No.1208-1355
Each And Miles 1500 After There |
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Miles Service |
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Service Performing Person of Name |
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Installed Filter & Oil |
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JIMS
555 Dawson Drive
Camarillo CA, 93012 805-482-6913 • www.jimsusa.com
Rev E
6-13
Owners Manual for all JIMS engines 120, 131, & 135
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 ____________________________________________________
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 __________________
1
Owners Manual for all JIMS engines 120, 131, & 135 Rev E 6-13
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
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 operat- ing in.• .0005 runout in a truing stand.
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
14
Owners Manual for all JIMS engines 120, 131, & 135
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. |
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5. |
Vary the rpm frequently. |
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Note: Do not hold a steady speed. |
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6. |
First 50 miles: |
• Do not let the engine rpm exceed 2500. |
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7. |
• Do not exceed 50mph. |
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Next 500 miles: |
• Do not let the engine rpm exceed 3000. |
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• Do not exceed 55 mph. |
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Oil Change Intervals: |
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Break-in: • At 50 miles |
• 500 miles |
• 1000 miles |
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Normal Oil change intervals:
•1500 to 2000 miles, depending upon usage.
•Change the oil filter every oil change.
Torque Checks:
•Re-check the to rque of all accessible engine and chass is fasteners at al l 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
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Owners Manual for all JIMS engines 120, 131, & 135 |
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Rev E |
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6-13 |
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Spark Plugs ____________________ Gaps ________________
Ignition System _________________Oil Pumps _____________________
Heads ____________________________
Modified Heads __________________________________
SECTION 3 ENGINE AND TESTING INFORMATION
Date of Installation ____________________ |
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( With Cover? • Yes • No ) |
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Motorcycle Serial Number ________________________________ |
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Transmission Ratio (Pulleys)_____________________ |
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Gear Ratio ____________________________ |
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Carb Jetting: Main ___________ Slow __________Needle ______________________
Bleed down Test Results Front: ___________ Rear: ____________
Systems: _____________
Compression Test Results Front: ____________________Rear: ______________________
Dyno Test Results HP _____________________ Torque ____________________________
Dyno Charts __________________________________________________________________
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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