- S&S Cycle
Contents
1. 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 in2. Recommended wristpin endplay is 010 to 060 and is determined by subtracting length of wristpin with button on each end from finished cylinder bore To make fitting easier S amp S buttons come in four widths A buttons are thinnest and D buttons are thickest Use two A buttons Part 94 9251 for bore sizes 37 6 std to 37 6 040 two B buttons Part 94 9252 for bore sizes 3746 050 to 3746 090 two C bottoms Part 94 9258 for bore sizes 3 std to 3 030 and two D buttons Part 94 9259 for bore sizes 3 040 to 3 070 6 Special notched aluminum buttons are supplied with Piston Series 92 3500 and 92 3700 When installed notch simulates oil ring groove and helps support oil ring Buttons should not protrude beyond ring land diameter when in place 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 be
3. all others is 015 to 035 E Compression ring end gap on big twins with 4 bore is 017 to 025 F Oil ring rail end gap on big twins with 4 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 Piston Series 92 1210 92 1550 92 1556 and 92 1560 have a ring support rail that needs to be installed before any other rings are installed 5 If your piston application uses oil ring support rails install ring support rail in front piston so that the end gap is toward the rear 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 The dimple in the ring must face down and be installed in the gap above the wrist pin on both pistons See picture below 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 NOTE Confirm that ends of expander do not overlap during installation Properly installed expander will appear larger than piston but will compress wh
4. be installed as desired unless piston skirt has piston to piston clearance bevel on one side In such case bevel must face center of engine If only one piston has bevel it will be for rear cylinder See 4 immediately below 4 Some piston sets have all piston to piston clearance machined into rear piston In such cases rear piston must be installed with bevel or notch toward front If dimple is present piston must be installed with dimple in correct position The dimple in the ring should face down and be installed in the gap above the wrist pin This dimple keeps the support rail from rotating 5 Check all installations for minimum of 060 clearance between pistons at closest point near bottom of stroke 6 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 Failure to establish proper clearances can result in severe engine damage not covered under warranty WRISTPIN RETAINER INSTALLATION NOTE Thoroughly clean wristpin before install
5. first 1000 miles the motor can be run in a normal but conservative manner You can be more liberal with the rom 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
6. 1556 002 to 0025 0032 to 0045 92 2510 002 to 0025 003 to 0035 92 1560 002 to 0025 0032 to 0045 92 2600 002 to 0025 003 to 0035 92 1620 002 to 003 0035 to 004 92 2610 002 to 0025 003 to 0035 92 1630 0015 to 002 0025 to 0035 92 2700 0015 to 002 0025 to 0035 92 1630 002 to 003 0035 to 004 92 2720 002 to 003 0035 to 004 92 1640 0015 to 002 0025 to 0035 002 to 003 0035 to 004 92 1640 002 to 003 0035 to 004 0025 to 003 0045 to 0055 92 1800 0025 to 003 0045 to 0055 0035 to 004 005 to 006 92 1800 0035 to 004 005 to 006 92 2900 0035 to 004 0035 to 004 92 1830 0035 to 004 005 to 006 92 3700 003 to 0035 0045 to 0055 92 1840 0035 to 004 005 to 006 _ With Slotted Oil Ring Groove With holed Oil Ring Groove PISTON INSTALLATION 1 Piston Series 92 1600 92 1620 92 1630 92 1640 92 2400 92 2420 92 2440 92 2460 92 2700 92 2720 and 92 2730 have offset wristpins and must be installed with dimple in piston dome toward right or cam side of engine Piston Series 92 1060 92 1070 and 92 1080 92 1210 92 1550 92 1556 92 1560 also have offset wristpins and must be installed with symbol fiCAM toward right or cam side of engine 2 Piston Series 92 3500 and 92 3700 have larger intake valve reliefs which must be installed toward intake valves or middle of engine 3 Most other pistons have no special features They can
7. Instruction 51 1028 SES Cycle Vue 02 18 13 14025 Cty Hwy G PO Box 215 Copyright 2009 2010 2013 Viola Wisconsin 54664 by S amp S Cycle Inc Phone 608 627 1497 Fax 608 627 1488 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com All rights reserved Printed in the U S A Website www sscycle com Installation Instructions for S amp S 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
8. ation 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 matter 2 Round wire style clips identical to and interchangeable with stock Harley Davidson Evolution 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 NOTE Round wire style clip ends must be deburred before installation 3 Tru Arc style clips should be installed with proper tool Clips should not be used with wristpins having chamfer on end greater than a Install clip with open side facing downward and sharp edge of clip to outside of wristpin hole away from wristpin Be sure clip is fully seated in groove 4 Spiral Loc style clips are installed by slowly working clip into wristpin hole using thumb nail small screwdriver or awl in circular turning motion Once entire clip is in hole push end of clip into groove followed by rest of clip Be sure clip is fully seated in groove 5 PTFE wristpin buttons must be used only in pistons where buttons are fully supported in wristpin hole Buttons are used in place of and not in conjunction with conventional wristpin clips
9. 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 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 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 The first 50 miles are most critical for new rings and piston break in Engine damage is most likely to occur during this period Keep heat down by not exceeding 2500 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
10. en cylinder installed B Top compression ring gap should be 135 or approximately 412 to left of oil expander gap C Second compression ring gap should be 135 or approximately 41 to right of oil expander gap NOTE Fit wristpins at 0007 to 001 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 Ifnew 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 gaskets 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
11. ion if an S amp S part is used in any other application GENERAL INFORMATION I 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 7 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 12 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 220 280 grit stone for final honing of stock bore and Sidewinder S amp S T124 and S amp S big bore cylinders 320 grit stone is recommended for engines using S amp S 92 4500 92 4510 or 92 4520 pistons 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 assemb
12. ion 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 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 Cast iron 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 32 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 31 2 bore is 015 to 035 D Oil ring rail end gap on
13. led engine Cylinders will distort if torque plates are not used i E T ii CAUTION Failure to follow instructions 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 Piston Fitment Chart Piston Series Loose Fit Piston Series Loose Fit 92 1060 0023 to 0025 0035 to 0045 92 1900 002 to 0025 003 to 004 92 1080 0023 to 0025 0035 to 0045 92 1910 002 to 0025 003 to 004 92 1100 0023 to 0025 0035 to 0045 92 1930 002 to 0025 003 to 004 92 1110 0023 to 0025 0035 to 0045 92 1940 002 to 0025 003 to 004 92 1120 0023 to 0025 0035 to 0045 92 2000 002 to 0025 003 to 004 92 1130 0023 to 0025 0035 to 0045 92 2010 002 to 0025 003 to 004 92 1200 002 to 0025 0032 to 0045 92 2020 002 to 0025 003 to 004 92 1210 002 to 0025 0032 to 0045 92 2030 002 to 0025 003 to 004 92 1400 002 to 0025 0032 to 0045 002 to 0025 003 to 004 92 1410 002 to 0025 0032 to 0045 002 to 0025 003 to 004 92 1420 002 to 0025 0032 to 0045 92 2420 0008 to 0013 002 to 0025 92 1430 002 to 0025 0032 to 0045 92 2440 0008 to 0013 002 to 0025 92 1436 002 to 0025 0032 to 0045 92 2460 0008 to 0013 002 to 0025 92 1550 002 to 0025 0032 to 0045 92 2500 002 to 0025 003 to 0035 92
14. neath 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 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 SaNa Figure 1 Figure 2 Figure 3 AX 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 tors
15. r 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 obligat
16. stallation 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 need no further course of action A part that is suspect of being defective must not be replaced by a Dealer without prio
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