Revolution Performance

There is no replacement for displacement and our 2009 Road King is being upgraded from 96” to 107” with Revolution Performance’s Monster Big Bore Kit. In Part 1, we teardown the Twin Cam top end in preparation for the kit. Revolution Performance’s aerospace-grade all aluminum cylinders have nickel-silicon-carbide

electroplated bores requiring no sleeves, allowing for larger bore size, less friction, lower temperature, and longer lifespan. To get the most out of the 107” Kit, Revolution Performance is giving the stock heads a Stage 2 treatment. The Stage 2 service includes 5-axis CNC porting, larger valves, new guides and seats, higher lift beehive springs, and sand rolled ports. While available in stock finishes, our Big Bore Kit and Stage 2 Heads are being powder coated a custom color, another feature that Revolution Performance offers. To see all of Revolution Performance products and services, visit www.RevPerf.com.Difficulty Level: 4/5 Estimated Time to Complete: 3.0 hours

Story by Jason Mook – Photos by Buck LovellTwin Cam 107” Big Bore Kit ’09 Road King Installation: Part 1

X-23 BOLT On TRees TECH

TooLs & suppLies Needed

1. SAE Wrench Set2. SAE Socket Set3. 3/8” Ratchet Driver4. SAE Allen Wrenches5. Torx Drivers6. Small Flat Head

Screwdriver7. Wrist Pin Removal Tool8. Pushrod Tube Removal/

Installation Tool9. Center Jack10. 3/8” Rubber Hose,

4” Long (4 Required)11. Clean Shop Rags12. Eye Protection

Revolution Performance’s 107” Big Bore Kit and Stage 2 Heads.

The 2009 Road King with stock displacement motor.

PRODUCT BEFORE

3 4

1 2

Lift the dash off of the top of the fuel tank. Disconnect the wiring for the speedom-eter, ignition switch, and indicator lights.

Use a T40 Torx to remove the four mounting bolts for the fuel tank. Unplug the vent line from the top of fuel tank. Disconnect the fuel line from the fitting on the left lower side of the fuel tank.

Remove the seat from the motorcycle. Disconnect the

negative cable from the battery.

Remove the hardware holding the dash to the fuel tank.

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X-23 BOLT On Trees IIIII Revolution PeRfoRmance Twin Cam 107” Big Bore Kit ’09 road King Installation: Part 1

Remove the hardware holding the exhaust system to the transmission

trap door. Loosen the exhaust flange nuts at the heads.

Lift the fuel tank up and off the backbone of the motorcycle.

Unplug the O2 sensor wiring. Remove the exhaust system from the motorcycle.

5 6 7

Use a 3/16” Allen wrench to remove the hardware holding the backing

plate to the induction module.

Remove the outer cover and filter element from the air cleaner.

Loosen the breather bolts with a 7/16” deep well socket. Remove the backing

plate from the induction module.

8 9 10

Use a T45 Torx to remove the bolt holding the stabilizer link to the frame.

With a 9/16” wrench or socket, remove the bolts holding the motor mount

bracket to the front head.

Loosen the hardware holding the rocker box tops to the lower rocker housings.

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Unplug the wires from the spark plugs. Use a specialty socket to remove the spark plugs.

Remove the rocker box tops from the housings.

Raise the frame of the motorcycle in order to bring the rear wheel off of the lift.

Shift the transmission into 6th gear.

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X-23 BOLT On Trees TECH

Use a 3/8” socket to loosen thetwo bolts on each side of the breather

in the rocker arm pedestal.

Rotate the rear wheel until the rear piston is at top dead center (TDC) of the compression stroke.

Remove the pushrod clips. Raise the pushrod tubes and verify the rear pushrods spin freely.

With a 1/2” wrench, loosen the four bolts holding the rocker arm pedestal. Loosen the bolts a 1/4” turn at a time, uniformly.

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Remove the rear pushrods and tubes from the motor.

Lift the rocker arm pedestal out of the rocker housing.

With a 7/16” socket, remove the six bolts holding the rocker housing to the rear head.

20

Unplug the connectors for the fuel injectors, map sensor,

induction module, and automatic compression releases.

Lift the rocker housing off of the rear head. Rotate the motor until the front piston is at TDC of the compression stroke. Repeat the process to re-

move the front rocker arm pedestal and pushrods.

Disconnect the positive and negative wires for the horn. Loosen the two bolts holding the

horn mount/top motor bracket with a 9/16” wrench. Remove the bracket from the motor.

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With a 1/4” Allen, loosen the four bolts holding the induction module to the heads.

Unplug the connector from the engine temperature sensor.

Remove the induction module from in between the cylinder heads from

the right side of the motorcycle.

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X-23 BOLT On Trees IIIII Revolution PeRfoRmance Twin Cam 107” Big Bore Kit ’09 road King Installation: Part 1

Lift the cylinder heads up and off the cylinders.

With a 1/2” 12 point socket, loosen the eight head bolts, four per head.

Keeping the motorcycle in gear, depress the rear brake pedal. Raise the cylinders up and off the cylinder studs. Place rubber hose over

the outer cylinder studs to rest the piston.

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Use a small flat head screwdriver to remove the wrist pin retaining clip from the piston. Wear eye protection during this step. Tap the wrist pins out

of the pistons with a small diameter socket.

Place clean shop rags in the case spigots. This is to prevent the wrist pin retaining ring from falling in to the engine case when removed.

Remove the pistons from the connecting rods. Maintain control of the connecting rod to prevent it from

damaging the spigot of the engine case.

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The 2009 Road King with the top end of the engine removed.

AFTER

Black Hills cycles- Work Performed By -

605.717.5009www.BlackHillsCycles.com

RevolutionPeRfoRmance

Twin Cam 107” Big Bore Kit, Black Highlight.

(Part # 201-119W)Stage II CNC Porting – Twin Cam Heads, with Valve Springs for up

to .650” lift cams. (Part # RHP-2)

866.892.2109www.RevPerf.com

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