- S&S Cycle
Contents
1. Instruction 51 1142 5 5 06 Copyright 2002 2005 2006 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tac 235 Causeway Blvd La Crosse Wisconsin 54603 Phone 608 627 1497 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Website www sscycle com Fax 608 627 1488 Because every industry has a leader Installation Instructions S amp S Rocker Arm Rebuild Kit for 1984 Up Big Twin and 1986 up Harley Davidson Sportster Models DISCLAIMER S amp S parts are designed for high performance off road racing applications and are intended for the very experienced rider only The installation of S amp 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 refere2. S amp S parts are designed exclusively for use in Harley Davidson and other American v twin motorcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application INTRODUCTION S amp S rocker arm rebuild kit will rebuild a complete set of S amp S rocker arms for 1984 up big twin and 1986 up Harley Davidson Sportster models The bushings in this kit also fit stock Harley Davidson rocker arms but they are not a direct replacement for stock bushings S amp S rocker arm bushings are wider than stock KIT CONTENTS 8 Bushings 4 Rollers 4 Pins 10 Retaining Clips Two extra clips included INSTALLATION A Remove install and machine bushings NOTE Rocker arm service tools including bushing pullers and installers are available from specialty tool suppliers They should be used according to the manufacturers instructions NOTE The instructions S amp S provides are for the experienced mechanic with access to an arbor press and bench vise for the removal and installation operations Important Read before bushing removal Bushings must be finish machined after installation The method used to finish size the rocker arm ID determines the order of disassembly assembly If using a line hone to finish size the bushings remove and install bushings on both sides of rocker per bushing removal and installation instructions below then finish machine both bushings at th
3. atigue 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 IMPORTANT NOTICE Statements in this instruction sheet preceded by the following words are of special significance A WARNING Means there is the possibility of injury to yourself or others A 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 amp S recommends you take special notice of these items WARRANTY All S amp 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 amp 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 amp S immediately with the problem Some problems can be recti
4. e same time using the appropriate sized hone If using a reamer H D 94804 57 or equivalent to finish size the bushings remove and install bushing on one side only per bushing removal and installation instructions below then ream to size using the bushing on the other end to align the reamer NOTE Some aftermarket reamers allow both new bushings to be reamed at the same time If using an aftermarket reamer follow manufacturer s instructions NOTE All reference to Harley Davidson part numbers is for identification purposes only We in no way are implying that any of S amp S Cycle s products are original equipment parts or that they are equivalent to the corresponding Harley Davidson part number shown 1 Bushing removal a Remove old bushing using an arbor press Turn a 18 tap into the bushing Press out the bushing and tap from opposite side of rocker arm See Picture 1 Picture 1 2 Bushing installation and machining NOTE use assembly lube on bushing and rocker arm bore during the press procedure a One end of each bushing has a lead in chamfer Position new bushing with chamfered end to bore of rocker arm Align rocker arm and bushing in arbor press then press in the bushing so the outside edge of the bushing is 005 015 recessed into the end of the rocker arm A socket with a slightly smaller O D than the bushing will work as a driver See Picture 2 R Picture 2 b Finish machine
5. fied 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 amp S If it is deemed necessary for S amp S to make an evaluation to determine whether the part was defective a return authorization number must be obtained from S amp S The parts must be packaged properly so as to not cause further damage and be returned prepaid to S amp 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 amp S and the part was found to be defective repair replacement or refund will be granted ADDITIONAL WARRANTY PROVISIONS 1 S amp S shall have no obligation in the event an S amp S part is modified by any other person or organization 2 S amp S shall have no obligation if an S amp 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 amp S part 3 S amp S shall not be liable for any consequential or incidental damages resulting from the failure of an S amp 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 amp S and a customer 4
6. nce only S amp S Cycle is not associated with Harley Davidson Inc SAFE INSTALLATION AND OPERATION RULES Before installing your new S amp 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 amp 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 amp 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 f
7. to 5546 5559 per the honing reaming notes at the beginning of these instructions c Wash rocker arms clean of all machining residue B Remove and install retaining clips pin and roller NOTE Pin is a press fit in rocker arm 1 Pin and roller disassembly a Remove outer retaining clip by grinding end of pin flush to the retaining ring NOTE Use care not to nick rocker arm with grinding wheel A nick could cause a stress riser leading to rocker arm failure b Press old pin from rocker to remove roller 2 Pin and roller assembly a Position new roller in fork of rocker b Press new pin into place using arbor press or bench vise See Picture 3 Picture 3 c Press retaining clip over end of pin and into grooves A small socket will work as an installation tool One side of clip has a slightly rounded inside edge Locate the rounded edge facing down towards pin Align components carefully in vise jaws before pressing retaining clip squarely onto end of pin See Picture 4 NOTE Clips are very brittle Do not force clip over pin or press on at an angle Do not use a clip damaged in the installation process Picture 4 d Roller should move freely on pin after clips are installed NOTE Apply assembly lube to bushings pins and rollers before installing rockers Because every industry has a leader
Download Pdf Manuals
Related Search