The process of doing stage 1 and 2 upgrades to my new 2025 Harley Davidson Fat boy
This is a very high level view with only the major milestones photographed. Each part involved multiple, rather time consuming steps. the entire process (not including the removal or install of the exhaust and intake) consisted of a 93 step process with a checklist I made myself
It took the better part of a very hot 12 hour day. A more experienced mechanic could have done it in a lot less time. Probably half. This was my first ever cam install so I did everything very slowly and deliberately.
Clicking any image will open a full-sized, more detailed image
Bone stock complete with big, klunky exhaust and air cleaner lookin like some star wars freighter
Exhaust and intake removed
It was hot. This fan saved my life.
Cam cover off. Showing cam and pinion sprockets, cam chain, and cam chain tensioner. On the M8 motor there is only one, on the outside of the cam plate.
Push rod covers pulled up and held with the ol rubber band and paper clip trick exposing the pushrods.
The pushrods get cut with a bolt cutter and are thrown away
Pushrods, covers, and tappet block covers removed, showing the tappet cuffs. Wait…is that a soldering iron???
So I heard rumors that the bolts holding the tappet cuffs are notorious for sheering off due to excessive locktite. To avoid any possible hassles I got them pretty hot before taking the wrench to them, and they actually broke free quite easily.
Tappet cuffs and lifters removed
Cam and pinion sprockets removed along with chain, chain tensioner, and cps rotor off.
A couple looks inside. A couple old o-rings still in there. dont worry, they got removed.
Inner cam bearing
Discarded OEM parts. Cam shaft, oil pump, cam plate, lifters
This is the tool that is used to pull out the inner cam bearing, and also to press in the new bearing
New S&S oil pump
New Andrews 485 camshaft in place, inserted into the new bearing. The red goop on everything is assembly lube. Everything gets a generous coating of this lube, which sticks better than regular motor oil, and lubricates the parts during initial startup when there isnt any significant oil pressure built up yet,
New S&S cam plate installed.
Cam and pinion sprockets reinstalled, and new S&S tensioner as well. Dont worry, I didnt forget the cps sensor rotor…
Theres a HUGE gap here where I installed the new lifters, tappet cuffs, tappet block covers, and the biggest pain in the ass of the whole operation, installing and adjusting the Fuel Moto adjustable push rods, and then getting the covers back into place.
I was SO ready to be done and just pushed ahead rather than stopping to take more pohotos. You can easily fund youtube videos that detail these steps if you are curious.
New Cobra El Diablo 2-1 exhaust system laid out
Exhaust installed.
Arlen Ness air cleaner installed. Job done
