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Pinging or ignition knock is an early sign of detonation and
possible impending engine damage. Should pinging occur,
the throttle must be backed off and the cause determined and
corrected. Excessive retard is less obvious but equally
destructive. For that reason, final timing should be confirmed
with a timing light or other accepted procedure.

a.

Remove timing plug from left-side engine crankcase.

See Picture 40. 

b.

Install timing mark view plug into crankcase. 

See

Picture 41.

c.

Refer to service manual or instructions specific to the
ignition system being used. Find the RPM in which the
ignition “fully advances”.

d.

Attach inductive pick-up from timing light to spark
plug wire.

NOTE- If the timing light being used requires an external power
source, it is advised to use a separate, stand-alone battery.
Charging system pulsing may cause a fluctuation in the timing
light strobe if the motorcycle’s battery is used.

e.

Start motorcycle. Run the engine to the “full advance”
RPM of the ignition system and look for the timing
mark through the view plug. The front cylinder
advance mark on the flywheel 

(F/30)

should be seen

through the view plug. 

NOTE- With the front cylinder advance mark centered in the
timing hole at the full advance rpm of the ignition system, the
timing will be set at 30º.

f.

S&S

®

suggests the following timing specifications:

1.

111”- 32º

(Timing mark at the right-side, or towards

the rear, of the timing hole.)

2.

117”- 30º

(Timing mark in the center of the timing

hole.) 

3.

124”- 28º

(Timing mark at the left-side, or towards

the front, of the timing hole.)

Proper ignition timing is essential to safe engine operation.
Timing that’s too advanced will result in detonation and
engine damage. Timing that’s too retarded will result in
engine over-heating and engine damage. 

NOTE- If S&S determines that engine damage was caused by
improper ignition timing, repair will not be covered under
warranty.

g.

Reinstall the crankcase timing plug.

SUGGESTIONS

1.

V.O.E.S.

- S&S Cycle does suggest the ignition system selected

for use with this 4

1

8

" bore engine utilize the V.O.E.S. (Vacuum

Operated Electric Switch). Check the switch using a hand
vacuum pump with a gauge and set the switch to trip at 6 in.
of vacuum-Mercury. 

See Picture 28.

2.

OIL TEMPERATURE -

Operating temperature for engine oil

should be between 180º - 240º F. If engine oil temperature
stays above 240º, and correct ignition timing has been
verified, S&S Cycle suggests that an oil cooler be installed.

19

CAUTION

CAUTION

S&S

®

Recommended Regular Service Intervals 

Item

Interval

Engine Oil & Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Change at 50, 500, 2,500 miles, every 2,500 miles thereafter. 

1

Air Cleaner   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspect at 50 and 500 miles, every 2,500 miles thereafter. Replace every 5,000 miles.

2

Tappet Oil Screen  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspect at 50 and 500 miles, every 2,500 miles thereafter. 
Petcock, Lines, & Fittings, Vacuum Lines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspect at 50 and 500 miles, every 2,500 miles thereafter. 
Fuel Tank Filter Screen & In-Line Fuel Filter (If used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Every 5,000 miles. 
Engine Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust as required. 
Operation of Throttle & Enrichment Device Controls  . . . . . . . . . .Inspect & lubricate throttle cables at 500 miles and every 2,500 miles    

thereafter. 

Spark Plugs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspect every 5,000 miles.  Replace every 10,000 miles or as needed. 
Ignition Timing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspect every 5,000 miles. 
Engine Mounts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspect every 500 miles and every 5,000 miles thereafter.
External Fasteners Except Engine Head Bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . .Re-torque at 500 miles and every 5,000 miles thereafter. 

1

S&S recommends that petroleum-based oil not specifically formulated for air-cooled motorcycles should be changed every
1,000 miles.

2

Replace more frequently if required or if engine is operated in a dusty environment.

Summary of Contents for V series

Page 1: ...nd 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 t...

Page 2: ...e 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 ASSEMBLY NOTE While S S has made every effort to insure that parts are correct it is the engine builder s responsibility to c...

Page 3: ...ract pinion shaft bearing surface diameter from 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 Pinio...

Page 4: ...p on the other Install snap ring with sharp edge out away from flywheels ASSEMBLE CRANKCASE HALVES 1 Noting solvent precautions on page 1 wipe down mating surfaces of crankcase halves with lacquer thinner Remove 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...

Page 5: ...stalled 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 freely Problem can usually be corrected by rotating gear 180 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 transmissi...

Page 6: ...110 in lbs 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 INSTALL PINION GEAR SPACER NUT 1 With chamfer on oil pump drive gear facing in towards shoulder on pinion shaft ...

Page 7: ...ty inside engine and coat of motor oil to cam lobes 3 Place camshaft lockwasher in case with ears down and flat edge towards rear of engine See Picture 16 4 Install thrust washer over end of cam and place assembly in engine During installation rotate engine so marks on cam gear and pinion gear align Second mark on cam gear must be at eight o clock position 5 Install breather gear and shim aligning...

Page 8: ...d with anti seize thread sealant or PTFE plumber s tape before installation in crankcase See Picture 20 NOTE Unused vent hole must be plugged with 51 8330 1 4 18 NPT pipe plug 2 Install length of hose on above elbow Check the orientation of the one way check valve Install the check valve onto length of hose so that it will allow passage of air out of engine but not back in NOTE Proper direction ca...

Page 9: ...pplied with kit prepare gaskets with Gasgacinch sealant before installation Refer to manufacturer s instructions for proper application of sealant and recommended set up times 2 Before installing heads spin each head bolt down on its respective stud to be sure threads are clean and free of contamination Place a drop or two of oil on threads and under head of each head bolt just prior to final asse...

Page 10: ... loosen screws and reposition housing to increase clearance then retighten screws 5 Place O ring in center of rocker housing 6 Repeat above procedure for other cylinder head Operating engine without sufficient clearance between valve spring and rocker cover will cause engine damage not covered under warranty ROCKER ARM PUSHROD INSTALLATION AND ADJUSTMENT NOTE S S pushrods are designed with emphasi...

Page 11: ...sh rods NOTE Upon initial start up after modification HL2T equipped lifters may be somewhat noisy for 10 20 miles 9 Install upper rocker cover gasket and O ring on rocker housing 10 Install one flat and one rubber washer on each of six 1 4 20 x 3 4 rocker cover screws Tighten screws to 120 in lbs 11 Extend pushrod tubes and install pushrod cover retainer clips 12 Rotate flywheels until rear piston...

Page 12: ...ection of the appropriate service manual Install the inner primary chaincase to the transmission and engine crankcase Make certain to use a new engine to primary O ring and lock tabs or safety wire on the inner chaincase fasteners Failure to use new lock tabs or safety wire on inner primary chaincase mounting hardware may result in the fasteners backing out and possible damage to the primary drive...

Page 13: ...lugs Electronic ignitions generally require a plug gap of between 038 043 b Apply an anti seize lubricant to spark plug threads install and torque to 11 18 ft lbs 4 Install and connect the ignition coil COMPRESSION RELEASES 1 Refer to included S S Instruction Sheet 51 1065 or 51 1115 for wiring cable routing of compression release mechanism if applicable EXHAUST SYSTEM 1 Install new woven metal ga...

Page 14: ... 4 Repeat step 2 for closing side throttle cable Closing side cable has a spring around inner cable wire See Picture 31 c Install carb on manifold 1 Bolt carb and insulator block to intake manifold using two 3 8 16 socket cap screws provided in kit O ring side of block faces manifold Tighten to 18 ft lbs NOTE If insulator block is not installed manifold bolts supplied in kit will be too long and m...

Page 15: ...h Connect vacuum hose from V O E S and or fuel petcock to vent fitting on top of carburetor intake manifold if applicable e Install and adjust cruise control cable if applicable Refer to the appropriate service manual for proper procedure 2 AIR CLEANER ASSEMBLY INSTALLATION a Prepare air cleaner backplate NOTE Fast idle lever screws part 11 2384 must not be over tightened Loctite or other thread l...

Page 16: ...n advance connections if applicable 6 Check crankcase to backplate vent hose connections 7 Check vent hose connection from front cylinder head to intake manifold 8 Check fuel overflow hose routing Avoid hot surfaces 9 Test throttle to be sure it opens and closes freely Turn handlebars to extreme left and open and close throttle then turn bars to extreme right and check throttle When released throt...

Page 17: ...t were removed or disassembled for installation Consult authorized Harley Davidson service manual for installation procedure for stock parts not covered in S S instructions c Check fuel needle and seat assembly Fill gas tank with just enough fuel to test system Lean motorcycle over towards carburetor side turn on fuel petcock and wait 20 seconds If gas runs out end of carb or out overflow hose tur...

Page 18: ... temperature for the final time you are ready to start the 1000 mile engine break in process ENGINE TUNING 1 Carburetor a Refer to Instruction Sheet 51 1012 Installation and Jetting Instructions for S S Super E and G Series Shorty Carburetors for initial set up and adjustment of the carburetor 2 Ignition Timing NOTE S S recommends using electronic ignition with adjustable advance curve in 41 8 bor...

Page 19: ...rded will result in engine over heating and engine damage NOTE If S S determines that engine damage was caused by improper ignition timing repair will not be covered under warranty g Reinstall the crankcase timing plug SUGGESTIONS 1 V O E S S S Cycle does suggest the ignition system selected for use with this 41 8 bore engine utilize the V O E S Vacuum Operated Electric Switch Check the switch usi...

Page 20: ... Lifters Specification Service Wear Limit Lifter Fit in Guide Loose 0006 0017 003 Connecting Rods Specification S S Suggestions Pinion Gear Nut 50 Ft Lbs Loctite 272 Rocker Box Hardware 1 4 120 in Lbs Loctite 243 Rocker Box Hardware 5 16 18 Ft Lbs Loctite 243 Tappet Guide Fasteners 120 in Lbs Loctite 243 Pushrod Locknuts 120 in Lbs Cylinder Head Bolts See Chart on Page 9 Crankcase Fasteners 1 4 12...

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