NOTE: We normally take three cuts to bore cases, 3.800"
diameter, 3.850" and final size 3.879". If you machine into boring
plate on final cut, this is of no consequence since hole in plate is
never used as machining reference point.
H. Repeat steps E to G for other spigot bore.
I. Deburr and remove any nubs or protrusions which could
accidentally br
eak off. Break the corner on outside of
spigot holes with a deburring tool. This insures that
cylinder will not hang up during installation causing oil
leaks due to inadequate gasket compression.
Figure 1
shows an exaggerated view.
5. Modify Crankcases for Oil Returning from Heads
NOTE: Oil return passageways in Sidewinder
®
cylinders are
moved out slightly compared with stock oil return holes to
accommodate 3
5
⁄8" bore. This creates misalignment between
cylinder oil return passage and crankcase oil return passage.
To modify cases and return oil properly, perform
following steps:
A. Place cylinder base gasket on cases and note amount
and direction of return hole mismatch.
B. Chamfer edge of hole accordingly at minimum of 45°
angle to insure adequate flow.
See Pictures 5 and 6.
6.
Convert Pinion Main Bearing
To 1987 & Later Style (1986 crankcases only)
A. Remove stock Torrington
®
style pinion needle
bearing assembly. Follow procedures outlined in
1986 Harley-Davidson
®
service manual for r
emoval.
B. Install 1987 and later style pinion bearing race H-D
®
#8881. Follow procedures outlined in 1987 and later
Harley-Davidson
®
service manual.
C
. Lap bearing race and fit bearings per procedures
outlined in 1987 and later Harley-Davidson
®
service
manual.
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
a
re equivalent to the corresponding Harley-Davidson
®
p
art
number shown.
7. Connecting Rod Preparation (79" kits only)
NOTE: If S&S
®
connecting rods are used, follow instructions that
accompany rods since rod preparation below has already been
d
one. Stock rods can not be used with Sidewinder kits larger
than 79". Longer than stock S&S connecting rods will be
provided with all kits larger than 79".
79" kit 91-3002 only - If S&S rods are not used, perform
following steps:
A. To insure adequate oil on sides of rods and matching
thrust surfaces of flywheels, S&S recommends that four
grooves be ground on each side of both front and rear
connecting rods.
See Figure 2. Make these grooves
.020" to .030" deep and .030" to .040" wide and should
be ground 90° from each other. After making grooves,
remove all sharp edges and burrs with emery cloth.
B. Thoroughly clean all parts to remove dirt, filings, etc.
Burrs, dirt, filings, etc. left on connecting rod components
may circulate in oil damaging other parts possibly causing
engine failure.
5
Figure 1
Picture 5
Pictur
e 6
CAUTION
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