INDEX

COMPANY HISTORY ...................................................................... 3 CAMSHAFTS - Twin Cam Engines All 07-11: Twins and 06 Dyna: Roller Chain Camshafts ................ 4 1999-2006: Roller Chain Conversion Camshafts ............................. 5 All 07-11: Gear Drive Cam Installation Kits ................................... 6 All 07-11: Twins and 06 Dyna: Gear Drive Camshafts ................... 7 1999-2006: Gear Drive Cam Installation Kits ................................... 8 1999-2006: Gear Drive Camshafts ................................................... 9 Twin Cam Valve Springs, Collars, Pushrods ............................ 6,8,10 1999-2006: Twin Cam Chain Drive Camshafts .............................. 11 EV 80 CAMSHAFTS AND KITS Springs, Collars .............................................................................. 12 EZinstall EV80 Pushrods ................................................................ 12 Standard EV80 Pushrods ............................................................... 12 EV 80 Camshafts ........................................................................... 13 EV 80 Cam Drive Gears ................................................................. 16 SHOVEL, PAN, KNUCKLE CAMS AND KITS Shovel and Pan Camshafts ....................................................... 14,15 Shovel Springs, Collars and Pushrods ........................................... 15 Knuckle Camshafts ......................................................................... 14 Shovel & Pan Cam Drive Gears ..................................................... 16 IGNITION COILS, CARB PARTS High Flow Accelerator Pumps (Keihin Carbs) ................................ 16 Replacement Ignition coils.............................................................. 17 POLARIS CAMS AND KITS Polaris Victory Camshafts (98-2001) ............................................ 19 Polaris Freedom Camshafts (2002-up) .......................................... 19 IRON SPORTSTER CAMS AND KITS Iron Sportster Cams ....................................................................... 24 Iron Sportster Collars, Pushrods .................................................... 24 EV SPORTSTER AND BUELL CAMS AND KITS EV Sportster Cams ........................................................................ 25 EV Sportster Pushrods and Valve Gear ......................................... 25 EV 80 Trans Gears (5 Speed) 5 Speed Gears ............................................................................... 26 5 Speed Transmission Shafts ......................................................... 26 5 Speed (Complete gear sets) ...................................................... 26 BELT PULLEY RATIOS & MILES PER HOUR Miles per Hour Chart .........................................................................28 TWIN CAM & EV 80 BELT PULLEYS Belt Drive Sprockets (29, 30, 31, 32, 33 and 34 Teeth).....................29 Belt Drive Sprocket (Belt ratios) ........................................................29 Sprockets (Installation notes) .............................................................29 TRANSMISSION GEARS 74 & 80 (4 SPEED) Close Ratio / Stock Ratio (Gears and Shafts) .......................... 30 & 31 74 & 80 (4 speed) (Complete Gear Sets) ..........................................31 4 Speed Parts Assembly Kits ............................................................31 4 Speed Transmission Shaft Lengths ................................................31 TRANSMISSION GEARS: EV SPORTSTER (5 SPEED) EV Sportster 5 Speed Gears and Shafts...........................................32 EV Sportster 5 Speed (Complete Gear Sets) ..................................32 Gear Ratios: (Sportster 5 speed) ......................................................32 TRANSMISSION GEARS: SPORTSTER (4 SPEED) Sportster (4 Speed Gears and Shafts) ..............................................33 Sportster 4 Speed (Complete Gear Sets) ........................................33 Gear Ratios: (Sportster 4 speed) .......................................................33 PHOTOS, TECH TOPICS and ENGINE TUNING EV-80 Dynamometer-Horsepower Chart ...........................................12 Pushrod Adjustments & Hydraulic Lifters ......................................... 17 Choosing a Cam ................................................................................18 Hydraulic Lifters..................................................................................18 Cam Gear Noise (EV80) ....................................................................20 Sportster Cam Gear Noise ...............................................................21 Sportster Cam Gear Size Modifications ...........................................21 Static Compression Pressure: (What is it?) .......................................22 Static Compression and Engine Performance .................................. 22 Valve Spring Height ...........................................................................23 Valve Clearance Measurements ........................................................23 Compression Ratios(head milling) .....................................................23 Cam and Gear Manufacturing Technology ........................................27 Frequently asked questions ...............................................................34 Horsepower - torque curve comparisons ...........................................34 SALES POLICIES ............................................................................35 LIMITED WARRANTY POLICY .......................................................35

ORDERING
FAX #: 847-759-0848

INFORMATION
TEL # : 847-759-0190
All Andrews Products parts in this catalog:

YOUR CUSTOMER NO: CUSTOMER TECHNICAL SERVICE: Available for customers during listed hours: Morning: 8:00 A.M. - 10:00 A.M. (Central Time) Afternoon: 2:00 P.M. - 4:00 P.M. (Central Time) Web address: www.andrewsproducts.com
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MADE IN USA
Harley-Davidson, Sportster, Evolution, H/D, Superglide, Buell are all trademarks of HarleyDavidson Motor Co. Andrews Products is not associated with the Harley-Davidson Motor Co.

ANDREWS PRODUCTS: COMPANY HISTORY

Andrews Products was founded in the spring of 1972 and for 38 years has specialized in making camshafts and transmission gears for the performance motorcycle market. On behalf of the entire Andrews Products organization, we proudly present this catalog to all motorcycle enthusiasts and to the many designers and builders of performance motorcycle engines and transmissions. Please review the pages of this catalog and see how Andrews Products can help you get the most out of the engine and transmission in your bike. Products unique and proprietary processing, innovative design and strict quality control, we can consistently deliver the highest quality camshafts and transmission gears. Many of the customers we work with include the top NASCAR Cup and Nationwide racing teams as well as other builders of racing engines for the automotive and motorcycle high performance markets. This is a very demanding group of people for whom second best is not an option; they simply demand the best. At Andrews Products, we share with our customers a passion for excellence and will not accept second place. Our customers rely on us to help them achieve top performance. This culture is well established throughout Andrews Products, its people and processes. And whether we are working with top race teams or making parts for street motorcycles, the same technology is used. The entire Andrews Products Team looks forward to helping you achieve top performance and take the checkered flag as leaders.

While we started making motorcycle transmission gears and shafts, performance camshafts and related valve gear parts soon became additional, distinct product lines. More new gear sets with better ratios soon followed. The results were gears which easily out-performed anything else available. Their superior performance was quickly recognized by everyone who tried them. The novelty and uniqueness of both the cams and gears resulted in a wave of demand for new Andrews Products cams and gears. And that was only the beginning. Today, Andrews Products is recognized throughout the Motor Sports world as an industry leader. We utilize state-of-theart engineering design and manufacturing technology for producing superior quality camshafts and transmission gears for both street and racing applications. As an industry leader, we at Andrews Products understand what keeps us on top also keeps our customers on top. Over the years and to this day, Andrews Products has made significant investments in new computer controlled production machinery and inspection equipment. Some of these machines are pictured in this catalog. Strategic purchases in the latest technologies keeps us and our customers right at the leading edge. With Andrews

In November of 2002, Andrews Products moved into a new 45,000 square foot facility in Mt. Prospect, Illinois. The two illustrations on this page show our new building. As a result, we now operate out of a fully equipped air conditioned facility with everything under one roof Our main office and manufacturing plant is eleven miles north of the Chicago, OHare International Airport. We are in one of the worlds great manufacturing areas with easy access to efficient transportation and shipping to anywhere in the US and most foreign countries. We are better equipped than ever to serve all of our customers with the first class quality and support that all of you deserve. Andrews Products is committed to the motorsports industry for the long haul.
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Performance Cams

All 2007 - 2011 Twin Cams and 06 DynaGlide

Crankshaft Sprockets: change cam timing + or - 4 degrees

Camshafts on all 2007-2011 twin cam engines and 06 Dynas use roller chain cam drives. Camshafts made for 99-06 engines will not fit the 07-11 (or 06 Dyna engines). Earlier twin cam engines run older type cam drive chains. Cams listed below are designed for use with stock H/D hydraulic lifters. Install kit includes gasket and inner bearings, similar to photo on page 6. Installation kit: gasket & bearings .........................Part# 216902 Part# Grind Timing(*) CL**
106 112.5 107 112.5 105 112 100 106 102 106 108 112 108 112 100 106 98 104 103 104 104 108 102 106 106 108 102 108

Matching EZ-install pushrods kits are also available from Andrews Products. EZ-install pushrods do not require removal of gas tanks or rocker boxes when installing bolt-in camshafts. Crankshaft sprocket: +4 or -4 degree cam timing change for all 07- 11 twin engines and 06 Dynaglides. Install at +4 degrees for more torque or -4 degrees for less compression pressure. Sprocket (+4 or -4 degree timing change) ...........Part# 216323 Springs
Stock Stock Stock Stock

Duration .053 .020

216 219 196 219 206 216 220 228 226 230 236 240 236 240 236 240 222 238 238 238 248 252 248 252 260 260 252 260 256 259 234 259 242 252 255 264 262 266 272 276 272 276 272 276 257 273 273 273 283 287 283 292 296 296 287 297

Valve Lift
.473 .474 .473 .474 .492 .486 .498 .498 .490 .490 .510 .510 .570 .570 .510 .510 .548 .548 .555 .555 .510 .510 .550 .550 .560 .560 .570 .570

Lift @ TDC
.087 .110 .087 .110 .075 .075 .134 .121 .138 .120 .131 .120 .131 .120 .174 .148 .153 .163 .165 .158 .184 .168 .197 .181 .205 .192 .209 .187

Application
Stock 06 Dynaglide cam data listed for reference: All 2006 Dynaglides are fuel injection only; no carburetors. Stock 07, 08, 09, 10 specs listed for reference. Short intake duration is stock on 07, 08, 09, 10 11 engines. New in 2010: Bolt-in cams: 07, 08, 09, 10, 11 engines. More power through entire RPM range; (1000 to 5400)! Bolt-in cam: 07, 08, 09, 10, 11: More torque for all around riding, heavy bikes, stock comp. ratios and pistons. Similar to #23 cam for EV80. (1700-4800 RPM). Bolt-in cam 96 - 103 inches and stock compression ratio. Great for two up touring, this cam will add torque and HP at lower and middle RPM ranges. (1800-5200 RPM). Great cam for motors with 96 inches and 9.8 to 10.2 C.R. Lower TDC lift for easy installation. Similar to TW37 with timing setup for higher compression. (2400-5600 RPM). High lift version of 31H. Much more power thru RPM range with 10:1+ Compression pistons. (2800-5600 RPM). Hot street cams for 96-103 inches. 80+ rear wheel HP possible with well tuned 88, more with 95 inches or bigger. Smooth idle, broad torque (2200-5600 RPM) 9.0 to 9.5 C.R. New in 2010: New design, broad tip cams for baggers with stock motors: max torque at low and mid RPMs. New in 2008: Specially designed for 96-103 engines with compression ratios to 10:1 (2200-5600 RPM range). Designed for easy installation in 96-103 inch motors with stock heads and 9.5 to 9.8 CR. (2400 to 6000 RPM). Great cam for 96-103 inch engines with 9.8 to 10.2 C.R. Max HP - torque at mid and upper RPMs. (2600-6200). For well prepped 95-103 inchers with 10.0 to 10.5 CR, 100+ HP is within reach. (2700-6500+ RPM). Performance cams for 96-110+ inches, 10.0 to10.8 C.R. with high flow head setup. (2600-6400+ RPM).

Stock Intake 02/34 06-Dyna Exhaust 42/-03 Stock intake 216309 216321 Intake -09/25 Exhaust 42/-03 09H 21H -02/28 40/-04 10/30 40/08 11/35 41/09 10/46 52/08 10/46 52/08 18/38 46/14 13/29 43/15 16/42 43/15 20/48 54/18 22/46 52/20 24/56 58/22 24/48 58/22

216326

26H

Stock

216331

31H

Stock

216332 216337

32H 37H

Hi-lift Stock

216348 216354 216350 216355 216360 216367

48H 54H 50H 55H 60H 67H

Stock Stock Stock Stock Hi-lift Hi-lift

(*) Timing and duration for .053 cam lift (**) Lobe Centerline angle

Twin Cam Conversion Kits Complete!

Camshaft Upgrades for all 1999-2006 Engines (Does not apply to 2006 Dyna)
Eliminate old style chain adjusters! Conversion camshaft kits fit all 99-2006* twin cam engines. (New 07 chain adjusters operate with engine oil pressure to maintain proper cam chain tension). Andrews Products conversion cam kits are available complete with all necessary parts as shown in picture. Kits include new HD high capacity 07 style oil pump and matching cam support plate! *For 2006, only Dyna Glide engines were made with new hydraulic roller chain cam adjusters! Conversion cam kits are complete as shown. All necessary parts are included. Rear cam bearing diameter on conversion cams = .875 Stock HD camshafts cannot be used for roller chain conversions!

1999-2001 kit: ........ Part# 288999 2002-2006 kit: ........ Part# 288902
NOTE: N cams cannot be installed with early Screaming Eagle cam support plate (HD part # 25284-08)!

Camshafts on all 1999-2006 H/D 88 engines (except 2006 Dyna) can be updated to new style roller chain drives. Cam grinds listed below are designed for stock H/D hydraulic lifters. The 07 type cams and chain drives are more efficient than old style chain tensioners. Installation requires Andrews N series camshafts as listed Part# Grind Timing(*)
-02/38 42/-03 02/34 42/-03 02/34 40/02 10/30 40/08 11/35 41/09 10/46 52/08 18/38 46/14 13/29 43/15 16/42 43/15 20/48 54/18 22/46 52/20 24/48 58/22

below. EZ-install pushrods are available from Andrews Products. EZ-install pushrods do not require removal of gas tanks or rocker boxes when installing bolt-in camshafts. This setup requires conversion kit parts and one set of N series camshafts with part numbers as listed above: Application
Stock cam data listed for 99-06 carbureted engines. (Stock engine output is approximately 62 HP). Stock cam data listed for 99-06 fuel injected engines. (Stock engine output is approximately 62 HP). Bolt-in cams for 1999 - 2006 engines. Similar cam timing to stock 88 engines for cooler running and more power! Bolt-in cam: More torque for all around riding with heavy bikes, stock compression ratios and stock pistons. Similar to #23 cam for EV80. (1700-4800 RPM). Bolt-in cam 88-95 inches and stock compression ratio. Great for two up touring, this cam will add torque and HP at lower and middle RPM ranges. (1800-5200 RPM). Great cam for motors with 95 inches and 9.8 to 10.2 CR. Lower TDC lift for easy installation. Similar to TW37 with different timing. (2400-5600 RPM). Hot street cams for 88 or 95 inches. 80+ rear wheel HP possible with well tuned 88 incher, more with 95. Smooth idle, broad torque (2200-5600 RPM). 9.0 to 9.5 CR. New in 2010: New design, broad tip cams for baggers with stock motors: max torque at low and mid RPMs. New grind in 2008: Great cam for 95 inches with 10:1 CR. RPM range: 2200-5600. Added as a conversion cam choice by popular demand. Designed for easy installation in 95 inch motors with stock heads and 9.5 to 9.8 CR. (2400 to 6000 RPM). Great cam for 95 inchers with 9.8 to 10.2 C.R. Max HP - torque at mid and upper RPMs (2600 to 6200). Performance cams for 95-107+ inches, 10.0 to10.8 C.R. with high flow head setup. (2600-6400+ RPM).

CL
110 112.5 106 112.5 106 109 100 106 102 106 108 112 100 106 98 104 103 104 104 108 102 106 102 108

Duration .053 .020

216 219 216 219 216 222 220 228 226 230 236 240 236 240 222 238 238 238 248 252 248 252 252 260 255 259 255 259 252 259 255 264 262 266 272 276 272 276 257 273 273 273 283 287 283 292 287 297

Valve Lift
.473 .474 .473 .474 .489 .489 .498 .498 .490 .490 .510 .510 .510 .510 .548 .548 .555 .555 .510 .510 .550 .550 .570 .570

Lift @ TDC Springs

.072 .110 .087 .110 .091 .095 .134 .121 .138 .120 .131 .120 .174 .148 .153 .163 .165 .158 .184 .168 .197 .181 .209 .187 Stock Stock Stock Stock

Stock 88 (A) Carburetors Stock 88 Injectors 216812 216821 (B) 12N 21N

216826

26N

Stock

216831

31N

Stock

216837

37N

Stock

216848 216854

48N 54N

Hi-lift Hi-lift

216850 216855 216867

50N 55N 67N

Stock Hi-lift Hi-lift

(*) Timing and duration listed for .053 cam lift.

GEAR DRIVE INSTALLATION KITS (2007 - 2011 Twin Cams & 06 Dyna)
OUTER GEARS AND CAM GEARS INSTALLATION KIT

Outer and Inner Drive Gear Kit ...................... Part# 216908 Complete kit includes all four cam drive gears with two retaining cap screws, three drive keys and one thrust washer. Inner Cam Drive Gears (2 pcs) ....................... Part# 216905 Two inner cam drive gears are supplied with drive keys.

Undersize inner gear(07-11 & 06 Dyna) ..............Part# 33-4287 Oversize inner gear(07-11 & 06 Dyna) ................Part# 33-4288

Gear Drive Installation Kit (as shown) .............. Part# 216901 Gasket and oil port cover plates shown are necessary to complete installation of gear drive cams. Camshafts for all 06 Dynas and all 07-11 Twin cam engines use needle bearings on inner journals - No ball bearings are used. Replacement bearings are included in above kit: Inner Case Needle Bearings (two required)...... Part# 316900

OUTER DRIVE GEARS

TWIN CAM PUSHRODS (99-UP)

Outer Drive Gear Kit ........................................ Part# 216903 Kit includes the crankshaft drive gear, camshaft pinion drive gear, two class 8 retaining cap screws, camshaft drive key and
one heat treated camshaft end thrust washer. Undersize pinion gear(07-11 & 06 Dyna) ......Part# 33-4160X-S Oversize pinion gear(07-11 & 06 Dyna) ........ Part# 33-4160Z-S

From left to right: Standard tip aluminum pushrods .............................. Part# 292388 Standard tip chrome moly pushrods ......................... Part# 292288 EZ-install aluminum pushrods ................................... Part# 292188 EZ-install chrome-moly pushrods .............................. Part# 292088 Twin cam pushrods are available with EZ-install ends or standard adjustable tips. Both types are made in anodized aluminum or chrome moly steel. EZ-install pushrods can be installed without removing gas tanks or rocker boxes. If you are installing bolt-in cams, this is a big plus! Andrews pushrods are a great match for cams listed on the previous page. Extra long or short pushrods are available as specials. Call if you need them.

TWIN CAM: GEAR DRIVE CAMS

(2007-2011 Twin Cams and 06 Dyna)

Series HG gear drive cams are made for ALL 07 - 11 Twin cam engines and 06 DynaGlides. They have been designed to run with new 2007 S&S gear drives. The cam lobe designs listed below are the same as those manufactured for 1999-2006 engines. Gear drives made for 99-2006 engines will not fit 2007 -11 Twin cam engines or 2006 Dyna engines. HG cam installation kits include two plates for blocking lubricating oil feed holes which were intended for stock chain drives, not 2007 style gear drives. Performance gains with the HG cams listed will be similar to 99-06 engines running with the same cam grinds.

Part#

Grind

Timing(*)
10/30 40/08 11/35 41/09 10/46 52/08 10/46 52/08 18/38 46/14 16/42 43/15 20/48 54/18 22/46 52/20 24/56 58/22 24/48 58/22 29/57 63/27 30/62 66/30

Duration .053 .020

220 228 226 230 236 240 236 240 236 240 238 238 248 252 248 252 260 260 252 260 266 270 272 276 255 264 262 266 272 276 272 276 272 276 273 273 283 287 283 292 296 296 287 297 303 307 307 312

Valve Lift
.498 .498 .490 .490 .510 .510 .570 .570 .510 .510 .555 .555 .510 .510 .550 .550 .560 .560 .570 .570 .590 .590 .640 .640

Lift @ TDC
.134 .121 .138 .120 .131 .120 .131 .120 .174 .148 .165 .158 .184 .168 .197 .181 .205 .192 .209 .187 .238 .218 .262 .232

Springs
Stock

Application
Bolt-in 88-96 cam: more torque for all around riding with heavy bikes, intended for stock compression ratio and pistons. Similar to #23 cam in EV80. (1700-4800 RPM). Bolt-in cam for 96 inches - stock compression ratio. Great for two up touring, this cam will add torque and HP at lower and middle RPM ranges. (1800-5200). Great cam for motors with 88+ inches and 10:1 CR Lower TDC lift means easy installation. Similar to 37HG but different timing. 2400-5800 RPM power range. High lift version of 31HG. Much more power thru RPM range with 10:1+ comp. ratio. 2800-5800 RPM range. Hot street cams for 88 or 96 inches. 80+ rear wheel HP possible with well tuned 88 motor; more with 95. Smooth idle, broad torque (2200-5600 RPM) Stock to 9.5 CR. New in 2008! Specially designed for 88 to 103 engines with CR up to 10:1 (2200-5600 RPM range). Designed for easy installation in 88 to 103 inch motors with stock heads and 9.5 to 9.8 C.R. (2400 to 6000 RPM). Great cam for 95 - 103 engines with 9.8-10.2 C.R. Max HP - torque at mid and upper RPMs (2600-6200). For well prepped 95 - 103 inchers with 10.0 to 10.5 CR, 100+ HP is within reach. (2700-6500+ RPM). Performance cams for 95 -107+ inches, 10.0 to10.8 C.R. with high flow head setup. (2600-6400+ RPM). Great cam for 95 -107+ inchers with 10:2 C.R. or higher. Max torque and HP (2700-6500+ RPM). Big cams for modified 95 - 116+ inch motors running 10:2 CR or higher. Heads must be set for .700 lift and modified for max air flow. (3000-6500+ RPM).

216321G 21HG

216326G 26HG

Stock

216331G 31HG

Stock

216332G 32HG 216337G 37HG

Hi-lift Stock

216354G 54HG 216350G 50HG 216355G 55HG 216360G 60HG 216367G 67HG

Stock Stock Stock Hi-lift Hi-lift

The following two cam grinds are available as gear drives only!
216359G 59HG 216364G 64HG Hi-lift Hi-lift

(*) Timing and duration listed for .053 cam lift.

TWIN CAM GEAR INSTALLATION KITS (99-06 except 06 Dyna)

OUTER GEARS AND CAM GEARS INSTALLATION KIT

Outer and Inner Drive Gear Kit ...................... Part# 288908 Complete kit includes four cam drive gears with two retaining cap screws, three drive keys and one thrust washer. Inner Cam Drive Gears (2 pcs) ....................... Part# 288905 Two inner cam drive gears are supplied with drive keys.

Gear Drive Installation Kit (as shown) .............Part# 288901 Gasket and bearings shown are necessary to complete the installation of gear drive camshafts. Gear drive camshafts for 99-06 (except 06 Dyna) use ball bearings on both shafts. Replacement bearings are included in above kit: Camshaft Ball Bearings ....................................Part# 388015 Inner Case Needle Bearings ..............................Part# 388900

Undersize inner gear(99-06) ........................ Part# 33-4272RX-S Oversize inner gear(99-06) .......................... Part# 33-4272RZ-S

OUTER DRIVE GEARS

TWIN CAM PUSHRODS (99-UP)

Outer Drive Gear Kit ............................................ Part# 288903 Kit includes one crankshaft drive gear, camshaft pinion drive gear, two class 8 retaining cap screws, camshaft drive key and one heat treated camshaft end thrust washer. Undersize pinion gear(99-06) .......................Part# 33-4160X-S Oversize pinion gear(99-06) ......................... Part# 33-4160Z-S

From left to right: Standard tip aluminum pushrods ............................. Part# 292388 Standard tip chrome moly pushrods ........................ Part# 292288 EZ-install aluminum pushrods .................................. Part# 292188 EZ-install chrome-moly pushrods ............................. Part# 292088 Twin cam pushrods are available with EZ-install ends or standard adjustable tips. Both types are made in anodized aluminum or chrome moly steel. EZ-install pushrods can be installed without removing gas tanks or rocker boxes. If you are installing bolt-in cams, this is a big plus! Andrews pushrods are a great match for cams listed on the next page. Extra long or short pushrods are available as specials. Call if you need them.

TWIN CAM: GEAR DRIVE CAMS (1999-2006 Twin Cams except 06 Dyna)

Andrews gear drive camshafts are available to run with S & S gear drives. Engines with gear driven cams show a 4 hp gain over cams with chains. If less power is needed to turn the camshafts, more power gets to the rear wheel. Also, gear drive cams do not have chain tensioner shoes to wear out. When deciding what cams to use in your 88 engine (see page 18 also), the most important consideration is the proper match between compres-

sion ratio and intake cam duration. For best street performance, the static compression pressure should be around 175-180 PSI. Drag motors can handle still higher static pressures. Lower static pressure of 160 PSI are great for all around riding. For a more complete explanation of static compression pressure, see page 22 in this catalog.

TOURING AND PERFORMANCE CAMS

Part# Grind Timing(*)
-02/38 42/-03 02/34 42/-03 02/34 40/02 10/30 40/08 11/35 41/09 10/46 52/08 10/46 52/08 18/38 46/14 16/42 43/15 20/48 54/18 22/46 52/20 24/56 58/22 24/48 58/22 29/57 63/27 30/62 66/30

Duration .053 .020

216 219 216 219 216 222 220 228 226 230 236 240 236 240 236 240 238 238 248 252 248 252 260 260 252 260 266 270 272 276 255 259 255 259 252 259 255 264 262 266 272 276 272 276 272 276 273 273 283 287 283 292 296 296 287 297 303 307 307 312

Valve Lift
.473 .474 .473 .474 .489 .489 .498 .498 .490 .490 .510 .510 .570 .570 .510 .510 .555 .555 .510 .510 .550 .550 .560 .560 .570 .570 .590 .590 .640 .640

Lift @ TDC Springs

.072 .110 .087 .110 .091 .095 .134 .121 .138 .120 .131 .120 .131 .120 .174 .148 .165 .158 .184 .168 .197 .181 .205 .192 .209 .187 .238 .218 .262 .232 Stock Stock Stock

Application
Carbureted engine: stock cam data listed for reference. (Stock engine output is approximately 62 HP). Fuel injected engine: stock cam data listed for reference. (Stock engine output is approximately 62 HP). Back by popular demand! Similar timing to earlier stock 88 cams but gear drive cams are used instead of chains. No engine retuning necessary with this timing! Bolt-in 88 cam: more torque for all around riding with heavy bikes, intended for stock compression ratio and pistons. Similar to #23 cam in EV80. (1700-4800 RPM). Bolt-in cam for 88-95 inches - stock compression ratio. Great for two up touring, this cam will add torque and HP at lower and middle RPM ranges. (1800-5200). Great cam for motors with 95+ inches and 10:1 CR. Lower TDC lift means easy installation. Similar to 37G but different timing. 2400-5800 RPM power range. High lift version of 31G. Much more power thru RPM range with 10:1 compression pistons. 2800-5800 RPM. Hot street cams for 88 or 95 inches. 80+ rear wheel HP possible with well tuned 88 motor; more with 95. Smooth idle, broad torque (2200-5600 RPM) Stock to 9.5 CR. New design in 2008! Specially designed for 96 and 103 engines with CR up to 10:1 (2200-5600 RPM range). Designed for easy installation in 95 inch motors with stock heads and 9.5 to 9.8 C.R. (2400 to 6000 RPM). Great cam for 95 inch engines with 9.8 to 10.2 C.R. Max HP - torque at mid and upper RPMs (2600-6200). For well prepped 95-103 inchers with 10.0 to 10.5 CR, 100+ HP is within reach. (2700-6500+ RPM). Performance cams for 95-107+ inches, 10.0 to10.8 C.R. with high flow head setup. (2600-6400+ RPM). Great cam for 95-107+ inchers with 10:2 C.R. or higher. Max torque and HP (2700-6500+ RPM). Big cams for modified 95-116+ inch motors running 10:2 CR or higher. Heads must be set for .700 lift and modified for max air flow. (3000-6500+ RPM).

Stock 88 (A) Carburetors Stock 88 Injectors 288112G (B) 12G

288121G

21G

Stock

288126G

26G

Stock

288131G

31G

Stock

288132G 288137G

32G 37G

Hi-lift Stock

288154G 288150G 288155G 288160G 288167G 288159G 288164G

54G 50G 55G 60G 67G 59G 64G

Hi-lift Stock Hi-lift Hi-lift Hi-lift Hi-lift Hi-lift

(*) Timing and duration listed for .053 cam lift

TWIN CAM PUSHRODS (1999-UP)

Twin 88 pushrods are available with EZ-install ends or standard adjustable tips. Both types are made in anodized aluminum or chrome moly steel. EZ-install pushrods can be installed without removing gas tanks or rocker boxes. If you are installing bolt-in cams, this is a big plus! These pushrods are a great match for cams listed on the next page. Extra long or short pushrods are available as specials. Call if you need them. Shown from left to right: Standard tip aluminum pushrods: Part# 292388 Standard tip chrome moly pushrods: Part# 292288 EZ-install aluminum pushrods: Part# 292188 EZ-install chrome moly pushrods: Part# 292088

TWIN CAM SPRINGS & COLLARS 1999-2004

High Lift Springs .................................... Part# 294150 Kit includes 4 inner and 4 outer springs: for valve lifts up to .560. Installation does not require head machining. High lift springs and collars make installing big cams a lot easier. Heat Treated Steel Spring Collars ......... Part# 293115 Designed to fit Twin cam engines. Provides .050" more spring travel than stock collars. Collars are stronger and 10% lighter than stock collars. Use stock keepers

TWIN 88 CAM DRIVE SPROCKET KITS (1999 style chain drive)

Andrews heat treated steel cam drive sprockets are an upgrade for rear camshafts on engines with silent chain cam drives. Kit includes three spacer shims and one grade 8 bolt and hardened washer. New sprockets can be set up to the same length specs as original stock sprockets. If you're into performance with an 88 engine and silent chains, steel sprockets are a must even with stock camshafts. From left to right:

34 tooth splined cam sprocket kit ......................Part# 288015 17 tooth steel crank sprocket ............................Part# 288020 34 tooth steel keyed cam sprocket kit ...............Part# 288010 (With square key drive for 99 engines only)

10

TWIN 88: CHAIN DRIVE CAMS AND KITS (99 - 06 except 06 Dyna)

Want more power for your Twin cam 88 engine? Andrews Products has eight proven cam grinds to get you there. More HP and torque for stock or modified engines is within easy reach. All cam grinds listed are designed for use with stock H/D hydraulic lifters. Matching pushrods and heat treated steel sprockets are

listed on the preceding page. For any bolt-in cam grind, EZ-install pushrods do not require removal of gas tanks or rocker boxes for installation. Also, see explanations regarding compression pressure and picking cams on page 18 and page 22.

TOURING AND PERFORMANCE CAMS

Part# Grind Timing(*)
-02/38 42/-03 02/34 42/-03 10/30 40/08 11/35 41/09 10/46 52/08 18/38 46/14 16/42 43/15 20/48 54/18 22/46 52/20 24/56 58/22

Duration .053 .020

216 219 216 219 220 228 226 230 236 240 236 240 238 238 248 252 248 252 260 260 255 259 255 259 255 264 262 266 272 276 272 276 273 273 283 287 283 292 296 296

Valve Lift
.473 .474 .473 .474 .498 .498 .490 .490 .510 .510 .510 .510 .555 .555 .510 .510 .550 .550 .560 .560

Lift @ TDC
.072 .110 .087 .110 .134 .121 .138 .112 .131 .120 .174 .148 .165 .158 .184 .168 .197 .181 .205 .192

Springs
Stock Stock Stock

Application
Carbureted engine: stock cam data listed for reference. (Stock engine output is approximately 62 HP). Fuel injected engine: stock cam data listed for reference. (Stock engine output is approximately 62 HP). Bolt-in cam: More torque for all around riding with heavy bikes, stock compression ratios and stock pistons. Similar to #23 cam for EV80. (1700-4800 RPM). Bolt-in cam 88-95 inches and stock compression ratio. Great for two up touring, this cam will add torque and HP at lower and middle RPM ranges. (1800-5200 RPM). Great cam for motors with 95 inches and 9.8 to 10.2 CR. Lower TDC lift for easy installation. Similar to TW37 with different timing. (2400-5600 RPM). Hot street cams for 88 or 95 inches. 80+ rear wheel HP possible with well tuned 88 incher, more with 95. Smooth . idle, broad torque (2200-5600 RPM) 9.0 to 9.5 CR. New in 2008! Specially designed for 95 inch + engines with CR up to 10:1 (2200-5600 RPM range). Designed for easy installation in 95 inch motors with stock heads and 9.5 to 9.8 CR. (2400 to 6000 RPM). Great cams for 95 inch engines with 9.8 to 10.2 CR. Max HP and torque at mid & upper RPMs (2600-6200) For well prepped 95-103 inchers with 10.2 to 10.5 CR and head work, 100+ HP is within reach. (2700-6500+)

Stock 88 (A) Carburetors Stock 88 Injectors (B)

288121 TW21

288126 TW26a

Stock

288131 TW31s

Stock

288137 TW37b

Stock

288154 TW54 288150 TW50 288155 TW55 288160 TW60a

Hi-lift Stock Hi-lift Hi-lift

(*) Timing and duration listed for .053 cam lift.

11

LETS TALK HORSEPOWER --- 165 hp & 151 ft. lbs. torque!
John Kownacki has dominated almost every dyno horsepower shootout he has entered. His FX bike has recorded an astounding 165 hp and 151 ft. lbs. of torque running an S & S 113 engine in a 1994 FX frame. This bike is owned by John and can be ridden on the street. Together with Kownackis legendary tuning skill and a custom designed Andrews camshaft, the bike has won every shootout contest it has entered; 20 for 20! (20 shootouts: 20 wins). The sound and power of this engine has to be seen up close to be truly appreciated. Every camshaft Andrews makes and all camshafts listed in this catalog have the same engineering design know how and built-in quality that helped this engine pull 165 horses. Think of what an Andrews cam can do for your bike!

EVOLUTION 80 PUSHRODS, SPRINGS & COLLARS

Pictured from left to right: Standard tip aluminum pushrods ............................ Part Standard tip chrome-moly pushrods ....................... Part EZ-install aluminum pushrods ................................. Part EZ-Install chrome-moly pushrods............................ Part

#292110 #292140 #292215 #292245

High Lift Springs ...................................................... Part #294150 4 inner and 4 outer springs: For Evolution engines used with steel spring collars, cam lifts of .550+ can be accommodated. Installation does not require head machining. Heat Treated Steel Spring Collars ........................... Part #293115 Heat treated steel spring collars for all Evolution 80 engines. Provides .050" more spring travel than stock collars. Andrews collars are stronger than stock, approximately 10% lighter and install with stock keepers.

12

EVOLUTION 80 CAMSHAFTS
Andrews Products performance cams mean extra power for an Evolution engine. H/D hydraulic lifters are capable of 6000+ RPM with stock springs and no valve float. Aluminum (T7) or chrome-moly pushrods (EZ-install type) are available to match any of our camshafts. Aluminum pushrods are lighter while the chrome-moly steel pushrods are more rigid for high performance. Notes on the cam listings below, please understand that an EV31 cam is NOT recommended for stock engines!

TOURING AND PERFORMANCE CAMS

Part# Stock 88-91 Grind (L) Timing(*) 01/37 53/-01 -02/30 31/-09 10/46 52/08 10/30 40/08 15/31 45/13 20/36 46/14 21/37 43/15 25/41 49/17 28/44 54/22 28/48 56/24 30/54 60/28 CL 108 117 106 110 108 112 100 106 98 106 98 106 98 104 98 106 98 106 100 106 102 106 Duration .053 .020 218 232 208 202 236 240 220 228 226 238 236 240 238 238 246 246 252 256 256 260 264 268 266 280 250 242 270 274 255 264 .270 .280 270 274 280 280 283 283 286 290 290 294 298 302 Valve Lift .495 .495 .472 .472 .495 .495 .498 .498 .485 .495 .495 .495 .495 .495 .495 .495 .510 .510 .560 .560 .560 .560 Lift @ TDC .091 .083 .070 .049 .133 .122 .134 .121 .161 .148 .182 .166 .197 .159 .207 .163 .233 .195 .236 .208 .246 .230 Springs Stock Stock Stock Application Listed for reference. 1984-1987 cam is 212 deg. intake, 202 deg. exhaust, .472" lift on both valves. Listed for reference. "N" cam is close to '84-'87 specs Fuel Injector "O" cams are 200 deg int. and 216 exh. Super power for supercharged engines; Basically an EV27 cam with timing set for superchargers or big inch motors with 10.5+ compression ratio. Mild bolt-in street cam with more torque and HP for all around riding with stock comp ratio. Similar to stock L cam but more output. Pulls from 1800-5200 RPM. Bolt-in street/touring cam for heavy bikes. Much more low and mid-range power than either stock cam. Best cam for 2 up riding with camping gear and side cars. A great bolt in cam for stock EV80 engines using state of the art design. Very strong, broad torque band which will pull hard from 2000 to 5500 RPM. Bolt-in street cam for light bikes (FXRS, etc.). Lots more mid-range and upper end power. Smooth idle 2800 to 6500 RPM cam with stock heads and springs. Bolt-in performance cam; state of the art ramp design. Longer duration than EV3 but higher static comp. pressure; wide torque band; 2600 to 6000+ RPM. Easy installation; longer duration for modified street engines with hydraulic lifters and 9.0 or higher compression ratio. Power range from 2800-6500 RPM. Upgraded EV57, fast ramps for modified 80 to 88 inch motors. Use with AP springs and collars. Very broad power band; 6000 RPM. OK for hydraulic lifters. Upgraded EV7, for 92 in. + street motors. For use with Andrews springs and heat treated steel collars. Very broad power band, 2800-6000 RPM. OK for hydraulic lifters. For 80-88 inches, 10.5+ C.R., head work. Broad nose very quick ramps for wide torque band. 6500+RPM. Quick ramps, broad nose type design means more power for 90-100 inch motors. 6500+ RPM. Same as above but more stuff for 100+ inch motors. Expert installation knowledge required. 6500+RPM. Special cams can be made to order with 2 front head setups, etc. Call for information & prices!

Stock (N) 92-up (w/carbs) 291117 EV31

291123 EV23

Stock

291113 EV13

Stock

291127 EV27

Stock

291130

EV3

Stock

291146 EV46

Stock

291151 EV51

Stock

291159 EV59

Hi-lift

291172 EV72

Hi-lift

Following three cam grinds require installation machine work and are intended for big inch engines and drag strips! 291581 EV81 291584 EV84 291588 EV88 32/60 66/30 32/64 70/30 104 108 106 110 272 276 276 280 306 310 310 314 318 322 .610 .610 .640 .640 .680 .680 .262 .244 .269 .246 .288 .264 Hi-lift 160 Lbs. Hi-lift 160 Lbs. Hi-lift 160 Lbs.

34/70 108 284 76/32 112 288 (*)Timing and duration listed at .053 cam lift.

13

SHOVEL AND PAN CAMSHAFTS

Three cam grinds were redesigned in 2008 using newest cam design technology! Whether you want a good street cam for a stock motor, a big cam for a dragster or something in between, Andrews Products can supply it. All of our cams for Shovel and Pan engines are computer designed and
Part# Year Grind
H H J

precision ground from alloy steel billets on Landis CNC cam grinders. Installation of S cams requires machine work. S series cams are not made for early Shovel or Pan engines. Rocker arm ratios: Shovel: 1.42, Pan: 1.5 and Knuckle: 1.00
Lift (**) TDC Springs
.051 .176 .129 .176 .154 .154 .156 .142 .136 .136 .133 .133 .187 .176 .156 .156 .206 .186 .234 .234 .237 .220 .241 .223 .254 .235 Stock Stock Stock

Duration Timing(*) .053 .020

-06/46 44/20 14/38 44/20 21/41 41/21 19/43 50/18 16/36 36/16 15/35 35/15 26/50 53/25 24/52 52/24 29/53 59/27 37/61 61/37 32/60 66/30 32/64 70/30 34/70 76/32 220 244 232 244 242 242 242 248 232 232 230 230 256 258 256 256 262 266 278 278 272 276 276 280 284 288 256 282 274 282 292 292 280 290 288 288 288 288 295 296 302 302 303 325 318 318 306 310 310 314 318 322

Valve Lift Shovel Pan

.390 .390 .390 .390 .405 .405 .450 .450 .427 .427 .490 .490 .485 .485 .450 .450 .510 .510 .525 .525 .590 .590 .630 .630 .660 .660 .412 .412 .412 .412 .425 .425 .470 .470 .450 .450 .512 .512 .507 .507 .470 .470 .535 .535 .550 .550 -------------

Application
Stock H/D front cylinder timing listed for comparison. Later stock "S" grind cams have similar specs. Stock H/D rear cylinder timing listed for comparison. Later stock "S" grind cams have similar specs. Mild street: Pans and Shovels, smooth idle, more power through RPM range. Bolts in with no head work. OK for stock heads. New in 2008! Shovel bolt-in (except 80-81) More mid-range - hi end power. Idle unaffected. (Head setup req'd on 80 & 81). (See note 1). Low compression piston version of an A grind cam for 74 - 80 engines with 7.5:1 pistons. Low compression version of a "B" grind cam. More power thu RPM range for engines with 7.5 pistons. New in 2008! Street/drags: More mid and high end power, smooth idle. Best cam for modified 74s - 80s & small strokers. Spring spacing reqd. Hydraulic version of a B cam. Usually a bolt-in but spring spacing required on stock 80 - 81 Shovel heads. New in 2008! Upgrade of original #6. Great street cam for 84/88 inch strokers. Maximum torque available from 2200 to 6500 RPM. Best cam made for big street engines. strokers from 84 to 96 inches will really turn on with this cam. Broad torque band from 2000 - 7000+ rpm. 74-84 inch Shovels with 10.5+ C.R. New design technique for wide, strong power band. 6500+ RPM Shovels: 84-96 inches, 10.5+ C.R. and head flow work for max HP in big inch engines. 6500+RPM. 100+ inch Shovels will benefit most from this quick ramp cam design. Broad power band to 6500+RPM

STOCK (Front cyl) STOCK (Rear cyl) 212011 (48-69) 212020 (70-77) 212030 (78-84) 212260 (48-69) 212263 (70-77) 212267 (78-84) 212130 (48-69) 212140 (70-77) 212150 (78-84) 212330 (48-69) 212340 (70-77) 212350 (78-84) 212351 (48-69) 212353 (70-77) 212358 (78-84) 212420 (48-69) 212430 (70-77) 212440 (78-84) 212533 (48-69) 212536 (70-77) 212539 (78-84) 212600 (48-69) 212610 (70-77) 212620 (78-84) 212823 (70-77) 212825 (78-84) 212834 (70-77) 212836 (78-84) 212855 (70-77) 212857 (78-84)

A2

Stock

Stock

Hi-lift

B2

Hi-lift

BH

Hi-lift

Hi-lift

Hi-lift

S82 S84 S86

Hi-lift 160 # Hi-lift 160 # Hi-lift 160 #

Note (1); 1980 and 1981 engines: The height of original stock H/D valve guides restricts spring travel (and valve lift) to .430 or less! (*) Timing listed at .053 cam lift. (**) TDC Shovel valve lift listed: TDC Pan valve lift will be 5% higher.

CAMS FOR KNUCKLE ENGINES

Part# 212965 212970 Grind N S Timing(*) 13/41 44/16 27/55 55/27 35/63 63/35 Duration .053 .020 234 240 262 262 278 278 270 276 308 308 318 318 Valve Lift .348 .348 .370 .370 .368 .368 Lift @ TDC .089 .105 .130 .130 .156 .156

Amazing, but there are still a lot of Knuckle engines going strong. They have been around for more than 65 years! How many other bikes can make this kind of a claim for long life and durability. Springs Stock Stock Application Stock Knuckle replacement cam. For stock motors and restoring an older classic engine, this is the cam to use. Bolt-in Knuckle performance cam for stock motors, smooth idle, strong pull to 6000 rpm. This cam is the Knuckle equivalent of a B cam in a shovel motor. Knuckle perf cam for stroked motors; strong pull to 6000 rpm. This is the Knuckle equivalent of a C cam.

212980

Stock

Knuckle cam bearings are ground to .8115 to fit stock bushings. (*) Timing listed at .053 cam lift.

14

SHOVEL AND PAN CAMSHAFTS

SHOVEL VALVE SPRINGS AND COLLARS

If you are installing cams in a shovel engine, the valve spring collars and related parts shown below will make things go a lot smoother. Our springs and collars are designed for easy installation and maximum reliability.

SHOVEL PUSHRODS
Andrews Products pushrods are available for all Shovel engines using stock diameter tubing so there is no cover tube interference. Extra long or short pushrods can be made up to order. Call us if you need them. A. Aluminum Pushrods and Adjusters........Part #240055 4 aluminum pushrods and adjusters - quiet operation. B. Chrome-Moly (4130) Steel Pushrods ......Part #240030 4 steel pushrods and adjusters - maximum strength.

KNUCKLE CAMS
A. High Lift Upper Spring Collars..................... Part #271100 High lift spring collars: 74/80 motors. Used with high-lift springs, .600 lift cams can be installed. Made of T6 aluminum, collars are light, hard coated and very strong. B. High Lift Springs ........................................... Part #272110 4 high lift springs - 74/80 inch motors; will provide correct spring force for any of our performance cams. Installation of these springs does not require complicated machining. C. Medium Lift Upper Spring Collars ............... Part #276150 4 medium lift upper collars for 74/80 inch motors; intended to work with stock springs and add.060"spring travel with no other modification. This is the easy way to install B2 grind or #2 cams in stock heads. D. Low Profile Lower Spring Collars ................ Part #273120 4 low profile lower collars for 74/80 motors: similar to stock 1980 style parts but low profile for easy high lift cam installation. Required parts for 1980 style valve guides which utilize "K" line stem seals. Made from heat treated steel.

15

CAMSHAFT GEARS: SIZE INFORMATION

Andrews Products standard sized cam gears (with one groove) will be correct size for most engines. For a small number of engines made with oversized drive gears (green or black color codes), large size Andrews cam gears (part # 212077) may be needed for quiet operation. There are four basic differences in late cam gears (1990-1999) and early cam gears (1989-earlier): 1. Starting in 1990 stock H/D 42 tooth drive gears have 2 grooves on face of gear while 1978-89 have one groove. Andrews drive gears (one groove) are designed to work with all EV-80 type engines 84-89 and 90-99. 2. For 1990, the difference between the largest and smallest gears was reduced from .006 to .003 inches. The largest gears for all years are the same (green or black color codes). 3. Measuring pin diameters in H/D service books were changed in 1990 from .105 to .108 inches. Measuring the same gear with .108 pins will show a .012 larger measurement than a measurement with .105 pins. 4. Beginning in 1992, stock cam gear outer diameters were reduced by .025 inches. Andrews cam gears as well as earlier stock cam gears are interchangeable with later gears.

EVOLUTION CAMSHAFT DRIVE GEARS (UNDERSIZE - OVERSIZE)

Gear Oversize Size* Size** Color Part# 212077 212033 ---------212055 2.7384 2.7495 BLACK 2.7394 2.7505 Undersize 2.7324 2.7455 ORANGE 2.7334 2.7465 H/D Stock 2.7354 2.7487 RED Andrews Std. 2.7365 2.7485 2.7364 2.7491 Gage pins: Part #212116 (set of two .108 dia. pins) Gage pins: Part #212105 (set of two .105 dia. pins)
*using .105 dia. pins **using .108 dia. pins

Gears measured over pins

SHOVEL CAMSHAFT DRIVE GEARS (UNDERSIZE - OVERSIZE)

Gear Oversize Undersize H/D Stock Andrews Std. CAM GEAR SIZES: MEASURED OVER .105 PINS Early (48-77) Late (78-84) Size* Color Part# Size** Color Part# 2.7384 2.7394 2.7324 2.7334 2.7365 2.7364 BLACK ORANGE RED 212077 212033 --------212055 2.7700 2.7705 2.7670 2.7675 2.7690 2.7695 YELLOW 212088 BLACK GREEN 212044 --------212066

Gage pins: Part #212116 (set of two .108 dia. pins) Gage pins: Part #212105 (set of two .105 dia. pins)
*using .105 dia. pins **using .108 dia. pins

HI-FLOW ACCELERATOR PUMP (1980-88)

For all 1980 through '88 H/D bikes with STOCK Keihin carburetors, this kit is an easy, inexpensive performance upgrade. Removing the float bowl and drilling one hole is all thats required. The carb body does not have to be removed. On 1980-'88 carbs, the stock accelerator pump has been restricted by eliminating the check valve in the pump. A high flow accelerator pump puts the check valve back. The result is increased fuel flow through the pump during throttle actuation and greatly improved low end and mid range throttle response. Not intended for 1989 and later CV carburetors. Hi-Flow accelerator pump .............................................. Part#269050

16

PUSHROD ADJUSTMENTS AND HYDRAULIC LIFTERS

Because we make many camshafts and pushrod sets for the H/D accessory market, we frequently hear the following question: What is the proper procedure for adjusting the pushrods on my bike? The diagram at the left shows a cutaway schematic view of an adjustable pushrod and hydraulic lifter assembly. Labels identify some of the components. (Note that for this explanation, no check valve is shown but it is part of the lifter). When hydraulic lifter units are first assembled (with no pushrod present), the compression spring pushes the hydraulic unit and pushrod seat upwards until the pushrod seat contacts the lower edge of the retaining ring. At this point the hydraulic unit cannot move any further upwards. It can however move down approximately .150 inches. This downward travel is the adjustment range. In other words, the adjustment length starts at 0.0 and can be as much as .150 inches. A correctly set adjustment positions the hydraulic unit in the middle of the .150 travel range. For hydraulic lifters to function correctly, the engine oiling system must operate with at least 10 to 15 psi oil pressure. Pressurized oil will then fill the area around the compression spring. And as far as hydraulic lifters are concerned, more oil pressure will not make the lifters run better. Pushrod adjustments may now be completed. First, lengthen the adjuster screw by hand until it makes tight contact with the pushrod seat in the lifter. Then, extend the adjuster screw down (making the pushrod longer) 3 or 4 full turns. (The exact number of turns is not critical). Andrews Products adjuster screws for EV80 and Twin Cam pushrods are manufactured with (5/16 x 32) threads so 3 turns will extend the pushrod length by .093 inches. (3 x 1/32 = .093 inches). Each turn of the adjuster screw changes the pushrod length by .032 inches. The pushrod seat and hydraulic unit will now operate in a correct position and will move up or down to compensate for engine expansion due to warming up or cooling down of the engine. As long as the hydraulic unit and pushrod seat can move up and down and not touch the upper retaining ring or bottom out during operation, the pushrod length has been correctly set and the lifters will function normally.

PERFORMANCE AND REPLACEMENT IGNITION COILS

Replacement coils for Harley Davidson engines. Andrews SuperVolt Coils deliver 30,000+ volts. Models are available for both electronic (pointless) systems as well as earlier conventional battery and point ignitions. Red coils fit 1985 and up engines. Black coils fit all H/D bikes thru 1980 with point type ignition sets. All of these coils will produce more voltage than stock coils. Black color coil, 4.8 ohms ............................ Part #237230 Red color coil, 2.8 ohms ............................... Part #237240

17

CHOOSING A CAM
The question What cam should I buy for my bike? is one we often hear. While there are no hard and fast rules for picking a cam for a specific application, some basic guidelines are worth considering. Keep in mind that performance camshafts are usually chosen for the basic purpose of producing more power from your engine. The three questions to answer before choosing a new cam are: 1. Primary application: Is the bike going to be used for all around street riding or is the goal to have an engine which is running at maximum torque and horse power for track or drag racing? 2. Type of riding: Do you spend a lot of your time riding two up on highway trips or is it more important to have the most power? In other words is your riding style conservative or more aggressive? 3. Engine/Bike combination: This question relates to displacement (cubic inches), compression ratio, bike weight and what kind of cylinder head modifications have been done. Have the intake and exhaust ports been changed to result in better flow efficiency? Does the engine have a higher than stock compression ratio to take advantage of a longer duration cam? Is the bike lighter like a Dyna or a heavy bagger? To get the best cam for your bike all of these factors have to be taken into account. Almost every type of engine modification imaginable has been performed on H/D type engines. Here is a short summary of modifications listed in order of increasing cost and installation complexity. 1. Relieved air cleaners 2. Higher output ignitions 3. Free flow exhaust system 4. Performance camshafts 5. Modified fuel injections 6. Larger carburetors 7. High compression pistons 8. Big bore cylinders and pistons 9. Long stroke flywheels It is impor tant to note that too much cam sometimes results in poor low RPM power. Street bikes will often perform better with a mild cam than a more radical cam. While bigger cams may have a higher peak horsepower, a more conservative cam may feel stronger to street riders because maximum torque occurs at a lower RPM. Changing cams is the easy way to more torque in the 2000-4000 RPM range. A cam with a longer intake duration will reduce static compression pressure at low speeds which in turn tends to reduce low RPM torque. But with a longer duration cam and a higher compression ratio, power at middle and high speeds will be increased which is what you wanted all along. This is the main benefit of a good performance camshaft and a properly tuned engine. For an engine with a cam properly matched to the displacement and compression ratio, the net result will be more power at middle and higher engine speeds. In general, higher compression ratios need longer duration cams. Bolt in type cams are intended for stock compression ratios.

CAMSHAFTS AND HYDRAULIC LIFTERS

There has always been a great amount of interest regarding the application of hydraulic lifters with performance camshafts. On H/D engines, this attention relates to Twin 88s, EV80 big twins and Sportsters (1991 and later) since all of these engines now use hydraulic lifters as stock components. Because we hear many questions about whether to use solids or hydraulics we felt that some discussion might help in deciding which type of lifter would be the best for specific applications. Each type of lifter design has distinct advantages. First, all Andrews Products H/D camshafts will operate properly with hydraulic lifters if the engine and heads are set up correctly. If hydraulic lifters are installed and correctly adjusted, they have some definite advantages: Quiet operation Long time service intervals No loss of lift and duration from heat expansion For hydraulic lifters to operate properly in your engine, the most important point at the time of installation is to make sure that the oil feed holes in the lifter blocks are in position to feed oil to the lifters when the cam is positioned at the lowest lift point. For this to occur with high lift cams, it may be necessary to modify the lifter blocks or lifters so oil can flow into the lifter feed hole from the tappet body. The real advantage of solid lifters relates to all out racing. For anything else including most street riding, we recommend that hydraulic lifters be used. For dragsters, a properly designed cam with solid lifters will be the best choice. But for most street bikes, the idea of low maintenance hydraulic lifters is pretty attractive. New H/D hydraulic lifters work so well that unless you really need 6500+ RPM, don't bother with solid lifters on a street bike. Hydraulic lifters are a little harder to install and adjust, but you will end up with a quieter engine that needs less ser vicing.
18

POLARIS CAMSHAFTS 2002-UP FREEDOM ENGINE

Polaris Freedom engines have a lot of potential. With 92 cubic inches, 4 valve heads and a 9.2 compression ratio, more performance is only a pair of camshafts away. The 438 makes a great setup with a street bike with stock engine or a tuned engine with stock or larger displacement. The 460 cams are a perfect match for the factory 100 kits. NOTE: 2008 and later Vision and 2009 Hammer and Jackpot use different cams.

Part# -------

Grind Stock

Timing(*) 08/40 40/04 17/45 46/11 18/54 48/16

Duration .050 .020 228 224 242 236 252 244 255 253 269 265 282 276

Valve Lift .388 .386 .412 .406 .434 .426

Lift @ TDC .078 .076 .108 .085 .113 .107

Springs Stock Stock

Application + Stock cams; valve event specs listed for comparison. More valve lift and duration means extra power thru RPM (2000-6000+) range for bolt-in or modified engines. Piston-valve clearance should be checked. Higher lift cams for modified Freedom motors with big cylinders and higher comp. ratio. More torque and HP with factory 100 kits. RPM range (2200-6500+).

268450 V-438

268460 V-460

Hi-lift

POLARIS CAMSHAFTS 1998-2001 (VICTORY ENGINE)

Don't be misled by the conservative ratings of the Polaris Victory V twins. With 4 valve cylinder heads and a big bore 1507cc engine, more power is now a readily available option. Victory engines can be tuned to output a lot more useable power by just changing camshafts. If you want more performance from your Victory bike, the first thing on your list of modifications should be a new set of Andrews Victory camshafts.

Part# Stock

Grind ----

Timing(*) -04/34 34/-04 13/37 41/09 04/32 36/00 12/48 48/12

Duration .050 .020 210 210 230 230 216 216 240 240 240 240 258 258 244 244 260 260

Valve Lift .433 .433 .402 .402 .420 .420 .440 .440

Lift @ TDC .037 .042 .095 .080 .062 .050 .091 .091

Springs Stock Stock Stock Stock

Application Stock cams specs listed for comparison. Centerline angles are intake=109; exhaust=109. Easy installation (no head work) with big boost in HP and torque over the entire RPM range. Similar to stock cams but timing advanced for more torque and HP at low and middle RPM speeds. Long duration cams for engines with higher comp. ratios and low restriction exhausts. Big boost in HP and torque at middle and upper RPM speeds.

268402 PL402 268420 PL420 268440 PL440

* Timing data listed for .050 lift at VALVE

19

CAM GEAR NOISE (EV 80 AND SHOVEL 74 & 80) HOW TO FIND IT AND ELIMINATE IT
WHY DO CAM GEARS CAUSE NOISE:
In the last few years there has been more interest in quieter engines. Since cam gear noise can sound like bad lifters, we thought the following section would be appropriate. Whenever the roller follower on a cam lobe passes the maximum lift point, the forces on the cam drive gear tooth change direction. If more than .002 inches (.005mm) backlash is present between the cam and pinion gear, this directional change of force will result in an audible "click" as the backlash moves from the back side of each gear tooth to the front side. While some positive backlash is necessary to prevent localized gear tooth overloads, excess backlash (and "clicking") may sound annoying but won't hurt anything. Tight fitting gears will cause very noticeable whining which is definitely a more serious problem. Gear tooth and bearing damage can result from running zero backlash. In this case, a smaller cam gear or pinion gear would be required. Different size gears permit custom fitting for a specific engine. By choosing two gears which are compatible sizes for a given engine, gear backlash can be minimized so that gears will not whine or click but just run quietly. If you need them, Andrews Products makes cam gears one size larger than standard and one size smaller. H/D makes pinion gears in a range of sizes. If you are working with an engine that does not have quiet running cam gears to use as a starting point, another method may be used to size drive gears when installing new cams. In this case it will be necessary to use either a larger cam gear, a larger pinion gear, (or both) to correct noisy gears. If the problem is excess whining, a smaller pinion or cam gear will be needed. Measure pinion and cam gear sizes (over pins) as in diagram. Look in H/D service manual for part numbers listed by pin sizes. A decision must now be made regarding what size pinion or cam gear to choose. Our recommendation would be to pick 2 sizes larger (to correct clicking) or 2 sizes smaller (to correct whining) as a starting point. If both gears are sized properly for the engine, a very slight whine is normal. Only a small percentage of engines are made with larger size cam drive gears. The two largest sizes of cam drive gears will be color coded green or black. If a particular engine has a stock cam with one of these color codes, matching cam drive gears and pinions for correct backlash can result in a quieter running engine whenever a new camshaft is installed. Engines having cam gears color coded red or blue should not require any cam or pinion gear changes.

WHAT CAN BE DONE TO REDUCE THE NOISE:

The factory service manual for Shovel and EV big twin engines lists different size pinion and cam gears. We are recommending that service manuals be used for reference. If you have changed cams and now notice that your engine makes noise like lifters out of adjustment, the noise is most likely a result of excessive pinion-cam gear backlash. There are several possible techniques for reducing gear noise. 1. Remove the stock cam gear and press it onto the new camshaft. Stock gears will work OK with Andrews Products camshafts. To press a new gear onto a camshaft, the center of the 1/4" keyway (in the camshaft) must be exactly 180 degrees (21 teeth) from the pinion timing mark on the drive gear. OR 2. Measure the stock cam gear and pinion gear (over pins) as shown in the diagram. Write down the measurements. 3. Now measure the new cam gear (over pins) and write down that number also. 4. Subtract the new gear size from the stock size. 5. If the new cam gear is smaller than the stock gear (for clicking), add the difference (from 4) to the size of the pinion gear to obtain a new (larger) pinion gear size. 6. If the new cam gear is larger than the stock gear (for whining), subtract the difference (from 4) from the size of the pinion gear to obtain a new (smaller) pinion gear size. 7. Then match this size to a new pinion gear part number in the H/D manual and install it. 8. Remember to use the same size pins as the manual lists for measuring your gears! (.108" D. or .105" D.) 20

SPORTSTER CAM GEAR NOISE

WHAT CAUSES CAM GEAR NOISE?
Whenever a roller lifter in a Sportster engine passes though maximum cam lift, the forces on the cam gear teeth change direction. If there is more than .002 backlash, the change of force and direction will result in an audible "click" as the backlash moves from one side of the tooth to the other. Gear noise always occurs at idle and lower engine RPM. Stock EV Sportster cams are made with different gear sizes. They are color coded by size and selectively fitted to engines at the factory to a minimum backlash which results in reduced gear noise during engine operation. Andrews Products cam gears for EV Sportsters are made with gears in the middle of the size ranges so there is only a small chance of cam gears fitting too tight. Cam gears which have excess backlash may rattle or click during operation. This clicking sometimes sounds like lifter noise. Unlike whining gears, rattling gears will not cause gear tooth failure or engine damage. If you don't mind the noise, it won't cause any engine problems. Gears which are operating without enough backlash (fitted too tightly) will whine during operation. This condition is serious and can cause localized gear overheating, tooth surface failure and engine damage. Cam gears which fit too tight must be corrected with smaller size cam gears. To fit Andrews Products cams in your EV Sportster engine, a procedure will be described.

MEASURING CAM GEARS FOR PROPER FIT

1. Install all 4 cam gears in cover (see photo below) for a trial fit. 2. Manually turn all four gears and verify that they roll freely. If there is no tightness, proceed to step 6. 3. If there is any tightness, remove #4 cam, then #1, then #3, in that order so that the tight fitting parts can be identified. 4. Measure each new cam gear with a micrometer using .108" dia. pins. Do the same with the stock cam gears. Note any differences in size. 5. Andrews Products makes undersize and oversize cam gears for all 3 production EV cam grinds. Unused parts may be returned and exchanged for under or oversized cam gears. 6. Install the cover onto the engine with no pushrods and only the #2 cam gear. Verify that the engine now freely turns. If so, the cam gear backlash is correct and you can continue to reassemble the engine. 7. If the #2 cam drive gear is tight, a smaller H/D pinion gear must be used. See page 20 for a procedure to determine the correct size of new pinion (procedure applies to Sportsters too). 8. Any 2 adjacent cam gears (1-2), (2-3), (3-4) can be installed in the cover to check for proper backlash by comparing the stock parts (2 at a time) to the new ones. 9. Any significant differences in sizes between the stock cam gears and new cam gears should be investigated and understood before proceeding.

CUSTOM FITTING SPORTSTER CAM GEARS: If the above procedure for checking Sportster cams clearly identifies any cams which will not turn freely because of tight gears, the teeth can be honed to a smaller size to fit correctly. It is very unlikely that you will ever need to do this but If there is a problem, Andrews Products can custom fit Sportster cam gears to eliminate any binding. Tooth sizing is performed on a National Broach GHH gear hone machine setup to adjust HD Sportster cam gear teeth. Please call us for a Return Merchandise Authorization (RMA) before sending any parts back. Sportster cam in GHH gear tooth hone machine
21

STATIC COMPRESSION PRESSURE; WHAT IS IT?

in lower cylinder compression pressure (at low RPM) which in turn can greatly reduce low RPM engine torque and power. Too much duration in a cam lobe design will not result in the best performance for your engine. What causes high static compression pressures: 1. Compression ratio set too high. 2. Intake cam duration too short. 3. Intake cam closing point advanced too much. Compression pressures which are too high can result in detonation or pinging, piston damage and possible rapid starter motor wear. What causes low static compression pressures: 1. Compression ratio set too low 2. Intake cam duration too long 3. Intake cam closing point set too late 4. Worn piston rings and/or burned valves Compression pressures which are too low will result in poor low RPM torque and sluggish throttle response. Static or cranking compression pressure is what each cylinder experiences when the starter motor is turning the engine or when the engine is running at idle RPM. Please dont confuse static compression with compression ratio which has to do with how much volume remains in the cylinder combustion chamber when the piston is at the top of its stroke. Static compression and compression ratio are related but the definition of each is different. Compression pressures that are too high can result in difficult starting and detonation or pinging which in turn can cause engine damage. Modifying an engine by changing pistons, camshafts or compression ratios will all have a direct effect on static or cranking compression pressure. If the static compression pressure is too high or too low, the engine will not run as well as it should and in some cases, the resulting problems can be serious. Static or cranking compression can easily be measured with a compression testing gauge. Cost is usually less than $25.00 and most auto supply stores or well equipped motorcycle shops sell them. When installing cams with high lifts and long durations, a few general observations are worth keeping in mind. Remember that additional cam duration can produce more usable power but too much duration may actually hurt overall performance. The problem of poor engine response begins when too much duration results How to Measure Compression Pressure With a warm engine (not hot, just warm), static compression pressure can be measured using the following procedure: 1. Turn off fuel valve 2. Make sure choke is off 3. Transmission in neutral 4. Remove both spark plugs 5. Insert pressure gage adapter into one head 6. Hold throttle wide open* - closed throttle will read low! 7. Turn engine with starter motor (or kick start bar) 8. Measure cylinder pressure with gauge 9. Repeat procedure for second cylinder *Important note: If the throttle is not held wide open and/or the choke is not off, the resulting pressure measurement will show a false low reading. Also some gauges have a rubber tip instead of a screw in adapter. Using either type of gauge, measuring static pressure in your engine is not difficult.

STATIC COMPRESSION PRESSURE AND ENGINE PERFORMANCE:

The figures below give some idea as to the significance of different pressure readings. Generally, higher static pressures mean more torque at lower RPM ranges. The trade off is that above a certain point (around185 PSI) detonation enters the picture. What happens at higher RPM is less predictable and cant be easily determined from a static pressure reading. For the best overall engine performance, compression ratio, cam timing, duration and fuel system tuning must be correctly matched.

1. Less than 115 psi: poor low speed response, hard starting. Pistons and cams not well matched or worn rings, valves. 2. 125 to 145 psi: OK for stock or modified shovel and pan motors. On the low end for a stock street motor. 3. 145 to 165 psi: OK for modified street motors. Static pressures in this range will be very good for street motors. 4. 165 to 185 psi: Marginal for large displacement street motors, possible hard starting, detonation and overheating. 5. Over 185 psi: High performance numbers. Motors over 185 PSI may need compression releases and/or octane booster. The above recommendations are not absolute but the point is that static compression is important. Proper matching of cams and compression ratios will allow engines to be modified for more performance and still run smoothly in street applications.

22

ENGINE TUNING INFORMATION

HOW TO FIGURE OUT WHAT THE INSTALLED SPRING HEIGHT SHOULD BE:
Spring shown compressed (in vise) SPRING SOLID HEIGHTS Andrews Ev80 & T88 . 1.190" Stock Ev80 .................1.250" Andrews Shovel ..........0.900" Stock Shovel ...............0.900" Iron Sportster..............0.910" 1.250"
1. Using both top and bottom collars, place spring assembly in a small vise and close the vise until the outer spring is solid. Be careful when compressing springs in a vise! 2. Now measure the distance between spring lands as in diagram and write down the number for later use. This is the Solid Height. 3. Calculate INSTALLED SPRING HEIGHT (min.) as follows: INSTALLED HT.= Solid Height + .060 + Max. Valve Lift 4. Max. valve lift can be taken from catalog figures. For example, max. valve lift for an EV59 cam is .560. 5. For an EV51 cam, using Andrews Products springs and collars; INSTALLED SPRING HEIGHT = 1.190+.060+.510 = 1.760 6. This technique will work for any cam and spring system as long as measurements are carefully made. 7. At time of installation, make sure that .050 (minimum) clearance is present between top of valve guide and bottom of upper spring collar at maximum cam lift. 8."Solid height + .560" (diagram at left) refers to spring forces when the valve is seated. (.560 is an assumed spring travel).

Measure only the solid length of spring.

Spring Loads Shovel Evolution & T88 Solid Height+.060* 350 lbs 350 lbs Solid Height+.560* 160 lbs 210 lbs

*Andrews Products springs

HOW TO CHECK FOR POSSIBLE VALVE TO VALVE INTERFERENCE

If your heads have large valves or new seats installed or if a new performance cam has been installed, being able to easily check for possible valve to valve interference is helpful. For all H/D heads (EV, FL, XL, etc.), a simple calculation can be done to see if valve to valve interference might be a problem which will need correcting before proceeding. 1. Andrews Products lists valve lifts at TDC (Top Dead Center) on all cam instruction sheets. For an EV51 cam, the TDC lift =.233" (see data on page 13) 2. Minimum valve to valve clearance should be .060". 3. Calculate the minimum valve separation distance as follows: Minimum Valve Separation Distance = TDC lift + clearance. 4. For EV51 cams, Minimum Valve Sep. Dist. = .233 + .060 = .293" 5. Measure minimum separation between the two valves when they are seated (as in diagram). If actual measurement is not at least .293, modifications will be necessary to avoid valve to valve interference. (Cut seats deeper or back cut valves) 6. Remember, this technique is NOT for checking piston to valve clearance.

Valves shown in seated position

Minimum Separation Distance

COMPRESSION RATIO CHANGES

One of the best ways to increase the efficiency of any internal combustion engine is to raise the compression ratio. As long as fuel with enough octane rating is available (so it will burn without detonation), raising the compression ratio is a very effective performance boost. The amount of material which must be milled from heads (or cylinders) to change compression ratios can be calculated. Although the formula listed in the next column may look too simple, it is correct and it does work! Also correction factors of 1.4 must be used for EV heads and 1.6 for TC heads since the outline shapes of the combustion chambers is not circular. The stroke length (SL) and initial and final compression ratios need to be known. As an example, how much must be milled off EV80 heads to raise the compression ratio from 8.5 to 9.0: Stroke length=4.25 for a stock EV80. With the formula, T=.056 (see next column). All of the values in the following table were calculated with this formula. With this information, a rough thickness (T), to mill from the heads (or cylinders) can be calculated. But, if the bore is changed or different heads are used, the only way to be sure of the CR is to measure the combustion chamber volume on a complete, assembled engine and calculate the CR. EV80: T = Stroke L x 1.4. x (1/(original CR-1)-1/(new CR-1)) T = 4.25 x 1.4 x (1/7.5 - 1/8.73) = .080 in. (EV80; 9.73:1) Twin Cam: T = Stroke L x 1.6 x (1/(original CR-1)-1/(new CR-1)) T = 4.00 x 1.6 x (1/8.9 - 1/9.5) = .045 in. (TW88; 10.09:1)

For EV80 and Twin 88 (Stock bore & stroke):

Head Compression Ratio Milling (T) EV80 Twin cam* .000 . . . . . . . . . . . 8.50 . . . . . . . . . . . . 9.00 .020 . . . . . . . . . . . 8.70 . . . . . . . . . . . . 9.20 .040 . . . . . . . . . . . 8.90 . . . . . . . . . . . . 9.40 .060 . . . . . . . . . . . 9.10 . . . . . . . . . . . . 9.65 .080 . . . . . . . . . . . 9.34 . . . . . . . . . . . . 9.90 .100 . . . . . . . . . . . 9.60 . . . . . . . . . . . . 10.15 *Data shown for TC-88 engine *Data for TC-96 engines will be different

23

SPORTSTER CAMS - 1957-1986 (IRON HEAD)

Pictured is a late style Sportster cam gear kit, lower collars and pushrods made from either steel or aluminum. Steel pushrods are the best choice for stroker motors and drag applications where the greatest strength is needed. For street applications where quiet operation is desired, aluminum pushrods are the recommended choice. Both pushrod kits are made from 7/16 diameter tubing which will not interfere with rod covers. Lower spring collars are

similar to late style H/D parts and will provide .060 more spring travel over stock collars. High lift cams are easier to install with these collars. Part #240040 .................................................. (4 steel pushrods) Part #240060 .......................................... (4 aluminum pushrods) Part #277160 ...........................................(4 lower spring collars)

TOURING AND HIGH PERFORMANCE CAMS

Part# Year Grind Timing(*) Q 10/32 35/07 34/40 43/31 CL 101 104 93 96 Duration(*) .053 .020 222 222 254 254 262 262 294 298 Max Lift .400 .380 .400 .410 TDC Lift .114 .114 .200 .192 Application Specifications for stock Q cams listed for reference and comparison purposes. Kit includes two PB+ exhaust cams (#1 & #4). Must be installed with stock P intake cams. Bolt-in power for all iron head Sportsters with no head work reqd. (Stock P exhaust is .380 lift, 242 deg. duration) Bolt-in replacement cams for stock 'P' or 'Q' cams; more horse power and torque with this great street grind. Stock springs will rev. to 7000 RPM.

STOCK (76-85)

214010 (57-70) P 214014 (71-80) PB+ 214020 (81-84)** 214025 (84-85)*** 214040 (57-70) PB+ 34/40 93 254 298 .410 .208 214045 (71-80) 43/31 96 254 298 .410 .208 214050 (81-84)** 214055 (84-85)*** 214075 (57-70) Y 35/47 96 262 310 .425 .206 Street 900/1000: Biggest cams available for no head 214080 (71-80) 53/29 102 262 310 .425 .182 work installation. Stock springs OK. Great mid-range 214085 (81-84)** and upper end power. Compression ratios should be 214090 (84-85)*** 9:1 to 10:1 for best output. 214105 (57-70) R5 33/41 94 254 306 .445 .209 Street/Drags: Stock or modified 900/1000 motors and 214110 (71-80) 43/31 96 254 306 .445 .200 strokers. Big boost in torque over stock cams (2000214115 (81-84)** 7500 rpm). Stock springs OK, but checking valve and 214120 (84-85)*** piston clearances is required. 214135 (57-70) X 35/55 100 270 314 .450 .210 Street/Drags: For stroker motors to 76 inches. More 214140 (71-80) 57/33 102 270 314 .450 .206 mid range and upper end power. Low lift cams means 214145 (81-84)** easier installation in 1977 and later engines. Stock 214150 (84-85)*** springs are OK but pistons should be 9 to 10 CR. 214190 (57-70) V9 32/52 100 264 311 .490 .207 Street/Drags: Excellent cams for 65-76 inches. High lift 214195 (71-80) 52/32 100 264 311 .490 .207 short duration cams for broad RPM and torque curve. 214200 (81-84)** RPM range: 2500-7000 rpm. 214210 (84-85)*** (*) Timing listed for .053 lift figures. (**) 1981-early 84 cam gear kits (with generators) do not have tachometer drive gears. (***) Late 84 to 1985 cam gear kits (with alternators) do not have generator

24

SPORTSTER EVOLUTION AND BUELL 1200 CAMS

Andrews Products performance cams are available for all EV Sportster engines. Many of the cams listed below will run to 6500 RPM with stock hydraulic lifters. H/D hydraulic lifters are very proven units. We recommend they not be changed to solid lifters. For lower lift EV Sportster cams, stock base circle sizes are used so stock, nonadjustable, pushrods can be used (except V9 or BV). Adjustable aluminum or chrome-moly steel pushrods are also available. Note: #2 cam drive gears used in 2000 and up EV Sportster cams uses 46 teeth; the 91-99 #2 gear has 36 teeth. 46 tooth gears will fit 91-99 #2 cams. EV Sportster Part #292020 Part #292090 Part #292030 Part #292085 Adjustable Length Pushrods ............................. (4 aluminum pushrods; 86-90) ....................... (4 chrome-moly steel rods; 86-90) .............................. (4 aluminum pushrods; 91 up) ........................ (4 chrome-moly steel rods; 91 up)

High Lift Evolution Springs .................................. Part #294150 4 inner and 4 outer springs. When used with heat treated steel spring collars, cam lifts of .550+ can easily be accommodated. Head machining is not required. Heat Treated Steel Spring Collars ........................Part #293115 Heat treated steel spring collars for all EV Sportster engines. Provides .050" more spring travel than stock collars. Collars are stronger and 10% lighter than stock collars. Use stock keepers.

TOURING AND HIGH PERFORMANCE CAMS

Part#
Stock Stock 298120 298125 298130 298135

Year
(86-90) (91-up)

Grind
D D W W V2 N2 N3 N3 V4 N4 V8 N8 V6 N6 V9 N9 BV NV V80 N80 V83 N83 V87 N87

Timing(*) CL
02/41 41/02 10/28 38/16 22/38 46/18 17/33 43/11 30/46 52/24 32/44 56/28 34/50 56/28 33/53 53/33 35/59 59/35 32/60 66/30 32/64 70/30 34/70 76/32 109.5 109.5 99 101 98 104 98 106 98 104 96 104 98 104 100 100 102 102 104 108 106 110 108 112

Duration .053 .020

223 223 218 234 240 244 230 234 256 256 256 264 264 264 266 266 274 274 272 276 276 280 284 288 270 270 256 272 290 290 278 270 296 296 296 302 302 302 309 309 316 316 306 310 310 314 318 322

Max Lift
.458 .458 .474 .474 .465 .440 .465 .482 .490 .490 .490 .500 .500 .500 .555 .555 .590 .590 .600 .600 .630 .630 .670 .670

TDC Lift
.094 .094 .122 .138 .180 .155 .181 .134 .216 .189 .226 .212 .241 .212 .240 .240 .260 .260 .264 .244 .267 .248 .283 .269

Application
Specifications listed for reference and comparison. (Note: 1986-1987 exhaust cam lift is .414). Late Sportster cam data listed for comparison. Late cams marked D (91 and later) have same specs as W cams. Bolt in cams for stock 883, 1100, 1200 engines. More duration and lift means extra power thru RPM range. Use stock springs & hydraulic lifters - 2000-6000 RPM. Bolt in power for 04 and later 883/1200s with stock springs and heads. Cams for 04-up heads with more than .550 lift may need new valves, springs, collars. Street/drags: Stock or modified 883/1100/1200. Stock springs-hydraulic lifters are recommended. RPM range: 2000-6000. Modified 1100-1200, stroked 883s with stock springs and hydraulic lifters. Same intake cam as N4: more exhaust cam duration. Great mid-range power: 2000-6500 RPM. Modified 1200s to 80 inches and/or high comp. pistons. Stock springs and hydraulic lifters are recommended: RPM range: 2500-6800. Cams for stroked engines from 80-88 inches. Broad torque range to 6000+ RPM. Andrews springs, collars and pushrods reqd. (91-up need long pushrods). Hi-lift cams; 88+ inches. Andrews pushrods, springs, collars reqd. BV/NV cams start easy - run strong; 20006000+ RPM with hyd. lifters. (91-up need long pushrods.) .600 lift for Sportsters with 10.5+ C.R. and head flow work will pull strong to 6500+ RPM: need long pushrods. For 80 to 96 inch motors with head work and 10.5+ CR. Quick ramps - 6500+RPM. Long pushrods required. Still more cam for 100+ cubic inches. Quick ramps, broad tip design-pull strong to 6500+ Long pushrods required.

(86-90) (91-99) (2000-up)** (2004-up)

298140 298145 298150 298180 298185 298190 298160 298165 298170 214210 214215 214219 214265 214268 214272 298880 298885 298830 298835 298870 298875

(86-90) (91-99) (2000-up)** (86-90) (91-99) (2000-up)** (86-90) (91-99) (2000-up)** (86-90) (91-99) (2000-up)** (86-90) (91-99) (2000-up)** (86-90) (91-99) (86-90) (91-99) (86-90) (91-99)

(*) Timing listed for .053 lift figures. (**) 2000 and later Sportster engines require a different #2 cam drive gear than 91-99 engines.

25

BIG TWIN 88 and 1340: 5 SPEED TRANSMISSION GEARS

A B C D E

F1 F2 F3

F5

F4

The EV Big Twin 5 speed gear box has been around since 1984 but the growing number of modifications for the 1340 engine continues to create more interest. In addition to close ratio first gears, Andrews Products also makes stock replacement gears for 1st, 2nd, 3rd, 4th and 5th gears. All Andrews
A) 3.24 STOCK RATIO 1ST GEARS Part #296120 (1st counter - 31T) Replaces H/D #35622-79A Part #296125 (1st main - 18T) Replaces H/D #35025-79 (B) 2.94 CLOSE RATIO 1ST GEAR SET Part #296110 (1st counter - 25T; 1st main - 16T) 2.94 1st gears - close ratio shifting; 1st to 2nd. At peak RPM, 2.94 gears will run +5 mph over 3.24 ratio. (C) STOCK 2ND AND 3RD GEARS Part #296330 (2nd counter - 27T; 3rd main 23T) Replaces H/D #35027-79A Part #296220 (2nd main - 23T; 3rd counter 27T) Replaces H/D #35026-79A (D) STOCK 4TH GEARS Part #296445 (4th main - 29T) replaces H/D #35028-79. Part #296440 (4th counter -19T) replaces H/D #35625-79A (1987-up); also replaces gear & spacer in earlier 5 speeds. (E) STOCK MAIN DRIVE GEARS (Belt Drive) Part #296585 (main-32T drive-belt) replaces H/D #35029-85 Part #296591 (main-32T drive-belt) replaces H/D #35029-91 Part #296555 (5th cntr gear-17T) replaces H/D #35626-79A STOCK MAIN DRIVE GEARS (Chain Drive) (Not shown) Part #296550 (main-32T drive-chain) replaces H/D #35029-79

Products five speed gears are made from high nickel alloy and heat treated and shot-peened to give maximum durability and strength. Also, where applicable, lead-in ramps have been machined into most gears to improve shifting and reduce wear on drive dogs and drive slots.
F) TRANSMISSION SHAFTS (All years) (1) Part #296800 (chain drive mainshaft, 1981-1984) (L=12.065) Replaces (H/D #35042-79) (2) Part #296850 (belt drive mainshaft, 1985-1989) (L=14.095) Replaces (H/D #35042-85) (3) Part #296900 (belt drive mainshaft, 1990 only) (L=13.605) Replaces (H/D #35042-90) (4) Part #296910 (belt drive mainshaft, 1991 - up) (L=13.605) Replaces (H/D #35042-91) (5) Part #296700 (countershaft-all years, 1984 - up) Replaces (H/D #35632-79) Complete gear sets are available. Each set includes: First gear (specify ratio) (ctr & mn) .......................................2 pcs Second gear (counter & main) ................................................2 pcs Third gear (counter & main) ....................................................2 pcs Fourth gear (counter & main) ................................................. 2 pcs Fifth gear (counter & main) .....................................................2 pcs Countershaft .........................................................................1 piece Mainshaft ..............................................................................1 piece Part #296081 ......................................... chain drive (1981-1984) Part #296085 .............................................. belt drive (1985-1989) Part #296090 ...............................................belt drive (1990 only) Part #296091 .................................................. belt drive (1991-up) Price sheet has listings of all combinations of gear kits and ratios.

26

ANDREWS PRODUCTS CAMS AND GEARS: THE INDUSTRY STANDARD

Andrews Products has been making cams and trans gears for H/D type engines for 37 years. We are the original maker of close ratio gears starting with 2.44 first gears for 4 speed gear boxes in 1972. The best gears and cams for American motorcycles continues to be Andrews. Our goal as a manufacturer is to maintain the highest level of quality and service for all of our customers.

Finish grinding gear teeth on CNC tooth form grinder. M & M 400 CNC gear inspection systems in temperature and humidity controlled room.

Cutting gear teeth with a Lorenz CNC gear shaper.

Cam lobe milling on Phillips CNC cam lobe mill.

Grinding camshaft journal bearings

Camshaft inspection on Adcole 911 Cam Gage.

27

TRANSMISSION RATIOS, PULLEYS and MPH

Miles per Hour and RPM in any gear MPH 15 20 25 30 35 40 45 50 55 60 65 70 75 80 5 speed - 85-93 (except 93 Softail) - stock 32T front / 70T rear pulley - 3.37 nal drive ratio 5th 4th 3rd 2nd 1st 2203 2937 2503 3671 2174 3003 4405 1950 2536 3504 5140 1812 2228 2899 4004 5874 2038 2507 3261 4505 2264 2786 3623 5005 2491 3064 3986 5506 2717 3343 4348 2944 3621 4710 3170 3900 5072 3397 4178 5435 3623 4457 -

5 speed - 94-06 (except 95 Softail) - stock 32T front / 70T rear pulley - 3.15 nal drive ratio 5th 4th 3rd 2nd 1st 2038 2717 2339 3397 1995 2806 4076 1823 2327 3274 4755 1693 2083 2660 3742 5435 1905 2344 2992 4210 2117 2604 3324 4677 2329 2865 3657 5145 2540 3125 3989 2752 3385 4322 2964 3646 4654 3175 3906 4987 3387 4167 -

6 speed - ANDREWS 30T front pulley / 70T rear pulley - 3.15 nal drive ratio 6th 5th 4th 3rd 2nd 1st 2122 2829 2444 3536 2185 2933 4243 2060 2549 3421 4950 1998 2354 2913 3910 5658 1905 2248 2649 3277 4399 2117 2498 2943 3642 4888 2329 2747 3237 4006 5376 2540 2997 3531 4370 2752 3247 3826 4734 2964 3497 4120 5098 3175 3746 4414 5462 3387 3996 4709 -

6 speed - ANDREWS 30T front pulley / stock 66T rear pulley - 2.97 nal ratio (06 Dynas with stock 32T front / 70T rear pulleys are similar - 2.95 nal drive ratio) 6th 5th 4th 3rd 2nd 1st 2000 2667 2306 3333 2060 2768 4000 1942 2404 3229 4667 1884 2220 2747 3690 5333 1796 2120 2497 3091 4151 1996 2355 2775 3434 4613 2196 2591 3052 3777 5074 2395 2826 3330 4121 2595 3062 3607 4464 2794 3297 3885 4808 2994 3533 4162 5151 3194 3768 4440 -

6 speed - 09-11 FLHT - stock 32T front / 68T rear pulley - 2.87 nal drive ratio 6th 5th 4th 3rd 2nd 1st 1933 2577 2226 3222 1989 2671 3866 1877 2321 3117 4510 1821 2145 2653 3562 5155 1735 2048 2413 2984 4007 1928 2276 2681 3316 4452 2121 2503 2949 3647 4898 2314 2731 3217 3979 2507 2959 3485 4310 2700 3186 3753 4642 2892 3414 4021 4973 3085 3641 4290 -

6 speed - All 07-08 FLHT, 07-11 Softail and 07-11 Dynas - stock 32T front / 66T rear pulley - 2.79 nal ratio (06 Dynas with ANDREWS 34T front / 70T rear pulley are similar with a 2.78 nal drive ratio) 6th 5th 4th 3rd 2nd 1st 1880 2506 2166 3133 1935 2600 3759 1825 2258 3033 4386 1771 2086 2581 3466 5013 1688 1992 2346 2903 3899 1875 2213 2607 3226 4333 2063 2435 2868 3548 4766 2251 2656 3128 3871 2438 2877 3389 4194 2626 3099 3650 4516 2813 3320 3910 4839 3001 3541 4171 -

For Twin Cam HD bikes the table above can be used to estimate vehicle speed in 5 MPH groups in any gear and desired RPM. Pick the chart box that matches your bike and transmission and number of belt pulley teeth. Then look up the RPM for the MPH you are looking for. Example: Stock 2007 FLHT (bagger), six speed trans, 32T front pulley, 66T rear wheel pulley will be listed in the last box above. In 5th gear and 45 MPH, the engine speed will be 1992 RPM as shown above in red text. 28

As a further illustration, what is the difference in engine RPM between a 2009 FLHT and a 2007 FLHT at 60 MPH in 6th gear? For the 2009 chart, engine speed at 60 MPH is 2314 RPM. For the 2007, RPM in 6th gear at 60 MPH is 2251 which is a difference of 63 RPM or approximately 3% lower for the 2007 set up. These differences may look small on paper but to a rider, they can feel very signicant.

BIG TWIN TRANSMISSION BELT PULLEYS (1985-2011)

Pulleys - 85-2006 (5 speed trans)

Pulleys are available to fit EV80 and Twin Cam transmissions. Pulleys have 29, 30, 31, 32, 33 & 34 teeth for 5 speeds and 30, 31 32 or 34 teeth for stock H/D 6 speed transmissions.

Pulleys - All six speeds (30T, 31T, 32T & 34T)

All 2007 - 2011 Twin cams and 06 Dynas MUST use 07 type pulleys. Pulleys made for earlier 5 speed transmissions will not fit new H/D 6 speeds! 31 tooth pulley on 09 -11 bagger changes the nal drive ratio from 2.87 to 2.97
Speedometer calibration modules are available from Dakota Digital for correcting speedometer for pulleys with different numbers of teeth than stock. Part number is: SIM-1 www.dakotadigital.com

Pulleys: 2007 - 2011 Baggers

Final Drive Ratio (07 & 08) = 2.79 with stk 32 T pulley Final Drive Ratio (07 & 08) = 2.97 with AP 30 T pulley Final Drive Ratio (09 & 11) = 2.87 with stk HD 32T pulley Final Drive Ratio (09 & 11) = 2.97 with AP 31T pulley (OK w/stock belt) Higher final drive gear ratios mean more power! New pulleys need belt lengths checked at time of installation
POWER PULLEYS: 30 Tooth .............................6.4% More RPM (200 RPM increase @ 60 MPH - hi gear) Part #290306 (All 07 - 11 & 06 Dyna) Part #290304 (94-06) except 06 Dyna Part #290300 (85-93) 29 Tooth ............................... 9% More RPM Part #290294 (94-06) except 06 Dyna Part #290290 (85-93) POWER PULLEYS: 31 Tooth . . . . . . . . . . . . . . . . . . . 3% More RPM Part #290316 (07-11 & 06 Dyna) Part #290314 (94-06) except 06 Dyna Part #290310 (85-'93) New for 2011 32 Tooth . . . . . . . . . . . . . . . Stock Replacement Part #290326 (07-11 & 06 Dyna) Part #290324 (94-06) except 06 Dyna Part #290320 (85-93)

New in 2010:

OVERDRIVE PULLEYS: NOTE: 34 Teeth; NOT for 07-11 baggers! 34 Tooth . . . . . . . . . . . . . . . . . . 6.4% Less RPM (187 RPM drop @ 60 MPH - hi gear) Part #290346 (06 Dyna) Part #290344 (94-06) Part #290340 (85-93) 33 Tooth . . . . . . . . . . . . . . . . . . . 3% Less RPM Part #290334 (94-06) except 06 Dyna Part #290330 (85-93)

Andrews sprocket pulleys match 1994 style design. This arrangement has the advantage of 50% longer internal spline length compared to the early design. 1994 style pulleys will fit both early (1985-1993) and late transmission shafts. Overall Belt drive ratio
Sprocket Tooth Counts & Ratios 1994-2006 (36 T clutch-25 T engine sprocket) TRANS. REAR WHEEL OVERALL 29 70 3.48 30 70 3.36 31 70 3.25 32 (Stock) 70 3.15 33 70 3.05 34 70 2.96 29 65 (95 softail) 3.23 30 65 (95 softail) 3.12 31 65 (95 softail) 3.02 32 (Stock) 65 (95 softail) 2.93 33 65 (95 softail) 2.83 34 65 (95 softail) 2.75

changes of 3%, 6% or 9% are very noticeable to a rider! All 8593 pulley kits have new style spacer, lock ring, retainer bolts and seals included as part of the kit. Pulley kits for 94-up must use original stock seal and lock ring.
Sprocket Tooth Counts & Ratios 1985-1993 (37 T clutch-24 T engine sprocket) TRANS. REAR WHEEL OVERALL 29 70 3.72 30 70 3.60 31 70 3.48 32 (Stock) 70 3.37 33 70 3.27 34 70 3.17 29 61 (93 softail) 3.24 30 61 (93 softail) 3.13 31 61 (93 softail) 3.03 32 (Stock) 61 (93 softail) 2.94 33 61 (93 softail) 2.85 34 61 (93 softail) 2.76

BELT DRIVE SPROCKETS - INSTALLATION NOTES

A new pulley with more or less teeth than stock requires moving the rear axle forward (34T sprocket) or backwards (30T or 29T). Rear axle position adjustment for each tooth change on transmission sprocket = + / - .125 inches (3.2mm) Rear axle position adjustment for each tooth change in belt length = + / - .280 inches (7.1 mm) If there is not enough axle adjustment at the rear frame for the new sprocket, use a belt with more or less teeth than stock.

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BIG TWIN: 4 SPEED TRANSMISSION GEAR SETS

E A

D G

F H J

Big Twin 4 speed transmissions have been built since 1936 in several versions. They were included on bikes with Knuckle engines, Pans, Shovels and some 84 and 85 Evolution 80's. They all used this transmission. With Andrews 4 speed gears, transmissions last longer, shift faster, and just plain run better. Bikes with Andrews gears feel so good that its hard to believe until you experience the difference for yourself.
(A) 2.44 1st GEAR SET (1959 thru 1984) Part #201105 Best choice for Superglides, choppers and lighter bikes with stock or smaller motor or trans sprockets. This is a no clunk 48 mph, 1st gear. Installation in 80-84 FX requires a 21 tooth 2nd gear. (17T & 20T on cluster; 24T on counter gear). 2.60 1st GEAR SET (59 thru 84) (Not pictured) (24T & 16T) Part #201145 This ratio works best with E glides and heavier bikes with motor or trans sprockets having more teeth than stock sprockets. Installation in 80-84 FX requires 21T (1.82 ratio) 2nd gear for this 1st gear. (16T & 20T on cluster; 24T on counter gear). 3.00 1st GEAR SETS (Original stock ratio) (Not pictured) Part #201090 (59 thru 84) (15T & 20T cluster; 26T counter gear). Part #201094 (36 thru 58) (15T & 20T cluster; 26T counter gear). Part #206215 (36 thru 58) (24T short length 3rd main gear). COMBINATION 2.24 1st - 1.65 2nd GEAR SET (Not pictured) Part #201020 If you want peak RPM thru the quarter mile, this gear set will provide the super close ratio shifting to handle it. OK for street or drags with any size motor.

(B) SHIFT FORKS Part #209750 (1-2 fork) (replaces H/D# 34159-36) Part #209760 (3-4 fork) (replaces H/D# 34158-36) One piece cold forged forks. Fully heat treated and black oxide coated, a must for all transmission rebuilds. (C) SHIFT CLUTCHES Part #205120 (1-2 clutch) (replaces H/D# 35665-36) Part #205340 (3-4 clutch) (replaces H/D# 35440-38) Replacement clutches are specially heat treated and shot peened for super durability. 3-4 clutches are face milled and have longer lead in ramps for more positive shifts. (D) STOCK 2nd GEAR (1.82 RATIO) (21T) Part #202160 (replaces H/D# 35751-36) Stock 2nd gear with drive slots include lead in ramps for more positive 1-2 shifts. This 21 tooth gear fits 1941-1979. It will also fit later transmissions but requires one of the first gear sets shown above. (E & F) CLOSE RATIO 3rd SET (1.35 RATIO) (18T & 23T) Part #203365 (early) Transmissions built before mid 76, to serial# U-8958 (or lower) with loose needle bearings. Part #203375 (late) For transmissions built after mid 1976, from serial# U-8959 (or higher) with caged needle bearings. New design drive slots include lead in ramps for quicker, more positive shifting (same as stock 3rd and 4th gears).

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BIG TWIN: 4 SPEED TRANSMISSION GEAR SETS

STOCK 3rd (1.23 RATIO) (Not shown) (17T & 24T) Part #206220 (replaces H/D# 35306-59) (Mainshaft 3rd) Part #206215 (replaces H/D# 35306-36) (Mainshaft 3rd) (This gear requires 1936-58 style cluster gear) Part #206330 (replaces H/D# 35700-36) (Cluster: 36-76) Part #206335 (replaces H/D# 35700-76) (Cluster: 76-86) Replacements for stock main and countershaft 3rd. The design of drive slots on mainshaft gear has been upgraded to include lead-in ramps for quicker, more positive shifting. (G) STOCK MAIN DRIVE GEAR (4th) Part #204260 (1936-1976) (26 Teeth) (replaces H/D# 35065-65) Part #204280 (1977-1986) (26 Teeth) (replaces H/D# 35067-77 and 35067-84) Replacement 4th gears are made with wider drive slots and steeper lead-in ramps for more positive 3-4 shifting. The "O" ring groove is a design update for all chain drive 4th gears from 1977 through 1986. (H) TRANSMISSION MAINSHAFTS Part #208500 (early) H/D# 35040-50, 1937-1964 Part #208650 (mid) H/D# 35039-65, 1965-1969 Part #208700 (late) H/D# 35039-70A, 1970-1985 chain Part #208800 (late) H/D# 35039-85, belt drive, Late 1984-86 Replacement mainshafts for all versions of big twin boxes. Made from aircraft alloy steel. Heat treated and finish ground to ensure maximum durability. (I) TRANSMISSION COUNTERSHAFTS Part #207650 (1941-early 1976) (replaces H/D 35614-65) Part #207770 (late 1976-1979) (replaces H/D 35614-77) Part #207800 (1980-1985) (replaces H/D 35614-80) Three types of countershafts fit transmissions thru 1985. They are not interchangeable, so make sure before you order. (J) TRANSMISSION REBUILDING KITS (Small Parts) Bushings, gaskets, locks, keys and ferrules for completing a 4 speed transmission rebuild. These parts are made by JIMS. Kit #210925 ................................................................. (1936-1976) Kit #210950 ................................................................. (1977-1979) Kit #210975 ................................................................. (1980-1984) TRANSMISSION GEAR KITS Gear kits must be ordered by part numbers listed below which specify year and 1st and 3rd ratios. Each gear kit includes 6 gears, 2 shift clutches and 2 forks as shown on previous page. (Shafts and small parts kits must be ordered separately). Kit #210150 (2.44 1st, 1.35 3rd) ............................... (1936-1976) Kit #210250 (2.44 1st, 1.23 3rd) ............................... (1936-1976) Kit #210350 (2.60 1st, 1.35 3rd) ............................... (1936-1976) Kit #210450 (2.60 1st, 1.23 3rd) ............................... (1936-1976) Kit #210550 (2.44 1st, 1.35 3rd) ............................... (1977-1984) Kit #210650 (2.44 1st, 1.23 3rd) ............................... (1977-1984) Kit #210750 (2.60 1st, 1.35 3rd) ............................... (1977-1984) Kit #210850 (2.60 1st, 1.23 3rd) ............................... (1977-1984)

4 SPEED TRANSMISSION MAINSHAFT LENGTHS

208500 (EARLY; 1937-1964) 11.730
Andrews Products makes four different versions of 4 speed big twin transmission mainshafts. For everyone who calls for transmission shaft lengths and asks us to look up blueprint dimensions, here they are!

208650 (MID; 1965-1969)

11.985

12.470 208700 (LATE; 1970-1985 - chain)

Regarding one additional mainshaft: H/D part number 35039-84 fits belt drives. This is the same part as H/D 35039-85 except that 35039-85 uses a different drive key. It is very important that the correct drive key be used. The H/D part number for the drive key is 3752385. Andrews Products part number for the belt drive transmission shaft is 208800.

13.725 208800 (LATE; 1984-1986 - belt)

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SPORTSTER GEARS (EV 5 SPEED) (91-2003 for complete sets)

All 5 speed Sportster gears are made from high nickel alloy steel. Gears are then heat treated and shot-peened to give maximum durability and strength. Also, where applicable, drive
(A) 2.61 CLOSE RATIO 1ST GEAR SET Part# 299110 (2 pieces) 2.61 1st gears provide true close ratio shifting into 2nd. Plus 7 mph of usable 1st gear. (20T & 30T) (B) STOCK 2ND AND 3RD GEARS Part #299102 (2nd main/3rd counter) (H/D #35771-89) (24T & 28T) Part #299103 (3rd main/2nd counter) (H/D #35772-89) (28T & 24T) (C) STOCK 4TH GEARS Part #299104 (4th main gear) (H/D #35773-89) (30T) Part #299144 (4th counter gear) (H/D #35775-89) (21T) (D) STOCK MAIN DRIVE GEARS Part #299105 (main drive) (H/D #35034-89) (33T) Part #299155 (counter drive gear) (H/D #35633-89) (19T) (E) TRANSMISSION MAINSHAFT Part #299180 (mainshaft) (H/D #35640-89) (F) TRANSMISSION COUNTERSHAFT Part #299170 (countershaft) (H/D #35641-89)

dogs have milled lead-in ramps to improve shifting and reduce wear on drive dogs and slots.
EV SPORTSTER 5 SPEED GEAR SETS Part #299900 (1991-2003) (later years have some differences) 2004 and later Sportsters cannot use many of the earlier gears. 5 speed EV Sportster transmission gear sets are available as complete kits. Each kit includes the parts as pictured: 1st, 2nd, 3rd, 4th, 5th gears, mainshaft and countershaft.

Internal transmission ratios are listed below. Gear 1st 2nd 3rd 4th 5th Close First 2.605 2.026 1.489 1.216 1.000 % Change 22% 27% 18% 18% Stock First 2.779 2.026 1.489 1.216 1.000 % Change 27% 27% 18% 18%

Special Ratio Sportster 5 Speed Racing Gears:

S Ratio Gears (1st and 2nd) Part# 299816 (2 gears) 2.368 1st gears. (22T & 30T) Part# 299724 (2 gears) 1.876 2nd gears. (25T & 27T) Y Ratio Gears (1st, 2nd, 3rd, 4th) Part# 299717 (2 gears) 2.026 1st gears. (24T & 28T) Part# 299727 (2 gears) 1.670 2nd gears. (25T & 26T) Part# 299737 (2 gears) 1.364 3rd gears. (22T & 28T) Part# 299747 (2 gears) 1.158 4th gears. (20T & 30T) Internal transmission ratios are listed below. Gear S Ratio % Change Y Ratio % Change 1st 2.368 2.026 21% 17% 2nd 1.876 1.670 21% 18% 3rd 1.489 1.364 18% 15% 4th 1.216 1.158 18% 14% 5th 1.000 1.000 Ratio "S" includes 1st and 2nd gears (4 piece set). Ratio "Y" includes 1st, 2nd, 3rd and 4th (8 piece set).

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SPORTSTER GEARS (4 SPEED)

H C

E F G D I

Transmission gears listed on this page will fit Sportster 4 speed transmissions made from 1956 through 1990. All Andrews 4 speed Sportster gears are made from high nickel alloy steel which is heat treated and shot peened for maximum durabil(A) STOCK 1ST GEARS. Part #251050 main 1st (27T) (replaces 35277-52A) Part #251060 counter 1st (17T) (replaces 35760-73 late only, 1973-1985). To fit 1986 and later requires early countershaft #259010 WIDE RATIO 1ST GEAR SETS (Not pictured) Changes 1st from 2.52 ratio to 2.68 for more low end torque with 21T or 22T trans sprockets. Part #251010 (late only, 1973-1985). To fit 1986 and later requires early countershaft #259010 (B) STOCK 2ND GEARS. Part #252020 2nd main (23T) (replaces 35296-56 & 56A) Part #252040 2nd counter (20T) (replaces 35750-58 & 58A) (C) STOCK 3RD GEARS. Part #253050 3rd main (20T) (replaces 35305-56 & 56A) Part #253030 3rd counter (23T) (replaces 35709-54A & 54B) TRANSMISSION SHAFTS. Replacement transmission shafts for standard H/D part numbers. Our shafts are made of super alloy material for maximum strength and durability on this most critical part. (D) Part #259010 countershaft (1956-mid-84) (replaces H/D# 35613-58) (E) Part #258080 early mainshaft (1956-69 kick start) (replaces 35044-56) (Drilled through for clutch rod) (F) Part #258120 late mainshaft (1971-mid-84) (replaces 35046-71) (Solid shaft; no through hole) (G) Part #258190 mainshaft (alternator) (mid-84-90) (replaces 35036-84A) (Solid shaft; no through hole)

ity. Shot peening greatly improves the wear resistance of drive edges and slots. All Sportster gearboxes run better with Andrews gears.
(H) EVOLUTION / ALTERNATOR C RATIO GEAR SET Part #254850 (Mid 1984-1990) (26T & 18T) Part #255620 (26T Countershaft drive gear-all years) The following gears fit all 84-90 alternator engines. All 1987-1990 4 speed Sportsters have C ratio main drive gears as stock parts. (I) C RATIO Part #254720 Part #254740 Part #255620 MAIN DRIVE GEAR SETS (1971-1978) (26T & 18T) (1979-mid 84) (26T & 18T) (26T Countershaft drive gear-all years)

STOCK RATIO MAIN DRIVE GEARS (17T & 27T) (Not Pictured) Part #254710 Clutch gear (71-78) (17T) (replaces 37448-71) Part #254730 Clutch gear (1979-mid 84) (replaces 37448-79) Part #255580 (27T Countershaft gear) (replaces 35695-58) COMPLETE Part #250100 Part #250200 Part #250300 Part #250400 GEAR SETS (includes the following par ts): (W 1st, stock 4th) .............................(1973-1978) (W 1st, C 4th) ................................(1973-1978) (stock 1st and 4th)..............................(1973-1978) (stock 1st, C 4th) ..............................(1973-1978)

Price sheet shows complete listing of all combinations of gear kits with available ratios for generator engines (1979-1984) and alternator engines (1984-1990). Sportster gear ratios are listed below for comparison. Stock 1st 2nd 3rd 4th ratios 2.52 1.83 1.38 1.00 W ratios 2.68 1.83 1.38 1.00
(1)

W ratios 2.44 1.66 1.26 1.00

(2)

C ratios 2.29 1.66 1.26 1.00

(1) "W" ratio 1st plus stock main drive (27/17 teeth) (2) "W" ratio 1st plus "C" ratio main drive (26/18 teeth)

33

Frequently Asked Questions

Why should I buy Andrews Products parts for my bike? Why is Andrews different than the competition? We simply have the best products. Weve been in the cam and gear business for over 35 years. Our 45,000 square foot plant located in Mt. Prospect, Illinois, has the most sophisticated manufacturing equipment in the industry. We make everything we sell, we are not in the business of distributing parts for others. Top NASCAR teams use Andrews Products transmissions and gears for their race cars. All Andrews parts are manufactured in the United States. We do not sell any parts from foreign countries. Do you have a written warranty for your products? Our written warranty is shown on the next page of this catalog. Do you exhibit at industry trade shows? Yes, at Daytona, Cincinnati and some regional dealer shows. Does Andrews offer custom manufacturing services? We will quote and make special camshafts to customer specications. We do not make custom gears unless the quantity justies a production run of parts. CAM RELATED QUESTIONS: What are conversion cams for Twin cam engines? Conversion cams allow engines made from 99 through 2006 to be tted with late style 2007 roller chain cam drives. What are the benets of using Andrews conversion cams? All 99-06 Twin cam engines (except 06 Dynaglides) use silent chains to drive the camshafts. To keep proper chain tension, spring powered shoes are used. But the heavy spring loads mean that chain tensioner shoes can wear and cause noise and potential engine damage if they fail. By changing to later 07 roller chains, long term engine reliability is improved. And the 07 style oil pump (included in kit) has a much higher oil ow rate for better engine cooling, a big added benet. How are conversion cam parts supplied? Andrews Products conversion kits have all parts needed. Conversion cams are made by Andrews Products; all other parts are stock HD catalog items. Can I use the stock 07 cams and chains on earlier engines? No, inboard bearings on 07 style camshafts will not t earlier engines. Inboard cam bearing size is different for earlier cams. I dont want to change from stock cams. What can I do to eliminate the old style chain drives and spring powered chain tensioners and still use conversion cams? There are two possibilities: First, install a conversion chain drive and a 12N cam which has similar performance to stock 99-06 cams. Second, 12G gear drive cams can be installed on any 99-06 twin cam engine. No retuning will be necessary with either 12N (chain drive) or a 12G (gear drive) camshafts. I plan on installing new cams in my twin cam motor. What can be done to simplify the installation? Stock pushrods can be cut and removed easily without removing gas tanks and rocker covers. Andrews EZ-install pushrods can then be installed after new camshafts are in place. Can I install gear drives in my stock twin cam engine? Yes, but gear drive cams require two new camshafts and set of four drive gears. Gear drives will not work with stock cams. Can Andrews make custom tted tooth sizes for Sportster cam gears? No, we cannot supply Sportster cam gear teeth to a specied size. But if your new Sportster cam gears are too tight in the engine, we can hone the cam gear teeth to t correctly. Can Andrews make custom cams to my specications? Yes, we can design and make custom cams with any lift, duration and timing for all current and most older HD engines. Call for pricing and delivery on all custom cams.

Horsepower and Torque Comparisons

#21 cam: 88 inches chain drive; stock heads

26G cams: 95 inches; 10:1 CR; modied heads

37 cams: 95 inches; 9:8 CR; Pro street heads

32 H cams: 110 inches CVO; slipon mufers

TC 96 cam data shown for comparison

#54 H cam: 2007 FL; head work; Free ow exhaust #67 cam: 107 inches; 10:4 CR; Pro street heads

Torque and horsepower curves are for various combinations of cam grinds, engine sizes and tuning levels. Different engine sizes (cubic inches), compression ratios and cylinder head efciency may show widely different HP and torque results on the dynamometer. The guide below shows what each curve means. Andrews cam: torque Andrews cam: horsepower Stock TC 96 cam: torque Stock TC 96 cam: horsepower

Keep in mind that dynamometers will show different results for a similar engine setup. When choosing modications for your engine, the most important part of the plan is to pick the right cams and head work for the application you want. The best cams for bolt in street use will be milder grinds that do not require head work. If you want a great running street bike stay away from 10.5 compression ratios and dragster grinds. Simple ideas and changes work best!

34

SALES POLICIES
Payment Terms:
Visa and Mastercard payments for orders are accepted. COD orders will be sent certified check or money order. COD orders sent company check OK must be approved by Andrews Products in advance.

Claims of Shortages:
Claims of shipment shortages should be made to Andrews Products, Inc., as soon as possible. Damaged shipment claims must be made directly to the shipping carrier.

Ordering Cams not listed in this catalog:

Cam grinds which are not currently listed in the catalog are available as special orders. Custom ground or special order cams are priced and quoted on an individual basis. Call for information.

Returned Goods:
Any parts returned for credit, exchange or inspection should not be sent without calling for a Return Merchandise Authorization number (RMA). A 20% charge will be deducted from the original invoice price on all items accepted for return. Custom or obsolete parts will not be accepted for return credit or adjustment unless there is a warranty question. Andrews Products reserves the right to make changes to prices or sales policies at any time without notice.

Foreign Shipments:
All foreign orders must be prepaid in U.S. dollars including freight and forwarding charges. Andrews Products, Inc., will provide bank wire transfer information for foreign orders upon request.

Shipping Carrier:
All shipments will be sent United Parcel Service (UPS) ground service unless other arrangements have been agreed upon in advance. All overnight shipping expense will be charged to customer.

Shipping Charges for Returned Goods:

Shipments must be sent freight prepaid. Any shipments sent freight collect will be refused. Goods must be packed to prevent damage in transit. Goods damaged because of improper packing will not be accepted for credit.

LIMITED WARRANTY POLICY

Andrews Products, Inc. warrants that its products as shown in this catalog are free from defects in material and workmanship. The warranty extends to original retail purchasers only and is not transferable. The warranty extends for 90 days from the purchase date. Because of the great variety of possible modifications and changes made to motorcycles and/or engines which may affect the performance or durability of other related components, Andrews Products, Inc., obligation under this warranty extends only to the repair or replacement of parts specifically manufactured or sold by Andrews Products, Inc. Not covered by warranty are parts which show evidence of misapplication, abuse, improper maintenance, any alterations from their original configuration, or failure to follow installation instructions. In addition, Andrews Products, Inc., reserves the right to change products or specifications at any time without obligation to modify previously manufactured parts.
0209

No person, company, or other organization is authorized to assume for Andrews Products, Inc., any warranty responsibility or make any binding judgements regarding warranties of any parts which may become the subject of a warranty claim. If you feel that you have a valid warranty claim call for a returned merchandise authorization (RMA) number and then ship parts to Mount Prospect, Illinois, with proof of purchase included! No claims will be considered without valid proof of purchase documentation. Freight charges must be prepaid. Returned parts will NOT be accepted freight collect. On specific parts which are returned showing damage due to normal wear, Andrews Products, Inc., may offer new replacement parts charged to the customer at a reduced cost. Any parts which have been replaced for any reason become the property of Andrews Products, Inc., and will not be returned under any circumstances.

35