S&S Cycle Crankcase for Harley-Davidson, Twin Cam 88, 106-4039, 106-4041, 106-4057 Installation Instructions Manual

Instruction 51-1255

11-29-11

Copyright®, 2003, 2006, 2008, 2009

b

y S&S Cycle, Inc.

All rights reserved.

P

rinted 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 41/

8" Bore Twin Cam 88

®

engine cases

with 1999-2006 and 1984-1999 engine mounts.

S&S

®

®

Cycle, Inc.

1

4025 County Highway G PO Box 215

V

iola, Wisconsin 54664

Phone: [phone] • Fax: [phone]

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

Technical Service Email: [e-mail]

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.

2

*Non-counter balanced only.

Breather Fitting

Oil Pressure Switch, H-D®26561-99

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 for some

Harley-Davdison

®

Dyna®Models

Oil Fitting Locations For 1984-’99 Chassis

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.

INTRODUCTION

S

&S

®

c

rankcase assemblies for Harley-Davidson

®

T

win Cam 88

®

non-counterbalanced engine 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

®

Hot Set Up Kit

®

for Twin Cam 88, and 41⁄8 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.

ADDITONAL OIL LINE INSTALLATION KIT REQUIRED

 Dyna

®

- PN 31-0424

 FL - PN 31-0425

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
 Special order crankcases offer your choice of cylinder spigot

bore, cylinder stud pattern, and your choice of rear motor
mount style - 1999-06 or 1984-1999.

KIT CONTENTS

 Crankcase with camshaft bearings and cylinder studs installed
 Sprocket Shaft Bearings
 S&S Reed Valve Assembly
 Pinion Bearing
 Hardware Package
 Certificate of Origin
 Instructions

POLISHING, PAINTING, PLATING, OR POWDERCOATING S&S CASES

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,
b

ore 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 [phone] or e-mail [e-mail]

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.

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.

Powdercoating - Subjecting heat-treated alloys such as those

used in S&S

®

crankcases to excessive heat 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!

3

S&S®Crankcases for 1999-’06 Big Twin Engines

Bore Size Silver Black Polished
Stock Bore 106-4039 31-0172 N/A
4" Bore 106-4041 31-0175 N/A

41⁄8” Bore (S

tock Stud Pattern)

106-4057 31-0181 31-0182

41⁄8" Bore (S&S Stud Pattern) 106-4043 31-0178 31-0179

CAUTION

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
t

o 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.

N

OTE: 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

c

learance 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