PREPARATION AND INSTALLATION
1-
Inspection
a-
Inspect crankcases to confirm that they are correct style
and machined for correct bore size. Refer to tag wired
to crankcases.
b-
Verify that serial numbers on crankcases match numbers
on packing carton and certificate of origin. Contact S&S
immediately if numbers do not match.
NOTE:
Valid certificate of origin is required for any transfer or sale
of aftermarket crankcases or complete engines built with
aftermarket crankcases. Certificate of origin is required to title
and license any motorcycle which is to be driven on public streets
and highways.
2-
Crankcase Test Fit
If possible, bare crankcase should be positioned in motorcycle
frame before assembly to check clearances.
a- Test-fit instructions for S&S crankcases with 1999-06
engine mounts.
Position case in frame, check for clearance at frame, and
alignment to transmission. It is a good idea to replace
rubber engine and transmission mounts at this time. Old
mounts deform over time and may and induce
unwanted stresses on the engine case.
b- Test-fit instructions for S&S crankcases with 1984-1999
engine mounts.
S&S crankcase for 1999-06 models being installed in
1984-1999 frames is essentially the same as stock,
although 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
concern are between cases and frame motor mounts.
Checking clearance around and between case mounting
bosses and frame is necessary to ensure that crankcase
rests squarely on motor mount pad and no stress is
applied to crankcases when mounting bolts are
tightened. Shimming may be required to compensate
for variances between frames. The oil lines for the
T124V engine connect to the engine on the bottom rear
of the cam chest. The supply to the engine is the pipe
thread on the right marked with an S. There are two
pipe threads for the return oil located to the left of the
supply pipe thread and marked with an R.
NOTE:
Crankcases damaged by improper installation are not
covered under warranty.
Improper alignment 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 to snug.
Torquing bolts to final specification is not necessary.
2- Clean frame engine mounts and carefully remove any
irregularities from mounting surfaces. Also inspect crankcase
mounting bosses for burrs.
3- Position case assembly in frame.
4- Install engine mounting bolts in motor mounts, and check
clearance between mounting bosses on cases and frame and
any other areas where frame and cases may contact each
other. Bolts may be difficult to install if contact is severe.
5- If cases contact frame, remove them and relieve just enough
material in offending area to provide clearance.
6- Place cases in frame, install one rear mounting bolt and
snug nut.
7- Measure gap between crankcase mounting bosses and
frame motor mounts with feeler gauge to determine if
shimming is required.
8- If gap exists, fabricate shim just thick enough to fill gap.
9- Install opposite corner shim and mounting bolt and nut, and
tighten identical to other bolt.
10- Check other corners with feeler gauge to confirm
thickness required is same as before. If not, determine
cause and correct.
3-
Pre-Assembly Cleaning
Clean crankcases in hot soapy water or solvent to remove
any dirt or contamination which may have been introduced
during shipping, handling, or set-up. Dry components and
check passages with compressed air.
Compressed air and particles dislodged by compressed air are
potentially harmful. Wear protective goggles when using
compressed air and always direct air stream away from
yourself and others nearby.
Hardware Identification and Installation
NOTES
When installing hardware, be careful not to cross-thread
fittings or damage threads. Damage caused by improper
installation of hardware will not be covered under warranty.
To prevent galling, apply anti-seize compound, pipe sealant,
or PTFE tape to threads of all steel fittings prior to
installation in crankcase.
If PTFE tape is used, loose tape must not enter crankcase or
oil passages. Do not apply tape to first 2-3 threads that screw
into hole. If fittings are removed or replaced be sure no tape
shreds remain in holes. Tape shred could block oil passages
causing restriction of oil flow.
4
CAUTION
WARNING
