Ss-worldwide Motorcycle Accessories User Manual download pdf

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: [email protected]

Website: www.sscycle.com

Because every industry has a leader

Installation Instructions: S&S

Sidewinder

⁄8" Big Bore Cylinders

for Harley-Davidson

Sportster

Models – 1986 and Later

nstruction 51-1030

4-27-06

1986, 1995, 2006

by S&S Cycle, Inc.

ll rights reserved.

rinted in the U.S.A.

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 instr

uctions 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 per

for

ming installation and operating

motorcycle. Good judgement begins with a clear head. Don't let

alcohol, dr

ugs 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.

ARNING

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 par

t that is suspect of being defective must not be r

eplaced 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 par

t 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 par

t is modified by

any other person or or

ganization.

(2) S&S shall have no obligation if an S&S par

t becomes defective in

whole or in par

t as a r

esult 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 par

ts ar

e designed exclusively for use in Harley-Davidson

and

other American v-twin motor

cycles. S&S shall have no war

ranty or

liability obligation if an S&S part is used in any other application.

1 2 3 4 5 6 ... 15 16

Cycle, Inc 1

Summary of Contents

Page 1 - Cycle, Inc

S&S®Cycle, Inc.235 Causeway Blvd.La Crosse, Wisconsin 54603Phone: 608-627-1497 • Fax: 608-627-1488Technical Service Phone: 608-627-TECH (832

Page 2

2. Rotate flywheels in opposite direction untilchecking pin contacts cylinder gasket surface again.Repeat procedure to rod again. If drag on papers i

Page 3

12. Piston to Head & Piston to Valve ClearancingNOTES:● The clearancing operations described in this section can bedone simultaneously as the same

Page 4

8. Assemble cylinder heads and bolt assemblies oncylinders with head gaskets in place. Installpushrods and adjust to simulate final assembly. NOTE:

Page 5

G. Finish Assembling Top End1. Install rocker arm bases per Harley-Davidson®specs. 2. 1991 and later five speed models only - Stock onepiece pushrod

Page 6

J. Reassemble gas tanks and all other parts that weredissembled during preparation for top end service. Besure there are no gasoline leaks and that t

Page 7

Carburetion ● All S&S®test engines are run using S&S carburetors. S&SSuper E and G carburetors are recommended for mostapplications with

Page 8

Because every industry has a leader

Page 9

INTRODUCTIONInstallation of an S&S®Harley-Davidson®Sportster®model 35⁄8"bore stroker Sidewinder®Kit is easy and can be performed byany Harley

Page 10

B. Refer to chart 1to determine increase over stock engineheight for the kit to be installed. S&S®recommends .100"minimum clearance between e

Page 11

4. Bore CrankcasesNOTE: Boring cylinder spigot holes in cases to accommodate bigbore cylinders will machine a notch on center case bolt. This boltmus

Page 12

NOTE: We normally take three cuts to bore cases, 3.800"diameter, 3.850" and final size 3.879". If you machine into boringplate on fina

Page 13

8. Lower End Assembly (All)NOTES:● All current production S&S®Evolution®Sportster®modelflywheels are made from closed die, heat treated, steelforg

Page 14

D. With key in shaft, insert into respective tapered hole inflywheel and check to see that key does not bottom ingroove. If key bottoms out, file fla

Page 15

9. Crankcase and Piston Skirt Clearancing (All) NOTE: Many of the clearancing operations described in thissection can be done simultaneously as the s

Page 16

2. Piston to Flywheel Clearancea. Perform Steps 1 through 3 in Connecting RodClearance (Step A). b. Rotate flywheel to position where frontpiston is

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Ss-worldwide Motorcycle Accessories User Manual

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