JIMS 120, 131, 135 User Manual

There After

1500 Miles

And Each

10500

12000

7500

9000

4500

6000

3000

1000

1500

500

250

Service Miles

50

Date

Actual Miles

Name of Person Performing Service

No.1208-1355

Rev E

6-13

JIMS

555 Dawson Drive

Camarillo CA, 93012

805-482-6913 • www.jimsusa.com

Oil & Filter Installed

OOwwnneerrss MMaannuuaall ffoorr aallll JJIIMMSS eennggiinneess 112200,, 113311,, && 113355 OOwwnneerrss MMaannuuaall ffoorr aallll JJIIMMSS eennggiinneess 112200,, 113311,, && 113355

Rev E

6-13

JIMS ENGINE INFO SHEET

SECTION 1 CONTACT INFORMATION

Customer # ____________________ Business Name ______________________________

First Name __________________________________________________________________

Last Name __________________________________________________________________

Phone # ____________________ Ext __________

Address _____________________________________________________________________

City ________________________________ State ____________ Zip _________________

Warranty Card_______________________________________________________________

SECTION 2 MOTORCYCLE INFORMATION

Motorcycle Model / Year ______________________________________________________

Engine Serial Number ____________________________________________________

4. Cylinder Head replace if more than:

• Valve guide, press fit in head .002

• Valve seat, press fit in head .002

• Head warpage .006

5. Cylinder, replace if more than:

• Taper .002

• Out of round .002

• Warpage at gasket surfaces .006

6. Piston replace if more than:

• Fit in cylinder .006

• Piston pin fit (wrist pin) .0012

• Compression rings .030

• Oil control rings .070

• Ring side clearance compression rings .004

• Ring side clearance oil control rings .008

7. Connecting rod, replace if more than:

• Piston pin fit (wrist pin) .0012

• Side play between flywheels (female rod end play) .024

• Fit on crank pin (up and down play) .002

8. Flywheel runout not to exceed:

• .005 in truing stand

• End play ( F/W in left bearing).006

• Inspect shaft bearing journals for scoring, galling or wear, not to exceed

• .0005 runout in a truing stand.

9. Oil Pressure at 2000 rpm with an oil temperature of 230 〫F. Should be 25 to 35 PSI,

using the correct oil viscosity for the ambient temperature engine will be operat­ing in.

10. Counter balance components: replace if more than:

• Balance chain guides (front & rear) .060 to .070

• Balance chain guides (lower) .060 to .070

• Inspect other balancer components using H-D service manual

Clutch _________________________________ Tire Size ____________________________

Actual Mileage __________________________ Mileage on Engine ___________________

Exhaust System _________________________ Air Cleaner __________________________

Ignition Setting _________________________

Rev Limiter set @ ________________________

Electronic Fuel Injection ______________________________________________________

Throttle Body_______________________________________________________________

Modifications (if any):Different Cams __________________

11 1144

gine.

Break-In Procedure:

Note: Follow the engine break-in procedures outlined in the Harley-Davidson

owner’s manual per your application.

1. Allow the engine to warm-up before riding.

2. Do not use full throttle.

3. Do not idle the engine for more than two minutes. Note: Even less if the air

temperature is above 80-degrees Fahrenheit.

4. Do not load the engine at low rpm.

Note: All engine loads must be moderate.

5. Vary the rpm frequently.
Note: Do not hold a steady speed.

6. First 50 miles: • Do not let the engine rpm exceed 2500.

• Do not exceed 50mph.

7. Next 500 miles: • Do not let the engine rpm exceed 3000.

• Do not exceed 55 mph.

Oil Change Intervals:

Break-in: • At 50 miles • 500 miles • 1000 miles

Normal Oil change intervals:

• 1500 to 2000 miles, depending upon usage.

• Change the oil filter every oil change.

Torque Checks:

• Re-check the torque of all accessible engine and chassis fasteners at all oil
changes. (Do not re-torque the head bolts)

Inspection and Service Wear information for Valve Train Components Used in
Performance Twin Cam Engines:

Valve Train Components should be inspected every 5000 miles of service more often
if an engine is used under severe riding conditions, i.e. full throttle race operation,
in city, dusty, low octane usage, trailering and two up. As with all high performance
engines, components are under or subject to more stress in one-way or another,
many times more then a stock engine. The following engine components will need
to be inspected and or replaced every 5000 miles or more often as needed.

1. Rocker Arm / Rocker Arm Shaft replace if more than:

• Shaft fit in bushing .0035

• End play, side clearance .025

• Shaft fit in support plate .003

2. Cam Support Plate, replace parts if more than:

• Cam chain tensioned shoe wear .090 or 1/2 thickness of shoe

• Crankcase bushing press fit in cam support plate .0008

• Crankshaft bushing maximum I.D. .8545

3. Hydraulic Lifter Replace if more than:

• Fit in crankcase .003

• Roller end clearance .015

• Roller fit on axle .0015 or any rough area or tight spot

OOwwnneerrss MMaannuuaall ffoorr aallll JJIIMMSS eennggiinneess 112200,, 113311,, && 113355OOwwnneerrss MMaannuuaall ffoorr aallll JJIIMMSS eennggiinneess 112200,, 113311,, && 113355

Spark Plugs ____________________ Gaps ________________

Ignition System _________________Oil Pumps _____________________

Heads ____________________________

Modified Heads __________________________________

SECTION 3 ENGINE AND TESTING INFORMATION

Date of Installation ____________________

Motorcycle Serial Number ________________________________

Transmission Ratio (Pulleys)_____________________

Gear Ratio ____________________________

Carb Jetting: Main ___________ Slow __________Needle ______________________

Bleed down Test Results Front: ___________ Rear: ____________

Systems: _____________

Compression Test Results Front: ____________________Rear: ______________________

Dyno Test Results HP _____________________ Torque ____________________________

Dyno Charts __________________________________________________________________

( With Cover? • Yes • No )

MOTOR WARRANTY / RETURNS

JIMS shall not be liable for any consequential or incidental damages resulting from a failure
of any JIMS motor, the breach of any warranties, the failure to deliver, delay in delivery, de­livery in non-conforming condition, or any other breach of contract between JIMS and a cus­tomer. Each part returned will be inspected for damage due to improper packaging/ shipping
or damage that occurred prior to JIMS receiving the part. After inspection of the motor is com­pleted and there is any incidental damage the customer will be notified immediately.

MOTOR WARRANTY PROCEDURE

See terms and conditions in the JIMS catalog for authorization to return parts.
The following requirements must be met before JIMS will authorize the war­ranty return of a motor/ transmission/ flywheel assembly:

1. Must provide proof of the date of sale from the dealer (copy of invoice, in­voice # or Warranty card).

2. Must provide detailed description of problem with motor.

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6-13

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