Instruction Sheet For #25254-93A
Polished Billet Cam Cover
1993-Up Big Twin Models
Refer to H.D.® service manual
for specifications.
Note: Read entire instruction
sheet before doing the job.
Rev C
2/96
25254-IS
1. Start with a clean motor and also a clean area to
work in.
2. Remove old cam cover per H.D.® service manual.
Be sure to disconnect the battery ground wire.
3. Remove wires from the coil on 1973 to 1979 mod-
els and on 1980 to present remove sensor wire
using JIMS® tool #2121.
4. Pull wires through old cam cover.
5. Push ignition wires through hole in new outer cover
and install connector then set aside for now.
6. Remove all old gasket material from motor case.
7. Next if your cam shaft end play was to specifications then measure the height of the old cam bush-
ing from cover base to top of bushing, it should be approximately .060 +/-.001. JIMS® cam
cover bushing will be the same. If your old bushing is different determine the difference and shim
cam as needed, see H.D.® service manual.
8. If you would like to check the centerline of your cam do so as follows: remove nut on pinion shaft
with JIMS® tool #94555-55A prior to 1993. Remove pinion gear from shaft using JIMS® tool
#96830-51. With cam shaft in motor, all shims off cam, and with your new JIMS® cam cover in
hand, lube bushing. seal and the two dowel pins on motor case. Set cam into inner bearing, slip
cam cover over end of cam, push into the two dowel pins. Lube the 6 mounting screws provided
in kit 1/4-20 x 1-1/8, torque to 90 inch/lbs. Turn cam with fingers 360 degrees from all the way
to the inward position to all the way outward position. Cam should turn freely without any tight
spots. If your cam does have a tight spot or will not turn recheck cam to bushing specifications
see H.D.® service manual. If bushing and cam are to specs you have a possible centerline
mismatch from inner cam bearing to cam cover. To fix this remove cam cover bushing, install new
JIMS® bushing #25581-70 with JIMS® tool #1012-70TB and ream from your motor case with
JIMS® cam line reamer tool #1023-70. It is also possible that your pinion bushing centerline may
be off. If you are replacing cam bushing do the pinion bushing also. Remove pinion bushing with
JIMS® tool #95760-TP, reinstall with JIMS® tool #1013-54TB and line ream with JIMS tool
#94805-57.
9. Using your favorite gasket sealer place gasket on motor case, followed by your new cam cover
with assembly lube in both bushings and the sealing lip of seal and just a tad on the two dowel pins.
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