S&S adjustable pushrods are crucial for hydraulic tappet systems, offering precise valve train geometry and optimal performance.
These instructions detail safe installation and adjustment, preventing damage and ensuring functionality.
This guide provides a comprehensive walkthrough, referencing factory service manuals and emphasizing meticulous component inspection for a successful outcome.
What are S&S Adjustable Pushrods?
S&S adjustable pushrods are precision-engineered components designed to optimize valve train performance in Harley-Davidson and other V-Twin engines utilizing hydraulic lifters.
Unlike fixed-length pushrods, these allow for precise adjustment of valve lash, compensating for manufacturing tolerances and wear.
They feature a threaded body allowing length customization, ensuring proper lifter preload for optimal operation. S&S pushrods are constructed from high-quality materials for durability and reliability, contributing to increased engine efficiency and reduced wear. Proper installation is key.
Why Choose Adjustable Pushrods?
Choosing adjustable pushrods, like those from S&S Cycle, is vital for achieving optimal engine performance and longevity. They eliminate guesswork in valve lash setup, accommodating variations in component manufacturing and wear.
Precise adjustment prevents valve-to-valve contact and potential cylinder head damage, ensuring reliable operation. Adjustable pushrods maximize horsepower, improve engine efficiency, and reduce noise. They are essential when rebuilding or modifying engines, guaranteeing a properly tuned valve train for peak performance.
Tools and Materials Needed
Installation requires standard mechanics tools, a factory service manual, new pushrod tube O-rings, and of course, the S&S adjustable pushrod kit itself.
Ensure you have the correct wrenches, sockets, and potentially a pushrod length checking tool for accurate setup.
Essential Tools List
For successful installation, gather a comprehensive toolkit. You’ll need a standard socket set, including both metric and standard sizes, alongside open-end wrenches to match your motorcycle’s hardware. A torque wrench is vital for securing the jam nuts to the manufacturer’s specifications.
Additionally, a pushrod length checking tool can be incredibly helpful for precise adjustments. Don’t forget screwdrivers (Phillips and flathead), pliers, and potentially a magnetic pickup tool for dropped parts. A clean workspace and adequate lighting are also essential for a smooth process.
Required Parts and Supplies
Beyond the S&S adjustable pushrods themselves, several supporting components are necessary. New pushrod tube O-rings are crucial to prevent oil leaks during and after installation. High-quality engine oil is needed for priming the hydraulic lifters.
Consider having a tube of threadlocker on hand for securing certain components. Cleaning solvent and rags are essential for preparing surfaces. Finally, ensure you have the correct replacement parts if any existing components are damaged during removal.
Preparation Before Installation
Prior to beginning, consult your factory service manual for specific procedures. Inspect new pushrods for defects and thoroughly clean all components to ensure a smooth installation;
Consulting the Factory Service Manual
Crucially, refer to the appropriate factory service manual specific to your engine’s model and year before removing existing pushrods. The manual provides vital torque specifications, removal sequences, and component locations unique to your motorcycle.
Ignoring this step risks damaging critical engine parts. The service manual details proper procedures for breather/rocker arm support loosening and re-tightening, essential for correct valve train function. It’s a foundational step for a successful S&S adjustable pushrod installation.
Inspecting New Pushrods
Thoroughly inspect each new S&S pushrod before installation. Carefully examine the entire length for any defects, bends, or damage incurred during shipping. Pay particular attention to the threads on both ends, ensuring they are clean and undamaged.
Critically, inspect the center oil hole for any obstructions. A blocked oil hole will starve the lifter of lubrication, leading to premature wear or failure. Clean and verify unobstructed oil flow before proceeding with the installation process.
Cleaning Components
Prior to installation, meticulous cleaning of all components is essential. Ensure the cylinder heads and rocker boxes are free from any debris, old gasket material, or oil residue. Clean the pushrod tubes thoroughly, paying attention to the seating surfaces for the O-rings.
Inspect and clean the breather bolts as well. Removing any contaminants prevents them from entering the oil system. A clean working environment contributes significantly to a successful and reliable installation of your S&S adjustable pushrods.
Installation Procedure, Step-by-Step
Begin by carefully removing existing pushrods, priming hydraulic lifters, and then installing the new S&S adjustable pushrods. Secure the jam nut properly for accurate adjustment.
Removing Existing Pushrods
Prior to installing the S&S adjustable pushrods, carefully remove the existing ones, referencing your engine’s factory service manual for specific procedures. This ensures a smooth and damage-free removal process.
Properly document the location of each pushrod during removal, as variations in length may exist. This documentation will aid in the correct placement of the new adjustable pushrods.
Inspect the removed pushrods for any signs of damage, such as bending or wear, which could indicate underlying valve train issues.
Priming Hydraulic Lifters
Before installing new pushrods, it’s absolutely crucial to fully prime the hydraulic lifters. This ensures they are properly filled with oil and functioning correctly, preventing premature wear and valve train noise.
Pumping up the lifters before installation is essential; under no circumstances should this step be skipped. Utilize an appropriate priming tool or method recommended by the engine manufacturer.
Verify each lifter has achieved full travel and maintains pressure before proceeding with the pushrod installation process.
Installing the New Pushrods
Carefully insert the new S&S adjustable pushrods into the pushrod tubes, ensuring they seat correctly within both the lifter and the cylinder head. Gently guide them into place, avoiding any forceful pressure that could damage the components.
Confirm the pushrod ends are fully seated before proceeding. Double-check alignment to prevent binding or misalignment during adjustment.
Remember to replace pushrod tube O-rings during this step to maintain a proper seal and prevent oil leaks.
Securing the Jam Nut
After achieving the initial pushrod length adjustment, carefully tighten the jam nut against the adjuster. This secures the desired length, preventing unwanted movement during engine operation. Ensure the jam nut is snug, but avoid over-tightening, which could damage the adjuster threads.
A properly secured jam nut is vital for maintaining accurate valve lash.
Allow the hydraulic lifters to completely bleed down – typically 20-30 minutes – before rotating the engine to prevent valve-to-valve contact and potential cylinder head damage.
Adjusting Pushrod Length
Begin the initial adjustment process, allowing lifters to bleed down completely before engine rotation. This prevents valve contact and ensures accurate valve train geometry.
Initial Adjustment Process
Start by loosening the jam nut on the adjustable pushrod, allowing for length adjustments. Rotate the engine until the valve for that cylinder is fully closed – typically at Top Dead Center (TDC) on the compression stroke.
Slowly tighten the pushrod adjustment screw until zero lash is achieved; this is when you feel slight resistance when rotating the pushrod.
Once zero lash is found, turn the adjustment screw an additional ½ to ¾ of a turn to achieve proper preload. This ensures the lifter maintains contact with the valve train.
Bleeding Down the Lifters
Allow the hydraulic lifters to completely “bleed down” before rotating the engine further. This crucial step prevents potential valve-to-valve contact and catastrophic cylinder head damage. A fully bled lifter will offer minimal resistance when rotating the pushrod with your fingers.
Typically, this process takes approximately 20-30 minutes per cylinder. Patience is key; rushing this stage can lead to significant engine problems. Confirm the pushrod rotates freely, indicating complete lifter depressurization before proceeding.
Rotating the Engine for Adjustment
After allowing the lifters to bleed down, carefully rotate the engine. This action allows for a more accurate pushrod length adjustment as the lifters begin to re-pressurize. Repeat the adjustment process for each cylinder individually, ensuring each valve train component is properly set.
Monitor the pushrod’s feel; it should have slight play. Continue rotating the engine through several cycles, re-checking and fine-tuning the adjustment until optimal valve clearance is achieved.
Fine-Tuning and Verification
Verify proper valve clearance and smooth operation after adjustment. Repeat the process for each cylinder, ensuring consistent performance and preventing valve-to-valve contact.
Checking for Proper Valve Clearance
After initial adjustment, meticulously check for correct valve clearance. This ensures optimal engine performance and prevents potential damage. Rotate the engine and verify that each valve opens and closes smoothly without binding.
Insufficient clearance can lead to burnt valves, while excessive clearance reduces power. Precise adjustment, guided by the factory service manual, is paramount.
Confirm the pushrods rotate freely with your fingers once the lifters have bled down, typically after 20-30 minutes, indicating proper adjustment and lubrication.
Ensuring Smooth Operation
Smooth engine operation post-installation hinges on meticulous adjustment and verification. After setting pushrod length, rotate the engine several times, listening for any unusual noises – ticking or clattering – which indicate improper valve train geometry.
Confirm each valve operates freely throughout its range of motion.
Properly bled lifters and correctly adjusted pushrods contribute to quiet, efficient performance. Re-check adjustments if any irregularities are detected, consulting the factory service manual for guidance.
Repeating the Process for Each Cylinder
Consistent valve train performance demands repeating the adjustment procedure for every cylinder. After completing one cylinder, rotate the engine to Top Dead Center (TDC) on the next cylinder’s compression stroke.
Then, re-establish the zero lash and adjust the pushrod length accordingly, securing the jam nut.
This systematic approach ensures uniform valve clearance across all cylinders, contributing to optimal engine efficiency and preventing potential issues like valve-to-valve contact.
Pushrod Tube Considerations
Replace pushrod tube O-rings during new pushrod installation to prevent oil leaks and maintain proper lubrication within the engine’s valve train system.
Replacing O-Rings
Carefully remove the old O-rings from the pushrod tubes, ensuring no debris remains in the grooves. Inspect the grooves themselves for any damage or wear that could compromise the seal.
Lightly lubricate the new O-rings with clean engine oil before installation; this aids in seating and prevents pinching during assembly. Gently roll the O-rings into the grooves, avoiding any sharp tools that might cause cuts or tears.
Properly seated O-rings are vital for preventing oil leaks and maintaining optimal hydraulic lifter performance, contributing to a reliable and efficient engine operation.
Inspecting Pushrod Tubes
Thoroughly examine each pushrod tube for any signs of damage, such as cracks, dents, or corrosion. Pay close attention to the areas where the tubes contact the cylinder heads and rocker arms, as these are prone to wear.
Check for straightness by rolling the tubes on a flat surface; any wobble indicates a potential bend. Ensure the oil holes within the tubes are clear and unobstructed, allowing for proper lubrication.
Replace any tubes exhibiting damage or significant wear to maintain optimal oil flow and prevent potential valve train issues.
Safety Precautions
Prevent valve-to-valve contact and cylinder head damage by allowing lifters to bleed down completely before rotating the engine.
Careful adjustment is essential for safe operation.
Preventing Valve-to-Valve Contact
Valve-to-valve contact is a serious risk during adjustable pushrod installation. Allowing hydraulic lifters to bleed down fully before engine rotation is paramount.
This ensures sufficient clearance, preventing catastrophic damage to valves and cylinder heads.
Once lifters are bled, pushrods rotate easily by hand, confirming proper adjustment. Rotating the engine prematurely, with pressurized lifters, can cause immediate and costly internal engine failure.
Prioritize complete lifter bleed-down for a safe and successful installation.
Avoiding Cylinder Head Damage
Cylinder head damage is a significant concern during S&S adjustable pushrod installation. Incorrect adjustment, or premature engine rotation with pressurized lifters, can lead to valve interference and severe head damage.
Prioritize complete lifter bleed-down before rotating the engine. This creates necessary clearance. Always double-check valve clearance after adjustment. Ignoring these precautions risks costly repairs and potential engine failure. Careful adherence to these instructions is vital for protecting your investment.
Troubleshooting Common Issues
Difficulty adjusting pushrods often stems from insufficient lifter bleed-down. Noise post-installation may indicate improper adjustment or inadequate lubrication; re-check all settings carefully.
Difficulty Adjusting
If encountering difficulty adjusting the S&S adjustable pushrods, the primary concern is ensuring the hydraulic lifters are fully bled down. Allow ample time – typically 20-30 minutes – for complete bleed-down, as this allows for easy rotation of the pushrods with your fingers.
Attempting adjustment before this occurs can lead to inaccurate settings and persistent issues. Double-check that the jam nut isn’t overly tightened, hindering smooth adjustment. Refer to the factory service manual for specific torque specifications.
Noise After Installation
If noise occurs post-installation of S&S adjustable pushrods, revisit the adjustment process for each cylinder. Insufficient or excessive valve clearance is a common cause. Confirm proper valve train geometry and ensure the jam nuts are securely tightened to prevent movement and maintain adjustment.
Inspect pushrod tubes for any potential contact points. Verify hydraulic lifter operation; a failing lifter can mimic pushrod noise. If the issue persists, consult a qualified mechanic.
S&S Cycle Contact Information
For technical assistance, contact S&S Cycle at 608-627-TECH (8324) or sstech@sscycle.com. Visit their website at www.sscycle.com for details.
Phone Numbers
S&S Cycle provides several phone numbers for customer support and technical inquiries regarding their adjustable pushrods and other products. For general inquiries and order placement, you can reach them at 608-627-1497.
Fax transmissions can be sent to 608-627-1488.
Specifically for technical support related to installation, adjustment, or troubleshooting of S&S adjustable pushrods, dial 608-627-TECH (8324).
Ensure you have your product information available when contacting technical support for efficient assistance.
Email and Website
For email support concerning S&S adjustable pushrods, or any other product-related questions, you can contact their technical service team at sstech@sscycle.com.
Expect a detailed response addressing your specific inquiries regarding installation, adjustment, or troubleshooting.
Furthermore, S&S Cycle’s comprehensive website, located at www.sscycle.com, offers a wealth of information, including product catalogs, technical documentation, and frequently asked questions.
This online resource is invaluable for researching and understanding their products.
Warranty Information
S&S Cycle provides coverage details for adjustable pushrods; refer to their documentation for specific terms and claim procedures.
Proper installation is key for warranty validity.
Coverage Details
S&S Cycle warranties its adjustable pushrods against defects in material and workmanship to the original purchaser. This warranty applies only when the pushrods are properly installed and used in accordance with S&S instructions and the factory service manual for your specific engine model.
The warranty does not cover damage resulting from improper installation, misuse, abuse, accidents, or alterations. Regular maintenance and inspection are crucial to maintaining warranty coverage. Proof of purchase is required for all warranty claims. Contact S&S directly for complete warranty details.
Claim Procedures
To initiate a warranty claim for S&S adjustable pushrods, contact S&S Cycle’s Technical Service department via phone at 608-627-TECH (8324) or email at sstech@sscycle.com. You will need to provide proof of purchase, a detailed description of the issue, and any relevant photographs.
S&S may request the return of the defective pushrod for inspection. All shipping costs are the responsibility of the claimant. Approved claims will result in repair or replacement at S&S’s discretion.
Legal Considerations
S&S Cycle disclaims liability for damages resulting from improper installation or use. Always adhere to proper guidelines and consult the service manual.
S&S Cycle, Inc. assumes no responsibility for any damage or injury resulting from the use or installation of these adjustable pushrods. Proper installation requires a thorough understanding of motorcycle mechanics and adherence to factory service manual procedures.
Modifying your motorcycle can void warranties, and S&S is not liable for any consequential damages. The user assumes all risks and responsibility for the safe and correct application of this product. Always prioritize safety and consult a qualified mechanic if unsure.
Proper Use Guidelines
These S&S adjustable pushrods are designed for hydraulic tappet systems and require precise adjustment following factory specifications. Always consult your motorcycle’s service manual for torque values and valve clearance settings during installation.
Ensure lifters are fully primed before adjustment, and allow them to bleed down completely to prevent valve contact. Regular inspection of the center oil hole is vital for maintaining lubrication. Improper use can lead to engine damage; proceed with caution.
Breather/Rocker Arm Support Loosening
When loosening rocker arm supports, always remove the breather bolts for proper access. Clean and inspect each component thoroughly after loosening for optimal performance.
Importance of Proper Loosening
Properly loosening the breather/rocker arm supports is paramount during S&S adjustable pushrod installation. Removing the breather bolts facilitates easier access and prevents potential damage to surrounding components.
Failing to loosen these supports correctly can hinder pushrod installation and accurate adjustment. It’s crucial to ensure complete removal before proceeding, allowing for unobstructed movement and precise valve train setup. This step directly impacts the engine’s performance and longevity, so meticulous attention is vital.
Cleaning After Loosening
Following the loosening of rocker arm supports and removal of breather bolts, a thorough cleaning process is essential. Inspect each new pushrod meticulously, paying close attention to the center oil hole for any obstructions.
Removing debris ensures unimpeded oil flow, vital for proper lubrication and preventing premature wear. A clean installation environment contributes to the longevity and optimal performance of the S&S adjustable pushrods, safeguarding against potential engine issues and maximizing reliability.
Center Oil Hole Inspection
Ensure unobstructed oil flow through each new pushrod’s center hole during inspection. Maintaining proper lubrication is critical for valve train health and longevity.
Ensuring Oil Flow
Proper lubrication is paramount for the longevity and performance of your valve train. Carefully inspect the center oil hole within each new S&S pushrod before installation. Verify that it is completely clear of any debris or obstructions that could impede oil passage.
A restricted oil hole can lead to insufficient lubrication of the lifters and valve train components, potentially causing premature wear or even catastrophic failure. Clean and inspect each pushrod thoroughly to guarantee unrestricted oil flow, contributing to reliable engine operation.
Maintaining Lubrication
Consistent lubrication is vital after installing S&S adjustable pushrods. Ensure the engine oil is at the correct level and meets the manufacturer’s specifications. Regular oil changes, using high-quality oil and filters, are crucial for maintaining optimal valve train lubrication.
Monitor for any signs of oil leaks around the pushrod tubes and rocker boxes. Address any leaks promptly to prevent oil starvation. Proper lubrication safeguards against wear, reduces friction, and extends the life of your engine’s valve train components.
Final Checks and Ride Testing
Post-installation, thoroughly inspect all components. Begin with a short ride, monitoring for unusual noises or performance issues, ensuring smooth operation and proper adjustment.
Post-Installation Inspection
Following installation, a meticulous inspection is paramount. Verify the jam nuts are securely tightened on each pushrod, preventing unwanted adjustments during operation. Carefully examine each pushrod tube, ensuring proper seating and the absence of leaks around the O-rings.
Double-check breather/rocker arm support tightness. Confirm the center oil holes within the pushrods are unobstructed, guaranteeing adequate lubrication to the valve train. Finally, visually inspect for any signs of valve-to-valve contact or potential damage before commencing ride testing.
Initial Ride Testing
Begin with a cautious initial ride, focusing on listening for any unusual noises emanating from the valve train. Gradually increase engine RPMs, observing for consistent operation and the absence of valve clatter or ticking sounds. Monitor engine temperature closely during this phase.
After a short ride, re-inspect the jam nuts and pushrod tubes for tightness and leaks. This confirms the initial adjustments held during operation and identifies any potential issues requiring further attention.