Instruction 51-1124
5-11-06
Copyright©2002, 2006
by S&S Cycle, Inc.
All rights reserved.
Printed in the U.S.A.
S&S®Cycle, Inc.
235 Causeway Blvd.
La Crosse, Wisconsin 54603
Phone: 608-627-1497 • Fax: 608-627-1488
Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: sstech@sscycle.com
Website: www.sscycle.com
Assembly and Installation Instructions:
®
S&S
41⁄8” Bore V-Series Engines
Because every industry has a leader
DISCLAIMER:
S&S parts are designed for high performance, off road, 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.
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 pe
installation steps.
● Before performing any installation steps disconnect battery to
eliminate potential sparks and inadvertent engagement of star
working on electrical components.
● Read instructions thoroughly and carefully so all pr
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 procedur
removed to facilitate installation.
● Use good judgement when performing installation and operating
motorcycle. Good judgement begins with a clear head. Don't let
alcohol, drugs or fatigue impair your judgement. Start installation
when you are fresh.
● Be sure all federal, state and local laws ar
installation.
● For optimum performance and safety and to minimize potential
damage to carb or other components, use all mounting hardwar
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.
es for any parts that need to be
rforming any
ter while
ocedures are
e obeyed with the
e that
IMPORTANT NOTICE:
Statements in this instruction sheet preceded by the following words
are of special significance.
WARNING
Means ther
Means there is the possibility of damage to the part or motorcycle.
Other information of particular importance has been placed in italic type.
S&S recommends you take special notice of these items.
e is the possibility of injury to yourself or others.
CAUTION
NOTE
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.
INTRODUCTION
Pinion Bearing Roller Diameter
41⁄8" bore engine instructions often refer to procedures described
®
in other S&S
instructions or a Harley-Davidson®Service Manual.
These materials should be cross-referenced as necessary.
1
⁄8" bore engines are designed for frames that accept 1984-'99
All 4
big twin engines, and will fit stock Harley-Davidson
®
and similar
frames without modification.
S&S strongly recommends trial-fitting every engine before frame
is painted or powder coated.
1
Because the 4
⁄8" bore crankcase is 1⁄4 inch wider than stock, fit of
exhaust, rear brake master cylinder, and foot controls must be
1
closely checked when installing the 4
⁄8" bore engine. Some
components may require modification.
WARNING
In some instances, brake master cylinder must be spaced out
om frame to clear crankcase. UNDER NO CIRCUMSTANCES
fr
SHOULD MASTER CYLINDER OR BRAKE LINE BE ALLOWED TO
CONTACT EXHAUST PIPE IN FINAL INSTALLATION. Heat
transferred to brake fluid may expand and cause brakes to seize,
resulting in possible fire hazard and loss of control of motorcycle
with injury or death to rider and others.
IMPORTANT NOTES
● Lubrication - S&S supplies Torco Engine Assembly Lube with
each engine. It should be used as specified in following
instructions. While other brands of assembly lube are
acceptable, other lubricants are not. In no instance should an
aerosol lubricant be substituted for assembly lube.
● Engine tuning - Ignition timing and carburetor jetting
are responsibilities of the customer
. If not thoroughly
familiar with these procedures, he should contact a
professional mechanic.
CAUTION
Incorrect ignition or carburetor tuning can cause extensive
engine damage not cover
ed under warranty.
Bearing Color Code Roller Size Total
Green
®
S&S
H-D
®
#31-4016
#24628-87A
.2502” .5004”
White
®
S&S
H-D
®
#31-4005
#24626-87A
.2503” .5006”
Blue
®
S&S
H-D
®
#31-4018
#24643-87A
.2504” .5008”
Red
®
S&S
H-D
®
#31-4017
#24628-87A
.2505” .5010”
● Powder coating and polishing - While S&S does manufacture
some powdercoated engines, it does not recommend having
engine parts powdercoated or otherwise modified
elsewhere. Many such procedures leave abrasive residues
which are dif
ficult to remove completely. Also, powder
coating is cured at high temperatures that can change the
strength characteristics of some metals.
CAUTION
Glass bead and polishing residues are abrasive and can be
ficult to remove from recesses and small passages.
dif
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.
ASSEMBLY
NOTE - While S&S has made every effort to insure that parts are
correct, it is the engine builder’s responsibility to confirm fit and
finish of all parts provided with engines prior to assembly. Parts
are deburred at S&S and usually require no further preparation,
but must also be inspected by installer. Individual parts should not
be removed from protective plastic wrappers until needed. After
removal from plastic, it is imperative that parts be thoroughly
cleaned and dried, preferably with compressed air. When
present, rust preventative must be completely removed.
Additionally, gaskets must be closely inspected for particles that
could become dislodged and damage engine. If assembly of
engine must be interrupted, seal openings and cover engine with
plastic to protect from destructive contaminants.
Chart 1
Big Twin Bearing Race
Diameter
Pinion Shaft Bearing Diameter
1.2498 - 1.2500 1.2500 -1.2502
Red
®
1.7511 to 1.7513
S&S
H-D
®
#31-4017
#24628-87A
Blue
®
1.7509 to 1.7511
S&S
H-D
®
#31-4018
#24643-87A
White
®
1.7507 to 1.7509
S&S
H-D
®
#31-4005
#24626-87A
All reference to Harley-Davidson®part numbers is for identification purposes only. We in no way are implying that any of S&S®Cycle’s products are
original equipment parts or that they are equivalent to the corresponding Harley-Davidson
2
S&S®Pinion Shaft Main Bearing Fitting Charts
Bearing Race Diameter
Minus Pinion Shaft
Bearing Diameter
S&S
H-D
S&S
H-D
S&S
H-D
®
®
®
Blue
®
#31-4018
#24643-87A
White
®
#31-4005
#24626-87A
Green
®
#31-4016
#24628-87A
.5005 to .5009
.5007 to .5011
.5009 to .5013
.5011 to .5015
®
part number shown.
Chart 2
Bearing Color Code
Green S&S®#31-4016
®
H-D
#24628-87A
White S&S®#31-4005
®
H-D
#24626-87A
Blue S&S®#31-4018
®
H-D
#24643-87A
Red S&S®#31-4017
®
H-D
#24641-87A
Picture 1 Picture 2
CAUTION
Failure to observe the previous instructions may result in
engine damage not covered under warranty.
FLYWHEELS
Confirm pinion shaft main bearing fit. Correct size bearing is
supplied with engine, but must be verified by engine builder.
Flywheel assembly can then be prepared for installation.
NOTES
● Refer to information tag on crankcases for final honed size
of pinion shaft main bearing race.
®
● S&S
● All measurements must be taken with parts at room
1. Fitment Method A - Use Chart 1.
EXAMPLE - Pinion shaft bearing surface diameter measures
1.2499” and is between 1.2498” and 1.2500” in left “Pinion Shaft
Bearing Diameter” column. Pinion bearing race inside diameter
is 1.7510” and falls between 1.7509” and 1.7511” in middle
“Bearing Race Diameter” column. Correct bearing color code
where two columns intersect is “BLUE”. Selecting color where
columns intersect provides proper fit for normal ser
fit is desired, select bearing color directly to right of color
indicated from selection process. If color indicated from selection
process is located in right color column, go to next row directly
below and select color in left color column.
2. Fitment Method B - Use Chart 2.
pinion shaft main bearing fitting charts #1 and #2 use
®
Harley-Davidson
temperature, approximately 70°
bearing color codes.
F.
a. Refer to information tag on crankcases to determine
final honed size of inside diameter of pinion shaft main
bearing race.
Measure pinion shaft bearing surface diameter.
b.
c. Cross reference pinion race inside diameter with pinion
shaft bearing surface outside diameter to determine
correct color code.
vice. If looser
a. Refer to information tag on crankcases to determine
final honed size of inside diameter of pinion shaft main
bearing race.
b. Measure pinion shaft bearing surface diameter.
Subtract pinion shaft bearing surface diameter from
c.
pinion bearing race inside diameter.
d. Select range in left “Bearing Race Diameter minus
Pinion Shaft Bearing Diameter” column where
difference best splits high and low parameters of range.
Corresponding color bearing set in right “Bearing Color
Code” column provides proper fit for regular service.
EXAMPLE - Pinion bearing race inside diameter is 1.7510”. Pinion
shaft bearing surface diameter is 1.2499”. 1.7510” minus 1.2499”
is .5011”. Dif
ference of .5011” splits .5009” to .5013” range in
third row exactly. Corresponding “BLUE” color code in right
column should be used. Notice that .5011” fits in several range
groups. Try to select group where difference falls closest to
middle of range. If you are not sure, select color that corresponds
with group closer to top of chart. This will provide slightly looser
bearing fit and help prevent bearing seizure. Selecting next color
up on chart may also be done if looser fit is desired for
competition applications.
CRANKCASES
NOTE - S&S crankcases are sold in matched sets only. Individual
case halves are not available.
1. Disassemble crankcases & wash in hot, soapy water. Rinse
case halves and blow dry with compressed air
. Check all
internal passages. Coat bearing surfaces with a light oil to
prevent rust.
2. Install piston oilers - right-side crankcase.
a. Lubricate O-ring with engine oil and install in
piston oiler.
®
b. Apply Loctite
243 to screws. Install oilers, tighten screws
to 25 in-lbs. See Picture 1.
ALL FLYWHEELS IN CRANKCASE
INST
1. Thoroughly clean parts according to instructions previously
mentioned. Apply coat of assembly lube to bearing surface
®
of sprocket shaft and inner race of T
imken
bearing. Install
bearing on shaft with appropriate tool. See Picture 2.
NOTE - S&S does not recommend using a press to install sprocket
shaft bearings, as this can push flywheels out of true. Correct
bearing installation tools are available from Harley-Davidson
and other sources.
®
3
Picture 3
A
C
D
E
F
G
H
B
Picture 4
2. Apply coat of assembly lube to Timken®bearing installed
in Step 1.
3. Place left side crankcase half on sprocket shaft and bearing,
insuring that connecting rods are in correct positions.
See Picture 3.
4. Install included Timken
5. Lubricate rollers of remaining Timken
assembly lube. Apply assembly lube to bearing inner race
and sprocket shaft bearing surface. Install bearing on shaft
with appropriate tool. See Picture 5.
NOTE - Pinion and sprocket shaft bearings should be correct sizes,
but it is engine builder’
endplay, connecting rod sideplay, bearing fit, and all clearances
in Unassembled engines at time of assembly. It is of particular
importance to check flywheel endplay and install different
Timken bearing spacer if necessary. The flywheel end-play
specification is .001”-.005”.
6. Lubricate pinion bearing and pinion shaft bearing boss with
assembly lube. Install bearing and secure with pinion shaft
main bearing snap ring. See Picture 6.
NOTE - Snap ring supplied by S&S
be used with pinion bearing supplied in Super Sidewinder
engine. Ends of snap ring are rounded on one side, sharp on the
other. Install snap ring with sharp edge out, away from flywheels.
®
bearing spacer. See Picture 4.
s responsibility to confirm flywheel
®
or identical replacement must
®
bearing with
®
Plus
ASSEMBLE CRANKCASE HALVES
1. Noting solvent precautions on page 1, wipe down mating
surfaces of crankcase halves with lacquer thinner
residue with clean, dry cloth, then apply sealant of choice to
both crankcase halves. Take care to avoid breather cavity
and other areas where sealant might reach inside of engine.
See Picture 7. Coat right main bearing race with assembly
lube. If applicable, allow sealant to cure according to
manufacturer’
crankcase halves.
NOTE - S&S uses Threebond
sealant carefully to prevent excess from entering engine and
obstructing oil passages or contaminating oil supply.
2. Install crankcase studs and washers according to crankcase
instructions.
NOTE - Alignment studs for S&S crankcases are in locations B,
E, & G. See Diagram 1. They must be installed before other
studs and bolts. Fit is tight, so alignment studs must be
lubricated with assembly lube, then tapped through case
assembly with plastic mallet.
3. Tighten 5⁄16” case bolts and studs to 18 ft-lbs,1⁄4” center bolt
to 120 in-lbs. See Diagram 1 for identification, and tighten
fasteners in following sequence: G-B-E-F-H-D-C-A.
Install drive sprocket spacer and sprocket shaft oil seal in
4.
main bearing race of left case.
s instructions, then join left and right
®
1104 to seal crankcase. Use any
. Remove
Picture 5
4
Diagram 1
Picture 6
Picture 7
NOTE - Because of sealed, wet primary in Harley-Davidson
Evolution®models drive trains, S&S®installs sprocket shaft seals
with spring facing out. See Picture 8.
5. Allow crankcase sealant to cure per mfr.’s instructions, then
pour four ounces of motor 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 binding.
INSTALL OIL PUMP
1. Disassemble, clean and inspect oil pump, leaving supply drive
gear, key, and snap ring in place on shaft.
2. Reassemble pump, applying assembly lube to gears and
gear cavities in pump body. Remove excess to avoid
contaminating gaskets. Rotate gears as preliminary
check for bind, and to confirm that drive gear keys are
properly installed.
NOTE - If bind occurs, determine whether problem is with supply
or return gears by removing idler gear from either side and
rotating pump. When binding gear is removed, pump will rotate
. Problem can usually be corrected by rotating gear 180°.
freely
®
CAUTION
Routing oil supply line to lowest fitting on models with oil
tank below transmission could allow air to enter oil pump
under certain cir
lubrication and engine damage.
3. Apply assembly lube to oil pump driveshaft and driveshaft
bushing in crankcase. See Picture 10. Install oil pump in
normal fashion, placing pump drive gear #33-4230 over
driveshaft as shaft is passed through crankcase bushing.
cumstances, causing “air lock”, loss of
NOTE - S&S HVHP oil pumps offer more than one location for oil
supply fitting. Lowest fitting should not be used on models with
oil tank below transmission. S&S recommends stock placement
for oil supply fitting in Dyna™ and late FL models. See Picture 9.
Picture 8
Picture 9
Picture 10
5
Incorrect
correct
Picture 11
NOTE - A dab of Hylomar®or other thin gasket sealer in corners
may be used to hold gaskets in place. Otherwise gaskets should
be installed dry.
4. Install driveshaft gear key and snap ring.
NOTE - Be sure drive shaft key and snap ring are installed
properly
correctly, “sprung,” or otherwise damaged, snap ring may come
off or allow gear key to come out. See Pictures 11 & 12.
, paying particular attention to snap ring. If not installed
CAUTION
Loss of oil pump drive gear snap ring or key will result in
disengagement of oil pump causing loss of oil pr
extensive engine damage.
5. Loosely install two (2) each 1⁄4 -20 x 1-1⁄2” top oil pump bolts,
followed by pump cover and 4 each 1⁄4 -20 x 2-1⁄2” mounting
bolts. Do not tighten at this time.
While turning oil pump drive gear to check pump for
6.
binding, gradually tighten 4 - 2-1⁄2” bolts in an X-pattern to
final specifications of 120 in-lbs. See Picture 13. Carefully
tighten short bolts “by feel” with thin box end wrench, or
preferably with a torque adapter
7. Prime pump by removing oil pump check valve ball assembly
and injecting clean motor oil into pump supply fitting while
turning oil pump drive gear. (A large plastic squeeze bottle
works well for priming pump.) Replace check ball, spring,
and cap after oil fills check valve cavity.
, and tighten to 110 in-lbs.
essure and
Picture 12
INSTALL PINION GEAR, SPACER & NUT
1. With chamfer on oil pump drive gear facing in towards
shoulder on pinion shaft (See Picture 14), install oil pump
drive gear and key on pinion shaft, followed by drive
gear spacer
.
CAUTION
Installing gear backwards can result in a stress riser and cause
shaft to break.
®
2. Apply red Loctite
pinion gear, key and nut on pinion shaft and tighten nut to
50 ft-lbs. See Picture 15.
NOTE - Drive gear spacer will not completely fill space between
oil pump drive gear and pinion gear. A gap of up to .125” will
exist and is normal. Engine rotation keeps oil pump gear in place
during normal operation. Spacer prevents gear and key from
becoming disengaged if engine is rotated backwards.
#272 to pinion gear nut threads. Install
CAUTION
Installing pinion gear or nut without Loctite can cause
damage to shaft, nut, or other parts.
Picture 13
6
Picture 14
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