEM 26432-76A) Pack of 10 Oil seal. OEM 16478-85A) Sold each. Pack of 50. OEM 27009-86A) Sold each. left engine case.1 Parts Catalog RevTech Gen 2 — 88 & 100 Motor Parts List CCI # 12328 14625 17714 19482 20029 20036 20091 20095 20213 20214 20215 20216 20217 20233 20235 20237 20238 20239 20240 20241 20242 20243 20244 20281 20283 20302 20645 21338 21351 23857 25177 25273 25300 25311 25335 25403 25404 26010 26011 26048 26054 26055 26173 28013 28014 28027 28081 28530 31657 31700 31701 32104 32105 32106 32108 32110 32111 32116 32787 32812 32813 35078 35623 35627 37064 54000 54006 54009 54014 54058 54082 54085 54086 54150 54250 54254 54414 54423 54440 54441 54442 58072 58076 58077 58079 Description Ignition plate studs and washers. Revtech hydraulic tappets. Pack of 10. Gasket. (repl. #10-24 x 5/8" hex screws. OEM25555-36) Pack of 5. Sold as a set for one valve. pinion gear. red. (repl. HSR 42mm Mikuni carburetor with chrome top cover & choke cable. OEM 26276-92) Pack of 10. Chrome 1/4-20 x 2-1/4" sockethead bolt. Includes hardware. Rear intake manifold flange.060" thick. +10° duration. 3/8" hose. Gasket. green.070" thick. (repl. lower rocker box cover to head. (repl. Chrome 1/4-20 x 3-1/2" hex bolt.030" oversize breather valve. OEM 26346-70) Spacer. Chrome oil filter housing. OEM 11157) Pack of 10. silicone lower rocker box. Cam shims . Valve guide intake and exhaust +. cover side (repl. Chrome 1/4-20 x 2" sockethead bolt. Pack of 50. Chrome 1/4-20 x 1" sockethead bolt. upper piston rod +. Gasket. (repl. OEM 26348-15) Pack of 10. OEM 24981-70) Pack of 5. OEM 11105) Pack of 10. OEM 24626-87A) Aluminum head breather washers. (repl. Pack of 10. Pack of 10. OEM 9058) Thrush washer. Pack of 10. Revtech EV-100 cam for 100" motor. (repl. OEM 32402-83) Screw and washer. OEM 12026B) Pack of 5. OEM 17375-83) Chrome Evo front & rear tappet block set. Pack of 10. Chrome Revtech 88" complete air cleaner & breather assembly . Inner pushrod cover set. OEM 25225-93) Pack of 10. blue. OEM 32591-80) Pack of 10. (repl. OEM 25550-57) Pack of 5. (repl. yellow. (repl. OEM 83162-51) Cam needle bearing. lower pushrod cover. 3/8" x 7/16" x 6. (repl. sump plate & case hardware. (repl. OEM 17356-92) Pack of 10. Polish Revtech oil pump cover. Tappet oil screen. Sold each. point cover. Pack of 4 with 4 different thickness. (repl. Chrome timing hole plug. Pack of 10. Revtech intake manifold. (repl. OEM 32601-78) Pack of 10. Pinion bearing. Revtech replacement air filter element. (repl. rocker box top bolts. cam cover. OEM 24023-54) Sold each. Plunger. Gasket. (repl. OEM 26207-83) Sold each. #10 flatwasher. upper pushrod cover. stainless steel. OEM 63554-90) Pack of 10. OEM 24641-87A) Pinion bearing. OEM 16779-84A) Pack of 10 Gasket. (repl. (repl. (repl. intake manifold. oil pump cover. (repl. Oil pressure switch.075" thick. oil pump drive shaft. Intake manifold flange set. Oil seal. OEM 26373-92) Pack of 10. OEM 24041-78) Pinion gear. sump plate & case hardware. rear tappet block. Spring. Chrome 1/4-20 x 7/8" sockethead bolt. Retaining ring. Set of 4 Outer pinion shaft plug . cylinder dowel. Gasket. engine sprocket shaft. OEM 63533-41) Sold each. Seal. front exhaust or rear intake. Black Revtech Gen II cases with studs.(repl. orange. Drive gear-oil return. Revtech breather valve. OEM 26262-80) Sold each. Revtech electronic ignition without break-in rev-limiter. Set of 4. Valve spring upper collar. (repl. Polish Gen II sump plate. (repl. Pack of 10. Set of 4. upper cylinder to head. OEM 26400-82) Sold each. oil pump. rear exhaust or front intake. Chrome Revtech 100" complete air cleaner & breather assembly. Chrome plug. white. Revtech electronic ignition with break-in rev-limiter. Cylinder studs. case side. Cam shims . (repl. Chrome oil pump cover with spacers & hardware. Chrome hose fitting.4. Pack of 10. lower cylinder to case. O-Ring. OEM 17611-83) Bushing. OEM 26317-68A) Drive gear-oil supply. 4-3/8" stroke for 100" Revtech motors. OEM 17355-92) Pack of 10 Gasket.(repl. Ignition rotor. OEM 24046-78) Complete Evo rocker box hardware kit. Natural Gen II sump plate. Chrome complete pushrod cover kit. Chrome 5/16"-18 nylon-inserted lock nuts. OEM 26263-80) Sold each. OEM 8873) Pack of 10. pinion bearing. OEM 24628-87A) Pinion bearing. (repl. OEM 11002) Pack of 10. stainless steel. Chrome 8-32 x 1/2" flathead screws. OEM 24043-78) Pinion gear. oil pump driven gear. tappet oil screen. breather. OEM 26561-84) O-Ring. (repl. Oil pump shaft.(repl. (repl. Chrome 1/4-20 x 1-1/2" sockethead bolt. ( repl. Oil pump driven gear 24 tooth.(repl. left side (repl.080" thick. Sold in pairs. sump plate & case hardware. (repl. Black Gen II sump plate. (repl. OEM 18523-86A) Sold each. Sold each Press-together flywheel assembly. Pinion gear. white/gray.(repl. Pack of 10. tappet oil screen & oil pump. (repl. (repl. (repl. silicone inner rocker box. Sold each. 1/8-27 NPT oil pump body. lower rocker box cover to head. Valve keepers. Front intake manifold flange.(repl OEM 17358-84A) Pack of 10. Chrome 5/16-18 x 3-1/2" hex bolt. Revtech +. 58089 58125 58162 58230 58235 58250 58251 58265 58270 58271 58284 58288 58289 58630 59240 59430 59431 59432 59613 59622 59623 59624 59628 59646 59654 59657 59660 59725 59726 59897 59898 59899 71014 75400 75585 92236 93500 93501 93537 93637 93987 94018 94034 94045 94046 94047 94048 94049 94050 94051 94053 94054 94055 94056 94057 94065 99196 657055 658034 658180 658181 659000 659001 659002 659005 659617 659626 659645 660350 660351 660352 660358 660360 660365 660367 660370 692040 692041 692042 694040 Revtech intake valve 1. Pack of 10. Oil pump shaft key. Pack of 10 O-Ring. Valve guide intake and exhaust standard size. (repl. Chrome banjo bolt. Rubber intake adapter flange with hose clamp for 42mm Mikuni carbs. Pack of 10 Thrust washer. OEM 24643-87A) Pinion bearing. Pack of 10 O-Ring. OEM 17428-57) Sold each. (repl.61" dia. ignition rotor. Valve guide seals. (repl. (repl. Pack of 100. oil pump shaft. (repl. Pack of 10. Chrome point cover with Revtech logo. middle pushrod cover. Retaining ring. Set of 4. Revtech polish complete oil pump assembly. Chrome 90° hose fitting. Gasket. cam gear. OEM 26345-73) Oil pump drive gear. O-Ring. red. right side (repl. Chrome banjo fitting. cover side (repl. Pack of 10. Zinc plated 12 point flanged inner head bolts. OEM 23985-54) Pack of 10. OEM 9028) Rocker arm. 1/8 NPT. O-Ring. Pack of 10 Brass 1/4" washer. OEM25556-79) Pack of 5.115" thick) Revtech valve springs. OEM 18634-48C) Pack of 10. Chrome 5/16" flat washer. cam cover. Pack of 10. (repl. OEM 11132) Pack of 10. Gasket. Revtech breather valve. Polish Revtech Gen II cases with studs. OEM 16480-92A) Sold each. Gasket. Revtech chrome cam cover. Pack of 6. oil pump relief valve. OEM 26349-73) Rocker arm shaft. OEM 25582-73) Left engine case Timken bearing set. (repl. Chrome 1/4" flatwasher with 7/16" o. Valve spring lower collar. oil pump check valve. OEM 26348-36) Pack of 10. blue. Spacer. O-Ring. 3/8" hose. Chrome plated 12 point flanged outer head bolts. Set of 8. (repl. OEM25554-36) Pack of 5. OEM 2611B) pack of 10. (repl. Chrome plug. (repl. (repl. OEM25553-36) Pack of 5. (repl. Revtech breather valve. Chrome 1/4" AN flatwasher. OEM 26326-62A) Spring. (repl. (repl. Natural Revtech Gen II cases with studs. (repl. Pack of 10. (repl. OEM 24040-78) Pinion gear.002" oversize. Pack of 10. (repl. Pack of 10. (repl.001" oversize. Inner valve spring spacer. Revtech EV-50 cam for 88" motor. Cam bushing. rocker arms. OEM 26856-89) Pack of 10. Seal. (repl. OEM 11177A) Pack of 10. breather. (repl. oil pump body to case. Pinion shaft nut. Gasket. (repl. case side. (repl. OEM 24982-70) Pack of 5. Chrome smooth profile rocker box cover set. (repl. OEM 2622-58) Pack of 10. Pack of 10. left hand thread. OEM 11241) Pack of 10. Chrome 1/4-20 x 3/4" sockethead bolt.d.( repl. O-Ring. oil pump relief valve. Flat washer. front tappet block.060" hole. OEM 11145) Pack of 10. Pack of 10. Chrome 5/16-18 x 3" hex bolt. (. OEM25552-36) Pack of 5. Sold in pairs. (repl. (repl. black. Sold each. B 35078 37064 637065 35627 20302 32813 32116 25300 59240 25273 54006 25311 32105 658161 659625 660358-F 660351-R 58720 58723 58726 654403 659621 659620 659628 32812 692042 35623 32813 692040 94054-7 660360 658150 694040 94045~51 20645 20036 58120 58130 25403 25404 20213~7 24309 658236 26010 93537 32110 26048 25335 26011 659645 657055 94018 20095 20091 32108 20243 19485 20244 54254 20233 31700 31701 32106 17714 20243 19485 20241 20242 620298 20095 94034 75585 658151 692041 93637 32111 20283 620299 54000 20029 658196 659624 20233 59900 59901 59902 21338 92236 71014 54423 32104 54250 20235 658198 658143 658195 658147 658197 658140 4-6 .001” 659616-In 659617-Ex 658166 58271 SEE CHART C. F 28312 58284 75400 628314 28310 92612 92607 660327 28027 659636 659637 28081 59628 653994 53891 92610 92609 59725 59726 92617 658180 12328 660370 58630 32787 53895 92606 53947 660328 92605 658165 658168 653994 SEE CHART G.4. D. H 654400 54009 SEE CHART A.1 Parts Catalog 110 Inch & 100 Inch 4x4 Motors 21351 94065 93987 59430 658164 RevTech Gen 3 Complete Motor Assembly 59431 675002 675010 32352 32213 32218 28311 675003 675011 28313 32116 32118 94003 658163 658167 58279 93987 32813 14625 25177 699296 699258 699206 699207 59657 699234 99196 659705 STD 659706 +. E. Sold each. Chrome 1/4" flatwasher with 7/16" o. Chrome 5/16" AN flat washer. oil pump body to case. (repl. Breather assembly lower housing. (repl. Tappet oil screen. Breather assembly top cover. OEM 16478-85A) Sold each. Revtech roller rocker arm. Flat washer. OEM 23985-54) Pack of 10. OEM 26400-82) Sold each. white. OEM 24643-87A) Pinion bearing. Plunger. OEM 17591-99). left hand thread. Gasket. cover side (repl. (repl. Ignition rotor. Revtech electronic ignition with break-in rev-limiter. Gasket. Chrome 5/16" flat washer. Oil pump drive gear. rocker box base to head. (repl. oil pump driven gear. (repl. OEM25556-79) Pack of 5. OEM 24042-78) Pinion gear. Chrome hose fitting. Polish Revtech Gen III cases with studs. Chrome oil filter housing. sump plate & case hardware. (repl. Black oxide 5/16-18 x 2-3/8" hex head flanged bolt. Chrome 1/4-20 x 2-1/4" sockethead bolt. Pack of 10. O-Ring. Bushing. Black Revtech Gen III cases with studs. (repl. OEM 24982-70) Pack of 5. oil pump relief valve. OEM25553-36) Pack of 5. Pinion shaft nut. OEM 9058) Thrush washer. yellow. OEM 17428-57) Sold each. Pack of 10. Valve guide seals.(repl. Chrome banjo bolt. (repl. OEM 24628-87A) Pinion bearing. Cam shims . Chrome smooth rocker box front base. Sold in pairs. Cam shims . stainless steel. OEM 24334-36) Sold each. Sold each. (repl OEM 26858-99). OEM 11002) Pack of 10. head breather assembly. (repl. Set of 4. stainless steel. OEM 11145) Pack of 10. (repl. engine sprocket shaft. (repl. ignition rotor. Chrome 5/16-18 x 3" hex bolt. Oil seal. sump plate & case hardware. OEM 26263-80) Sold each. front tappet block. (repl. Pack of 10. Chrome complete pushrod cover kit.4. (repl. Set of 8. Pack of 10.080" thick. Pack of 10. HSR 45mm Mikuni carburetor with chrome top cover & choke cable.065" thick. Cam shims . (repl. rocker arms. Includes hardware. Gasket. Pack of 10. point cover. Pack of 10 Revtech polish complete hi-flow oil pump assembly. (repl. Gasket. Outer valve spring.(repl. 3/8" hose.002" oversize. breather. (repl. OEM 17611-83) Bushing. OEM 24023-54) Sold each. cover side (repl. Chrome banjo fitting. OEM 18633-48D) Pack of 10. OEM 18523-86A) Sold each. OEM 12026B) Pack of 5.( repl. Cylinder studs. OEM 17592-99) Pack of 10. Chrome Evo front & rear tappet block set. white/gray. OEM 27010-86A) Sold each. (repl. (repl. Press-together flywheel assembly. OEM 27009-86A) Sold each. OEM 63533-41) Sold each. (repl. red.060" hole. Retaining ring. (repl. Pack of 10. Chrome point cover with Revtech logo.070" thick. Chrome Revtech 100" air cleaner insert. breather baffle. OEM 26317-68A) Drive gear-oil supply. Pack of 10.30". OEM 9028) Rocker arm shaft. Includes fittings & mounting hardware. Umbrella Valve. OEM 26561-84) O-Ring. 71014 75400 75585 92236 92605 92606 92607 92609 92610 92612 92617 93537 93637 93987 94018 94034 94045 94046 94047 94048 94049 94050 94051 94054 94055 94056 94057 94065 99196 620298 620299 628314 637065 653994 654400 654403 657055 658140 658143 658147 658150 658151 658161 658163 658164 658165 658166 658167 658168 658180 658181 658195 658196 658197 658198 658236 659616 659617 659620 659621 659624 659625 659628 659635 659636 659637 659645 659705 659706 660327 660328 660351 660358 660360 660370 675002 675003 675010 675011 692040 692041 692042 694040 699206 699207 699234 699258 699296 Chrome 90° hose fitting. OEM 24626-87A) Aluminum head breather washers. Sold in pairs. blue. Pinion gear. Pack of 10. cam cover with silicon bead. Gasket. Chrome 1/4-20 x 3-1/2" hex bolt. Seal. Black oxide #8-32 x 3/8" button head screw. Chrome smooth 2-piece rocker box set. Chrome 5/16-18 x 1-3/4" sockethead bolt. Chrome plug. OEM 11270). OEM 25225-93) Pack of 10. Pack of 10. O-Ring. O-ring. Cam shims . upper piston rod +. (repl. 4-3/8" stroke for 110" Revtech motors. lower pushrod cover. Revtech roller rocker arm complete set. OEM25552-36) Pack of 5. (repl. 3:1 ratio. oil pump check valve. Chrome plated 12 point flanged outer head bolts. orange. 600 lift. Breather assembly middle housing. OEM 24046-78) Pinion bearing. (repl. Rear intake manifold flange. OEM 32591-80) Pack of 10. Pack of 10. pinion gear. OEM 24045-78) Pinion gear. OEM 63554-90) Pack of 10. Cam bushing. Revtech intake manifold. OEM 24040-78) Pinion gear. Natural Revtech Gen III cases with studs. Pack of 6. OEM 63815-99). Oil pressure switch. Pack of 10. Revtech oil pump. front exhaust or rear intake.1 Parts Catalog RevTech Gen 3 – 110 & 100 4x4 Motor Parts List CCI # 12328 14625 17714 19482 20029 20036 20091 20095 20213 20214 20215 20216 20217 20233 20235 20241 20242 20243 20244 20283 20302 20645 21338 21351 24309 25177 25273 25300 25311 25335 25403 25404 26010 26011 26048 28027 28081 28310 28311 28312 28313 28317 31700 31701 32104 32105 32106 32108 32110 32111 32116 32118 32213 32218 32352 32787 32812 32813 35078 35623 35627 37064 53891 53895 53947 54000 54006 54009 54250 54254 54423 58120 58130 58271 58284 58630 58720 58723 58726 59240 59430 59431 59432 59628 59657 59725 59726 59900 59901 59902 Description Ignition plate studs and washers. O-Ring. Black Gen III sump plate. OEM 26326-62A) Revtech EV-110/100 smog cam for EPA motors. Chrome 1/4-20 x 1" sockethead bolt. Sold each. red. intake manifold. cam cover. Natural Gen III sump plate. black. OEM 11132) Pack of 10. Revtech chrome cam cover.61" dia. Sold each. oil pump. (repl. case side. OEM 24641-87A) Pinion bearing. OEM 11241) Pack of 10. (repl. 600 lift. Cam shims . 3/8" x 7/16" x 6. Pack of 100 Chrome 8-32 x 1/2" flathead screws.001" oversize. cam cover. (repl. Revtech intake valve 2" dia. oil pump drive shaft. OEM 2611B) pack of 10. Polish Gen III sump plate. Chrome timing hole plug. Check ball. rear tappet block. Inner pushrod cover set. breather top cover. sump plate & case hardware. #10 flatwasher. Sold each. Pack of 10. 3/8" hose. Revtech electronic ignition without break-in rev-limiter. Valve spring lower collar. case side. OEM 8873) Pack of 10. Chrome Revtech 100" 4x4 complete air cleaner & breather assembly. Gasket. lower cylinder to case. breather. breather assembly. (repl. Set of 4. O-Ring. Oval rubber intake adapter flange with hose clamp for 42mm Mikuni carbs. Black oxide 5/16-18 x 2-5/8" hex head flanged bolt. Retaining ring. (repl. (repl. (repl. HSR 42mm Mikuni carburetor with chrome top cover & choke cable.(repl. OEM 32601-78) Pack of 10. Sold each Revtech exhaust valve 1. Chrome 1/4-20 x 7/8" sockethead bolt. Pack of 10 Chrome smooth rocker box rear base. OEM 26348-15) Pack of 10. OEM 11157) Pack of 10. (repl. O-Ring. 3:1 ratio. oil pump outer cover to body. Pack of 10. tappet oil screen. OEM 26348-36) Pack of 10. (repl. Pack of 10. Oil seal. Spring. Pack of 10. Metal gasket. #10-24 x 5/8" hex screws. Revtech high performance spin-on oil filter. Pack of 10. (repl. Valve guide intake & exhaust standard size. Gen III sump plate. OEM 16480-92A) Sold each. Chrome 5/16-18 x 3-1/2" hex bolt. upper pushrod cover. O-Ring. (repl. (repl. Oil pump driven gear 21 tooth. Front piston oil squirter. Chrome 1/4-20 x 1-1/2" sockethead bolt. Pack of 10. OEM 26262-80) Sold each. Pack of 10. Valve guide intake & exhaust +. Chrome 1/4-20 x 3/4" sockethead bolt. Chrome 1/4-20 x 2" sockethead bolt. Pack of 10. middle pushrod cover. Revtech replacement air filter element. (repl. Pack of 10 Outer pinion shaft plug . oil pump cover. Sold each. Retaing ring. Chrome smooth rocker box top cover. Pack of 10. Pack of 10. Set of 4. Chrome 5/16"-18 nylon-inserted lock nuts. (repl. Oil pump shaft key. OEM 11177A) Pack of 10. (repl. blue. Pack of 10.( repl. Sold each. 1/8-27 NPT oil pump body & sump plate. Chrome plug. Drive gear-oil return. Spacers. cam cover. Oval rubber intake adapter flange with hose clamp for 45mm Mikuni carbs. Sold each. (repl. OEM 26346-70) Spacer. Press-together flywheel assembly. (repl.060" thick. Breather assembly filter element. OEM 24041-78) Pinion gear. (repl. Revtech hi-flow oil pump body only. Spacer. Rubber gasket. left engine case. Pack of 50. Pack of 10. OEM 26315-68A) Idler gear-oil return. green. OEM 24981-70) Pack of 5. underneath breather assembly. oil pump end cap. (repl. Polish Revtech oil pump cover. Chrome 5/16" sockethead plugs. Exhaust studs. OEM25554-36) Pack of 5. 4" stroke for 100" 4x4 Revtech motors. Pack of 10. (repl. OEM 24044-78) Pinion gear. OEM 26207-83) Sold each. (repl. green. Support tower. Pack of 10 O-Ring. (repl. (repl. Pack of 10 Chrome complete pushrod cover kit for 100" 4x4 motors only. (repl. tappet oil screen & oil pump plug. 1/8 NPT. Seal. Pack of 10. Sold in pairs. cylinder dowel / drain. (repl. OEM25555-36) Pack of 5. Chrome Revtech 110" air cleaner insert. Revtech EV-72 cam for 110" & 100" 4x4 motor. piston oil squirters. Chrome 1/4" AN flatwasher. OEM 26328-74) Idler gear-oil supply. Pack of 10. Pack of 10. 4-7 . (repl. Sold in pairs. Chrome Revtech 110" complete air cleaner & breather assembly . Oil pump shaft. (repl. Pack of 10. OEM 24002-70) Pinion shaft key. (repl. Chrome 5/16-18 x 1-3/4" Smooth sockethead bolt. (repl. (repl. Set of 4 Gasket. Chrome 5/16-18 x 1-1/4" sockethead bolt. front & rear. Rear piston oil squirter. Chrome oil pump cover with spacers & hardware. pinion bearing. OEM 83162-51) Cam needle bearing. Revtech roller rocker arm. Revtech hydraulic tappets. OEM 25550-57) Pack of 5.075" thick. Intake manifold flange set.(repl. Valve spring upper collar. OEM 24043-78) Pinion gear. Pack of 10. between pinion & oil drive gear. Zinc plated 12 point flanged inner head bolts. Chrome 5/16-18 x 3/4" Smooth sockethead bolt. Sold each. rocker arms.(repl. cam gear. (repl. Black oxide 5/16-18 x 3/4" sockethead bolt. (repl. (repl. (repl. ( repl. (repl. Pack of 10. Black oxide 1/4-20 x 2-1/4" hex head flanged bolt. Spring. OEM 18634-48C) Pack of 10. Gasket. Smooth rocker boxes. rear exhaust or front intake. Spring. Gasket. OEM 32402-83) Screw and washer. Front intake manifold flange. (repl. OEM 25582-73) Left engine case Timken bearing set. Valve keepers. OEM 25581-70) Pinion bushing.d. Pack of 10. oil pump shaft. Pack of 100. Pack of 10. OEM 11105) Pack of 10. Pack of 50. tappet oil screen & oil pump. Inner valve spring. oil pump relief valve. In 659617 .1 Parts Catalog RevTech Gen 4 Complete Motor Assembly 115 Inch & 125 Inch Motors 21351 94065 93987 59430 658164 684664 54227 684665 59431 675003 675011 675002 58282 684663 93987 32813 92277 58285 58284 22183 58283 684638 684666 684660 684659 684661 58278 58287 658167 58276 14625 25177 699296 699258 699206 699207 699234 99196 659705 659616 .Ex 684672 684673 58279 27177 684669 684670 684658 684676 684677 684674 684675 28027 32106 32812 32108 SEE CHART 654403 659636 659637 28081 92609 32219 32813 59628 SEE CHART 684662 684667 54009 94008 684671 SEE CHART SEE CHART 59725 59726 684662 658180 35078 20302 32813 32116 37064 35627 94007 94005 25300 94000 684657 684655 684656 59240 36050 54006 94004 25311 20036 26048 684637 25403 684652 20213~7 24309 658236 26010 94077 93537 32107 684635 684636 32105 684651 658161 695625 58072 660359 25335 32108 32107 684668 17714 20243 19485 20243 19485 20241 20242 94055~7 12076-F 12077-R 684629 684630 684631 654403 684649 695628 28014 694040 94045~51 20645 26011 657055 94018 658150 684653 20091 93537 684634 35623 94034 75585 28013 620298 20095 684647 32813 692040 93637 32107 620299 20233 684641 32812 93637 20321 20244 54254 692041 33386 684650 53893 684633 21253 54000 684646 684645 684644 684632 684648 71014 54250 684642 684643 684640 648157 684639 4-8 .4. Valve guide intake & exhaust +. lower pushrod cover. Gasket. Chrome complete pushrod cover kit. OEM 26561-84) O-Ring. Pack of 50. Flat washer. Cylinder Alignment Dowel Base Gasket. 5/16-18x1 Screw w/washer. OEM 9058) Cam bushing. OEM 24626-87A) Aluminum head breather washers. High Flow Wide Body Oil pump body Oil Pump cover Supply drive gear Supply driven gear Return drive gear Return driven gear Drive shaft. OEM25555-36) Pack of 5. (repl. Pack of 10. (repl. OEM 18523-86A) Sold each. Chrome 1/4" AN flatwasher. (repl. OEM 63533-41) Sold each. (repl. OEM 17611-83) Bushing.30". Bushing. Spacer. long. O-Ring. OEM 17428-57) Sold each. breather. 1/8-27 NPT oil pump body & sump plate. Pack of 10. RevTech hydraulic tappets. 4. tappet oil screen. 3/8" hose. oil pump outer cover to body. Valve guide intake & exhaust standard size.( repl. OEM 26400-82) Sold each. RevTech oil pump. 1/4-20x3/4 Screw w/washer. Chrome 5/16-18 x 3" hex bolt. Pack of 100. Chrome 1/4-20 x 1" sockethead bolt.070" thick. Pack of 6. Includes fittings & mounting hardware. HSR 45mm Mikuni carburetor with chrome top cover & choke cable. OEM 24043-78) Pinion gear.060" thick.001" oversize. Black oxide 5/16-18 x 2-5/8" hex head flanged bolt. Gen4 Air Cleaner Kit. Seal. #10-32x1/2" Rocker Box Kit Rocker Box. Black RevTech Gen IV Cases with studs & case hardware. 1/4-20x1 Sealing washer. (repl. RevTech electronic ignition with break-in rev-limiter. 4. Drian Plug O-Ring. (repl. Sensor block off Screw. Pack of 10. Exhaust studs. Outer valve spring. Chrome plug. ( repl. OEM 24041-78) Pinion gear.(repl. cam cover. Sold in pairs. OEM 24023-54) Sold each. OEM25556-79) Pack of 5. Pack of 10. Valve keepers. OEM 16478-85A) Sold each. (repl. middle pushrod cover. OEM 24982-70) Pack of 5. 1/8 NPT. rear tappet block. oil pump relief valve. 1/4-20 x 1" sockethead bolt . Pack of 10. Black oxide 5/16-18 x 3/4" sockethead bolt. Pack of 10. Sold in pairs. 115" Head Gasket. (repl. orange. Intake manifold flange set. (repl. (repl. Spring. upper piston rod Chrome plated 12 point flanged head bolts. (repl. Spacer. O-Ring.060" hole. breather valve Thrust Washer.300" stroke for 115" RevTech motors. OEM 24643-87A) Pinion bearing. green. OEM 25225-70B) Pack of 10. Pack of 10. 115" Insert. Pinion gear. O-Ring. oil pump Driven gear. (repl. RevTech roller rocker arm. OEM 27010-86A) Sold each. Oil pressure switch. base Rubber gasket. Pack of 10 Oil seal. upper pushrod cover. O-Ring. OEM25552-36) Pack of 5. Includes hardware. OEM 11105) Pack of 10. Air Cleaner 125" Insert. (repl. Sold each. Sold each. Inner valve spring. top Rocker Box. Spring. (repl. Ignition Cover Screw. Plunger. button head Breather Valve Shim. OEM 24981-70) Pack of 5. OEM25554-36) Pack of 5. yellow. 1/4"npt 4-9 . cam cover. Oval rubber intake adapter flange with hose clamp for 45mm Mikuni carbs. base Rocker Support. (repl. OEM 9028) Rocker arm shaft. pinion bearing. Valve spring lower collar. support Screw w/washer. Gen4 5/16-18 x 2" sockethead bolt . oil pump relief valve. OEM 24044-78) Pinion gear. Chrome 1/4-20 x 2-1/2" sockethead bolt. OEM 26207-83) Sold each. Pack of 10. OEM 25582-73) Left engine case Timken bearing set. Cam shims . oil pump check valve. left hand thread. front exhaust or rear intake. 1/4-20 x 1-1/2" sockethead bolt . 3/8" x 7/16" x 6. black. Sold in pairs.(repl.065" thick. 600 lift. oil pump driven gear. Front intake manifold flange. Oil pump shaft key. blue.080" thick. Cam shims . RevTech EV-72 cam for 115" & 125" 4x4 motor. 659625 659628 659636 659637 659705 659706 660351 660358 675002 675003 692040 692041 694040 699206 699207 699234 699258 699296 CCI# 684629 684630 684631 684632 684633 684634 684635 684636 684637 684638 684639 684640 684641 684642 684643 684644 684645 684646 684647 28014 28013 684648 684649 660359 684650 53893 33386 684651 58072 684652 684653 684654 684655 684656 684657 684658 684659 684660 684661 684662 684663 684664 684665 54227 684666 684667 32219 32106 32108 684668 684669 684670 654403 684671 22183 668230 684673 684674 684675 684676 684677 93918 Cylinder studs. Ignition Unit. tappet oil screen & oil pump. OEM25553-36) Pack of 5. rear exhaust or front intake. oil pump 1/4-20x2-1/2" screw Squirter Unit Gasket. (repl. oil pump drive shaft. Pack of 10. OEM 63554-90) Pack of 10. (repl. Chrome timing hole plug. Pack of 10. OEM 26262-80) Sold each. OEM 18633-48D) Pack of 10.075" thick. OEM 32402-83) Screw and washer. Cam shims . Press-together flywheel assembly. intake manifold. RevTech roller rocker arm. (repl. Chrome 5/16-18 x 3-1/2" hex bolt. 600 lift. Pack of 10.4. (repl. (repl. (repl. (repl. OEM 24628-87A) Pinion bearing. Chrome banjo bolt. Pack of 50. (repl. OEM 2611B) pack of 10. Seal. front tappet block.(repl. white/gray. Chrome Evo front & rear tappet block set. OEM 18634-48C) Pack of 10. red. Sold each. oil pump Modified Key Drive gear.(repl.(repl. (repl. OEM 24002-70) Pinion shaft key.61" dia. Ignition Cable Holder Head Gasket. Chrome banjo fitting. drain plug Chrome 1/4-20 x 3-1/4" cap screw Press-together flywheel assembly. left engine case. Pack of 10. Sold each. (repl. OEM 25581-70) Pinion bushing. Retaining ring. OEM 11002) Pack of 10. Sold each. RevTech intake valve 2" dia. OEM 23985-54) Pack of 10. Pack of 10 Outer pinion shaft plug . Set of 4. rocker arms. Inner pushrod cover set. Pack of 10. OEM 24042-78) Pinion gear. green. pinion gear. 1/4" Metal Gasket. #8-32 x 3/8" button head screw. 1/4-20x5/8". Pack of 10. Oil seal. engine sprocket shaft. RevTech EV-110/100 smog cam for EPA motors. Chrome 1/4" flatwasher with 7/16" o. (repl. Pinion shaft nut. (repl. Polish RevTech Gen IV Cases with studs & case hardware.1 Parts Catalog RevTech Gen 4 – 115 & 125 Motor Parts List CCI# 14625 17714 19482 20036 20091 20095 20213 20214 20215 20216 20217 20233 20235 20241 20242 20243 20244 20302 20645 21351 24309 25177 25300 25311 25335 25403 26010 26011 26048 28027 28081 32105 32106 32107 32108 32112 32812 32813 35078 35623 35627 37064 54000 54006 54009 54250 54254 58284 59240 59430 59431 59432 59628 59725 59726 71014 75585 92609 93537 93637 93987 94018 94034 94045 94046 94047 94048 94049 94050 94051 94054 94055 94056 94057 94065 99196 620298 620299 654403 657055 658147 658161 658164 658167 658180 658181 658236 659616 659617 Description Chrome 5/16"-18 nylon-inserted lock nuts. red. OEM 26263-80) Sold each. Rear intake manifold flange. Description Natural RevTech Gen IV Cases with studs & case hardware. Set of 4. Chrome 5/16" flat washer. (repl. Pack of 10. RevTech high performance spin-on oil filter. Chrome 90° hose fitting. OEM 24045-78) Pinion gear. RevTech electronic ignition without break-in rev-limiter. Chrome hose fitting. Ignition rotor. OEM 27009-86A) Sold each. piston oil squirters. oil pump shaft. (repl. OEM 24046-78) Pinion bearing. (repl. 125" Air Cleaner Kit. Chrome 1/4-20 x 7/8" sockethead bolt. OEM 24040-78) Pinion gear. Pack of 10. Pack of 10. Pack of 10. (repl.410" stroke for 125" RevTech motors. Gen4 Spark Plug Compression Release **Use # for Motorway's part** Intake Manifold. (repl. Tappet oil screen. 3/8" hose. Valve guide seals. 125" O-Ring. OEM 24641-87A) Pinion bearing. Set of 4 Gasket. (repl. OEM 11145) Pack of 10. cam cover with silicon bead.d. between pinion & oil drive gear. OEM 11177A) Pack of 10. tappet oil screen & oil pump plug. rocker box. OEM 11132) Pack of 10. Retaining ring. RevTech replacement air filter element. Sold each. (repl. Chrome oil filter housing. Camshaft Cam Cover Kit Cam Cover Ignition Cover Screw. Sold each RevTech exhaust valve 1. (repl. (repl. oil pump body to case. Chrome 1/4-20 x 1-1/4" sockethead bolt. Retaing ring. Cam shims . blue. Check ball. (repl. (repl. OEM 12026B) Pack of 5. Chrome 1/4-20 x 1-1/2" sockethead bolt. (repl. (repl. Pack of 10. Set of 8. (repl. ignition rotor. OEM 26348-15) Pack of 10. Spring. Oil Pump Kit. cam cover. Chrome 5/16" AN flat washer. (repl. Pack of 10 O-ring. Gasket. oil pump. (repl. breather. Air Cleaner 115" Plug. OEM 26348-36) Pack of 10. Pack of 10.( repl. Sold each. OEM 83162-51) Cam needle bearing. OEM 8873) Pack of 10. (repl. (repl. Gasket. (repl. OEM 11157) Pack of 10. Sensor Block off O-Ring. white. Chrome plug. Valve spring upper collar. Cam shims . Pack of 10. Sold in a set for 1 piston 100" Piston ring set. front 51127 88" Black cylinder 3-5/8" bore. front intake. 3-5/8" +. Sold in a set for 1 piston 100" Piston ring set. wrist pin & clips Piston 4" bore front. +. +. 3-5/8" +.030" os.005"oversize. +.005" oversize with rings. wrist pin & clips Piston 4" bore rear. 3-13/16" standard size.020" os with rings. seal & O-ring kit for RevTech® 110" engines 658513 Top end gasket. Sold each 58243 88" Piston ring set. front 110" Polish cylinder 4" bore. front 51125 88" Natural cylinder 3-5/8" bore. Sold each Pushrod. rear 51130 100" Natural cylinder 3-13/16" bore. seal & O-ring kit for RevTech® 110" engines 4-22 .5/8" bore front & rear.020" oversize with rings. Sold each Pushrod.010" oversize with rings.005"oversize. +. wrist pin & clips 58816 100" Piston 3-13/16" bore front & rear. Sold in a set for 1 piston Chart 58245 58246 58247 58248 58249 B Rings For Revtech 100" Motors 100" Piston ring set.005" oversize with rings. Sold in a set for 1 piston Chart A 658840 658841 658842 658843 658890 658891 658892 658893 Chart B 658930 658931 658932 658933 Chart C 51161 51162 51163 51164 51165 51166 Chart D 651167 651168 651169 651170 651171 651172 Chart E 58471 58472 58473 58474 58475 58476 Chart F 658477 658478 658479 658480 658481 658482 Chart G 694070 694071 694072 694073 Chart H 694074 694075 694076 694077 Piston With Rings For Revtech 110" & 100" 4x4 Motors Piston 4" bore front. +. std size with rings. 3-13/16" +. front 100" Black cylinder 4" bore. for 88" & 100" motors Natural rear head. Sold each Pushrod. B SEE CHART G. 3-13/16" +.010" oversize with rings. +. Sold in a set for 1 piston 100" Piston ring set.030" os with rings. rear 110" Polish cylinder 4" bore. front 51129 100" Polish cylinder 3-13/16" bore. front 51131 100" Natural cylinder 3-13/16" bore. +. wrist pin & clips 58815 100" Piston 3-13/16" bore front & rear. rear intake. 3-5/8" standard size. seal & O-ring kit for RevTech® 100" and 88" engines with 97/98 Casting Marked Rocker Boxes 658511 Complete engine gasket. +. wrist pin & clips Piston 4" bore front. +. for 88" & 100" motors Natural front head. Sold in a set for 1 piston 4" bore piston ring set. B RevTech Gen 3 – 110 & 100 4x4 Motor Parts List Charts SEE CHART A. Sold in a set for 1 piston 88" Piston ring set. 3-13/16" +. front 100" Polish cylinder 4" bore. +. +. front exhaust. rear exhaust. rear 51126 88" Black cylinder 3-5/8" bore. with rings. Sold in a set for 1 piston 4" bore piston ring set.005"oversize.RevTech Gen 2 – 88 & 100 Motor Parts List Charts SEE CHART A. with rings. Sold each Push rods for Revtech 110" Motors Pushrod.020" oversize.010" os with rings.010" oversize.010" oversize. Sold each Pushrod. front 100" Natural cylinder 4" bore. rear Chart E 59791 59792 59793 59794 59795 59796 Cylinder Heads for Revtech 88" & 100" Motors (Valve guides & valve seats installed) Black front head for 88" & 100" motors Black rear head for 88" & 100" motors Polish front head for 88" & 100" motors Polish rear head. wrist pin & clips 58810 88" Piston 3-5/8" bore front & rear. Sold in a set for 1 piston 58244 88" Piston ring set. standard size. Sold each Pushrod. standard size with rings.020" oversize.005" os. standard size with rings. wrist pin & clips 58808 88" Piston 3-5/8" bore front & rear. D. Sold in a set for 1 piston Chart C Cylinder for Revtech 88" Motors 51122 88" Polish cylinder 3-5/8" bore. rear exhaust. +. 3-5/8" +. +. rear Chart D Cylinder for Revtech 100" Motors 51128 100" Polish cylinder 3-13/16" bore. for 88" & 100" motors Gaskets and Seals 658510 Complete engine gasket. D.020" oversize with rings. wrist pin & clips Piston 4" bore rear. Sold in a set for 1 piston 88" Piston ring set. front exhaust. rear 110" Black cylinder 4" bore.010" os.005" os with rings. Sold in a set for 1 piston 4" bore piston ring set. front 110" Black cylinder 4" bore. std size with rings. wrist pin & clips 58809 88" Piston 3-5/8" bore front & rear. wrist pin & clips 58814 100" Piston 3-13/16" bore front & rear. with rings.030" oversize. wrist pin & clips Chart A Piston With Rings For Revtech 100" Motors 58813 100" Piston 3-13/16" bore front & rear. rear 100" Polish cylinder 4" bore. wrist pin & clips 58817 100" Piston 3-13/16" bore front & rear. rear intake. +. E Chart A Piston With Rings For Revtech 88" Motors 58807 88" Piston 3. wrist pin & clips 58811 88" Piston 3-5/8" bore front & rear. H SEE CHART C. front 51123 88" Polish cylinder 3-5/8" bore. rear intake. with rings. F SEE CHART C.020" oversize. +. rear 100" Black cylinder 4" bore. wrist pin & clips Piston 4" bore rear. Sold each Pushrod. rear Cylinder Heads for Revtech 110" Motors (Valve guides & valve seats installed) Black front head for 110" motors Black rear head for 110" motors Natural front head for 110" motors Natural rear head for 110" motors Polish front head for 110" motors Polish rear head for 110" motors Cylinder Heads for Revtech 100" 4x4 Motors (Valve guides & valve seats installed) Natural front head for 100" 4x4 motors Black front head for 100" 4x4 motors Polish front head for 100" 4x4 motors Natural rear head for 100" 4x4 motors Black rear head for 100" 4x4 motors Polish rear head for 100" 4x4 motors Push rods for Revtech 100" 4x4 Motors Pushrod. rear 51132 100" Black cylinder 3-13/16" bore. rear 51124 88" Natural cylinder 3-5/8" bore.020" os. +. 3-13/16" +. wrist pin & clips Chart 58240 58241 58242 B Rings For Revtech 88" Motors 88" Piston ring set. +. wrist pin & clips Ring Set For Revtech 110" & 100" 4x4 Motors 4" bore piston ring set. front 51133 100" Black cylinder 3-13/16" bore. Sold in a set for 1 piston 100" Piston ring set. E. wrist pin & clips Piston 4" bore front. front 110" Natural cylinder 4" bore. rear Cylinder for Revtech 100" 4x4 Motors 100" Natural cylinder 4" bore. wrist pin & clips Piston 4" bore rear.010" oversize. Sold in a set for 1 piston Cylinder for Revtech 110" Motors 110" Natural cylinder 4" bore.030" oversize. Gaskets and Seals 658512 Complete engine gasket. seal & O-ring kit for RevTech® 100" and 88" engines with 99/00 Casting Marked Rocker Boxes 59784 Sump-plate gasket 54095 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. 3-5/8" +. H SEE CHART C. F Chart A 684678 684679 684680 684681 684686 Chart A 684687 684688 684689 684690 684686 Chart B 684696 684697 684698 684699 Chart B 684700 684701 684702 684703 Chart E 684704 684705 684706 684707 684708 684709 Chart E 684710 684711 684712 684713 684714 684715 Chart F 684716 684717 684718 684719 684720 684721 Chart H 684722 684723 684724 684725 Gaskets 684726 684727 684728 684729 Piston With Rings For Revtech 125" Motors Piston Set 4-1/4" bore. Valve guides & valve seats installed. Polish front head for Gen 4 motors. standard size with rings. Sold each and Seals Complete engine gasket. Black front head for Gen 4 motors. Push rods for Revtech 125" & 115" Pushrod. Piston 4-1/8" bore front. 4-1/8" bore piston ring set. +. front. 125" Natural cylinder 4-1/4" bore. Piston 4-1/8" bore front. Valve guides & valve seats installed.010" oversize with rings.005" oversize with rings. 125" Black cylinder 4-1/4" bore.010" oversize. rear. +. seal & O-ring kit for RevTech 115" engines 4-23 . Sold each Pushrod. Sold in a pair. Sold in a set for 1 piston. Piston Set 4-1/4" bore. Piston Set 4-1/4" bore. rear intake. +. rear. wrist pin & clips. Sold in a set for 1 piston.020" oversize. 125" Black cylinder 4-1/4" bore. 125" Polish cylinder 4-1/4" bore. B RevTech Gen 4 – 115 & 125 Motor Parts List Charts SEE CHART G. +. 115" Black cylinder 4-1/8" bore. Polish rear head for Gen 4 motors. 4-1/4" bore piston ring set.005"oversize. Natural rear head for Gen 4 motors.005"oversize. wrist pin & clips. +. front. standard size. rear. wrist pin & clips. rear intake. Piston With Rings For Revtech 115" Motors Piston Set 4-1/8" bore. Sold in a set for 1 piston. standard size with rings. 4-1/4" bore piston ring set. 4-1/8" bore piston ring set. Cylinder Heads for Revtech 125" & 115" Natural front head for Gen 4 motors. Piston Set 4-1/4" bore. Retaining clip. wrist pin & clips. 4-1/4" bore piston ring set. rear exhaust. wrist pin & clips. +. 115" Polish cylinder 4-1/8" bore. front exhaust. wrist pin & clips. rear. Sold in a set for 1 piston. Sold in a set for 1 piston. Retaining clip. 115" Natural cylinder 4-1/8" bore. +. seal & O-ring kit for RevTech 115" engines Tep End gasket. Cylinder for Revtech 125" Motors 125" Natural cylinder 4-1/4" bore. Sold in a set for 1 piston. front. Sold in a set for 1 piston. rear. Cylinder for Revtech 115" Motors 115" Natural cylinder 4-1/8" bore. Black rear head for Gen 4 motors. Sold in a set for 1 piston. front. +.010" oversize. Sold each Pushrod. 125" Polish cylinder 4-1/4" bore. Valve guides & valve seats installed. 115" Black cylinder 4-1/8" bore.005" oversize with rings. Valve guides & valve seats installed. Valve guides & valve seats installed. Sold in a pair.SEE CHART A. +. rear. +. standard size.010" oversize with rings. Ring Set For Revtech 115" Motors 4-1/8" bore piston ring set. +. Ring Set For Revtech 125" Motors 4-1/4" bore piston ring set. +. Piston 4-1/8" bore front.020" oversize with rings. seal & O-ring kit for RevTech 125" engines Complete engine gasket. front. seal & O-ring kit for RevTech 125" engines Tep End gasket. wrist pin & clips. wrist pin & clips. wrist pin. E. 4-1/8" bore piston ring set. Sold each Pushrod.020" oversize with rings.020" oversize. 115" Polish cylinder 4-1/8" bore. Valve guides & valve seats installed. front. wrist pin. D. published in the USA .Notes © 2009 Custom Chrome All rights reserved.