S&S Cycle V series Assembly And Installation Manual Download

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Specifications for 4

⁄

” Bore Engines

Displacement

Bore

Stroke

Compression Ratio

111”

⁄

”

⁄

”

9.7:1

117”

⁄

”

⁄

”

10.2:1

124”

⁄

”

⁄

”

10.8:1

Cylinder Heads

Specification

Valve Guide in Head (tight)

.0015” - .003”

Valve Seat in Head (tight)

.005” - .0075”

Crankcase

Specification

Service Wear Limit

Timkin

Race in Case (tight)

.001” - .003”

less than .0025”

Pinion Race in Case (tight)

.001” - .003”

less than .0025”

Valves (Fit in Guide)

Specification

Service Wear Limit

Intake

.0012” - .0015”

.0025”

Exhaust

.0018” - .0023”

.0035”

Seat Width

.040” - .062”

Stem Protrusion

2.045” - 2.060”

2.080”

Flywheels

Specification

Service Wear Limit

Runout (Shaft at Flywheel)

.0005” - .001”

.003”

End Play

.001” - .005”

exceeds .005”

Pinion Bearing Fitment

.0004 - .001”

.002”

Rocker Arms

Specification

Service Wear Limit

Shaft Fit in Bushing (Loose)

.0007” - .0018”

.0035”

Bushing Fit in Rocker

Arm (Tight)

.002” - .004”

Connecting Rods

Specification

Service Wear Limit

Crankpin Bearing

Running Clearance

.001” - .0012”

.002”

Piston Pin Fitment in Red

.0005” - .001”

.002”

Connecting Rod Side-play

.015 - .035”

.040”

Hydraulic 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

⁄

”

120 in.-Lbs

Loctite

243

Rocker Box Hardware

⁄

”

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

⁄

”

120 in.-Lbs

Crankcase Fasteners

⁄

”

15 Ft.-Lbs

Gearcover Fasteners

120 in.-Lbs

Loctite

243

Intake Manifold-to-Head

16 Ft.-Lbs

Loctite

243

Intake Manifold-to-Carb

18 Ft.-Lbs

Loctite

243

Exhaust Flange-to-Head

60-80 in.-Lbs

Anti-seize

Tappet Screen Plug

120 in.-Lbs

Timing Hole Plug

120 in.-Lbs

Spark Plug

11-18 Ft.-Lbs

Anti-seize

Cylinder Studs

10 Ft.-Lbs

Loctite

262

Pistons

Specification

Service Wear Limit

Fit in cylinder

.002” - .0025”

.005”

End Gaps: Top Two

Compression

.017” - .025”

.028”

Oil Control Rails

.015 - .035”

.050”

Gearcase

Specification

Service Wear Limit

Breather Gear End-play

.005” - .015”

Breather Gear Running

Clearance

.0015” - .0025”

.004”

Camshaft in Bushing

.0007 - .002”

.003”

Camshaft End-play

.005” - .015”

Pinion Shaft in Bushing

.001” - .0025”

Bushing Fit in

Gearcase (Tight)

.002” - .004”

Oil Pump Shaft Clearance

.0007” - .0023

.0035”

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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