51-1124 SSW+ Instr.
Contents
1. h Connect vacuum hose from V O E S and or fuel petcock to vent fitting on top of carburettor 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 amp INSTALLATION a Prepare air cleaner backplate NOTE Fast idle lever screws part 11 2384 must not be over tightened Loctite or other thread locking compound may be used sparingly on threads to prevent screws from vibrating loose CAUTION Over tightening fast idle lever screws may damage backplate 1 Press plug part 50 8312 into hole on left in air cleaner backplate as shown in Picture 33 2 Screw vent hose elbow fitting part 50 8110 into remaining hole at right See Picture 33 3 Assemble fast idle mechanism as shown in Figure 3 Picture 33 b Install Air Cleaner Backplate 1 Locate crankcase venting valve at rear of crankcases Connect crankcase venting hose from this valve to installed elbow fitting on the air cleaner backing plate See Picture 34 2 Determine which of the provided shims correctly fills the gaps between backplate thick aluminum spacer and cylinder heads 3 Install backplate and gasket Confirm that fast idle lever has properly engaged enrichment plunger Tighten screws holding backplate to carburetor to 11 ft lbs NOTE Air cleaner backplate screws supplied with kit have thread locking compound on threads2. S amp S uses Threebond 1104 to seal crankcase Use any sealant carefully to prevent excess from entering engine and obstructing oil passages or contaminating oil supply 2 Install crankcase studs and washers according to crankcase instructions NOTE Alignment studs for S amp S crankcases are in locations B E amp G See Diagram 1 They must be installed before other studs and bolts Fit is tight so alignment studs must be lubricated with assembly lube then tapped through case assembly with plastic mallet 3 Tighten 7 case bolts and studs to 18 ft lbs center bolt to 120 in lbs See Diagram 1 for identification and tighten fasteners in following sequence G B E F H D C A 4 Install drive sprocket spacer and sprocket shaft oil seal in main bearing race of left case Picture 5 Diagram 1 Picture 6 NOTE Because of sealed wet primary in Evolution style drive trains S amp S installs sprocket shaft seals with spring facing out See Picture 8 5 Allow crankcase sealant to cure per mfr s instructions then pour four ounces of motor oil over bearing end of connecting rod assembly and into flywheel cavity Rotate flywheels several times to distribute oil over connecting rod bearings Assembly should turn freely and without binding INSTALL OIL PUMP 1 Disassemble clean and inspect oil pump leaving supply drive gear key and snap ring in place on shaft 2 Reassemble pump applying assembly lube to gears a
3. a well ventilated area and wear protective clothing to avoid personal injury if the motorcycle has been running wait until the engine and exhaust pipes have cooled before performing any installation steps to avoid getting burned Before performing any installation steps disconnect and remove the battery to eliminate potential sparks and inadvertent engagement of the starter while working on the motorcycle Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps Contact S amp S if you have questions if any steps are unclear or if any abnormalities occur during final assembly installation or operation Contact an authorized H D service manual for correct disassembly reassembly and installation procedures for any parts that need to be removed to facilitate the installation Use good judgment during assembly installation and when operating the motorcycle Good judgment begins with a clear head Don t let alcohol drugs or fatigue impair judgment Perform the assembly and installation when fresh For optimum performance and safety and to minimize potential damage to the Long Block or other components use correct hardware and follow procedures outlined in S amp S instructions and an authorized H D service manual Be sure all oil and fuel lines are routed correctly with clamps in place and tightened Lines must not contact exhaust pipes or other
4. cause shaft to break 2 Apply red Loctite 272 to pinion gear nut threads Install pinion gear key and nut on pinion shaft and tighten nut to 50 ft lbs See Picture 15 NOTE Drive gear spacer will not completely fill soace between oil pump drive gear and pinion gear A gap of up to 125 will exist and is normal Engine rotation keeps oil pump gear in place during normal operation Spacer prevents gear and key from becoming disengaged if engine is rotated backwards CAUTION Installing pinion gear or nut without Loctite can cause damage to shaft nut or other parts INSTALL BREATHER GEAR CAMSHAFT AND GEAR COVER Picture 14 Picture 15 Thoroughly clean and dry all parts including camshaft lockwasher and thrust washer Carefully inspect breather gear for burrs and remove as necessary Inspect edges of crankshaft breather window for burrs and smoothness Cam thrust washer and breather gear shims should be correct size but endplay of camshaft and breather gear must be verified by customer a Breather gear end play should be between 005 015 Install breather gear with supplied spacer into the breather bore of the gearcase With a new uncrushed gasket installed on the gearcase use a straight edge and measure the distance to the spacer Subtract 006 007 for gasket crush and this will be the breather gear end play Select correct thrust washer to achieve proper end play b Camshaft end play sh
5. hot surfaces where they could melt or leak and catch fire Motorcycle exhaust fumes are toxic and must not be inhaled Run motorcycle only in a well ventilated area where fumes can dissipate S amp S Long Blocks are substantially more powerful than the stock engines they often replace It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use The user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith S amp S parts are intended for experienced riders only 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 motorcycle or a component NOTE Other information of particular importance has been placed in italic type S amp S urges you to take special notice of these advisories 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 S amp S by the purchaser within the 12 month warranty period or within 10 days thereafter In the event warranty se
6. leader 19
7. of Long Block gearcase cover and secure with provided retainer If applicable static time ignition as per manufacturer s instructions 2 If applicable install and connect the V O E S Vacuum Operated Electric Switch NOTE V O E S S amp S Cycle does suggest the ignition system selected for use with this Super Sidewinder Plus engine utilize the V O E S Vacuum Operated Electric Switch Check the switch using a hand vacuum pump with a gauge and set the switch to trip at 6 in of vacuum Mercury See Picture 28 3 Install the ignition manufacturer s recommended spark plugs a Refer to ignition manufacturer s suggested spark plug gap and check spark plugs 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 amp 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 gasket into exhaust ports of cylinder heads 2 Inspect the exhaust pipe header flanges and retaining rings Replace if distorted warped or otherwise damaged 3 Apply a high temp anti seize lubricant to threads of exhaust studs at cylinder heads 4 Install exhausts to cylinder heads Hand tighten exhaust stud nuts Picture 29 5 Attach exhau
8. per instructions rotate flywheels several revolutions in direction of normal flywheel travel to confirm that engine turns freely NOTE Do not force engine If resistance encountered determine and correct cause before continuing CAUTION Forcing engine against resistance may cause damage not covered under warranty INSTALL INTAKE MANIFOLD 1 Identify front and rear intake manifold flanges 2 Apply alight coat of silicon lubricant or Vaseline to the outside diameter of the manifold the inside diameter of the flanges and the two intake seals Install the flanges in appropriate positions on manifold smaller diameter towards center of manifold 3 Install seals onto manifold with the thicker end towards cylinder head 4 Install manifold assembly onto cylinder heads using the four mounting screws Snug screws finger tight 5 Install breather hose from front cylinder head to vent fitting on top of carburettor intake manifold NOTE Refer to engine installation section of this manual for carburettor installation throttle cable installation and adjustment and air cleaner assembly installation FINAL INSTALLATION Finished engine should be installed in frame according to appropriate Harley Davidson Service Manual Clean gas and oil tanks thoroughly before installing and be sure all traces of solvent are removed Old oil lines should be flushed or replaced and a new oil filter installed With engine installation complete
9. reposition housing to increase clearance then retighten SCrews Place o ring in center of rocker housing Repeat above procedure for other cylinder head Picture 25 Picture 24 CAUTION 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 amp S pushrods are designed with emphasis on strength Weaker pushrods may flex under load resulting in loss of power increased cranking compression and detonation Is Rotate flywheels in direction of normal engine rotation until both lifters for front cylinder at lowest position on camshaft Front piston will be at or near TDC on compression stroke when lifters in correct position Identify pushrods as explained in previous section Hold pushrod tube for front intake in place and pass correct pushrod adjuster end down through cylinder head and pushrod tube Repeat for front exhaust NOTE Some engine builders prefer to install and adjust pushrods one at a time beginning with intake 3 Lubricate rocker shafts with assembly lube Place rocker arms in support and slide shafts through support and rocker arm Reliefs in shafts must face the center of the cylinder and align with the right cam side bolt holes See Picture 26 Driveside Camside Figure 2 Picture 26 4 Check rocker arm endplay by sliding rocker arm to
10. room temp Follow the same cautions as for the initial start up and continue to watch for problems 18 Picture 40 11 Repeat this procedure 3 or 4 times Each successive time it should take slightly longer to warm up and you can increase the temp slightly each time 10 You can be more liberal each time with the rpm gently vary rom continuously from idle up to 2500 rpm in the final cycle Don t be too concerned with final carb settings at this time because idle speed and mixture cannot be correctly set until the engine reaches full operating temperature The engine should not reach that temperature during these cycles Do not allow engine temperature to become excessive After the engine has cooled to room temperature for the final time you are ready to start the 1000 mile engine break in process ENGINE TUNING 1 Carburettor a Refer to Instruction Sheet 51 1012 Installation and Jetting Instructions for S amp S Super E and G Series Shorty Carburettors for initial set up and adjustment of the carburettor 2 Ignition Timing NOTE S amp S recommends using electronic ignition with adjustable advance curve in Super Sidewinder Plus Long Blocks Adjustable curve permits slowing rate of advance to control or eliminate pinging under heavy load or when elevated temperatures or poor quality gasoline encountered Install ignition according to manufacturer s instructions Leave spark plugs out while static timing to e
11. 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 WARNING Loose fasteners inside of primary chaincase may cause the transmission to lock up resulting in possible loss of control of motorcycle with injury or death to riders and others 5 Tighten primary housing to engine crankcase and transmission case a Torque inner primary housing engine mounting fasteners to 22 ft lbs b Refer to the appropriate service manual for the torque specifications of the inner primary housing transmission mounting fasteners Tighten the four lower engine mounting fasteners to 35 ft lbs Install the upper engine mounting bracket Tighten bracket to head to 35 ft lbs Refer to specific frame make model year service manual for torque specification of upper engine mounting to frame fasteners 8 Refer to the drive section of the appropriate service manual for reassembly of the primary drive and case Make certain to install new chaincase lubricant if applicable ah D Picture 28 IGNITION SYSTEM NOTE If installing the stock ignition from the removed engine refer to the ignition section of the appropriate service manual for removal and installation 1 Install the ignition timing sensor as per manufacturer s instruction using provided ignition cover standoff screws Route ignition sensor wire through channel in lower part
12. If screw without thread locking compound is used a thread locking product such as Loctite 243 must be applied and screws properly tightened CAUTION Failure to apply thread locking compound or properly tighten screws may cause screws to loosen and fall into engine resulting in engine damage not covered under warranty Picture 34 Figure 3 Picture 35 4 Fill gap between backplate mounting ears and cylinder heads with aluminum spacer and correct shims See Picture 35 5 Bolt backplate to cylinder head with 7 18 bolts flat washers and lockwashers NOTE The manifold flange bolts may need to be loosened to align backplate mounting ears with breather fittings in cylinder heads A long 4 ball end Allen socket will aid in accessibility to the cam side fasteners of the flanges Adjust carburettor air cleaner assembly as necessary for proper alignment with mounting holes in cylinder head Retighten flange bolts evenly to 16 ft Ibs c Final assembly and checks 1 Check carb to manifold mounting bolts 2 Check carb to air cleaner backplate mounting screws 3 Check the air cleaner backplate to head mounting bolts 4 Check fuel line connections and routing Avoid hot surfaces 5 Check vacuum operated 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
13. SES Cycle Tue 14025 County Highway G P O Box 215 Viola Wisconsin 54664 Phone 608 627 1497 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Instruction No 51 1124 Revised 3 5 02 Copyright 2002 by S amp S Cycle Inc All rights reserved Printed in the U S A Fax 608 627 1488 Because every industry has a leader Assembly and Installation Instructions for S amp S Super Sidewinder Plus Style Long Block Safe Installation and Operation Rules Before finishing and installing your S amp S Long Block it is your responsibility to read and follow the installation and maintenance procedures in these instructions and to follow the basic rules below for your personal safety Gasoline is extremely flammable and explosive under certain conditions and the fumes toxic when inhaled Do not smoke around gasoline Perform the installation in a well ventilated area away from open flames or sparks Compressed air and particles dislodged by compressed air are harmful to eyes and body Wear protective goggles when using compressed air and always direct the air stream away from your eyes and body and other people nearby Some solvents degreasers and other chemicals are harmful especially to skin and eyes Many chemical compounds such as lacquer thinner are also flammable and present a fire hazard Read the manufacturer s instruction label for precautions and proper use Use in
14. aft key and snap ring are installed properly paying particular attention to snap ring If not installed correctly sprung or otherwise damaged snap ring may come off or allow gear key to come out See Pictures 11 amp 12 CAUTION Loss of oil pump drive gear snap ring or key will result in disengagement of oil pump causing loss of oil pressure and extensive engine damage 5 Loosely install 2 each 20 x 1 top oil pump bolts followed by pump cover and 4 each 20 x 2 mounting bolts Do not tighten at this time 6 While turning oil pump drive gear to check pump for binding gradually tighten 4 2 bolts in an X pattern to final specifications of 120 in lbs See Picture 13 Carefully tighten short bolts by feel with thin box end wrench or preferably with a torque adapter and tighten to 110 in Ibs 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 Picture 13 Correct Picture 12 INSTALL PINION GEAR SPACER amp NUT 1 With chamfer on oil pump drive gear facing in towards shoulder on pinion shaft See Picture 14 install oil pump drive gear and key on pinion shaft followed by drive gear spacer CAUTION Installing gear backwards can result in a stress riser and
15. and seat assembly Fill gas tank with just enough fuel to test system Lean motorcycle over towards carburettor side turn on fuel petcock and wait 20 seconds If gas runs out end of carb or out overflow hose turn off petcock and check needle and seat d Check fuel inlet fitting and fuel line connections for leaks Hose clamps must be tight NOTE Fuel needle and seat assembly must completely shut off fuel supply to carburetor bowl Fuel inlet fittings and fuel line connections must not leak CAUTION Gasoline leaking past inlet needle may flood engine causing contamination of oil supply and damage to engine WARNING Any gasoline leak represents a health and fire hazard INITIAL START UP 1 Remove tappet screen plug and screen assembly from crankcase See Picture 39 2 Remove wires from spark plugs Ground plug wires to cylinder head with either a jumper wire or through a test plug Picture 39 CAUTION It is possible to damage certain types of electronic ignitions if the high tension side of the ignition coil is left open Always ground the spark plug side of ignition coil when turning engine over 3 Engage manual compression release if applicable 4 Turn ignition on and turn the engine over with the starter motor until you get engine oil at the tappet screen port CAUTION Avoid excessive time of starter engagement Overheating of starter motor will result in damage After 30 seconds of continuous starter runnin
16. are 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 it s 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 assembly NOTE Light coating of oil on head bolt threads minimizes friction so torque values will not be distorted It cannot be emphasized enough that these steps must be done carefully Maintaining a good head gasket seal depends on it CAUTION Improper torquing sequence and head bolt torque values may cause head gasket failure Picture 22 3 Bolt heads on cylinders Follow the stock bolt tightening sequence and use stock three stage procedure and torque values shown in Figure 1 See Figure 1 IMPORTANT NOTE Proper first time engine start up and break in is critical to achieve permanent and lasting head gasket seal Follow Engine Break In procedures at end of section CAUTION Improper first time engine start up and break in procedure may cause head gasket failure PUSHROD PREPARATION 1 Disassemble pushrods and pushrod tube covers Clean thoroughly and dry with compressed air 2 Blow compressed air through oil passage in each pushrod to confirm that passage is clean and free of debris and obstruction See Picture 22 3 Asse
17. ase flywheel rotation Flywheels in S amp S Super Sidewinder Plus Long Blocks have three timing marks F 30 Front cylinder firing mark 30 degrees before front cylinder piston TDC with vertical line in center of hole See caution below R 30 Rear cylinder firing mark 30 before rear cylinder piston TDC with dot in center of hole T F Front piston Top Dead Center with colon in center of hole Most fully electronic ignitions are timed at TDC Points and other ignitions with mechanical advance are timed at front cylinder firing mark With correct mark centered in timing inspection hole ignition at full advance will occur 30 before TDC CAUTION Operating Long Block with timing too advanced can cause detonation and damage to engine not covered under warranty Picture 41 Additional minor adjustment of timing may be required due poor quality gasoline extremely hot climate etc but ignition should occur between 28 and 32 BTDC when fully advanced and engine closely monitored for heat build up In general excessive ignition advance will cause engine to kick back against the starter during start up and buck when ridden at steady speed with partial throttle An advanced condition can also cause pinging or ignition knock and possible piston damage These symptoms may not be noticed if electronic ignition with soft advance curve is used Excessive ignition retard causes sluggish performance and severe ov
18. carburetor and air cleaner assembly can be installed INSTALLATION NOTE The Super Sidewinder Plus Long Block is designed to be installed in a stock Harley Davidson Evolution Big Twin style chassis If this Long Block is to replace an existing engine refer to the appropriate service manual regarding engine removal S amp S recommends that the primary drive and housing be removed when installing this long block in order to ensure all components are in proper alignment 12 NOTE Install the charging system to the crankcase as per the appropriate service manual according to the specifications for the particular model Use new stator fasteners if applicable If necessary install spacer for 45 amp alternator This step is not required for all models After installation of flywheel assembly S amp S drive sprocket spacer 31 4011 and Timken main bearing seal place S amp S spacer 31 4033 not provided on sprocket shaft between spacer 31 4011and alternator rotor See Picture 27 Dimensions of spacer 31 4033 are 1 130 i d x 1 730 0 d x 325 thickness CAUTION Failure to use spacer 31 4033 with 45 amp alternator will cause rotor to bottom against crankcase when sprocket nut is tightened causing damage to crankcase rotor or both WARNING To insure safe operation of motorcycle these operations must be performed correctly and in a professional manner SOLID MOUNT CHASSIS 1 Refer to the drive section of th
19. d through front lifter guide opening to support lifters 6 Insert Harley Davidson alignment tool HD 33443 or similar tool from other source in lifter guide screw hole by oil passage See Picture 19 Install and tighten guide screws in three remaining holes to 6 ft lbs Remove tool install fourth screw and tighten all four screws to 120 in Ibs 7 Repeat procedure for front lifter guide assembly Assembly lube will usually hold lifters in guide during installation If resistance encountered during installation check to see if lifter has become dislodged 8 Apply thread sealant to threads of oil pressure switch and install INSTALL VENT HARDWARE 1 Install 45 elbow 31 2022 in vent opening at rear of crankcase Steel fittings must be coated with anti seize thread sealant or Teflon tape before installation in crankcase See Picture 20 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 can be checked by blowing through valve before installation Picture 20 INSTALL PISTONS AND CYLINDERS 1 Identify front and rear pistons The rear piston will have a notch in the skirt for clearance with the front piston The rear piston is to be installed with this notch to the center of the engine or towards the front of the motorcycle 2 Inspect pistons esp
20. e 18 CAUTION Having to force gear cover indicates an alignment problem Problem must be identified and corrected before operating engine Operating engine with forced gear cover could result in broken pinion shaft or other engine damage 10 Rotate flywheels to check for binding If present cause of bind must be determined and corrected If assembly rotates freely pour approximately four ounces of oil into gear compartment after allowing crankcase sealant to cure per manufacturer s instructions T oT me i 4 at i Picture 19 INSTALL LIFTERS AND LIFTER GUIDES NOTE S amp S installs HL T Hydraulic Lifter Limited Travel kit in lifters in assembled and unassembled Super Sidewinder Plus Long Block engines Install V Style lifters and guides as follows 1 Ifinstalled remove oil pressure sending unit behind rear lifter guide opening 2 Identify gaskets for front and rear lifter guides Gaskets are not interchangeable 3 Coat lifter guide bores with assembly lube and insert lifters Work lifters back and forth in guides assuring that they move freely and without binding Apply engine oil to lifter rollers and remove any excess 4 Thoroughly clean and dry gasket surfaces of lifter guides and crankcase Place rear gasket on crankcase assuring that oil hole in gasket aligns with passage in case 5 Taking care not to dislodge or contaminate gasket lower rear guide assembly into place Fingers can be inserte
21. e appropriate service manual and loosen the transmission to frame mounting hardware 2 Place the engine on the mounting pads of the frame Install and tighten the two rear mounting bolts Check the relationship of the front engine mount to frame NOTE With the rear crankcase fasteners tightened there should not be any space between the engine mounting pad and the front crankcase mount Due to variations with different frames a gap may exist here If this situation is found use the appropriate thickness of shims to eliminate this gap Failure to correct this may cause the crankcases to be in a bind when the front engine mounting fasteners are tightened resulting in an engine vibration 3 Install the two front engine mounting bolts NOTE The front two engine mounting fasteners should install easily through the frame and crankcase If it requires that these bolts be driven through the mounting holes the crankcases may again be in a bind resulting in an engine vibration 4 Loosen all four lower mounting fasteners 5 Refer to the drive section 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 CAUTION Failure to use new lock tabs or safety wire on inner primary chaincase mounting hardware may result in the fasteners backing out and possib
22. ecially areas around machined surfaces such as ring grooves and wristpin holes for burrs De burr as necessary taking care to remove particles that could become dislodged inside engine 3 Measure ring end gaps and adjust as necessary a Compression ring end gaps should be between 017 to 025 b Ojilring rail end gaps should be between 015 to 035 4 Thoroughly clean cylinders pistons rings wristpins and wristpin retainers in solvent then hot soapy water Take special care to flush oil passages and pass clean white cloth back and forth through wristpin bores Dry all with compressed air and place on clean dry surface 5 S amp S recommends installing all cylinder base gaskets dry Be sure holes in gaskets align with cylinder base dowels and oil holes 6 Install rings on pistons a The moly faced ring is to be installed in the top piston ring groove chamfer side up b The plain cast ring is to be installed in the second piston ring groove dot up c Lubricate wristpin wristpin bushing and wristpin bore in piston with assembly lube Install wristpin through piston and connecting rod secure with new retaining clips NOTE S amp S recommends the use of clip installer part number HD 42317 available from Kent Moore through Harley Davidson or similar tool for clip installation d Install the oil ring support rail in the lower ring groove of piston See picture 21 e Install the oil ring separator
23. erheating with possible subsequent damage to the engine and must also be avoided Immediate or rapid exhaust pipe discoloration is usually a sign of retarded ignition timing CAUTION Pinging or ignition knock is an early sign of detonation and possible impending engine damage Should pinging occur the throttle must be backed off and the cause determined and corrected Excessive retard is less obvious but equally destructive For that reason final timing should be confirmed with a timing light or other accepted procedure a Remove timing plug from left side engine crankcase See Picture 40 b Install timing mark view plug into crankcase See Picture 41 c Refer to service manual or instructions specific to the ignition system being used Find the RPM in which the ignition fully advances d Attach inductive pick up from timing light to spark plug wire NOTE If the timing light being used requires an external power source it is advised to use a separate stand alone battery Charging system pulsing may cause a fluctuation in the timing light strobe if the motorcycle s battery is used e Start motorcycle Run the engine to the full advance RPM of the ignition system and look for the timing mark through the view plug The front cylinder advance mark on the flywheel F130 should be seen through the view plug NOTE With the front cylinder advance mark centered in the timing hole at the full advance rpm of the ignit
24. et shaft bearing surface Install bearing on shaft with appropriate tool See Picture 5 oS NOTE Pinion and sprocket shaft bearings should be correct sizes but it is engine builder s responsibility to confirm flywheel endplay connecting rod sideplay bearing fit and all clearances in Unassembled Long Block at time of assembly It is of particular importance to check flywheel endplay and install different Timken bearing spacer if necessary The flywheel end play specification is 001 005 6 Lubricate pinion bearing and pinion shaft bearing boss with assembly lube Install bearing and secure with pinion shaft main bearing snap ring See Picture 6 NOTE Snap ring supplied by S amp S or identical replacement must be used with pinion bearing supplied in Super Sidewinder Plus Long Block Ends of snap ring are rounded on one side sharp on the other Install snap ring with sharp edge out away from flywheels Picture 4 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 7 Coat right main bearing race with assembly lube If applicable allow sealant to cure according to manufacturer s instructions then join left and right crankcase halves NOTE
25. g allow 5 minutes for the starter motor to cool NOTE If oil fails to appear at tappet screen port verify that oil line routing is correct and that the oil tank is full to the proper level Remove the check ball spring from under the cap of the shorter tower on the oil pump Replace cap to avoid losing oil from pump 5 Once oil is seen at the tappet screen port reassemble all removed or disconnected components 6 Start motorcycle Verify oil pressure NOTE Oil pressure indicator lamp should light when ignition is turned on Lamp will go out after engine is started and there is oil pressure at the switch in the crankcase 7 Verify that engine oil is returning to oil tank CAUTION Improper first time engine start up and break in procedure may cause head gasket failure 8 Initial start up Run engine approximately one minute at 1250 1750 rom DO NOT crack throttle or subject to any loads during this period as head gaskets are susceptible to failure at this time During this time check to see that oil pressure is normal that oil is returning the oil tank and that no leaks exist 9 Shut off engine and thoroughly check for any leaks or other problems Let engine cool to the touch 10 After engine has cooled start again and allow the motor to build some heat Engine should be run no longer than three to four minutes When the cylinders become warm hot to the touch approximately 150 shut the motor down and let it cool to
26. ge Engine damage caused by powder coating polishing glass bead blasting or other modification will not be covered under warranty HD 24626 87A Blue S amp S 31 4018 HD 24643 87A Red S amp S 31 4017 HD 24628 87A ASSEMBLY NOTE While S amp S has made every effort to insure that parts are correct it is the engine builder s responsibility to confirm fit and finish of all parts provided with Long Blocks prior to assembly Parts are deburred at S amp S and usually require no further preparation but must also be inspected by installer Individual parts should not be removed from protective plastic wrappers until needed After removal from plastic it is imperative that parts be thoroughly cleaned and dried preferably with compressed air When present rust preventative must be completely removed Additionally gaskets must be closely inspected for particles that could become dislodged and damage engine If assembly of Long Block must be interrupted seal openings and cover engine with plastic to protect from destructive contaminants CAUTION Failure to observe the above may result in engine damage not covered under warranty S amp S Pinion Shaft Main Bearing Fitting Charts Chart 1 Race Diameter Red S amp S 31 4017 HD 24628 87A Blue S amp S 31 4018 HD 24643 87A White Blue S amp S 31 4018 HD 24643 87A White S amp S 31 4005 HD 24626 87A Green S amp S 31 4016 HD 24628 87A i 1 7507 to S am
27. hot surfaces ignition advance 1 Top Oil Return Hole 2 Top Oil Supply Hole 3 Lower Oil Return Hole 4 Lower Oil Supply Hole 5 Middle Oil Supply Hole Picture 37 Picture 36 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 throttle should snap closed in all positions 10 Install air cleaner element and air cleaner cover using three 20 x 1 mounting screws provided Flat side of pleated filter element 17 0376 goes against air cleaner backplate Insure that element goes around outside edge of locating tang at 9 o clock position on backplate Rounded side of element with S amp S Part goes toward outside Correctly installed element will remain in place on backplate without support OIL LINE INSTALLATION 1 Refer to service manual Remove and wash oil tank thoroughly Clean or replace oil lines Reinstall oil tank 2 Install and connect oil filter mounting bracket to the front of engine crankcases if applicable Refer to service manual for oil hose routing and specifications Install new oil filter CAUTION Improper installation of oil lines or fittings may result in parts damage not covered under warranty NOTE S amp S Cycle recommends the use of Harley Davidson oil filters part numbers 63805 80A black or 63796 77A chrome or equivalent 3 Locate and install
28. ible fire hazard and loss of control of motorcycle with injury or death to rider and others IMPORTANT NOTES Lubrication S amp S supplies Torco Engine Assembly Lube with each Long Block It should be used as specified in following instructions While other brands of assembly lube are acceptable other lubricants are not In no instance should an aerosol lubricant be substituted for assembly lube Engine tuning Ignition timing and carburetor jetting are responsibilities of the customer If not thoroughly familiar with these procedures he should contact a professional mechanic CAUTION Incorrect ignition or carburetor tuning can cause extensive engine damage not covered under warranty Powder coating and polishing While S amp S does manufacture some powdercoated Long Blocks it does not recommend having engine parts powdercoated or otherwise modified elsewhere Many such procedures leave abrasive residues which are difficult to remove completely Also powder coating is cured at high temperatures that can change the strength characteristics of some metals Pinion Bearing Roller Diameter Bearing Color Code Roller Size Green S amp S 31 4016 2502 5004 H D 24628 87A White 2503 5006 2504 5008 2505 5010 S amp S 31 4005 CAUTION Glass bead and polishing residues are abrasive and can be difficult to remove from recesses and small passages Abrasive residues can cause oil contamination and extensive engine dama
29. in the lower ring groove then install one oil ring rail on either side of the separator S amp S recommends covering cylinder studs with i d fuel line to protect piston and rings until cylinder installed 7 Install cylinder head alignment dowels in cylinder 8 Apply very light film of motor oil to piston skirts and cylinder bores and install rear cylinder Install rear cylinder head referring to following section as necessary Picture 21 NOTE On Super Sidewinder Plus style Long Block if engine builder chooses to install front cylinder before installing rear head rear cylinder should be temporarily secured with head bolt and washers If cylinder not secured piston can lift cylinder and disturb base gasket if flywheels rotated 9 Repeat piston installation for front cylinder and cylinder head INSTALL CYLINDER HEADS NOTE If different camshaft or S amp S heads assembled by other source are used engine builder must confirm lift capability of valve springs and collars as well as valve to valve clearance Refer to Installation Information for S amp S Big Twin Camshafts CAUTION Failure to establish correct clearances can cause extensive engine damage not covered under warranty 1 Place head gasket on top of cylinder Locate on dowels installed in cylinder NOTE If Keviar reinforced graphite head gaskets are supplied with engine they are to be installed dry If copper head gaskets are supplied with kit prep
30. ion system the timing will be set at 30 f S amp S suggests the following timing specifications 111 32 Timing mark at the right side or towards the rear of the timing hole 117 30 Timing mark in the center of the timing hole 124 28 Timing mark at the left side or towards the front of the timing hole w N CAUTION Proper ignition timing is essential to safe engine operation Timing that s too advanced will result in detonation and engine damage Timing that s too retarded will result in engine over heating and engine damage NOTE If S amp 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 Vs V 0 E S S amp S Cycle does suggest the ignition system selected for use with this Super Sidewinder Plus engine utilize the V O E S Vacuum Operated Electric Switch Check the switch using a hand vacuum pump with a gauge and set the switch to trip at 6 in of vacuum Mercury See Picture 28 OIL TEMPERATURE Operating temperature for engine oil should be between 180 240 F If engine oil temperature stays above 240 and correct ignition timing has been verified S amp S Cycle suggests that an oil cooler be installed SYNTHETIC OILS S amp S Cycle suggests that the engine be broken in using a petroleum based oil After the break in there should be no problem in going with a s
31. ld 1 Bolt carb and insulator block to intake manifold using two 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 may bottom in holes Shorter manifold bolts must be used if insulator block is not installed CAUTION If insulator block is not installed lower manifold bolt may damage carburetor bowl causing possible gasoline leak WARNING Gasoline is extremely flammable and explosive under certain conditions Do not smoke around gasoline Gasoline fumes are toxic when inhaled Any gasoline leak or spill constitutes a health and fire hazard d Adjust throttle cables Picture 31 NOTE Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation Throttle must snap closed when released Cable routing must be free of tight bends to minimize friction between cable and housing 1 Turn threaded throttle pull open cable adjuster to remove excessive freeplay Adjust this cable to fully open the throttle plate when the throttle grip is twisted completely open 2 Remove the slack in the idle pull close cable with the cable adjuster and leave approximately of freeplay at the throttle grip 3 Test throttle to insure that it opens and closes freely Turn handlebars to extreme left and open and close throttle then turn bars to e
32. le damage to the primary drive WARNING Loose fasteners inside of primary chaincase may cause the transmission to lock up resulting in possible loss of control of motorcycle with injury or death to riders and others 6 Refer to the drive section of the appropriate service manual Tighten the transmission to the frame 7 Tighten the four lower crankcase fasteners to 35 ft lbs Picture 27 8 Install the upper engine mounting bracket Pay particular attention to alignment with frame Shim as needed Tighten bracket to head to 35 ft lbs Refer to specific frame make model year service manual for torque specification of upper bracket to frame fastener 9 Refer to the drive section of the appropriate service manual for reassembly of the primary drive and case Make certain to install new chaincase lubricant if applicable RUBBER MOUNT CHASSIS 1 Lift and support the transmission case to bring the rear engine mount pad relatively level with the bottom frame tubes 2 Place engine in position on rear engine mounting pad 3 Install and hand tighten rear engine mounting fasteners Install front mount with stabilizer if applicable and hand tighten 4 Refer to the drive section 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 CAUTION Failure to
33. mble pushrod tube cover assemblies Lubricate all o rings with a light coat of engine oil Top View Driveside Stage2 18 Ft Lbs Stage3 Turn additional 90 Figure 1 aor Ol l a a ae P P l if Picture 23 Insert pushrod tube O ring washers in lifter blocks See Picture 23 Install O rings in lifter blocks Install thick pushrod tube O rings in cylinder heads Determine pushrod placement by comparing lengths of each pushrod not including adjuster Longest pushrod is for front exhaust next longest for rear exhaust shortest for rear intake remaining pushrod for front intake See Picture 24 Screw pushrod lifter adjusters in to shortest length Set pushrods aside INSTALL ROCKER COVERS 1 All parts must be clean and dry To install place lower rocker cover gaskets on cylinder head A small amount of Hylomar or other thin gasket sealant may be used in corners to hold gasket in place on head No other sealant should be used Place lower rocker cover on gasket and cylinder head Install two of the 18 x 1 screws in front and rear left driveside holes of rocker housing Tighten screws two turns to hold rocker housing and gasket in place Install four remaining rocker housing screws Gradually tighten six screws to 18 ft lbs Using sequence illustrated in Figure 2 Measure clearance between rocker housing and valve spring See Picture 25 Minimum is 025 If necessary loosen screws and
34. nd gear cavities in pump body Remove excess to avoid contaminating gaskets Rotate gears as preliminary check for bind and to confirm that drive gear keys are properly installed 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 amp S HVHP oil pumps offer more than one location for oil supply fitting Lowest fitting should not be used on Dynas late FL s or other models with oil tank below transmission S amp S recommends stock placement for oil supply fitting in Dynas and late FL s See Picture 9 Picture 7 CAUTION Routing oil supply line to lowest fitting on models with oil tank below transmission could allow air to enter oil pump under certain circumstances causing air lock loss of lubrication and engine damage 3 Apply assembly lube to oil pump driveshaft and driveshaft bushing in crankcase See Picture 10 Install oil pump in normal fashion placing pump drive gear 33 4230 over driveshaft as shaft is passed through crankcase bushing Picture 8 Picture 10 Incorrect Picture 11 NOTE A dab of Hylomar or other thin gasket sealer in corners may be used to hold gaskets in place Otherwise gaskets should be installed dry 4 Install driveshaft gear key and snap ring NOTE Be sure drive sh
35. ntil pushrod can be rotated with the fingers with slight drag Continue loosening shortening pushrod one full turn 6 flats NOTE Shortening adjuster an additional six flats or full turn from zero lash often results in quieter pushrod operation This provides additional travel for the hydraulic piston assembly which can improve the ability of the hydraulic unit to maintain zero lash under normal operating conditions NOTE perform this operation on one cylinder at a time Do not turn engine until pushrod adjustment is complete CAUTION Turning engine while valve is held off the seat could result in valve to valve or valve to piston contact and serious valve train damage c Tighten lock nut d Follow the same procedure for all four push rods 1 NOTE Upon initial start up after modification HL T 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 20 x 7 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 reaches TDC on compression stroke 315 flywheel degrees past front piston TDC and both rear lifters are in lowest position on cam Repeat procedure for installing pushrods rockers and covers installing longer remaining pushrod in exhaust 13 After pushrod adjustment completed
36. of instructions NOTE Turn idle mixture screw in only far enough to contact seat Do not over tighten CAUTION Over tightening idle mixture screw may cause irreversible damage to carburetor body 14 Picture 30 2 Checksetting of idle speed adjusting screw part 50 0038 See Picture 30 Turn screw counterclockwise until it no longer contacts throttle linkage spool part 11 2385 Next turn screw clockwise until it just contacts spool Then turn additional turn clockwise to slightly open throttle plate b Install throttle cables on carburetor 1 Locate the correct throttle cable housing bracket in carburetor kit NOTE The carburettor kit is supplied with two different throttle cable brackets The shorter bracket part 11 2339 is designed for 1989 amp earlier style throttle cables The longer bracket part 11 2338 is for the throttle cables supplied with 1990 amp later motorcycles originally equipped with a CV carburettor 2 Apply drop of Loctite 243 or equivalent to threads of cable bracket screw and install bracket on carburetor 3 Install opening side throttle cable barrel fitting and throttle cable in throttle linkage and appropriate side of throttle cable housing bracket Opening side cable housing outside diameter is smaller and measures 190 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 manifo
37. oil tank vent hose to fitting above the oil pump on crankcase See Picture 36 4 Verify location of oil pump feed fitting on the pump cover and install oil supply hose from oil tank See Picture 37 5 Fill the oil tank to the proper level NOTE S amp S Cycle recommends the use of a lubricant oil developed specifically for 4 stroke roller bearing air oil cooled motorcycle engines SAE 20W50 Ambient Temperature F Above 20 100 SAE 50 Above 60 100 SAE 60 Above 80 100 Picture 38 FINAL ASSEMBLY 1 Refer to service manual for installation of foot rest assemblies if removed for engine replacement 2 Reassemble transmission shift linkage if necessary NOTE On certain models it may be necessary to switch the shift linkage to the outside of the shift lever See Picture 38 Make certain that there is clearance between the shifter rod and the engine crankcases 3 Reinstall and connect the fuel tank Refer to appropriate service manual Inspect fuel lines and clamps replace as necessary a Check fuel line connections and routing Avoid hot surfaces Make certain that the protective cover has been placed over fuel line and that it is clear from sharp edges and abrasive surfaces b Reassemble components that were removed or disassembled for installation Consult authorized H D service manual for installation procedure for stock parts not covered in S amp S instructions c Check fuel needle
38. one side as far as possible and measuring gap between rocker arm and support at opposite end The specification for endplay is 001 012 If endplay is insufficient carefully remove material from end or rocker arm to achieve correct endplay Leave a smooth non abrasive surface finish 5 Apply Loctite 243 to rocker arm support bolts Insert two 18 x 2 socket head bolts and washers in left drive side of support and two 18 x 27 hex head bolts in right cam side of support 6 Place rocker arm support assembly in rocker housing Align pushrod ends with sockets in rocker arms and tighten the four support bolts to 18 ft lbs 7 Apply Loctite 243 to the 20 x 1 and 20 x 2 socket head screws Install washers on both screws Insert 1 screw with washer in center left side of support and 2 screw with washer in center right side of support Tighten both to 120 in Ibs 8 The HL T kit is installed in the lifters and the pushrods must be adjusted as follows a Extend pushrod until it contacts the hydraulic piston assembly in the lifter body then extend pushrod an additional four complete turns until piston assembly is in contact with HL T spacer and the valve is lifted off of its seat If tappets contain oil as when pushrods are readjusted after engine has been run or if all oil was not removed during installation allow at least 10 minutes for piston assembly to bleed down b Loosen pushrod adjustment u
39. ooser fit is desired for competition applications CRANKCASES NOTE S amp S crankcases are sold in matched sets only Individual case halves are not available 1 Disassemble crankcases amp wash in hot soapy water Rinse case halves and blow dry with compressed air Check all internal passages Coat bearing surfaces with a light oil to prevent rust 2 Install piston oilers right side crankcase a Lubricate o ring with engine oil and install in piston oiler b Apply Loctite 243 to screws Install oilers tighten screws to 25 in lbs See Picture 1 INSTALL FLYWHEELS IN CRANKCASE 1 Thoroughly clean parts according to instructions previously mentioned 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 2 NOTE S amp S does not recommend using a press to install sprocket shaft bearings as this can push flywheels out of true Correct bearing installation tools are available from Harley Davidson Jim s Machine and other sources Picture 3 2 Apply coat of assembly lube to Timken bearing installed in Step 1 3 Place left side crankcase half on sprocket shaft and bearing insuring that connecting rods are in correct positions See Picture 3 Install included Timken bearing spacer See Picture 4 Lubricate rollers of remaining Timken bearing with assembly lube Apply assembly lube to bearing inner race and sprock
40. ormal service If looser fit is desired select bearing color directly to right of color indicated from selection process If color indicated from selection process is located in right color column go to next row directly below and select color in left color column 2 Fitment Method B Use Chart 2 a Refer to information tag on crankcases to determine final honed size of inside diameter of pinion shaft main bearing race b Measure pinion shaft bearing surface diameter c Subtract 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 Picture 2 EXAMPLE Pinion bearing race inside diameter is 1 7510 Pinion shaft bearing surface diameter is 1 2499 1 7510 minus 1 2499 is 5011 Difference of 5011 splits 5009 to 5013 range in third row exactly Corresponding BLUE color code in right column should be used Notice that 5011 fits in several range groups Try to select group where difference falls closest to middle of range If you are not sure select color that corresponds with group closer to top of chart This will provide slightly looser bearing fit and help prevent bearing seizure Selecting next color up on chart may also be done if l
41. ould be 005 015 Install camshaft with lockwasher and thrust washer into cam bearing Install gearcase cover with new gasket and tighten all fasteners to 120 in lbs Measure camshaft end play with a feeler gauge or dial indicator at four different positions of crankshaft rotation Select correct thrust washer to achieve proper end play Apply light coat of assembly lube to cam bearing camshaft lockwasher thrust washer breather gear and to breather gear cavity inside engine and coat of motor oil to cam lobes Place camshaft lockwasher in case with ears down and flat edge towards rear of engine See Picture 16 Picture 17 8 9 la Picture 16 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 Install breather gear and shim aligning breather gear timing mark with mark at eight o clock on cam gear See Picture 17 Use connecting rods to rotate flywheels and insure gears rotate freely Apply assembly lube to ends of shafts and meshing surfaces of gears and remove excess Apply assembly lube to gear cover bushings Install gasket and cover and tighten screws to 120 in Ibs NOTE Gear cover should slide smoothly over alignment dowels and must not be forced Confirm that gasket material does not overlap oil passages in crankcase and gear cover See Pictur
42. p S 31 4005 1 7509 HD 24626 87A Chart 2 Bearing Race Diameter Minus Pinion Shaft Bearing Color Code Bearing Diameter cot ST vie Sas S amp S 31 4018 HD 24643 87A S amp S 31 4017 HD 24641 87A Picture 1 FLYWHEELS Confirm pinion shaft main bearing fit Correct size bearing is supplied with engine but must be verified by engine builder Flywheel assembly can then be prepared for installation NOTES Refer to information tag on crankcases for final honed size of pinion shaft main bearing race S amp S pinion shaft main bearing fitting charts 1 and 2 use H D bearing color codes All measurements must be taken with parts at room temperature approximately 70 F 1 Fitment Method A Use Chart 1 a Refer to information tag on crankcases to determine final honed size of inside diameter of pinion shaft main bearing race b Measure pinion shaft bearing surface diameter c Cross reference pinion race inside diameter with pinion shaft bearing surface outside diameter to determine correct color code EXAMPLE Pinion shaft bearing surface diameter measures 1 2499 and is between 1 2498 and 1 2500 in left Pinion Shaft Bearing Diameter column Pinion bearing race inside diameter is 1 7510 and falls between 1 7509 and 1 7511 in middle Bearing Race Diameter column Correct bearing color code where two columns intersect is BLUE Selecting color where columns intersect provides proper fit for n
43. re of an S amp S part the breech 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 anda customer 5 S amp S parts are designed exclusively for use on Harley Davidson motorcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application INTRODUCTION Super Sidewinder Plus Long Block Instructions often refer to procedures described in other S amp S instructions or a Harley Davidson Service Manual These materials should be cross referenced as necessary All Super Sidewinder Plus Long Blocks are designed for frames that accept Harley Davidson Evolution Big Twin engines and will fit stock H D and similar frames without modification S amp S strongly recommends trial fitting every engine before frame is painted or powder coated Because the Super Sidewinder Plus crankcase is inch wider than stock fit of exhaust rear brake master cylinder and foot controls must be closely checked when installing the Super Sidewinder Plus Long Block Some components may require modification WARNING In some instances brake master cylinder must be spaced out from frame to clear crankcase UNDER NO CIRCUMSTANCES SHOULD MASTER CYLINDER OR BRAKE LINE BE ALLOWED TO CONTACT EXHAUST PIPE IN FINAL INSTALLATION Heat transferred to brake fluid may expand and cause brakes to seize resulting in poss
44. rvice is required the original purchaser must notify S amp S of the problem immediately Some problems can be rectified by a telephone call and need no further action A part that is suspected of being defective must not be replaced 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 it must be packaged properly to avoid 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 was made by S amp S and the part was found to be defective repair replacement or refund will be granted Additional Warranty Provisions 1 No part shall be returned to S amp S without first contacting the company and obtaining a Return Authorization RA number 2 S amp S shall have no obligation in the event an S amp S part is modified by any other person or organization or if another manufacturer s part is substituted for one provided by S amp S 3 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 break in or maintenance improper use abnormal operation or any other misuse or mistreatment 4 S amp S shall not be liable for any consequential or incidental damages resulting from the failu
45. sts to lower mounting bracket Shim if necessary Hand tighten mounting hardware 6 Tighten exhaust flange nuts at head to 60 80 in Ibs 7 Refer to specifications for the appropriate model and tighten the remaining mounting hardware to the recommended torque values WARNING In some instances brake master cylinder must be spaced out from frame to clear crankcase UNDER NO CIRCUMSTANCES SHOULD MASTER CYLINDER OR BRAKE LINE BE ALLOWED TO CONTACT EXHAUST PIPE IN FINAL INSTALLATION Heat transferred to brake fluid may expand and cause brakes to seize resulting in possible fire hazard and loss of control of motorcycle with injury or death to rider and others NOTE Make certain that the exhaust system is not pre loaded or in a bind at the lower mounting points Make all spacing adjustments prior to final tightening of the upper exhaust mounting hardware at the cylinder heads Failure to follow this procedure may cause excessive vibration and result in failure of exhaust pipes or mounting hardware CARBURETOR 1 Install Carb a Check idle mixture and idle speed screw settings 1 Check setting of idle mixture screw part 11 2354 on top of carb body See Picture 29 Turn screw clockwise to close screw counting number of turns to fully closed position setting should be 17 turns Reset by turning screw counterclockwise to 1 turns open After engine is started screw must be reset as explained in Adjusting Idle Mixture section
46. xtreme right and open and close throttle If throttle binds loosen idle cable adjuster to put more freeplay in cable Tighten adjusting screw locknuts after making final adjustments NOTE Throttle must not bind and must snap shut to fully closed position when released WARNING If throttle does not return to fully closed position when released it may inadvertently stick open causing possible loss of control of motorcycle and personal injury to operator or others e Slip fuel overflow hose onto fitting on carb bowl and neatly route behind rear cylinder pushrod tubes Exit end of overflow hose must extend down below engine and away from exhaust pipes See Picture 32 WARNING Overflow hose must not contact hot surface such as exhaust pipe where it could melt and catch fire f Slip hose clamp over end of fuel line with 90 bend Apply thin coat of oil to carb fuel inlet fitting and slip end of fuel line with 90 bend on fitting Position fuel line in such a way as to avoid contact with cylinders and other hot engine parts Tighten hose clamp Slip protective fuel line covering over fuel line and position where contact with engine parts could occur On models equipped with fuel line support guide use guide if possible Connect other end of fuel line to gas tank petcock using hose clamp provided g Verify installation and connection of vent hose from front cylinder head to vent fitting on top of carburettor intake manifold
47. ynthetic oil using the same viscosity range according to ambient temperature as a petroleum oil The synthetic oil should also be motorcycle specific S amp S Recommended Regular Service Intervals nee interval Engine Oil amp Filter Change at 50 500 2 500 miles every 2 500 miles thereafter 1 Air Cleaner Inspect at 50 and 500 miles every 2 500 miles thereafter Replace every 5 000 miles 2 Tappet Oil Screen Inspect at 50 and 500 miles every 2 500 miles thereafter Petcock Lines amp Fittings Vacuum Lines Inspect at 50 and 500 miles every 2 500 miles thereafter Fuel Tank Filter Screen amp In Line Fuel Filter If used 0 0 0 cc cccccccecceseeesssseeaeeeeeeeseeeeeeeenens Every 5 000 miles Engine Idle Speed Operation of Throttle amp Enrichment Device Control Adjust as required Inspect and lubricate throttle cables at 500 miles and every 2 500 miles thereafter Spark Plugs Inspect every 5 000 miles Replace every 10 000 miles or as needed Ignition Timing Inspect every 5 000 miles Engine Mounts Inspect every 500 miles and every 5 000 miles thereafter External Fasteners Except Engine Head Bolts Re torque at 500 miles and every 5 000 miles thereafter S amp S recommends that petroleum based oil not specifically formulated for air cooled motorcycles should be changed every 1 000 miles 2 Replace more frequently if required or if engine is operated in a dusty environment Because every industry has a
Download Pdf Manuals
Related Search