S&S® Cycle, Inc.
Contents
1. 0045 to 0055 0045 to 0055 0045 to 0055 0045 to 0055 0035 to 004 0045 to 0055 106 5515 0035 to 004 0045 to 0055 0045 to 0055 OLD S amp S PN S THAT ARE SUPERCEDED 92 2500 92 2510 92 2501 92 2511 92 2502 92 2512 92 2503 92 2513 92 2504 92 2514 92 2606 92 26 92 2607 92 261 92 2608 92 26 co 92 2609 92 261 o 92 2506 92 25 92 2507 92 2517 106 5521 106 5522 106 5527 106 5516 106 5517 iston Set 37 020 HC 791 WP 1936 84 bt Piston Set 3 2 030 HC 791 WP 1936 84 bt iston Set 3746 x 434 Std HC 791 WP 1936 84 bt 0035 to 004 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 0045 to 0055 92 2508 92 25 co 92 2509 92 2519 92 2800 92 2720 92 2730 106 5528 106 5529 106 5523 106 5524 iston Set 3746 x434 010 HC 791 WP 1936 84 bt iston Set 3746 x 434 020 HC 791 WP 1936 84 bt 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 93 2900 92 2801 92 2721 93 2901 92 2731 92 2802 92 2722 92 2732 106 5530 106 5777 106 5525 106 5526 iston Set 3746 x 434 030 HC 791 WP 1936 84 bt iston Set 3746 x 434 040 HC 791 WP 1936 84 bt 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 93 2902 92 2803 92 2723 93 2903 92 2733 92 2804 92 2724 92 27342. 106 5778 106 5779 106 5783 106 5784 iston Set 3746 x 434 050 HC 791 WP 1936 84 bt iston Set 3746 x 434 060 HC 791 WP 1936 84 bt 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 93 2904 92 2805 92 2725 93 2905 92 2735 92 2806 92 2726 92 2736 106 5780 106 5781 Piston Set 3746 x 434 070 HC 791 WP 1936 84 bt iston Set 3746 x 434 080 HC 791 WP 1936 84 bt 106 5785 106 5786 106 5787 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 92 2807 92 2727 92 2737 93 2906 93 2907 92 2808 92 2728 92 2738 106 5782 106 5535 106 5536 106 5788 106 5532 Piston Set 3746 x 434 090 HC 791 WP 1936 84 bt Piston Set 354 Standard HC 791 WP 1936 84 bt iston Set 3 010 HC 791 WP 1936 84 bt 0035 to 004 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 0045 to 0055 f 93 2908 92 2809 92 2729 92 2739 93 2909 106 5537 106 5538 iston Set 3 020 HC 791 WP 1936 84 bt iston Set 3 030 HC 791 WP 1936 84 bt 106 5533 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 92 1801 92 1831 92 1841 92 1621 92 1631 92 1641 92 1802 92 1832 92 1842 92 1622 92 1632 92 1642 106 5789 106 5542 106 5534 106 5790 106 5539 iston Set 3 060 HC 791 WP 1936 84 bt iston Set 33
3. 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 A WARNING Means there is the possibility of injury to yourself or others special significance 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 atelephone call and need no further course of action A part that is suspect of being defective must not be replaced by a Dealer without
4. 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 exclusively for use in Harley Davidson and other American v twin motorcycles S amp S shall have no warranty or liability obl
5. 46 010 HC 791 WP 1972 85 xl 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 92 1803 92 1833 92 1843 92 1623 92 1633 92 1643 92 1806 92 1836 92 1846 92 1626 92 1636 92 1646 106 5543 106 5544 106 5540 106 5541 iston Set 3346 4 020 HC 791 WP 1972 85 xl iston Set 3346 030 HC 791 WP 1972 85 xl 0035 to 004 0035 to 004 0045 to 0055 0045 to 0055 92 3701 92 3702 106 5791 106 5548 106 5549 iston Set 3346 060 HC 791 WP 1972 85 xl 106 5792 Piston Set 3 2 Standard DD 792 WP 106 5545 883 to 1200 conversion 1986 up xl Piston Set 31 010 DD 792 WP 106 5546 883 to 1200 conversion 1986 up xl 0035 to 004 0025 to 0030 0025 to 0030 0045 to 0055 0035 to 0045 0035 to 0045 92 3703 92 3706 92 2447 106 5550 cc Piston Set 37 020 DD 792 WP 883 to 1200 conversion 1986 up xl 106 5547 Piston Set 32 Standard FD 792 WP 1984 99 bt Piston Set 314 010 FD 792 WP 1984 99 bt Piston Set 314 020 FD 792 WP 1984 99 bt Piston Set 314 030 FD 792 WP 1984 99 bt 0025 to 0030 0025 to 0030 0025 to 0030 0035 to 0045 0035 to 0045 0035 to 0045 0025 to 0030 0035 to 0045 106 5794 0025 to 0030 0035 to 0045 92 2448 92 2426 92 2427 92 2428 92 2429 PISTON INSTA
6. 500 rpm Avoid lugging the motor riding in hot weather or in traffic Vary the engine speed Do not lug the engine We recommend changing the oil at 50 miles F The next 500 miles should be spent running engine no faster than 3500 rpm or 60 mph Avoid continuous steady speeds and do not lug the engine Vary engine rpm We recommend changing the oil again at 500 miles Lugging or running engine prematurely at sustained high rpm may result in damage to pistons and other engine components S amp S voids its guarantee if engine is not broken in properly G For the balance of the first 1000 miles the motor can be run in a normal but conservative manner You can be more liberal with the rpm range and motorcycle can be operated at normal highway speeds Avoid overheating or putting any hard strain on the engine no drag racing dyno runs excessive speed trailer towing or sidecar operation H After 1000 miles verify carburetor jetting and adjustment Change the engine oil Motorcycle can now be operated normally l Have Fun
7. 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 impair your judgment Start installation when you are fresh Be sure all federal state and local laws are obeyed with the
8. Do not shorten expander for any reason Installation is straightforward with one rail placed above expander other rail below expander Rails may be shortened to correct gap but burrs must be carefully removed NOTE In some cases same expander is used for several bore sizes Oversize rings will not necessarily have a larger expander SE Su Figure 1 Figure 2 Figure 3 CAUTION Failure to remove burrs may cause engine damage incorrect installation of rings may result in poor performance excessive oil consumption or engine damage 3 For ring kits in which section 2 above does not apply compression rings may be of plain cast iron type chrome faced cast iron type moly faced cast type or chrome type A The most common combinations are 1 Two chrome faced cast rings 2 One chrome faced cast ring amp one plain cast ring 3 One moly faced cast ring amp one plain cast ring B Install as follows 1 Chrome faced or moly faced ring always goes in top groove 2 Plain cast ring usually goes in second groove Plain cast type is usually a reverse torsion ring distinguished by an inside diameter bevel on one side of ring and a dot or oversize mark on other side See Figure 1 above If two cast iron compression rings are supplied in a set check to see if one is reverse torsion style ring with dot and bevel Reverse torsion style ring always goes in second groove with dot up if present C The following rules apply to compression ring
9. Instruction 106 6072 2 18 10 Copyright 2009 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Vue 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 Website www sscycle com Fax 608 627 1488 Installation Instructions for S amp S Forged Pistons 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 used in reference only S amp S Cycle is not associated with Harley Davidson Inc SAFE INSTALLATION AND OPERATION RULES
10. LLATION Picture 1 NOTE Pistons may have piston to piston clearance on both the front and rear The notches must face each other Pistons for pre 1984 application have no wristpin offset and can be installed in the front or rear Pistons for 1984 up applications should be installed according to the marks on the top of the piston 1 Check all installations for minimum of 060 clearance between pistons at closest point near bottom of stroke 2 Check all installations for minimum of 060 clearance between pistons and flywheels at bottom of stroke Replacement pistons may or may not have adequate clearance Compare replacement pistons with ones being replaced and make corrections accordingly NOTE In all cases it is the engine builder s responsibility to confirm proper clearances when assembling an engine This is especially critical with performance components such as higher compression pistons and high lift camshafts In addition to clearances mentioned 060 valve to piston clearance must be confirmed Peto 0 Failure to establish proper clearances can result in severe engine damage not covered under warranty WRISTPIN RETAINER INSTALLATION NOTE Thoroughly clean wristpin before installation paying particular attention to bore Pass clean lint free cloth back and forth through wristpin bore several times to insure removal of contaminants 1 If wristpin clips are used insure that groove in piston is free of burrs and foreign matt
11. askets are susceptible to failure at this time During this time check to see that oil pressure is normal that oil is returning to the oil tank and that no leaks exist B Shut off engine and thoroughly check for any leaks or other problems Let engine cool to the touch C After engine has cooled start up 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 room temp Follow the same cautions as for the initial start up and continue to watch for problems D 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 rpm 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 motor reaches full operating temperature The motor should not reach that temperature during these cycles Do not allow engine temperature to become excessive After the motor has cooled to room temperature for the final time you are ready to start the 500 mile engine break in process E Thefirst 50 miles are most critical for new rings and piston breal in Engine damage is most likely to occur during this period Keep heat down by not exceeding 2
12. er 2 Round wire style clips identical to and interchangeable with stock Harley Davidson Evolution clips Round wire clips require wristpins with specially chamfered ends Install wire clips using procedure recommended in a Harley Davidson service manual End of clip must rest over notch in piston below wristpin hole to allow removal of clip in future Be sure clip is fully seated in groove RING INSTALLATION 1 Ring widths on some piston series have changed from time to time Part numbers of rings originally supplied with pistons should be recorded for future reference in the event replacement rings are required 2 The majority of ring kits presently supplied by S amp S contain a moly faced top ring a cast reverse torsion second ring and a three piece oil ring This may be confirmed as follows A Top compression ring has a gray finish that is relatively light in color and may or may not have a slight bevel along the inner edge It has no dot or other identifying mark The light color can best be recognized by comparing compression rings to each other beneath a good light Install light colored ring without dot in top groove bevel up If there is no bevel ring can be installed either side up B Second compression ring has a darker charcoal gray finish and slight bevel along inner surface This ring has a dot See Figure 1 Install in second or middle groove with dot up C Oil rings are three piece type with two rails and one expander
13. identification and placement Rules are listed in order of priority In other words if both Rule 2 and Rule 4 apply for example Rule 2 will be followed and Rule 4 ignored 1 Chrome or moly ring goes in top groove 2 Castiron regular or reverse torsion ring goes in second groove 3 Any identifying pip marks dots or oversize marks go to top of piston 4 Ring with one dot goes in top groove ring with two dots goes in second groove 5 If both rings are identical and have one dot or two dots either ring can go in either groove 6 If ring has dot and inside diameter bevel dot goes to top of piston See Figure 1above 7 If ring has no dot but does have inside diameter bevel bevel goes to top of piston See Figure 2 above 8 If ring has no dots and no bevel it can go either way See Figure 3 above 4 Ring Gap Measurements A Compression ring end gap on big twins with 3746 3 2 and 3 bore is 014 to 022 B End gap on all other compression rings is 016 to 024 C Oil ring rail end gap on big twins with 3746 3 and 35 bore is 015 to 035 NOTE In certain instances the next oversize ring set may be supplied with pistons for example 060 oversize rings with 050 pistons In this case end gaps must be measured and rings filed as necessary Ends must then be carefully deburred Failure to deburr rings may result in engine damage 5 Install ring support rail in front piston so that the end gap is toward the rear
14. igation if an S amp S part is used in any other application GENERAL INFORMATION For maximum piston and ring life fit pistons using close fit dimensions Close fit requires absolute adherence to new engine break in as described on page 6 For immediate drag strip use fit pistons using loose fit dimensions Break in rings and pistons with 50 easy miles if possible Piston and ring life will be reduced with loose fit dimensions Measure all pistons at widest point across thrust face perpendicular to wristpin hole Several measurements should be taken to locate widest point Typically this will be at bottom of piston skirt for pre 1984 big twins and approximately below level of wristpin hole in pistons for Harley Davidson Evolution and Twin Cam 88 engines If pre 1984 piston is notched for placement in rear cylinder use measurement directly above notch for skirt measurement S amp S recommends 4220 4280 grit stone for final honing of stock bore and Sidewinder S amp S T124 and S amp S big bore cylinders Follow procedure recommended in Harley Davidson service manual for boring and honing stock bore big twin and Twin Cam 88 cylinders Follow instructions included with S amp S Cylinder Torque Plate Kit when boring and honing S amp S 3 or 4 4 bore cylinders Torque plates must be used to simulate compressive stress in an assembled engine Cylinders will distort if torque plates are not used CAUTION Failure to follow instruct
15. ions and perform required clearancing installation and or break in procedures may result in damage to pistons and or other engine components not covered under warranty SET PART NUMBER 106 5495 106 5496 106 5497 106 5498 106 5773 106 5504 106 5506 106 5775 106 5511 106 5513 106 5519 106 5520 PART STAMPED ON PISTON DESCRIPTION Piston Set 3746 Std LC Forged 791 WP 1936 84 bt Pis Pis Piston Set 374 amp Standard HC 791 WP 1936 84 bt Pis Piston Set 3746 020 HC 791 WP 1936 84 bt Piston Set 3746 030 HC 791 WP 1936 84 bt Piston Set 3746 040 HC 791 WP 1936 84 bt on Set 3746 010 HC 791 WP 1936 84 bt Piston Set 32 Standard LC 791 WP 1936 84 bt Piston Set 3 010 LC 791 WP 1936 84 bt Piston Set 31 020 LC 791 WP 1936 84 bt Piston Set 37 030 LC 791 WP 1936 84 bt Piston Set 3 Standard HC 791 WP 1936 84 bt Piston Set 314 010 HC 791 WP 1936 84 bt 0035 to 004 LOOSE FIT 0045 to 0055 Piston Set 3746 010 LC Forged 791 WP 1936 4 bt 0045 to 0055 on Set 3746 020 LC Forged 791 WP 1936 84 bt 0045 to 0055 Piston Set 3746 030 LC Forged 791 WP 1936 84 bt 0045 to 0055 on Set 3746 040 LC Forged 791 WP 1936 84 bt 106 5774 0035 to 004 0045 to 0055 0035 to 004 0045 to 0055 0035 to 004 0045 to 0055 0045 to 0055 0045 to 0055
16. of the cylinder 90 from wristpin Install ring support rail on rear piston so that the end gap is toward front of the cylinder 90 from wristpin 6 Ring Gap Placement A Oil ring 1 Expander gap must be in center of thrust face rear of piston or 90 from wristpin 2 Bottom rail gap should be approximately 1 5 or 45 to right of expander gap 3 Top rail gap should be approximately 1 5 or 45 to left of expander gap 5 NOTE Confirm that ends of expander do not overlap during installation Properly installed expander will appear larger than piston but will compress when cylinder installed B Top compression ring gap should be 135 or approximately 41 to left of oil expander gap C Second compression ring gap should be 135 or approximately 4 2 to right of oil expander gap NOTE Fit wristpins at 0007 to 0014 ENGINE BREAK IN PROCEDURE NOTES S amp S engines are designed for high performance and as such are not as tolerant of inadequate break in Correct break in will assure longer engine life and will prevent unnecessary engine damage Engine damage caused by improper break in is not covered under the S amp S warranty f new pistons have not been installed only steps A B and C are required f new pistons have been installed all break in steps are required A Initial start up Run engine approximately one minute at 1250 1750 rpm DO NOT crack throttle or subject to any loads during this period as head g
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