S&S Cycle Motorcycle Accessories Assembly And Installation Instructions Manual Download Page 2

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SAFE INSTALLATION AND OPERATION RULES:

Before installing any S&S engine part, it is your responsibility
to read and follow all instructions. The rules below are for
your personal safety, and must be kept in mind at all times.

Gasoline is extremely flammable and explosive under

certain conditions, and toxic when inhaled. Do not smoke
around gasoline. Perform the installation in a well-ventilated
area away from sparks or open flame. 

After installation, be sure all fuel lines are routed correctly

with clamps in place and tightened securely. Even with
protective cover, gas lines must not contact extremely hot
surfaces where they could melt or leak and catch fire.

Compressed air and particles dislodged by

compressed air are potentially harmful. Wear protective
goggles when using compressed air and always  direct
the air stream away from yourself and others nearby. 

Some solvents, degreasers and other chemicals are

harmful, especially to skin and eyes. Many chemical
compounds such as lacquer thinner are also flammable and
present a fire hazard. Read the manufacturer’s instruction
label for precautions and proper use. Use in a well ventilated
area and wear protective clothing to avoid personal injury.

If the motorcycle has been running, wait until the engine

and exhaust pipes have cooled before performing any
mechanical work. 

Before beginning the installation, disconnect and remove

the battery to eliminate potential sparks and possible
inadvertent engagement of the electric starter while working
on the motorcycle.

Read instructions thoroughly and carefully so all

procedures are completely understood before beginning
installation. Contact S&S if you have questions, if any steps
are unclear, or if any abnormalities occur during final
assembly, installation, or operation.

Consult an authorized H-D service manual for correct

disassembly, reassembly, and installation procedures for any
parts that need to be removed or disassembled to facilitate
the installation.

Use good judgment during assembly, installation, and

when operating the motorcycle.  Good judgment begins with
a clear head. Don’t let alcohol, drugs, or fatigue impair
judgment. Perform installation when fresh and alert.

For optimum performance and safety and to minimize

potential damage to the cylinder heads or other components,
use correct hardware and follow procedures outlined in S&S
instructions and authorized H-D service manual. 

Motorcycle exhaust fumes are toxic and must not be

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

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 S&S 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 notify S&S of the problem immediately.
Some problems can be rectified by a telephone call and need
no further action. A part that is suspected of being defective
must not be replaced 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, it must be
packaged properly to avoid 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 was made by S&S and the part
was found to be defective, repair, replacement, or refund will
be granted.

ADDITIONAL WARRANTY PROVISIONS:

(1) No part shall be returned to S&S without first contacting
the company and obtaining a Return Authorization (RA)
number.

(2) S&S shall have no obligation in the event an S&S part is
modified by any other person or organization, or if another
manufacturer’s part is substituted for one provided by S&S.

(3) 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 break-in or maintenance, improper use,
abnormal operation, or any other misuse or mistreatment.

(4) S&S shall not be liable for any consequential or incidental
damages resulting from the failure of an S&S part, the breech
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.

(5) S&S parts are designed exclusively for use on
motorcycles with Harley-Davidson style V-twin engines. S&S
shall have no warranty or liability obligation if  an S&S part is
used in any other application.

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
motorcycle or a component.

NOTE

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

S&S urges you to take special notice of these advisories.

Summary of Contents for Motorcycle Accessories

Page 1: ...tions S S Cycle Inc 14025 County Highway G Box 215 Viola Wisconsin 54664 Phone 608 627 2080 Fax 608 627 1488 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Websit...

Page 2: ...a well ventilated area where fumes can dissipate 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...

Page 3: ...include oil pump oil pressure switch cam support plate cam cover tappets tappet covers and oil filter bracket Installation can be performed by any Harley Davidson repair shop equipped to do complete...

Page 4: ...avidson Service Manual These materials should be cross referenced as necessary IMPORTANT Before proceeding verify that serial numbers on crankcases match numbers on packing carton and certificate of o...

Page 5: ...ing polishing glass bead blasting or other modification will not be covered under warranty Powder Coating Subjecting heat treated alloys such as those used in S S crankcases to excessive heat can dras...

Page 6: ...additional clearancing and shimming may occasionally be required When this style of case is solid mounted instead of rubber mounted additional care must be taken in installing the case Main areas of c...

Page 7: ...wheels in crankcase 1 Thoroughly clean parts according to instructions previously mentioned Apply coat of assembly lube to bearing surfaces 2 Place flywheel assembly onto a suitable holding fixture wi...

Page 8: ...otor oil over bearing end of connecting rod assembly and into flywheel cavity Rotate flywheels several times to distribute oil over connecting rod bearings Assembly should turn freely and without bind...

Page 9: ...9 Use tool to guide bearing rollers onto inner race Picture E9 Picture E12 Picture E10 Picture E13 Picture E11 Figure 1 Picture E7 1 2 3 4 5 6 7 8 9 Picture E8...

Page 10: ...b Lubricate wristpin wristpin bushing and wristpin bore in piston with assembly lube Raise the previously installed support ring in the lower groove to allow the wrist pin to slide in under it Install...

Page 11: ...e 6 S S Reed Valve installation The S S Reed Valve Assembly 31 2071 included with the crankcase is an effective way to control internal air pressures inside the crankcase reducing oil carry over blow...

Page 12: ...s are handled automatically by the S S IST ignition 2 Once the IST ignition has been installed per the included instruction sheet 51 1155 no other adjustments are necessary NOTES If the S S IST igniti...

Page 13: ...ere is no gas leakage at any point in the system I Oil Tank Fittings and Oil Lines 1 Oil Tank Preparation 1 Remove and flush oil tank thoroughly before installing oil lines Flush oil cooler also if so...

Page 14: ...ps CAUTION Improper installation of oil lines or fittings may result in parts damage not covered under warranty 3 Oil recommendations NOTES S S Cycle suggests that the engine be broken in using a regu...

Page 15: ...failure of exhaust pipes or mounting hardware K Initial Start Up And Engine Break In NOTE engines are designed for high performance and as such are not as tolerant of inadequate break in as stock or l...

Page 16: ...speed trailer towing or sidecar operation 5 After 1000 miles verify Ignition and fuel system settings and adjustments Change the engine oil The break in process is complete L Tuning Guidelines Ignitio...

Page 17: ...in case tight 001 003 less than 0025 Connecting Rods Specification Service Wear Limit Crankpin bearing 001 0012 002 Running clearance Piston pin fitment in rod 0005 001 002 Connecting rod side play 0...

Page 18: ...iles and every 2 500 miles thereafter Spark Plugs Champion RA8HC or equiv Inspect every 5 000 miles Replace every 10 000 miles or as needed Ignition Timing 28 deg total advance max Inspect every 5 000...

Page 19: ...ing internal spiraloc HD 35114 02 2 required 50 8160 18 Oring oil pump 11 16 I D x 15 16 O D x 1 8 CS HD 11293 50 8039 19 Switch oil pressure HD 26561 99 N A 20 Plug sump HD 765 50 8330 21 Plug magnet...

Page 20: ...Because every industry has a leader...

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