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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

Because every industry has a leader

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 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 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, 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.

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.

Assembly and Installation Instructions: 

S&S

®

4

1

8

” Bore V-Series Engines

Instruction 51-1124

5-11-06

Copyright

©

2002, 2006

by S&S Cycle, Inc.

All rights reserved. 

Printed in the U.S.A.

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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