Instruction 106-4500
0-29-08
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Copyright®2008
y S&S Cycle, Inc.
b
ll rights reserved.
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rinted in the U.S.A.
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Installation Instructions: S&S®T111 Engine Assembly
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®
S&S
Cycle, Inc.
14025 Cty Hwy G
Viola, Wisconsin 54664
hone: 608-627-1497 • Fax: 608-627-1488
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Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: sstech@sscycle.com
Website: www.sscycle.com
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
all H-D part numbers and model designations are used in reference only.
S&S Cycle is not associated with Harley-Davidson, Inc.
®
, Harley-Davidson®, H-D®, Sportster®, Evolution®, and
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.
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.
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Instruction Contents:
1- Introduction
2- Additional Features
3- Modification Notes
- Engine to Frame Assembly
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5- Ignition System
6- Fuel System
Please read these instructions carefully before starting work. Proceed with the installation only after the instructions are
completely understood. These instructions should be supplemented by the appropriate OEM service manual for your
motorcycle. Follow all safety information.
7- Oil Line Installation
8- Exhaust System
9- Initial Start-up and Engine Break-In
10- Tuning Guidelines
1- Engine Specs and Torque Values
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12- Service Intervals
1- Introduction
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T111 Engines are designed and intended for
S&S
installation in a stock Harley-Davidson
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Twin Cam 88
chassis. It will bolt directly to the stock transmission and
engine mounts of chassis designed for stock Twin Cam 88
engines. The T111 Engine is available in silver powder
coat or black powdercoat finish.
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
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building operations are required.
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NOTES
Installation of a fuel injected engine in a motorcycle that
was originally equipped with a carburetor is fairly difficult
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and expensive. This conversion requires a fuel pump
equipped gas tank as well as wiring harness.
All S&S T111 assemblies are for Twin Cam 88
counterbalanced engine applications, and are not for use
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in Twin Cam 88B
counterbalanced applications.
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non-
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Torque
Horsepower
Dynomometer chart showing typical horsepower and torque curves for S&S 111” T111 engine.
Horsepower and torque curves will vary, dependent on the engines state of tune, and the ignition and fuel systems
used on the completed engine.
2- 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 cam support
plate are O-ring sealed.
Compatible with stock components. Use stock oil pump,
cam support plate, gear cover, etc.
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Uses 1999-2002 Timken
style sprocket shaft bearing.
Uses 2003-up pinion shaft bearing
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T111 instructions often refer to procedures
S&S
described in other S&S instructions or a Harley-Davidson
Service Manual. These materials should be crossreferenced as necessary.
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IMPORTANT
Before proceeding, 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 longblock assemblies. Certificate of origin is
required to title and license any motorcycle which is to be
driven on public streets and highways.
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3- Modification Notes
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Cycle cautions against modifying these crankcases
S&S
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
hey and the information tag attached to them be
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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.
Under no circumstance will S&S be held responsible for
xpenses related to the modification of any S&S part in
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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 608-627-1488 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.
Glass bead and polishing residues are abrasive and can be
difficult to remove from recesses and small passages.
Abrasive residues can cause oil contamination and
extensive engine damage. Engine damage caused by
powder coating, polishing, glass bead blasting, or other
modification will not be covered under warranty.
- Engine To Frame Assembly
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The engine should be installed into the frame before
the ignition, fuel, exhaust, and oil system components
are installed.
Follow the engine to frame fitting below:
Engine to Frame Test Fit
NOTE - The engine must be fitted to the frame it is installed
into. It must rest squarely on its attachment points, and bolted
olidly to the frame without stressing the engine case at any
s
point.
CAUTION
Failure to correctly mount the engine can cause problems not
covered under warranty including but not limited to,
excessive vibration, driveline mis-alignment, and broken
castings.
- Test-fit instructions for T111 style cases with stock
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1999-up engine mounts.
1- Clean frame engine mounts and carefully remove
any irregularities from mounting surfaces. Also
inspect crankcase mounting bosses for burrs.
2- Position engine in frame, check for clearance at
frame, and alignment to transmission. It is a
good idea to replace rubber engine mounts at
this time. Old mounts deform over time and can
induce unwanted stresses on the engine case.
Replace all other motorcycle components removed for
engine installation. Consult authorized Harley-Davidson
service manual for installation procedure for stock parts
not covered in S&S instructions.
NOTE- On certain models it may be necessary to switch the
shift linkage to the outside of the shift lever. Make certain
that there is clearance between the shifter rod and the engine
crankcases.
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Powder Coating - 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!
S&S strongly recommends trial-fitting every engine
before frame is painted or powdercoated.
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