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Instruction 51-1255

11-29-11

Copyright®, 2003, 2006, 2008, 2009

by S&S Cycle, Inc.

All rights reserved.

Printed in the U.S.A.

Installation Instructions: S&S

®

Crankcase for

Harley-Davidson

®

Twin Cam 88

®

Engines

For all S&S Stock Bore, 4" Bore, and 4

1

/

8

" Bore Twin Cam 88

®

engine cases

with 1999-2006 and 1984-1999 engine mounts.

S&S

®

®

Cycle, Inc.

14025 County Highway G  PO Box 215

Viola, Wisconsin   54664

Phone: 608-627-1497   •   Fax: 608-627-1488

Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: [email protected]

Website: www.sscycle.com

SAFE INSTALLATION AND OPERATION RULES:

Before installing your new S&S part it is your responsibility to read and
follow  the  installation  and  maintenance  procedures  in  these
instructions and follow the basic rules below for your personal safety.

 

Gasoline  is  extremely  flammable  and  explosive  under  certain

conditions and toxic when inhaled.  Do not smoke.  Perform installation
in a well ventilated area away from open flames or sparks.  

 

If motorcycle has been running, wait until engine and exhaust pipes

have  cooled  down  to  avoid  getting  burned  before  performing  any
installation steps.

 

Before  performing  any  installation  steps  disconnect  battery  to

eliminate potential sparks and inadvertent engagement of starter while
working on electrical components.  

 

Read  instructions  thoroughly  and  carefully  so  all  procedures  are

completely  understood  before  performing  any  installation  steps.
Contact S&S with any questions you may have if any steps are unclear
or  any  abnormalities  occur  during  installation  or  operation  of
motorcycle with a S&S part on it.

 

Consult an appropriate service manual for your motorcycle for correct

disassembly and reassembly procedures for any parts that need to be
removed to facilitate installation.

 

Use  good  judgment  when  performing  installation  and  operating

motorcycle.    Good  judgment  begins  with  a  clear  head.    Don't  let
alcohol, drugs or fatigue impair your judgment.  Start installation when
you are fresh.

 

Be  sure  all  federal,  state  and  local  laws  are  obeyed  with  the

installation.

 

For  optimum  performance  and  safety  and  to  minimize  potential

damage to carb or other components, use all mounting hardware that
is provided and follow all installation instructions.

 

Motorcycle exhaust fumes are toxic and poisonous and must not

be inhaled.  Run motorcycle in a well ventilated area where fumes
can dissipate.

DISCLAIMER:

S&S  parts  are  designed  for  high  performance,  closed  course,  racing
applications and are intended for the very experienced rider only. The
installation  of  S&S  parts  may  void  or  adversely  effect  your  factory
warranty.  In  addition  such  installation  and  use  may  violate  certain
federal, state, and local laws, rules and ordinances as well as other laws
when  used  on  motor  vehicles  used  on  public  highways,  especially  in
states where pollution laws may apply. Always check federal, state, and
local laws before modifying your motorcycle. It is the sole and exclusive
responsibility of the user to determine the suitability of the product for
his or her use, and the user shall assume all legal, personal injury risk and
liability and all other obligations, duties, and risks associated therewith.

The  words  Harley

®

,  Harley-Davidson

®

,  H-D

®

,  Sportster

®

,  Evolution

®

,  and

all H-D part numbers and model designations are used in reference only.
S&S Cycle is not associated with Harley-Davidson, Inc.

IMPORTANT NOTICE:

Statements in this instruction sheet preceded by the following words
are of special significance.

WARNING

Means there is the possibility of injury to yourself or others.

CAUTION

Means there is the possibility of damage to the part or motorcycle.

NOTE

Other information of particular importance has been placed in italic type.

S&S recommends you take special notice of these items.

WARRANTY:

All  S&S  parts  are  guaranteed  to  the  original  purchaser  to  be  free  of
manufacturing  defects  in  materials  and  workmanship  for  a  period  of
twelve (12) months from the date of purchase.  Merchandise that fails
to  conform  to  these  conditions  will  be  repaired  or  replaced  at  S&S’s
option if the parts are returned to us by the purchaser within the 12
month warranty period or within 10 days thereafter.  

In the event warranty service is required, the original purchaser must
call or write S&S immediately with the problem.  Some problems can be
rectified by a telephone call and need no further course of action. 

A  part  that  is  suspect  of  being  defective  must  not  be  replaced  by  a
Dealer without prior authorization from S&S. If it is deemed necessary
for  S&S  to  make  an  evaluation  to  determine  whether  the  part  was
defective, a return authorization number must be obtained from S&S.
The parts must be packaged properly so as to not cause further damage
and be returned prepaid to S&S with a copy of the original invoice of
purchase and a detailed letter outlining the nature of the problem, how
the part was used and the circumstances at the time of failure.  If after
an  evaluation  has  been  made  by  S&S  and  the  part  was  found  to  be
defective, repair, replacement or refund will be granted.

ADDITIONAL WARRANTY PROVISIONS:

(1)  S&S shall have no obligation in the event an S&S part is modified by
any other person or organization.

(2)    S&S  shall  have  no  obligation  if  an  S&S  part  becomes  defective  in
whole  or  in  part  as  a  result  of  improper  installation,  improper
maintenance, improper use, abnormal operation, or any other misuse
or mistreatment of the S&S part.

(3) S&S shall not be liable for any consequential or incidental damages
resulting from the failure of an S&S part, the breach of any warranties,
the  failure  to  deliver,  delay  in  delivery,  delivery  in  non-conforming
condition, or for any other breach of contract or duty between S&S and
a customer.  

(4) S&S parts are designed exclusively for use in Harley-Davidson

®

and

other  American  v-twin  motorcycles.  S&S  shall  have  no  warranty  or
liability obligation if an S&S part is used in any other application.

Summary of Contents for 106-4039

Page 1: ...tate and local laws before modifying your motorcycle It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use and the user shall assume al...

Page 2: ...9 Crankcase Breather Oil Pressure Switch Location Oil Return Fitting Oil Supply Fitting Oil Return Fitting Oil Supply Fitting Oil Supply Return Fitting Locations Oil Supply Return Fitting Locations fo...

Page 3: ...y and the information tag attached to them be inspected beforehand to confirm that the correct model style bore size etc have been provided The customer must confirm that crankcases and related parts...

Page 4: ...ment of engine and frame mounts may cause abnormal stresses resulting in damage to crankcases or other parts To check clearance perform following steps 1 Assemble case halves using case bolts Tighten...

Page 5: ...apered pipe threads 1 Remove the stock oil supply and return fittings from the transmission 2 Install two supplied 3 8 NPT pipe plugs S S PN 50 8330 in the oil fitting location NOTE Apply thread seala...

Page 6: ...cut the oil hoses The straight hose connects the 90 degree fittings of the oil line block and oil pan The bent hose runs between the oil return fittings on the oil line block and oil pan See PIcture 4...

Page 7: ...Change Engine Oil in the Future 1 Slide hose clamp off of fitting along hose See Picture 7 2 Place an oil drain pan under front of oil pan 3 Remove hose from fitting to drain oil 4 Reinstall hose and...

Page 8: ...ake sure no chips or pieces are left on the 1 2 hole and then clean the oil pan and baffle with solvent before reinstalling the pan with a new gasket on the motorcycle 5 Remove the transmission top co...

Page 9: ...both the transmission top cover and crankcase and press down until lines are firmly seated in the counterbores in the crankcase and transmission cover 12 Press the oil line retention plates into place...

Page 10: ...0 0255 10 SHC 1 4 20 x 21 4 50 8455 11 SHC 1 4 20 x 13 4 50 8458 12 SHC 1 4 20 x 11 4 50 7463 13 Washer 50 8451 14 Gasket tranny top cover 56 1256 15 Template 53 0080 16 Fitting 50 8289 17 Hose 90 deg...

Page 11: ...Harley Davidson flywheel assemblies can easily result in serious damage to the flywheel assembly a Sprocket shaft bearings Use 1999 2002 style taper roller bearings included with the crankcase They m...

Page 12: ...shaft Fits all S S and OEM 2000 02 Balanced models only all OEM 2003 up H D 24604 00D 31 4085 19 Retaining ring internal spiraloc 2 required H D 35114 02 50 8160 S 20 O ring oil pump 11 16 I D x 15 1...

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