Installation Instructions
Contents
1. 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 17 Continued Replacement Parts for S amp S Crankcases for Harley Davidson Sportster Models and Buell 14 Washer flat See Bolt Position Diagram below 24 Bearing transmission countershaft LH H D 8998 cc ssessssecsseesseesseessseen 56 3026 Position A J K 25 Ring transmission countershaft bearing retainer H D 35021 89 50 8053 Vio MATA ROO ian e cathe veceScsulat estan vacdaeobeieesdedethebentatetaivn tocsaeee 50 7020 26 Bearing transmission mainshaft LH H D 35030 89 essecssesseesesseesees 56 3027 Position B C D N amp Tappet guide 27 Ring transmission mainshaft bearing retainer H D 35038 89 00e 50 8052 DIG Ns DAO MAG E E E A N E Senaastes 50 7025 28 O ring 32mm x 1 5mm CS Shifter drum bushing sssssssssssssrssssssssssessesesreses 50 8007 Position E F G H 29 Bushing shifter drum unfinished H D 9187 cssssscssesseesssesseecseerseeeseeen 56 3030 Me Wie 6 HD 0 107 D sranane nenna teemeoren anaeentietocete 50 7033 30 Screw HHC 346 18 x 14 H D 2871 W o sesssecssesssesseessecssesssesssesseceseceseesseesees 50 0110 Position L M 31 Lock nut hex 14 28 H D 7683 ccsccsscasasicsasavssedc2. measured at room temperature approximately 70 F Failure to establish correct bearing clearance can result in extensive engine damage not covered under warranty 1 Refer to information tag on crankcase to determine inside diameter of pinion shaft main bearing race 2 Measure bearing surface diameter of pinion shaft 3 Cross reference pinion race inside diameter with pinion shaft bearing surface o d to find correct color code See Chart 1 below Pinion Pinion Shaft Main Bearing Color Race I D Color Code for Sportster Models 1 5656 to 1 5658 1 5654 to 1 5656 1 5652 to Blue White 1 5654 1 5650 to Blue White Green 1 5652 1 5648 to Blue White Green 1 5650 1 5646 to White Green 1 5648 Pinion 1 2496 to 1 2498 to 1 2500 to 1 2502 to Shaft O D 1 2498 1 2500 1 2502 1 2504 Chart 1 EXAMPLE Pinion shaft bearing surface O D measures 1 2499 Number is between 1 2498 and 1 2500 in Pinion Shaft O D row Pinion race I D is 1 5651 and falls between 1 5650 and 1 5652 in Pinion Race I D column Correct bearing color code where two columns intersect is BLUE Selecting color where columns intersect provides proper fit for regular service If looser fit is desired select bearing color directly to right of color indicated by normal selection process If color indicated from selection process is located in column on extreme right go to row directly below and select color in column on extreme left B Establish Cr
3. 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 S amp S parts are designed exclusi
4. to other engine components Insufficient thread engagement between stud and base nut or stud and crankcase could result in thread failure and major engine damage e When using flanged or shovelhead cylinders cylinder base studs must be long enough to provide adequate thread engagement for nuts It is engine builder s responsibility to verify thread engagement Longer studs must be installed if thread engagement is insufficient Failure of cylinder studs could cause violent engine disintegration under power resulting in possible loss of control of motorcycle with subsequent injury to operator and others 6 Crankcase Flywheel Assembly NOTE Review Section 2 Clearance Frame before proceeding A Fit Pinion Bearing Stock Harley Davidson procedures and specifications for 1987 and later engines should be used to fit pinion main bearing However type of intended service must be taken into consideration Engine that will receive recommended break in and is intended for regular service may have bearing fit on tight side of range for longer engine life Race engines that will receive little or no break in require looser fit to avoid bearing seizure NOTE Bearings included with S amp S crankcases for Sportster models have been fit to tight side of clearance range It is engine builder s responsibility to substitute bearing of different size to provide clearance appropriate for intended use if necessary For correct clearance parts must be
5. 26 Bearing trans countershaft LH H D 8998 56 3027 Bearing trans mainshaft LH H D 35030 89 50 8052 Snap ring int ret Tru arc trans mainshaft bearing H D 35038 89 50 8053 Snap ring int ret Tru arc trans idler shaft bearing H D 35021 89 50 0110 Screw 16 18 x 1 HHC hex head cap H D 2871W 50 0102 Screw 6 18 x 4 HHC positions E F G H S amp S xl crankcases H D 4100HW Qty 4 50 7033 Washer flat 316 x 16 x 1 8 steel H D 6107B Qty 5 31 1000HC hardware package includes 31 2005 Plug timing hole H D 720 Qty 2 50 0004 Screw stator mounting 10 24 x 1 H D 2720 Qty 4 50 0023 Screw stator wire cover 10 24 x Qty 2 31 2050 Cover stator wire 50 0044 Stator screw 10 24 x 1 50 8112 45 deg 1s NPT fitting 50 5119 90 deg 1s NPT fitting 31 1000HB Hardware package xl case w trans includes 50 7021 Washer 44 flat Qty 2 50 5010 Nut HH lock 4 28 Qty 2 50 8115 Fitting hose 1 27 pipe Qty 2 50 0014 Screw 14 20 x Y2 HHC 50 7018 Washer flat copper 106 3134 Oil Filter Mount Kit 106 2682 90 Pipe Fittings 27 NPT Qty 2 106 4423 Oil Filter Mount Gasket 106 4427 Oil Filter Mount 50 8110 90 Brass Fitting 50 8112 45 27 NPT Fitting Qty 2 50 8115 Straight 1 27 Fitting Qty 2 Following parts are also provided 8 Studs cylinder mounting Part depends on cylinder type and length 31 1000BA Bolts S amp S xl crankcase one set 56
6. 3029 Seal oil trans output shaft belt drive H D 12050 33 2329 Pinion shaft S amp S special xl 31 4057 Bearing assembly right main H D 24659 87 31 4060 Seal left main bearing H D 35151 74 OR 31 4010 Seal left main bearing for 1970 up big twin sprocket shaft mainshaft spec order crankcase only 31 4059 Bearing assembly Timken sprocket shaft main less races installed by S amp S OR 31 4013 Bearing assembly Timken sprocket shaft main H D 9028 for 1955 65 big twin mainshaft spec order crankcase only 56 3028 Bearing trans output shaft H D 8996 2 Installation instructions Certificate of origin Optional 31 2055X Cover assembly transmission inspection includes 31 2055 Cover trans inspection hole S amp S xl cases 50 8081 Stud 6 24 x 1 370 xl trans inspection hole door Qty 8 50 7034 Washer flat 546 x 16 x Ye steel H D 6702 Qty 8 50 5023 Nut hex 6 24 H D 7833 Qty 8 Other additional hardware may be included depending upon individual order INTRODUCTION S amp S Crankcases for Harley Davidson Sportster motorcycles require minimum preparation Because of their many special features and requirements it is recommended that a skilled engine builder having considerable experience with Sportster models and high performance engines assemble them It is also recommended that the engine be mocked up and installed in the chassis to check exterior clearances before final
7. 51 44 Bearing transmission output shaft H D 8996 ou sessssssesseccssessesssecseesseen 56 3028 45 Bearing transmission countershaft RH H D 8977 cssecssessssessesssesseesseen 56 3031 46 Nut press in 38 24 H D 16240 82 c cssssssssssssesssssssssesssseescsessecsscsscsseeees 31 2048 47 Cover transmission inspection window S amp S SA ssssessesseessssessecscsesssesseseseeeenes 31 2055 48 Stud 6 18 Ae 24 x 1 370 S amp S SA essesssesssessssssesssscssscsssssscsssesssessessecesseessen 50 8081 49 Washer flat 346 x 16 x 146 H D 6016 6702 seecsecsecssessesscssesseessesseesees 50 7034 50 Nut hex 6 24 H D 7833 farses nieces ace nenieliasela aali des 50 5023 51 Nut hex 14 28 H D 7675 7676 cssssscsscescssccsscsscssesssssscsscsscssesssessceseeses 50 5011 52 Nut NOM e 24 H D 7861 ccvsts coccacee ei eres salles eiced avenge casa neaelgeneiee 50 5037 53 Hydraulic tappet assembly WO BG 90 tattle ascent anon A E E T ETSE 33 5352 Bolt Position Diagram POO POO es rst os att ne E Necsticy fa caper A eases An N A 54 45 hose fitting 14 pipe male female Oil pump N S c sesssessesseessecseesees 50 8112 All reference to Harley Davidson part numbers is for identification 55 ed 3 A GS eee men en Ren 50 0319 purposes only We in no way are implying that any of S amp S Cycle s Bs Ab Ks ob SIUM eck esse aa a oa a le can cola lata ae 50 7044 products a
8. Incorrect placement of oil lines or oil line fittings can cause extensive engine damage not covered under warranty K If present connect pressure switch wire and tighten nut L Replace any engine oil that was drained during installation M Install new oil filter by placing a small coating of oil over the rubber seal and thread the filter onto the filter adapter nut until sung Rotate the filter an additional to 1 2 turns 9 Install Pinion Gear and Camshafts A Install oil pump drive gear onto the pinion shaft A CAUTION Failure to use thread lock compound may cause inaccurate torque readings and allow parts to loosen in use resulting in extensive engine damage B Install pinion gear insuring that mark on rear of gear aligns with corresponding mark on pinion shaft See circled areas of Picture 14 below Picture 13 Picture 14 12 C Apply Loctite 271 red or equivalent to threads then install lockwasher pinion nut and tighten to 35 ft lbs Secure lockwasher by bending tabs over flats of pinion nut See Picture 15 below Picture 15 NOTE 1986 90 four speed cams require 1986 90 gearcase cover Harley Davidson part 25219 86 1991 03 cams require 1991 03 gearcase cover H D part 25219 91A which must also be used with S amp S gearcase cover gasket 31 2052 Cover 25219 91B is not compatible with S amp S Crankcase for Sportster models S amp S offers billet cam cover kits for 1986 90 and 1991 03 st
9. Instruction 51 1050 02 12 03 Copyright 2009 2013 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tue 14025 Cty Hwy G PO Box 215 Viola Wisconsin 54664 Phone 608 627 1497 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Fax 608 627 1488 Website www sscycle com Installation Instructions S amp S Special Application and 3 2 amp 35 Bore Crankcases for 1991 03 Harley Davidson Sportster Models and 1994 03 Buell Models DISCLAIMER S amp S parts are designed for high performance closed course racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely affect 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 u
10. Mall sccsssstcsaiectesestasess esanictsbanabettedeisiatastthenstotenceeamaiteninnitine N A 10 Screw SHC A6 18 x 1 H D 270BA sssssssssccsscssscascsnscsnscesscnsecnseanseaneesseens 50 0101 Race right main bearing Standard H D 8881 secsscssssssssessssersessseseeeees 31 4050 11 O ring Pinion shaft assembly SA sssssscssscssssssssssssesssssssscsessssssscsescsssesseessesseesneessess 33 2329 1 1 D x 1346 0 D x 342 CS upper H D 11167A eecesecsesesesessesseeseeeeees 50 8004 SO SS UD ELSEOCK CASES roan a ia 33 2325 1 1 D x 1 0 D x 46 CS lower H D 11168A we eeesesesesesesseeseeseeeeees 50 8005 Right main bearing assembly 3 1 D x V2 0 D x Ve CS oil hole H D 11110 we eeeseessesseeseessseseeseens 50 8006 BIU 4 HD 24647 87 rerai iN 31 4055 12 Cylinder stud 1991 up xl H D 16832 86A secssessecssssscsecseesessecssseseeeseens 31 2331 Red ESD 2465087 pinsaia a a a 31 4056 S amp S Super Stock H D 16837 850 ssssssssesssssssseesssssnsssssssreeesensssssssssseeeeee 31 2321 White H D 24659 87 ccsisscctsesssssccasscuahecahoesta diaustatevaclanduehocarsactuctenassacbuteease 31 4057 Standard S amp S SA H D 16837 78 cssssscsscsssssscsscsscssssescsssssecsscsscsessssesseeeees 31 2322 Green H D 24660 87 sssssseessssssseessnsssseesessnsseseesonsssseesensssseseeosssssseeseonssseeeee 31 4058 kie WONG Cl S501 5 SA nainen via ceatea aia ole a itcataa ca
11. and sprocket shaft bearing surface Install bearing on shaft with appropriate tool Lubricate pinion bearing and pinion shaft bearing boss with petroleum jelly Install bearing on shaft and secure with pinion shaft main bearing snap ring Pinion and sprocket shaft bearings supplied should be correct sizes but it is engine builder s responsibility to confirm flywheel endplay connecting rod sideplay bearing fit and all clearances at time of assembly It is of particular importance to check flywheel endplay and install different Timken bearing spacer if necessary Refer to Harley Davidson Service Manual for detailed explanation of required procedure Harley Davidson has used different style pinion bearings in various models some requiring different snap rings Snap ring supplied by S amp S or identical replacement must be used with pinion bearing supplied by S amp S Ends of snap ring are rounded on one side sharp on other Install snap ring with sharp edge out away from flywheels D Check Clearances With left crankcase mounted securely on engine stand and pinion shaft well supported temporarily install cylinders and pistons without rings Rotate flywheel assembly several revolutions and check following clearances 1 2 3 4 Connecting rod to crankcase Piston to piston Piston to flywheel Connecting rod to cylinder spigot NOTE S amp S recommends at least 060 clearance between parts mentioned Remove minimum amount
12. ankshaft Endplay S amp S recommends using dummy sprocket shaft a few thousandths smaller in diameter than standard shaft when possible to establish crankshaft endplay This eliminates need to press flywheel assembly out of case if end play must be adjusted Proper flywheel endplay is 001 to 005 Sprocketshaft bearings must be preloaded to obtain an accurate endplay reading NOTE Crankshaft endplay must be confirmed prior to permanent installation of flywheels Bearings and race must be clean and oil free when endplay is checked Bearing spacer other than one provided may be required for correct endplay It is engine builder s responsibility to establish correct endplay Picture 4 C Install Flywheel Assembly 1 Thoroughly clean all parts Apply coat of assembly lube to bearing surface of sprocket shaft and inner race of Timken bearing Install bearing on shaft with appropriate tool See Picture 4 above NOTE S amp S does not recommend using press to install sprocket shaft bearings as this can push flywheels out of true Preferred bearing installation tools are available from Harley Davidson and other sources ot ee hy NOTES Apply coat of petroleum jelly to Timken bearing installed in Step 1 Place left side crankcase half on engine stand and place flywheel assembly in case Install Timken bearing spacer Lubricate rollers of remaining Timken bearing with petroleum jelly Apply assembly lube to bearing inner race
13. assembly of the engine and motorcycle S amp S produces crankcases to fit 1986 03 Sportster Models There are a wide range of variations offered plus custom special order configurations These variations can be split in to some common groups Early 1986 90 4 speed chassis and Late 1991 03 5 speed chassis are designations used to describe which valvetrain configuration the cases are machined for So you may see parts marked as early 4 or 4 speed Any of these descriptions would describe cases lifters lifter blocks or heads for early 1986 90 4 speed pushrod geometry Another variation in pushrod geometry is the difference between stock and Special application SA cases S amp S Special application cases use a 5 longer than stock pinion shaft This requires different cylinder head pushrod tube machining and unique lifter blocks Stock geometry heads and lifter blocks will be identified by ST SA cases will require parts marked with SS or SA Heads cams cam covers tappets cases and tappet blocks from different groups should not be mixed and matched Also S amp S does not produce lifter blocks that allow the use of 2000 up lifters If S amp S cases are being used in 2000 to 2003 applications use 1991 1999 lifters and lifter blocks Read all instructions thoroughly When they are completely understood proceed with assembly and installation NOTE Because of the additional width of S amp S SA crankcases an
14. case and belt or chain may result in accelerated wear and damage to components involved Air lock or cavitation can occur if trapped air is not released from the oil pump It can occur when oil has been removed from feed and return lines and interferes with oil circulation It is installer s responsibility to remove trapped air by priming the pump prior to running the engine and to confirm correct pump operation with engine running Models with oil tank below transmission require precautions to prevent air from entering oil pump during oil changes 15 H If necessary re prime oil pump by loosening the oil feed connection at the pump and starting the engine at idle Allow a few ounces of oil to leak out of the line and then tighten l Turn off engine and check oil for correct level in tank J Restart engine and check for leaks tighten fittings or clamps if necessary NOTE Oil circulation must be confirmed after initial start up This can be accomplished by removing oil tank cap to observe oil returning to tank It is also suggested that oil pressure be confirmed with a professional quality gauge known to be accurate insufficient oil circulation will cause extensive engine damage not covered under warranty Improperly connected oil lines may loosen and deposit oil on tire or brakes causing possible loss of control resulting in injury or death ENGINE LUBRICATION AND BREAK IN Race engine break in is at discretion of engine builder an
15. ccssecseecsseesseccseerseecnseesees 50 8022 40 Speedometer hole plug Kit c ccessessssscsssecsessssesssesssesssecsssessecsssessseesseeeseesseees 56 1063 19 Plug timing hole S amp S Super Stock H D 720 cessessesssssssecsesseesecsseeseeeseens 31 2005 a SHCS 14 20 x 34 Chrome ssessssesssessssecesesessssussesseteeoesnssssseseecterososssussereereeeeee 50 0067 20 Stud 14 20 14 28 x 1 4 Shifter shaft H D 5226A cssessesssesseeseesees 50 8080 b Flat washer 14 Chrome c ccssssssessessesssessesseessesssssscssessesscssesssesscssesseessesssesees 50 7017 21 Spring pin Shifter spring H D 24530 90 sssssssssssssssssssssssssssssssssesesesee 31 2049 GsO iN 1D 7620 AEA ATE EA AT EEE E A T 50 8032 22 Dowel pin 14 diameter x 1 2 ssssssssssssssseseesssssssssssesreeeeeensnnsssssrerererersenssssssrerees 50 8020 41 Fitting 90 e 27 pipe male x 6 flared tube e ssessscssesseesseesseesseeseeesen 50 8119 390 1 D x 558 0 D x 1 2 H D 16573 83 ssssssssssssessssssseesssesssessseesssssssessss 50 8023 42 Bearing transmission shifter drum RH H D 9151 eessesseessesseesseeseesees 56 3032 23 Transmission access door assembly 43 Ring transmission output shaft bearing retainer Includes 1 each transmission access door 50 8007 56 3030 s sssssecseeseeeees 56 3025 109 x 3 734 tru arc H D 11161 seescssessessescsecssssecsesscseceesesseeseeesseesee 50 80
16. d cylinders heads and rocker covers to be used on completed engine C Place mock up in frame to determine if additional clearance is required D Note locations of drain plugs for future maintenance needs In some instances frame modification may be required 3 Prepare Crankcases for Assembly NOTE Crankcases have been cleaned extensively by S amp S prior to shipping Nonetheless it remains engine builder s responsibility to inspect all parts before final assembly and to deburr parts or perform further cleaning as needed AX CAUTION Metal filings dirt or other contamination in engine can cause extensive damage not covered under warranty A Clean crankcases in solvent and hot soapy water to remove contaminants which may have been introduced during shipping handling or set up B Clear oil passages with compressed air and verify that passages are free of obstruction AX CAUTION Oil passages must be clean and free of obstruction for proper engine lubrication Blocked or contaminated oil passage will cause extensive engine damage not covered under warranty AX WARNING Compressed air and particles dislodged by compressed air are potentially harmful Wear protective goggles when using compressed air and direct air stream away from others nearby C Clean all pre installed bearings with compressed air to remove possible debris and moisture 4 Hardware Identification and Installation Refer to Kit Content on pages 2 4 for identif
17. d possible changes in engine height due to increased stroke and or deck height pay particular attention to clearances between the engine and drive belt or chain foot controls rear brake master cylinder and kickstand mount Areas above the rocker covers also require close inspection In some instances the frame or other components will require modification 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 FEATURES AND REQUIREMENTS In addition to special design elements for large displacement high performance applications S amp S crankcases for Sportster models incorporate what S amp S believes to be the best features of four and five speed Sportster engines Crankcases require the following parts for completion Charging system transmission and clutch five speed Sportster models 1991 03 S amp S cylinder heads amp billet lifter guides See important notes below NOTE While it is possible to use stock 4 speed lifter guides and cylinder heads they require extensive modification It is usually more time and cost effective to use S amp S products designed specifically for Special Application crankcases Cases can be ordered for 1986 90 4 speed or 1991 03 5 speed style cams Correct cams and gearcase cover m
18. d rider S amp S recommends the use of Mobil 1 V Twin 20W 50 synthetic oil in our engines First 50 miles are critical for new rings and pistons Most engine damage occurs during this period Keep heat down by avoiding heavy traffic and not exceeding 2500 RPM or approximately 50 60 MPH depending on gearing during this time Vary speed and do not lug engine Change oil and filter at 50 miles and inspect magnetic drain plugs at same time Small metallic build up is normal with new engine excessive build up must be investigated to determine cause For next 500 miles engine may be taken to 3500 RPM or approximately 60 70 MPH depending upon gearing for brief periods Speed should be varied and lugging and heavy traffic avoided Change oil and filter at end of first 500 miles Modest increases in speed are permissible during next 1500 miles but full throttle and heavy loads must be avoided Some operation at in town speeds 40 45 MPH is recommended although lugging and heavy traffic should still be avoided Change oil and filter at 500 mile intervals until 2000 miles Oil and filter should be changed every 2000 miles after break in Change more often if oil appears dirty engine is subjected to extreme temperatures or dusty conditions ridden for only short periods of time or frequently operated in heavy traffic 16 REPLACEMENT PARTS FOR S amp S CRANKCASES FOR HARLEY DAVIDSON SPORTSTER MODELS AND BUELL Crankcase assembly
19. ermined by builder 8 Install S amp S Oil Filter Mount S amp S Part 106 4426 This Oil Filter Mount kit provides parts and hardware for several different year models of big twin and Harley Davidson Sportster models Pay attention to existing engine configurations oiling system set ups and routing It is the responsibility of the installer to correctly identify engine make and to ensure proper installation of prescribed parts in this kit Hardware included in this kit are the correct sizes for use with Stock and S amp S manufactured parts or combination there of but may not be correct for other aftermarket parts and accessories Additional fittings are provided for special oil line routing applications See Picture 7 on next page for parts in kit Picture 7 Bracket Oil Filter 1 Fitting 45 4 27 NPTF Fitting 90 4 27 NPTF Sold in 5 pack Hose Fitting Straight 27 NPTF Taper Pipe Plug 27 NPTF Sold in 10 pack Screw SHC 6 24 x 3 5 Zinc i Hose Oil Return 375 x 12 SAE 30R7 1 50 1005 Pipe fitting 90 s 27 NPT x 375 Brass UNS Sold in 5 pack 106 2121 Screw HH Countersunk 5 16 24 x 3 1 4 Cadmium Plated Sold in 5 Pack 2 Item 6 50090 Screw SHC 346 24 x 234 Zinc Sold in 5 pack 8 a Always apply pipe sealant to the threads of fittings before assembling fittings or installing fittings Failure to install fittings correctly may damage mount and void warranty Apply tape and
20. ication of hardware NOTES Hardware may include items not needed in all applications Unless otherwise noted threads of all fittings should be coated with pipe sealant or anti seize compound prior to installation in crankcase If PTFE plumber s tape is used loose tape must not enter crankcase or oil passage Do not apply tape to first few threads that enter hole If taped fittings are removed insure that no particles which could reach oil passage or other critical area remain behind AX CAUTION Crankcase and other engine damage caused by improper hardware installation is not covered under warranty A Hose Fitting 31 6009 See Picture 2 next page Location Primary drive compartment vent opening Function Vents primary drive compartment Installation All applications with transmission and sealed primary case 1 Install fitting 31 6009 in opening 2 Install hose on fitting and connect to hose from transmission vent via T fitting not supplied een Picture 2 Picture 3 B Timing Hole Plugs 31 2005 2 each Location Timing mark access openings Function Exposes flywheel timing marks for ignition timing Installation Tighten after static ignition timing has been set before starting engine NOTE S amp S Crankcases for Harley Davidson Sportster models have timing inspection holes in both left and right side cases This allows access to four speed style flywheels with timing marks on left as well as five speed sty
21. le flywheels with marks on right C 10 24 x 1 socket head cap screws 31 2013 10 24 x 3 socket head cap screws 50 0023 and stator wire cover 31 2050 Location Left drive side crankcase Function Mount alternator stator and clamp wires on case half Installation Install in all applications equipped with alternator Apply Loctite 242 blue or equivalent to threads tighten to 30 40 in lbs D Magnetic Drain Plugs 31 2006 3 each See Picture 3 above Location Underside of flywheel transmission and primary compartments Function Drain lubricant collect debris Installation Tighten securely NOTE Drain plugs should be safety wired for racing and other extremely high performance applications 5 Cylinder Studs Unless otherwise requested S amp S crankcases for Sportster models with Evolution Sportster cylinder studs installed at stock height If different stud is installed by customer thread engagement in crankcase must be at least 750 NOTE Certain engines with longer than stock cylinders require big twin style cylinder studs Removal of interference fit studs may result in damage to crankcase or stud and is not recommended Cylinder studs are easily damaged Protect studs with sections of 12 I D rubber or plastic tubing until cylinders are installed Do not use studs as handle to lift or position crankcases Seemingly minor damage to studs may cause stress risers which can lead to stud failure and possible damage
22. mpede oil flow by kinked lines D On 1986 90 Sportster models the factory return line will not be used This line is replaced with the supplied hose in the kit and the 90 fitting The factory supply line is used and can be installed in port 1 3 or 4 The hose routing and an example oil mount setup is shown in Pictures 10 and 11 below Picture 10 Restricted oil supply may cause extensive damage not covered under warranty a i Picture 11 E Ifthe 45 or 90 fittings are used thread the straight barbed fitting into the female side of the angled fitting and tighten F Place the new gasket provided in the kit between the filter mount and the crankcase aligning its features with the filter mount facing the S amp S logo outward See Picture 12 on next page G Place the filter mount into the proper location on the gear case aligning the flat side towards the crankcase 11 j Picture 12 Using components other than those provided by S amp S may result in oil leaks insufficient oil pressure and possible engine damage H Use the 3 5 cap screws for stock Harley Davidson Sportster models or S amp S SB engines Place a small amount of LOCTITE 242 blue onto the threads to secure the filter mount to the gear case Toque screws to 13 16 ft lbs J Place hose clamps over hoses that will be slipped over barbed fittings Slip the return line onto the return fitting noted by the R on the mount AX WARNING
23. of material needed to obtain correct clearance Remove cylinders and pistons after clearances verified 8 E Install Reed Valve Install reed valve part 31 2051 in recess in left case With screws toward rear of engine flapper should point down See Picture 5 previous page F Assemble Crankcases 1 Clean case half gasket surfaces with lacquer thinner remove residue with clean dry cloth and apply thin film of preferred sealant to mating surface of one case half Avoid areas where excess sealant could reach inside of engine Do not apply sealant to area of crankcase that separates flywheel compartment from sump 2 Lubricate pinion bearing and I D of case race with petroleum jelly 3 Assemble crankcase halves Tighten fasteners in pattern specified in Figure 1 below Crankcase bolt torque specs are Position A 4 12 ft lbs Positions B to H e 15 18 ft lbs 4 Remove excess sealant Tighten gradually in order N J B L K A M Figure 1 7 Install Oil Pump A If five speed 1991 03 oil pump is to be used install provided 90 brass elbow in opening just forward of oil pump mounting surface in right case See Picture 6 below Elbow is not needed for four speed 1986 90 pump Opening in case will be covered by pump body Picture 6 B Install oil pump and correct gasket according to manufacturer s instructions Tighten bolts evenly to 120 150 in Ibs C Install oil lines Oil line routing must be det
24. or altering crankcases in any way paint etc inspect them to insure correct bore size flywheel diameter cam style and other options have been provided Under no circumstance will S amp S be held responsible for expenses related to the modification of any S amp S part in the event warranty service is required Painted or otherwise modified parts cannot be accepted for credit or exchange Inspect all parts closely immediately upon unpacking them B Confirm that crankcase serial numbers match numbers on packing carton and certificate of origin Contact S amp S immediately if numbers do not match 4 NOTE Valid certificate of origin is required for any transfer or sale of aftermarket crankcase or complete engine built with aftermarket crankcase Certificate of origin is required to title and license any motorcycle operated on public streets and highways 2 Clearance Frame NOTE Clearances between crankcase and frame rocker cover and frame tubes and rocker cover and gas tank must be checked and corrected as needed It is recommended that clearances in these areas be measured before stock engine is removed from frame and measurements then compared to those obtained with mock up of new engine A Before removing stock engine from frame measure clearances between rocker covers and frame and other areas where fit appears tight Areas of least clearance are usually above and behind rear rocker cover B Mock up new engine with S amp S cases an
25. pair your judgment 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 breathed 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 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 rectified by a telephone call and
26. pipe sealant to threads only Avoid using excessive amounts that may protrude into and obstruct oil passages or contaminate engine oil Incorrect use of PTFE tape or pipe sealant may cause engine damage not covered under warranty NOTE In Picture 8 port 1 3 and 4 are oil feed and port 2 is oil return For Harley Davidson Sportster applications use hole 4 or 1 for the pressure switch placement hole 2 for return line fitting and hole 3 for oil feed line fitting Place a NPT pipe plug into the hole that is not used by 1 or 4 See Picture 8 below a Picture 8 10 A To properly install the Sportster pressure switch use a 90 degree fitting from the hardware packet and thread it into hole 4 B Next thread the pressure switch into the fitting and tighten to 8 12 ft lbs See Picture 9 below Picture 9 Improper filter mount installation due to incorrect identification of crankcase year group may result in engine damage not covered under warranty NOTE There is no pressure regulator bypass designed into the S amp S filter bracket since modern oil filters contain a bypass valve relieving oil pressure that could potentially collapse the filter media S amp S Sportster cases should use oil filters for 1986 03 Sportster applications C Install the straight 45 or 90 fittings that will optimize the oil line routing of the engine into the side holes as indicated in Picture 10 below Ensure that oil line placement does not i
27. r gasket to seal properly Correct Sportster cams must be used Case is machined for four speed OR five speed cams according to information provided with case S amp S crankcases for Sportster models accept cam lift up to 710 without modification S amp S strongly recommends that builder degree camshafts before final installation Improperly degreed cams can cause sluggish performance or excessive cylinder pressure resulting in hard starting and or detonation 13 10 Install HL2T Kit OPTIONAL Lifters and Guides A If desired disassemble lifters and install S amp S Hydraulic Lifter Limited Travel Kit according to S amp S HL2T Instructions No 5038 B Lubricate lifter guide O rings and install on guide Thick O ring goes nearest top of guide Install small O rings around oil passages in lifter guide areas of crankcase See Pictures 18 amp 19 below e Picture 18 E Picture 19 Lifter blocks are marked with R F 4 5 or SA depending on application See Pictures 20 amp 21 below Picture 20 Picture 21 Example of Marks LEFT 1991 99 Lifter and lifter block TOP Rear special application 5 speed 1991 99 RIGHT 1986 90 Lifter and lifter block BOTTOM Right intake special application 1986 90 C Install lifter guide assemblies in crankcase Use H D lifter 18526 89 for 1991 03 applications 2000 03 lifters will not fit S amp S blocks 11 Install Top End Transmission and Primary A Pass clean white lint free clo
28. re original equipment parts or that they are equivalent to the SY EMAL eo Vb PEN E EEA ETE A TA A E TR Te 50 0013 corresponding Harley Davidson part number shown 58 Gasket gearcover N S othe ssh et cated ata Merete ea tt eect 31 2052
29. rge cylinder bores the cam compartment in S amp S Special Application for Sportster model crankcases has been moved out 12 This requires a special pinion shaft and flywheels machined to accept the special S amp S shaft S amp S flywheels for Evolution Sportster models utilize the 1987 style splined pinion shaft because it is stronger than the later style shaft S amp S pinion shafts require the 1986 87 style pinion gear Available from S amp S Part depends upon size required and oil pump drive gear S amp S Part 33 4228 See Picture 13 on page 12 The modified cam compartment in Special Application cases required the lifter guide openings to be relocated as well resulting in misalignment between lifter guides and cylinder heads if stock guides and heads are used For this reason S amp S cylinder heads and billet tappet guides will likely be required for completion While it is possible for a skilled welder machinist to relocate the cylinder head pushrod openings it is extremely difficult to modify stock lifter guides satisfactorily Crankcase standard features include Clearance for all S amp S connecting rods and strokes to 5 Modified crankcase breather system to improve oil scavenging and reduce oil loss out breather Oil scraper machined to provide proper clearance for flywheel diameter specified at time of order Transmission trap door easily sealed to separate lubrication supplies for engine transmission and primary hou
30. sassaccdtdesdeossaseaastaeseohsesiearetei 50 5010 Te KYE MAG H D 6400 cise le seals iexesievud carctestued ERENER 50 7053 32 Washer flat 14 x38 x Vio H D 6245 esseessessesscsssssecsscssecsecsscesecssessceseesees 50 7021 15 Screw SHC 46 18 x 3 See Bolt Position Diagram 33 Fitting hose 27 pipe male transmission vent H D 6353341 04 50 8115 Positions BG D TH Serpii ENA 50 0021 34 Dowel pin 309 1 D x 430 0 D x12 H D 24754 75 sssssssssssesssssssssssssssss 50 8018 16 Screw SHC 35 Screw HHC 20 x 12 primary oil lever H D 3728 sssessecssesseececseesees 50 0014 10 24 x34 Stator wires cover asesvesessnesaastsctstesradhustvarsaushctnetaeadiaetintseatuanideinian 50 0023 36 Washer flat 14 x 34 x 42 copper primary oil level H D 63858 49 50 7018 10 24 x 1 Stator H D 2720 sesssssessssesssesssessssesssessseessssssseesseensssssseessessssses 50 0044 37 Mfg after 5 1 2000 2 20 thread Includes O0 ring c scesssssseessecssesssesseesees 50 8335 17 Cover stator wires S amp S Super Stock 38 Reed valve assembly Optional c sscsscssesssecsssssssssssssesssssessssesssesseessesseessees 31 2051 H D 29950 9 recen dota beestagdsdebaath secutive dt dedtacbeha ty 31 2050 39 Dowel pin 46 diameter x Yo H D 215 cesessessessessssecsesseseseesessesseeecseeseenes 50 8019 18 Dowel pin 250 diameter x 2 H D 358 oo essessse
31. sed in reference 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 breathed 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 judgment when performing installation and operating motorcycle Good judgment begins with a clear head Don t let alcohol drugs or fatigue im
32. sing if desired Universal fit into 1994 03 Buell frame The following options can be specified at time of order Deck height up to 1 taller than stock Machining for 4 speed 1986 90 or 5 speed 1991 03 cams Oil filter boss machined for standard Harley Davidson Sportster models bolt on oil filter mechanism or homemade high capacity breather valve for all out competition Transmission inspection window to monitor transmission for damage Available with Special Order part number only Not available when electric starter is used because window cover interferes with starter location e Machining for 1991 03 sprocket shaft or 1955 65 big twin style sprocket shaft Big twin shaft available with Special Order and no transmission crankcase part numbers only Big twin shaft option requires special flywheels machined to accept big twin shaft Machining for 1995 03 magnetic speedometer sensor POLISHING POWDERCOATING ETC S amp S does not recommend having engine parts polished powder coated glass bead blasted or otherwise modified Such procedures often leave abrasive residues which are difficult to remove from recesses and small passages Glass bead and polishing residues can cause extensive engine damage Engine damage caused by powder coating polishing glass bead blasting or other modification will not be covered under warranty INSTALLATION INSTRUCTIONS 1 Inspect Crankcases A Prior to assembling engine
33. ste cata cae ease 31 2324 Ring main bearing retainer H D 11177 11177A secsscssesseessssseessceseeseeeees 50 8057 13 Bolt case HH See Bolt Position Diagram Cam needle bearing assembly H D 9057 c sssssssecssessecseeesccseecseesseenseeseents 31 4061 Position A 1991 03 Left Timken main bearing assembly S amp S Super STOCK V4 228 X5Y2 secde AA 50 0090 S amp S Super Stock H D 24729 74 c csscssscesssssssscsessscsscescessssscsscesecsscssctsceeees 31 4059 SOE VAs 2B Osha chad A 50 0020 DOSS Ay HED 9028 ncia Ra ear euceseesntuare 31 4013 Position B C D Seal sprocket shaft oil 1991 03 S amp S Super Stock 76 18 X3 cacceetcs cerccctsascsnedestensavtadsatnancelndestarsueiuere 50 0021 S amp S Super Stock H D 35151 74 ssssssssssssssssseessnsssseesensseseseeosssssseesonsseseesee 31 4060 Position E F G H Tappet guide assembly All S amp S 1991 03 S amp S Super Stock 76 18 X 4 esssssssssssssssessscssssessssssssecesseaseaseseessees 50 0102 Position J K 1991 03585 SuperStock 20 nnn 50 002 stock sa stock sa Position Set 335375 33 5365 33 5389 f 33 5369 1991 03 S amp S Super Stock 6 24 x 510 vsssssssssssissssissorisnerosnenosrnoreonisesrrneen 50 0170 Position N Fewhaust a 33 s3oi_ 33 5365 355391 SE Super tc 6 18 38 a soon Cime ssn ase ses ase remas 3s ase ssw ase Came sm ase ssw ase All reference to Harley Davidson
34. th back and forth through wristpin bores until clean Clean pistons rings wristpins cylinders cylinder heads and lower rocker covers in solvent then hot soapy water Take special care to flush oil passages thoroughly and dry with compressed air Install components according to manufacturer s instructions and Harley Davidson Service Manual Picture 22 14 NOTE Heads should have push rod geometry to match the year group style of the cam chest and lifter blocks S amp S identified their heads with the following codes STE Stock Non SA for 1986 90 cams and lifters STL Stock Non SA for 1991 03 cams and lifters SSE S amp S SA for 1986 90 cams and lifters as shown in circled area of Picture 22 previous page SSL S amp S SA for 1991 03 cams and lifters Wristpins and other engine parts may retain honing compound or other abrasive contaminants that will damage engine S amp S will not be responsible for this or other damage caused by inadequate cleaning or preparation of parts prior to assembly NOTE Clearance between pushrods and pushrod bores in cylinder head must be sufficient to prevent contact S amp S cylinder heads should require little or no modification To check clearance install top end including pushrods but not pushrod covers and rotate engine several revolutions while observing for contact between pushrods and cylinder head B Install push rods with cover assemblies and adjust pushrods according to manufact
35. urer s instructions and install pushrod cover assembly clips NOTE If S amp S Limited Travel Kit is used pushrods must be adjusted according to S amp S HL2T Kit instruction Sheet No 51 1039 C Install transmission according to procedure outlined in Harley Davidson Service Manual Transmission fluid capacity in S amp S crankcase for Sportster models is twelve ounces Primary housing fluid capacity is 10 12 oz NOTE S amp S cases for Sportster models are designed to use 1991 03 transmission primary clutch shifting components charging system and starter Stock transmission trap door does not fit S amp S cases Reference H D service manual for 1991 03 Sportster for proper assembly of the transmission and primary components D Install transmission inspection door if applicable See Picture 23 below NOTE Electric starter cannot be installed on crankcase with trans inspection door option E Install electric starter and magnetic soeedometer sensor if applicable F Install engine in frame and connect oil lines Check clearance between drive belt or chain and crankcase S amp S recommends at least 1 If necessary remove metal from crankcase to obtain proper clearance G Sportster Configuration Install part 50 0319 16 x 2 button head cap screw w loctite Torque to 13 15 ft lbs to plug the hole on the front of the cam chest See Item 55 in Exploded Diagram page 17 Failure to establish proper clearance between
36. ust be used 1986 90 cams require 1986 90 style gearcase cover Harley Davidson 25219 86 1991 03 cams require 1991 03 style cover 25219 91A S amp S gasket 31 2052 must be used with 1991 03 style cover See following Caution concerning late 5 speed cover H D part 25219 91B S amp S offers various styles of gear covers for the different year groups Lifter blocks are not available for 2000 03 style lifter 1991 03 applications require H D part 18526 89 lifter NOTE S amp S crankcases are compatible with some early Sportster model gearcase covers Late model covers have different oil passage locations Use of 25219 91B cover or incorrect cover gasket on S amp S crankcase will cause oil starvation and extensive engine damage not covered under warranty See Picture 1 next page This style cover is not available from H D S amp S offers billet covers for both 1986 90 and 1991 03 style cams Any Harley Davidson Evolution Sportster model oil pump can be used Gearcase used on S amp S crankcases must have oil passages located in the indicated positions or oil starvation and engine damage will result All reference to Harley Davidson part numbers is for identification purposes only We are in now way 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 Picture 1 IMPORTANT NOTES To permit la
37. vely 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 KIT CONTENTS Crankcase assembly S amp S Special Application for Harley Davidson Sportster models Part 31 1001 special order with following parts installed 31 1000LD Insert left main bearing w bearing race installed 31 4050 Race right main bearing H D 8881 Race is final honed with size marked on tag wired to case 31 4061 Bearing cam H D 9057 Qty 4 31 2048 Nut press in 3s x 16 xl rear motor mount H D 16240 82 Qty 2 31 2049 Pin shifter spring H D 24530 90 50 8018 Dowel primary cover locating H D 24754 75 Qty 3 50 8019 Dowel gear cover alignment H D 215 Qty 2 50 8080 Stud transmission shifter shaft H D 5226A Qty 2 31 2005 Plug timing hole Qty 2 31 2006 Plug magnetic drain Qty 3 50 7044 Shim 346 x 34 x 350 50 0013 SHC Screw 1 4 20 x 2 50 0319 BHC Screw 16 x 12 56 3028 Bearing trans output shaft H D 8996 56 3031 Bearing trans countershaft RH H D 8977 56 3032 Bearing trans shifter drum RH H D 9151 31 2051 Valve assembly reed 56 3020 Door kit transmission access includes 56 3025 Door assembly trans access S amp S xl cases 56 3025A Door trans access 50 8020 Pin dowel 18 x 34 trans access door 56 3030 Bushing shifter drum H D 9187 56 30
38. yle cam chests H D does not currently make a cover that fits S amp S cases Using gear cover 25219 91B or non S amp S gasket with cover 25219 91A will cause oil starvation and extensive engine damage See Picture 1 Page 4 for reference D Apply petroleum jelly to cam bearings and bearing surfaces of camshafts See Picture 16 below left Place cams in respective positions assuring that timing marks on cams and pinion gear align Be sure to install the cam thrust washers between the cam shafts and crankcase See Picture 17 below right The chamfer on the thrust washer should face the cam Apply assembly lube to gear cover bushings and remove excess to avoid contaminating gasket surface Roll the crankshaft a few degrees back and forth to check timing marks Picture 16 Picture 17 E Install gear cover and gasket after cleaning gasket surfaces of cover and crankcase Torque to 80 110 in lbs evenly and in pattern specified in Harley Davidson Service Manual F Establish camshaft endplay according to procedure in the Harley Davidson Service Manual S amp S recommends 005 030 G Confirm lash between pinion gear and 2 cam gear Proper lash exists if cam can be moved back and forth between crankcase and gear cover but there is no perceptible play between pinion and cam gears Reinstall cover and torque to spec NOTES S amp S has had best results installing gasket without sealant Gasket and gasket surfaces must be clean and dry fo
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