- S&S Cycle
Contents
1. A part that is suspect of being defective must not be replaced by a Dealer without prior authorization from S amp S If it is deemed necessary for S amp S to make an evaluation to determine whether the part was defective a return authorization number must be obtained from S amp S The parts must be packaged properly so as to not cause further damage and be returned prepaid to S amp S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem how the part was used and the circumstances at the time of failure If after an evaluation has been made by S amp S and the part was found to be defective repair replacement or refund will be granted ADDITIONAL WARRANTY PROVISIONS 1 S amp S shall have no obligation in the event an S amp S part is modified by any other person or organization 2 S amp S shall have no obligation if an S amp S part becomes defective in whole or in part as a result of improper installation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the S amp S part 3 S amp S shall not be liable for any consequential or incidental damages resulting from the failure of an S amp S part the breach of any warranties the failure to deliver delay in delivery delivery in non conforming condition or for any other breach of contract or duty between S amp S and a customer 4 S amp S parts are designed exclusively for use in Harley Davidson2. thick 5 Pack 56 5092 6 Plate 1 300 OD x 960 ID x 0150 28 ga thick 5 Pack 56 5093 Clutch Pres SURG eerta 56 5076 1 300 OD x 960 ID x 0240 24 ga thick 5 Pack 56 5094 Hydraulic Clutch Pressure w ssssssscsssssssssssssssssssssssssssessssssssen 56 5144 1 300 OD x 960 ID x 0470 18 ga thick 5 Pack 56 5095 7 Spring Pressure Plate Clutch 14 Pinion Gear 1994 later BT Optional 0 eeseseseeeseeseees 56 1037 Light Duty 334 Ibs 6 Pack blue sessssssssusssssuseussensen 56 5109 15 Clutch Kit Not Shown Standard 370 IDS 6 PACK sescccccssssssssssssssssessssssssesssssesseee 56 5105 36 TOOTH StANAAMA u ce cesessssssesesessssssssesssessssesessssssessssessseees 56 5150A Heavy Duty 468 Ibs 6 Pack White secsassssssssssessesee 56 5106 37 tooth standard ssessssessesesesscssscsssessesssesssosseeseesseesseessess 56 5151A 36 tooth MY CAI Cs casicessenstannsreivendanadiesnasavensanaanesdansoncanvsasniinds 56 5152A 37 TOO bry CUI e a naanalvreciaasneinanscseinns 56 5153A
3. Primary Fluid 1 2 3 Primary fluid should be changed after the first 500 miles and every 5 000 miles thereafter S amp S recommends the use of ATF or equivalent fluid Fill primary with approximately 32 ounces of fluid Inspect Clutch Pack As Follows 1 Measure clutch pack wear by placing entire clutch pack on a precision flat surface frictions and steels only Use a caliper or depth micrometer to measure the overall clutch pack height A new clutch pack will measure 1 900 020 inch Replace the clutch pack if the overall height is less than 1 825 inch 2 Steel Plates Steel plates that are blued should be replaced as they are likely warped and distorted Plates that are grooved or worn excessively should be replaced Straw colored and browned steel plates are still within the range of normal operation Check each steel plate for distortion by laying plates on a precision flat surface and inserting a feeler gauge between the surface and the plate in several places Replace the clutch pack if any plates are warped more than 006 inch 3 Friction Discs e Clean and visually inspect both sides for worn cracked or damaged friction material Measure the thickness of each disc with a caliper or micrometer If the thickness of any disc is less than 107 inch replace the clutch pack S amp S P N 56 5085 4 Clutch Basket Inspection Rotate clutch hub in basket to check bearing for smoothness Replace bearing if it
4. and other American v twin motorcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application Disconnect the negative battery cable before performing any clutch work on your motorcycle to prevent personal injury The use of specialized installation and removal tools are required for this procedure Do not attempt to install the S amp S clutch without the proper specialty tools SPECIAL TOOL REQUIREMENTS e Feeler Gage Set e Inner Race Puller S amp S PN 56 5141 or equivalent e Primary Locking Tool e Micrometer or Caliper e Inner Race Installer S amp S PN 56 5145 or equivalent The S amp S clutch is designed with 11 plates to offer better grip and performance Additionally it has six 6 pressure plate springs that can be changed to adjust clamping and lever pressure e 6 Light Duty Blue Springs optional 334 lbs S amp S PN 56 5109 6Heavy Duty White Springs optional 468 lbs S amp S PN 56 5106 e 6 Standard Springs 370 Ibs S amp S PN 56 5105 e 3 Stock amp 3 Heavy Duty 419 Ibs requires purchasing both set of springs CLUTCH KIT CONTENTS PICTURED BELOW e Clutch Assembly Shim Kit e Red Threadlock Not Shown e 207 Thick Washer e Inner Bearing Race Clutch Hub Washer Clutch Adjuster amp Nut Manual Clutch Kit Hydraulic Clutch Kit INSTALLATION 1 Disconnect the negative battery cable and route it away from any metal parts in the area 2 Loosen all t
5. clip on the end of the pushrod See Picture 20 Picture 20 6 Pump the clutch lever to achieve proper actuation Pressure plate should move between 040 and 110 NOTE S amp S offers three different capacity spring kits The S amp S clutch is sold with standard springs PN 56 5105 brown with pink stripe We recommend the standard spring for up to 150 HP You can decide which combination of springs to use Six of the light springs PN 56 5109 blue will yield the easiest clutch pull recommended for 90 HP or less Using six of the heavy springs PN 56 5106 white will give the hardest lever pull and most clutch capacity You can use three of each to create a mid pressure lever feel 18 Mock up your outer primary cover with a gasket and a few lightly tightened bolts Some models will require clearance on the inside of the primary cover To determine if clearance is required remove derby cover pull the clutch lever and confirm 050 clearance between the clutch pressure plate and the outer cover Remove any interference material from the inside of the outer cover with a die grinder and recheck to confirm appropriate clearance with a feeler gauge 19 Once proper clutch to primary cover clearance has been confirmed finish installing the outer primary cover according to the recommended procedures in your factory service manual 20 Fill the primary as suggested in your factory service manual with ATF or equivalent CLUTCH SERVICE
6. ft lbs using Loctite 262 or equivalent You will need to place the transmission in gear and have someone hold the brake to tighten to clutch hub nut 15 Soak fiber discs in primary oil for a minimum of five minutes prior to installation S amp S recommends ATF or equivalent fluid 16 Install the first 5 fiber discs and steel plates by sliding a fiber disc in followed by a steel plate Step 1 Picture13 When 10 are in place 5 fiber discs 5 steel plates slide the narrow fiber disc in followed by the flat jutter and then the out facing angled jutter Step 2 Picture 13 A detailed view of the assembly is in Picture 14 and 15 Finally install the remaining 10 plates by installing a steel plate followed by a fiber disc until all 10 are in place Step 3 Picture 13 Steel Plate Picture 13 Picture 14 Angled jutter installed 7 Narrow Fiber E A Baa Coss section of assembled S amp S clutch pack Picture 15 5 17 Refer to the appropriate steps below to install a manual or hydraulic clutch pressure plate A Manual pressure plate installation 1 Confirm that the adjustment rod is threaded all the way in the pressure plate as illustrated in Picture 16 NOTE The rod can only be installed from the back of the pressure plate so make sure it is in place before you move on Picture 16 2 Confirm the clutch actuator pushrod is inserted into the mainshaft 3 Put the pressure plate in place install the springs and
7. torque the screws to 72 96 in lbs NOTE S amp S offers three different capacity spring kits The S amp S clutch is sold with standard springs PN 56 5105 brown with pink stripe We recommend the standard spring for up to 150 HP You can decide which combination of springs to use Six of the light springs PN 56 5109 blue will yield the easiest clutch pull recommended for 90 HP or less Using six of the heavy springs PN 56 5106 white will give the hardest lever pull and most clutch capacity You can use three of each to create a mid pressure lever feel 4 Run the adjustment rod in until it lightly bottoms out Back it off between and 3 4 of a turn and lock it in place by installing and tightening the retaining nut as shown in Picture 17 Picture 17 5 Finally adjust the clutch cable to provide to 346 of free play at the handlebar clutch lever B Hydraulic pressure plate installation for use with Harley Davidson Screamin Eagle hydraulic clutch system only 1 Install the thrust bearing and bearing housing into the S amp S hydraulic pressure plate so the bearing housing is flush with the outside of the pressure plate See Picture 18 2 Install retaining ring as shown in Picture 19 Picture 18 3 Confirm the clutch actuator pushrod is inserted into the mainshaft 4 Put the pressure plate in place install the springs and torque the screws to 72 96 in lbs 5 Install the clutch actuator pushrod retaining
8. Instruction 106 5860 5 18 10 Copyright 2009 2010 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tue 14025 Cty Hwy G PO Box 215 Viola Wisconsin 54664 Phone 608 627 1497 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Website www sscycle com Fax 608 627 1488 A eer nM ANS Installation Instructions S amp S High Performance Clutch for 1991 06 Big Twin Except 2006 Harley Davidson Dyna Models DISCLAIMER S amp S parts are designed for high performance closed course racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely affect your factory warranty In addition such installation and use may violate certain federal state and local laws rules and ordinances as well as other laws when used on motor vehicles used on public highways especially in states where pollution laws may apply Always check federal state and local laws before modifying your motorcycle It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use and the user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith The words Harley Harley Davidson H D Sportster Evolution and all H D part numbers and model designations are used in reference only S amp S C
9. ation when you are fresh Be sure all federal state and local laws are obeyed with the installation For optimum performance and safety and to minimize potential damage to carb or other components use all mounting hardware that is provided and follow all installation instructions Motorcycle exhaust fumes are toxic and poisonous and must not be breathed Run motorcycle in a well ventilated area where fumes can dissipate IMPORTANT NOTICE Statements in this instruction sheet preceded by the following words are of special significance A WARNING Means there is the possibility of injury to yourself or others CAUTION Means there is the possibility of damage to the part or motorcycle NOTE Other information of particular importance has been placed in italic type S amp S recommends you take special notice of these items WARRANTY All S amp S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve 12 months from the date of purchase Merchandise that fails to conform to these conditions will be repaired or replaced at S amp S s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter In the event warranty service is required the original purchaser must call or write S amp S immediately with the problem Some problems can be rectified by a telephone call and need no further course of action
10. he tension in the clutch cable or refer to your factory service manual for instructions on how to remove your hydraulic clutch 3 Remove the entire primary and clutch assembly by following the instructions in your factory service manual It is also required that the clutch actuator pushrod be removed from the mainshaft 4 Use an inner primary race removal tool to take the stock Harley Davidson race off of the mainshaft and discard S amp S PN 56 5141 inner bearing race puller shown in Picture 1 Do not use stock Harley Davidson inner primary bearing race with the S amp S clutch If the stock inner bearing race is used with the S amp S clutch damage to primary components and the clutch will occur The S amp S clutch requires a step on the main shaft to prevent the clutch from moving inward this step is created by the S amp S inner bearing race PN 56 5089 5 The S amp S inner primary race has an internal taper that will engage on the tapered portion of the mainshaft to assure that it mounts to the proper depth Use an inner primary race installation tool and assembly lube for this procedure Be sure to install the bearing race with the taper facing out Be sure race is seated on the taper by tightening tool to 35 ft lbs as shown in Picture 3 NOTE Lubricating the race will make the installation easier Apply lubricant to D of race i lt z ae 2 wa paN Bearing Race Installation Tool S amp S PN 56 5145 Picture 2 P
11. icture 3 6 Install the included 207 thick washer on the mainshaft as shown below Picture 4 7 If your clutch is assembled remove the six screws and springs that hold the pressure plate on the S amp S clutch Put them aside and then turn the clutch upside down to remove the clutch pack NOTE Be sure to remove the complete jutter assembly See Picture 16 It has a tendency to stay seated on the clutch hub Picture 5 3 8 Slide the clutch basket in place in front of the 207 washer as shown in Picture 6 Picture 6 9 Thread the stock LEFT HAND THREAD nut on to the mainshaft Tighten the nut to 70 80 ft lbs of torque as illustrated in Picture 7 NOTE Do not use threadlock at this time 10 The next step is crucial to proper installation Use a set of feeler gages to determine the clearance between the back of the clutch hub and the 207 thick washer See Picture 8 Picture 7 Picture 8 11 Remove the nut washer and basket from the mainshaft Now select shims to create 001 010 of clearance between the 207 washer and inner primary bearing race Repeat Steps 8 9 and 10 to achieve 001 010 clearance with shims After the inner primary is installed the shims will be positioned between the 207 washer and the inner primary race as shown in Picture 9 Install the inner primary following the factory service manual for your motorcycle S amp S recommends that you replace the inner primary beari
12. ng and seal at this time See Picture 10 iL J f X T i j 5 AY o 207 Washer N Picture 9 Picture 10 NOTE If you are having problems getting the feeler gage measurement or your clearance is zero with the above method the race may not be installed far enough onto the shaft Be sure that the bearing race was installed to 35 ft lbs torque The S amp S clutch assembly is sold with a package of four shims 0075 015 024 and 047 When multiple shims are required to achieve desired endplay install narrow shims next to 207 washer Likewise install widest shims next to bearing race 4 Zero clearance will cause mainshaft to be axially loaded and force inner bearing race or mainshaft to fail 12 Assemble the starter pinion shaft components using the optional S amp S pinion gear PN 56 1037 required on 1994 and up models as illustrated in Picture 11 Be sure that the coupler is oriented so it sits flush with the pinion shaft splines as shown in Picture 12 If it is installed the other way you will not have proper starter engagement Now install the pinion shaft assembly and use a new locking tab to hold the bolt in place Picture 11 Picture 12 13 CLUTCH INSTALLATION e Be sure that the shims and 207 washer are in place on the mainshaft as shown in Picture 8 e Place the primary chain over the clutch sprocket and slide it onto the mainshaft 14 Now install the washer and LEFT HAND THREAD nut and torque to 70 80
13. turns rough or binds Check slots which engage the discs and plates on both the basket and hub Replace clutch basket or hub if slots are worn or damaged Inspect primary chain sprocket and starter ring gear for damage Replace clutch basket if either part is severely worn or damaged 5 Inspect pressure plate for excessive wear grooving or damage at the friction surface Replace pressure plate if cracking grooving or excessive damage exists REPLACEMENT PARTS FOR S amp S HIGH PERFORMANCE CLUTCH 8 Nut Flange M10 x 1 25 cracccsnsedesassnasasincvansestecnasiavarstasvecensnstaivs 50 8411 1 Race Inner Bearing 5 6 Speed Main Shaft pkg 56 5089 9 Screw Clutch Adjuster M10 X 1 25 ssssseessssceesssseeessseeeese 50 8414 2 Washer 1 750 OD x 960 ID X 207 thick un 56 5099 10 Bolt Special M6 x 30 wW Washer 6 PACK ssesseceeeeree 50 8413 3 Basket 11 Jutter Spring with Seat uuu ssscsssssesssceccssscsscsccecscsecssesesees 56 5110 Clutch 36 tOOtH esssssssssssssssesesntnsesetnsssieesesetete 56 5081 12 Clutch Pack 11 Fibers 10 Steels ssosssssnrsnsennsnen 56 5085 Clutch 37 tOOtH esssssvsssssssssstssstnsnsssnsssistetstetete 56 5082 13 Kit Shim Clutch Inner Race 56 5090 4 Bearing Clutch Basket to HU b s sssssssssssrsssrsssrsssresersseness 56 5102 Shim 5 6 Speed Main Shaft 5 Hub CIUtCE sssnsnsnsnrnsstsnvrssnneneneeensnsnensnnnnnesnennenetonnen 56 5075 1 300 OD x 960 ID x 0075 36 ga
14. ycle is not associated with Harley Davidson Inc SAFE INSTALLATION AND OPERATION RULES Before installing your new S amp S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed Do not smoke Perform installation in a well ventilated area away from open flames or sparks If motorcycle has been running wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps Contact S amp S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S amp S part on it Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation Use good judgment when performing installation and operating motorcycle Good judgment begins with a clear head Don t let alcohol drugs or fatigue impair your judgment Start install
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