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Instruction Sheet #51-1127
5-08-03
Copyright®, 2003
by S&S Cycle, Inc.
All rights reserved. Printed in the U.S.A.
Because every industry has a leader
S&S Twin Cam Style Engine Case Instructions
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
Website: www.sscycle.com
For all S&S Stock Bore, 4" Bore, and 41/
8" Bore Twin Cam style engine cases
with Twin Cam style, or Evolution style engine mounting.
All S&S Twin Cam style engine cases are for use in
Type "A" style (non-counterbalanced) applications.
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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. Apart 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 W ARRANTY 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.
Instruction Contents:
A. Introduction
B. Additional Features
C. Kit Contents
D. Polishing, Painting, Plating, or Powdercoating S&S
Crankcases
E. Preparation and Installation
F. Replacement Parts
Please read these instructions thoroughly before starting
work. Proceed with the installation only after they are
completely understood. These instructions should be
supplemented by the appropriate OEM service manual for
your motorcycle. Follow all safety information.
A. Introduction
S&S T win Cam Style crankcase assemblies are for Twin
Cam “A” (non-counterbalanced) engine applications,
and are not for use in Twin Cam “B” (counterbalanced)
applications. Installation can be performed by any
Harley-Davidson repair shop equipped to do complete
engine overhauls. No special tools other than those
used in normal engine building operations are required.
Stock bore cases are perfect for stock replacement
applications, 4" bore cases are a natural for use with the
S&S Twin Cam style Super Sidewinder™Hot Set Up kits,
and 4-1/8 bore cases make it possible to build really large
displacement custom engines.
NOTE - S&S crankcases are sold in matched sets only.
Individual case halves are not available.
B. Additional features:
● Greater overall strength than stock crankcases,
especially in the front motor mount, an important
consideration in high performance applications.
● All oil passages between the crankcase and gear
cover are o-ring sealed.
● Compatible with stock components. Use stock oil
pump, cam support plate, gear cover, etc.
● 1999-2002 Timken style sprocket shaft bearing.
(Included)
● Uses 2003-up pinion shaft bearing (Not Included)
● Special order Twin Cam style crankcases offer
your choice of cylinder spigot bore, cylinder stud
pattern, and your choice of rear motor mount style
(Twin Cam style or Evolution style).
C. Kit Contents
Crankcase with camshaft bearings and cylinder studs installed
Sprocket Shaft Bearings
Oil Conduit Block
S&S Reed Valve Assembly
Hardware Package
Certificate of Origin
Instructions
D. Polishing, Painting, Plating, or Powder Coating S&S
Crankcases
S&S Cycle cautions against modifying these
crankcases due to the possibility of damaging or
weakening them. Modifying S&S crankcases in any
fashion voids all manufacturer warranties. Should the
customer elect to modify the crankcases regardless, it
is imperative that they 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 are correct before assembling them
or having them modified in any manner, and assumes
all liability for modifications.
The customer must also verify that the serial numbers
on the crankcase and attached information tag
correspond with those on the certificate of origin and
packing carton.
Under no circumstance will S&S be held responsible
for expenses related to the modification of any S&S
part in the event warranty service is required. Modified
parts will not be accepted for credit or exchange. This
will apply regardless of cause or fault: customer,
retailer, manufacturer, or other.
For further information, contact S&S Technical Services
at 608-627-8324, FAX 608-627-0766 or e-mail
sstech@sscycle.com
NOTE - “Modification” includes but is not limited to
appearance changes such as painting, powdercoating,
plating, and polishing. Proper preparation for these
procedures as well as the processes themselves may
require the use of polishing compounds, chemicals or
procedures that are potentially harmful to crankcases.
CAUTION - Passages and internal cavities may become
obstructed by residues from materials used to polish,
paint, plate or powdercoat surfaces. Additionally,
surface finishing processes can damage critical
machined surfaces. Any of the above may cause
premature wear, damage or failure of other engine
components as well as the crankcases themselves.
Powder Coating - Subjecting heat-treated alloys such
as those used in S&S crankcases to excessive heat
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S&S Twin Cam Style
Crankcase Selection Chart
Bore Size Natural Black Polished
Stock Bore 31-0101 31-0102 31-0103
4" Bore 31-0104 31-0105 31-0106
4-1/8” Bore 31-0107 31-0108 31-0109
Special Order 31-0110 31-0120
can drastically alter their strength and their critical
properties. The degree of change depends upon the
temperatures reached and the duration of exposure.
When powder coating or otherwise processing alloy
parts, S&S exposes them to a maximum temperature
of 370°F for no longer than 20 minutes. Under no
circumstances should parts be heated past 400°F!
E. 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 Twin Cam style
cases with stock Twin Cam style engine
mounts.
Position case in frame, check for clearance at
frame, and alignment to transmission. It is a
good idea to replace rubber engine to
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 Twin Cam style
cases with Evo Style motor mounts.
S&S Twin Cam style crankcase installation in
Evolution style motorcycle frame 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 insure 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.
NOTE - Crankcases damaged by improper installation are
not covered under warranty.
CAUTION - 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 setup. Dry components and check passages with
compressed air.
WARNING - 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 Teflon tape to threads of all steel fittings prior to
installation in crankcase.
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5
●
If Teflon 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.
CAUTION - Restricted oil flow may result in extensive
engine damage not covered under warranty.
4. Piston Jet Installation
a. Apply a thin film of clean engine oil to new o-ring.
b. Seat o-ring in groove of piston jet mounting
flange.
c. With pinhole in the jet pointing upward, install
using two T20 TORX screws. Apply LOCTITE
243 Blue, then tighten to 20-30 in-lbs.
CAUTION - Piston jets must be installed using the
correct o-ring. Leaving out a piston jet o-ring, installing
too small of an o-ring, or pinching an o-ring at
assembly will cause oil to by-pass the jet, resulting in
low oil pressure.
NOTE - Always use a new o-rings when re-installing jets.
5. Transmission Oil Tank Fittings Installation
a. Remove the OEM fittings from the existing oil
tank.
b. Install S&S supplied fittings using LOCTITE
PIPE SEALANT 565. Tighten to 120-144 in.-lbs.
NOTE - S&S oil line, oil tank fittings, and oil conduit block
fittings have a larger diameter than OEM components.
CAUTION - Do not use the existing OEM oil tank
fittings with S&S oil line #50-8157. The OEM fittings are
not large enough diameter for the S&S oil line.
6. Oil Conduit Block And Oil Hose Installation
NOTES
●
For installations using a transmission mounted oil
tank,It is easier to connect the oil hoses between the
transmission and engine by installing the Conduit Block
after the oil hoses have been attached to the transmission.
●
Use only the supplied oil line to connect the engine to
the transmission oil tank. The supplied oil line is higher
quality and has a higher heat rating than common oil line.
The supplied piece is long enough for both inlet and outlet
oil lines. Cut as required
a. After engine installation, position oil hoses as
they will be routed, and mark for length.
b. Trim hoses as required.
c. Slide all four clamps onto hoses. (Two clamps
per hose.)
d. Attach oil hoses onto installed oil tank fittings
and secure with clamps.
NOTE - Installations must use supplied S&S oil tank fittings
instead of the smaller diameter OEM fittings.
e. Slide both conduit block fittings into the oil
hoses
f. Seat new o-rings in grooves of oil conduit block.
g. Secure o-rings in position with a dab of clean
grease.
h. Use 1/4"-20x2” hex head bolt to attach oil
conduit block to case. Tighten to 100 in.-lbs.
i. Secure hoses onto conduit block with clamps
See Picture 1
7. Crankcase Cylinder Studs
S&S T win Cam style crankcases are shipped with cylinder studs
installed Before assembling engine, verify that the lower collar of
each stud is contacting the case deck, and that the studs are
torqued to 10 ft.-lbs.
a. Removal
1. Thread two 3/8”-16 nuts onto end of stud
and tighten them together.
2. Use a wrench on the lower nut to remove
stud.
b. Installation
1. Place a ball bearing into the end of a head
bolt then place the head bolt on end of the
stud without a collar.
2. Screw stud into the case, collar side down,
until collar contacts case. Torque stud to
10-ft.-lbs.
Use only S&S #31-2325 stud in
S&S Twin Cam style
crankcases. Threaded end with
collar is .230” shorter than OEM
studs (clearance requirements)
Picture 1
Conduit Block
Grade 5 bolt and washer
O-rings
Oil tank fittings
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CAUTION - Do not carry the crankcase by the studs. It
stresses the crankcase and studs in ways they are not
designed to handle. Also, it is easy to drop and damage
the case when it is carried by the studs.
8. Flywheel Assembly
S&S Twin Cam style crankcases are designed to
use any S&S T win Cam style flywheel assembly, or
1999-2002 Harley-Davidson flywheel assembly.
NOTE - 2003-up Harley-Davidson flywheel assemblies will
not fit in S&S crankcases. For 2003, HD started using a flat
roller bearing on the sprocket shaft. S&S cases must use
Twin Cam style flywheel assemblies that use dual taper
roller bearings.
NOTE - 2003-up flat roller sprocket shaft bearing is not
compatible with S&S cases
CAUTION - It is not recommended to attempt using a
2003-up flywheel assembly by changing the sprocket
bearing from the flat roller style to the earlier dual taper
style. The sprocket bearing inner race of the 2003-up
sprocket shaft is a non-serviceable item, per the OEM
service manual. Attempting to remove the pressed on
sprocket bearing inner race from the sprocket shaft of
2003 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 must be used with a 19992002 style flywheel assembly, purchased
separately.
CAUTION- Installing and setting the clearances for
1999-2002 style taper roller bearings is a critical
operation. install and set clearances per 1999-2002
Twin Cam OEM service manual.
b. Pinion shaft bearing: Use 2003-up pinion
shaft bearing, part number H-D 24604-00.
Bearing is not included with the crankcase.
This bearing is not available from S&S at this
time, and needs to be obtained from HarleyDavidson.
NOTES
●
S&S crankcases secure the pinion bearing in place
with a snap ring. 2003 up OEM cases do not.
●
1999-2002 pinion shaft bearing is not compatible with
S&S crankcases. It has a larger outside diameter than the
2003-up style used by the S&S cases.
9. Camshaft And Cam Plate Installation
S&S Camshafts install using the instructions
packaged with them. Harley-Davidson camshafts
install per 1999-2003 OEM T win Cam service manual.
10. 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-by, and oil leakage. It is a one-way valve that allows
for the smooth passage of air through and out of the engine
breathing system. Installation of the S&S Reed valve is
optional. It is not required for crankcase assembly.
However, its use is highly recommended. It installs easily,
and requires no extra machining. A separate Instruction
sheet is packaged with the Reed Valve. See Picture 2
11. Oil Pump, Lifters, Lifter Covers, and Cam Cover
Installation
These and any other crankcase components not
listed install per 1999-2003 Twin Cam OEM
service manual.
F. Replacement Crankcase Parts
Use the line drawings to identify replacement parts.
Parts designed to fit as direct stock replacements are
listed with corresponding H-D part number. If no H-D
part number is shown, S&S part cannot be used in
stock application and vice versa.
NOTES
●
Right and left crankcase halves are not available
separately .
●
Parts marked N/A are not available. Parts marked N/S
are available but not shown on line drawing.
Picture 2
S&S Reed Valve assembly and wave washer
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1
2
6
4
5
33
31
18
14
12
11
16
17
12
14
10
7
19
25
27
24
26
13
15
30
29
28
20
25
32
21
23
22
3
9
8
7
1. Bolt, stator 10-24 x1" SHC - 4 required
(HD#2720) (10 Pack). .....................50-0194
2. Seal, sprocket shaft
(HD#12068) ...................................31-4035
3. Bearing, timken
(HD#9028) ...........31-4013
4. Bolt, case
5/16”" -18 x 3-1/2" HHC - 8 required
(5 Pack) ........................................50-0147
5. Washer, flat
5
⁄16" x 11⁄16" x 1⁄16" - 8 required
(10 Pack) ......................................50-7069
6. Bolt center case 1/4" -28 x 5-1/2" HHC
Grade 8 (5 Pack)....................50-0126
7. Washer, flat, 1⁄4" x .474" x .050"
(10 Pack) ......................................50-7076
8. Cylinder studs .............................31-2325
9. Dowel, cylinder deck - 2 required
(HD#16595-99) (10 Pack) ................50-8179
10. Nut
1
⁄4"-28 Grade 8 - 1 required
(10 Pack) ......................................50-5014
11. Bolt, camplate
1
⁄4"-20 x 1" SHC - 4 required
(10 Pack) ......................................50-0244
12. Bolt, camplate
1
⁄4"-20 x 11⁄4"SHC - 2 required
(10 Pack) ......................................50-0153
13. Oring, camplate - 7 required
(HD#11301) (10 Pack).....................50-8066
14. Dowel, camplate - 2 required
(HD#16589-99)
. ...............................50-8148
15. Bearing, inner cam
(HD# 9198)
.....31-4080
16. Bearing, right main.
2003-up all TC
(HD#24606-00C)......................................N/A
17. Retaining ring, internal, spiraloc,
(HD#35114-
02).................................................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, magnetic drain ..................50-8335
22. Baffle Plate ..................................31-01 19
23. Screw 10-24 -3/8" pan head - 2 required
(10 Pack). .....................................50-0139
24. Dowel, case alignment - 2 required
(HD#16574-99) (10 pack) ..............50-8109
25. Oring, case alignment,
9
⁄16" I.D. x 11⁄16" O.D. x 1⁄6" CS - 2 required
(HD#26432-76A) (10 Pack) .............50-8102
26. Piston oilers - kit of 2
(HD#22371-99) ................................31-2026
27. Oil line fitting- vent
(HD# 26314-99)..............................50-8147
28. Oil conduit block .........................31-2076
29. Washer, flat
1
⁄
4" chrome
(10 Pack).....................................50-7013
30. Bolt,
1
⁄4"-20 x 2" HHC - 1 required
....................................................50-0303
31. Hose, oil, inlet/outlet....................50-8157
32. Spring clips - 4 required ..............50-8156
33. Oil line fittings, inlet/outlet
2 required ...................................50-8158
Replacement Parts for S&S Twin Cam Style Crankcases
Because every industry has a leader
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