- S&S Cycle
Contents
1. A unique label with the heading Vehicle Emissions Control Information is provided with the engine This label contains the engine family identification engine tune up specifications and the serial number of your engine The label must be installed on the motorcycle frame or on a part that is permanently attached to the frame and the label must be located so that it is visible with the seat removed NOTE Clean the area where the label will be affixed before installing it Once affixed the label is permanent and can not be removed without the label being destroyed Installation Notes S amp S Engines may include instruction sheets for individual components Most instructions apply to all S amp S Engines In the following instances however components or procedures supplied with and described for S amp S 49 State EPA Certified Engines are different from those for other S amp S Engines A B Some S amp S Engines may be configured to allow crankcase pressure to exit via the crankcase and or cylinder head vents S amp S 49 State EPA Certified Engines must only utilize cylinder head venting The camshaft supplied in S amp S 49 State EPA Certified Engines is of proprietary S amp S design This camshaft has been designed to allow the engine to meet exhaust emission standards Substitution of a camshaft with different specifications is not permitted and would be in violation of the Clean Air Act S amp S 3 bore engines come equipped wi2. Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation Cable routing must be free of tight bends to minimize cable to cable housing friction Throttle must not bind and must snap shut to fully closed position when released Incorrect cable adjustment may cause throttle to stick open causing loss of control of motorcycle serious injury or death 6 Connect compression releases 4 and 4 bore engines only A The compression release wires have Deutsch connectors that are installed in line to allow separation of the releases from the main wiring harness B Push the lead wires into the Deutsch connector until you hear a click from them as they slide into position Verify that the wires are in place by firmly pulling them while you hold the connector When making these connections there is no proper orientation to worry about just be sure to make solid connections In the main wiring harness the green wire is powered during cranking and the black is the ground C Slide the orange wedge into the connector and listen for an audible click as it goes into position D Connect the compression release solenoid lead wire Deutsch connectors to the main wiring harness E Slide the supplied 4 foot black sleeve over the wire harness until it reaches the connectors but keep in mind that you will have to cut the sleeve to allow access for a fuse holder in a few steps F Use the drawing below to
3. PN 19 0449 to 1 22 2 to 25 4mm Adapter sleeve PN 19 0235 NOTE 1981 to 1990 OEM style cables may be used as replacement cables for throttle kits above 4 Throttle Cables A Install new throttle assembly l Install new throttle assembly and cables Position grip and cables so cables can be angled towards carb for easy adjustment and free operation ll Apply light coat of clean cable lubricant to cables and fittings Loosen cable adjustment locknuts and turn adjusting screw so half of the threads are exposed 5 Throttle Cable Assembly A Install throttle cables on carburetor l Remove throttle cable housing bracket PN 11 2339 ll Install opening side throttle cable barrel fitting and throttle cable in throttle linkage on appropriate side of throttle cable housing bracket Opening side cable housing outside diameter is smaller and measures 190 4 826mm lll Repeat step II for closing side throttle cable Closing side cable has a spring around inner cable wire IV Reinstall throttle cable housing bracket on carburetor B Turn throttle cable adjusters to remove excessive free play Test the throttle to ensure it opens and closes freely The throttle should snap shut when released Turn handlebars to extreme left and open and close throttle then turn bars to extreme right and repeat If throttle binds loosen cable adjusters to put more free play in cables Tighten the adjusting screw locknuts after final adjustments are made NOTE
4. 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 A part that is suspect of
5. H20 V111E Specifications V89E Specifications V79E Specifications Maximum N V Ratio 43 3 Maximum N V Ratio 43 3 Maximum N V Ratio 43 3 Maximum Vehicle Weight 1058 Ib 480 kg Maximum Vehicle Weight 992 Ib 450 kg Maximum Vehicle Weight 992 lb 450 kg Exhaust Backpressure Exhaust Backpressure Exhaust Backpressure Maximum 9 5 H20 Maximum 5 0 H20 Maximum 5 0 H20 Minimum 4 7 H20 Minimum 0 6 H20 Minimum 0 6 H20
6. Instruction 51 1271 1 23 07 Copyright 2007 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tue 235 Causeway Blvd La Crosse Wisconsin 54603 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 Because every industry has a leader Emission Related Installation Instructions for S amp S 49 State EPA Certified Engines DISCLAIMER S amp S parts are designed for high performance off road racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely effect 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 Har
7. at steady speed or rpm l There may be a restriction in fuel supply system gas tank vent plugged needle and seat not working properly etc ll Faulty ignition system Check for fouled plugs defective coil defective electronic module or improper ignition timing GENERAL INFORMATION NOTE When the motorcycle is not running the petcock should always be turned off to prevent possible fuel leakage past the needle and seat CONCLUSION Complete remainder of installation according to the applicable service manuals Refer to the S amp S 49 State EPA Certified Engine Owner s Manual for important information on breaking in the engine ENGINE SPECIFICATIONS V124E Specifications V96E Specifications V88E Specifications Maximum N V Ratio Maximum N V Ratio 43 3 Maximum N V Ratio 43 3 Maximum Vehicle Weight 1058 Ib 480 kg Maximum Vehicle Weight 992 Ib 450 kg Maximum Vehicle Weight 992 Ib 450 kg Exhaust Backpressure Exhaust Backpressure Exhaust Backpressure Maximum 9 5 H20 Maximum 5 0 H20 Maximum 5 0 H20 Minimum 4 7 H20 Minimum 0 6 H20 Minimum 0 6 H20 V117E Specifications V93E Specifications V80E Specifications Maximum N V Ratio Maximum N V Ratio 433 Maximum N V Ratio 43 3 Maximum Vehicle Weight 1058 Ib 480 kg Maximum Vehicle Weight 992 Ib 450 kg Maximum Vehicle Weight 992 Ib 450 kg Exhaust Backpressure Exhaust Backpressure Exhaust Backpressure Maximum 9 5 H20 Maximum 5 0 H20 5 0 H20 Minimum 4 7 H20 Minimum 0 6 H20 0 6
8. 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 Davidson and other American v twin mo
9. ble throttle mechanism must be converted to the two cable pull open pull closed type S amp S offers a variety of these throttle assemblies Single braided wire cable throttle mechanisms cannot mechanically close the throttle If the throttle inadvertently sticks in the open position loss of control of motorcycle and personal injury to you or others may result Any motorcycle equipped with single cable throttle system must be converted to a two cable system Kits with 36 91cm 39 99cm 42 107cm 48 122cm or 52 132cm length cables are available Throttle assembly kits may be ordered separately See descriptions on next page Two cable throttle systems designed for a butterfly type carburetor have cable fittings that can simply be plugged in to the S amp S Super E or G carburetor throttle linkage 5 Optional S amp S Two Cable Throttle Kits Kits fit 1 25 4mm O D handlebars and can be used on most chassis An adapter sleeve is available for use with handlebars having 7 22 2mm ends Fittings on provided cables readily plug in to S amp S Super E G or stock H D 1981 and later butterfly type carburetors Kits include one opening side cable one closing side cable left and right handlebar grips and handlebar clamps Throttle kit with 36 91cm cables PN 19 0450 Throttle kit with 42 107cm cables PN 19 0482 Throttle kit with 39 99cm cables PN 19 0448 Throttle kit with 48 122cm cables
10. d connections C Test throttle to ensure it opens and closes freely Turn handlebars to extreme left and open and close throttle and then turn bars to extreme right and repeat Throttle must snap closed in all positions D Reassemble any remaining components E Install emission control label on motorcycle frame F Verify all emission related instructions and requirements have been met G Fill gas tank H Check carburetor fuel inlet fitting and fuel line connections for leaks NOTE Fuel needle and seat assembly must completely shut off fuel supply entering bowl Fuel inlet fitting and fuel line connections must not leak CAUTION Gasoline leaking past inlet needle may flood engine causing fire hazard or damage to components Gasoline leaks at inlet o rings fuel line connections or inlet needle may flood engine and overflow into surrounding area creating fire hazard l See S amp S 49 State EPA Certified Engine Owner s Manual for engine starting instructions A CAUTION Failure to break in engine according to correct procedure may result in serious damage to engine that is not repairable under warranty 7 10 Troubleshooting Tips A Engine will not start l Fuel tank may be empty or petcock may be in closed position Il Weak or no spark condition may be caused by a discharged battery damaged ignition module or damaged coil Verify the condition of components Ill Spark plug gap may be too wide B Engine will not run
11. e of protective sleeve over the remaining fuse holder wire that runs up to the connection point Install Fuel Tank A Install fuel tank making sure it does not come in contact with engine or sensors Fuel Line A Slip hose clamp over end of fuel line with 90 bend Lubricate the fuel inlet fitting on the carburetor by applying a thin coating of oil Slip end of fuel line with 90 bend over fitting B Position fuel line to avoid contact with hot cylinders or other engine parts Tighten hose clamp Slip protective fuel line covering over fuel line and position to prevent direct contact between fuel line and cylinders or other engine parts C Connect fuel line to gas tank petcock using hose clamp provided N P Gasoline is extremely flammable and explosive under certain conditions Do not smoke or expose gasoline to sparks or open flame CAUTION Gasoline fumes are toxic when inhaled Perform installation in a well ventilated area away from open flames or sparks Unwarranted sparks and inadvertent engagement of starter while working on electrical components can cause serious injury or death Engines vented through heads must not have breather bosses plugged as oil leakage and damage may occur Fuel line must be clamped securely and not contact any hot surfaces where it could melt or catch fire causing serious injury or death 9 Final assembly and checks A Connect vacuum petcock hose if equipped B Check fuel line routing an
12. ed knowledge skills and tools For this reason installation should be performed by a professional mechanic Improper installation of engine or related components could result in injury or death to the operator and or passenger and damage to the motorcycle Installation 1 2 Install the S amp S engine into the motorcycle chassis according to the chassis service manual Install the ignition module A For engines equipped with Super Stock ignition l Mount VOES switch with the included bracket as close to the carburetor as possible Il Connect the VOES hose from the switch to the nipple in the manifold Trim the hose to be as short as possible without stretching or kinking it lll Make electrical connections according to following chart and wiring diagram Tachometer Diagnostic Port Tab assembly male VOES Switch Ignition module Receptacle assembly female TO KEY ON o C VOES VACUUM SWITCH CHASSIS Super Stock Ignition Module Pedag ASSEMBLY ASSEMBLY STATUS O MALE FEMALE VOES O TO CHASSIS I comer yas TO DIAGNOSTIC gt en B For engines equipped with IST ignition system follow installation instruction included with module 3 Install Oil Lines A First flush the oil tank and lines and install a new oil filter that has been filled with oil CAUTION New oil tanks and lines must be flushed to remove any debris that could damage the engines oiling system B Connect oil lin
13. es following the diagram on the following page Do not connect the oil feed line to the engine at this time VENT TO TANK V SERIES i OILING SYSTEM DIAGRAM re TO FILTER A FILTER TO TANK B VENT TO TANK C TANK TO PUMP IN D PUMP OUT TO FILTER E FILTER IN F FILTER OUT G SUPPLY FROM TANK H CAM CHEST C Clamp off the open end of the oil feed line and fill the oil tank with oil of the appropriate type and grade recommended in the S amp S 49 State EPA Certified Engine Owner s Manual D Unclamp the feed line to allow the line to fill with oil then quickly attach it to the fitting on the oil pump The oil pump was primed at the factory so no further priming should be necessary It is necessary to confirm that oil is circulating properly prior to operating the motorcycle E To confirm proper circulation of oil 1 Remove both spark plugs 2 Remove the oil return line from the oil tank and place the end in a suitable container 3 Using the starter turn the engine several rotations Oil should come out the return line If not repeat the procedure as needed 4 Reconnect the return line to the oil tank and install the spark plugs CAUTION Lack of oil circulation through the engine will cause damage to the internal engine components Throttle Requirements NOTE S amp S Super E amp G carburetors require the use ofa two cable pull open pull closed throttle assembly All models equipped with a single ca
14. help locate the wiring connection points on your motorcycle Typical Wiring Diagram GREEN WIRE one CONNECTION POINT C B RUN STOP a e F FUSE 15A G Position the main harness with the compression release lead wires so they are not pulled tightly against anything Once the best position is found zip tie the connectors and that end of the harness securely to the frame to prevent movement H Working from the end that you secured earlier work out a routing position for the remaining portion of the wire harness making sure the wires will not be crushed cut scuffed or otherwise damaged by operation of the motorcycle The black wire will need to be routed to a ground and the green wire to power supplied during cranking only l Find a suitable place to splice the supplied fuse holder into the green wire of the harness as close to the power source as possible J Once the position of the fuse holder has been determined cut the protective sleeve at that point being careful not to damage the wires inside K Cut the green wire of the harness where it meets the fuse holder lead wire and slide one of the supplied pieces of shrink wrap on it L Strip the green wire and a wire from the fuse holder and connect them with the supplied butt connector After making sure the wires are securely connected seal them in place with heat shrink Use the same procedure to connect the other side of the fuse holder M Install a small piec
15. ley 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 judgement when performing installation and operating motorcycle Good judgement begins with a clear head Don t let alcohol drugs or fatigue impair your judgement Start installation when you are fresh
16. must also be met when installing this engine Specifications for your engine are listed at the end of the instruction sheet Gear Ratio This engine may only be installed in a highway motorcycle or kit with an N V ratio less than or equal to the N V ratio given for your engine The N V ratio is the engine RPM divided by the vehicle speed in miles per hour in high gear This determines the maximum RPM of the engine for a given vehicle speed in high gear To find the N V ratio for your application divide the engine speed by the vehicle speed while traveling in high gear The following table gives maximum RPM s for the given speed and N V ratio ce cc E NOTE This N V ratio is equivalent to 1990 99 Harley Davidson FXD and FLH models with stock gearing and tire size Weight This engine may only be installed in a highway motorcycle with a final weight that is equal to or less than the weight listed in the specifications for your engine at the end of this manual Exhaust The exhaust system used on the motorcycle must meet backpressure specifications The total stagnation pressure must be in the range given in the specifications for your engine found at the end of this manual This measurement is taken 6 5 from the inlet of the front exhaust header with the engine operating at 2000 RPM in neutral The total stagnation pressure can be measured using a pitot tube facing into the exhaust stream and a manometer that reads in inches of water Label
17. th an S amp S Super Stock ignition system that is preset at the factory Breaking the tamper proof seal will void the warranty on the engine The Super Stock and IST ignition system requires the use of a 3 OHM single fire coil like the S amp S coil PN 55 1571 The carburetor supplied with S amp S 49 State EPA Certified Engines is not to be adjusted For service requirements contact S amp S Cycle Technical Services 608 627 1497 The tuning instructions described in S amp S Carburetor Instruction Sheet No 400 do not apply to carburetors supplied with S amp S 49 State EPA Certified Engines More specific information can be found in your S amp S 49 State EPA Certified Engine Owners manual The carburetors included with 49 State Engines are butterfly type carburetors with a preset idle mixture screw and preset midrange and high speed jets The carburetors also feature an accelerator pump and variable fast idle device for improved throttle response engine starting and warm ups The Super E carburetor has a 17 47 6mm bore at the butterfly and a 1 9 16 39 6mm venturi The Super G carburetor has a 2 116 52 3mm bore at the butterfly and a 134 44 5mm venturi Installation Instructions This S amp S 49 State EPA Certified Engine has been manufactured assembled and calibrated by S amp S Cycle Inc Before proceeding verify that this engine fulfills the requirements for your motorcycle Installing an S amp S engine into a motorcycle requires specializ
18. torcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application INSTALLATION OVERVIEW This S amp S 49 State EPA Certified Engine is approved for use in assembled highway motorcycles and conforms to USEPA regulations applicable to the model year in which it was produced A small volume manufacturer kit manufacturer or assembler using this engine does not have to apply for a separate emission certificate with the EPA A vehicle built according to the requirements given is considered a certified vehicle by the EPA Included in these instructions are requirements the manufacturer of the motorcycle kit manufacturer or assembler is required to follow in order to insure the engine meets exhaust emission standards Prior to starting installation of this engine these requirements should be read and understood Failure to meet the requirements outlined in the instructions is a violation of the Clean Air Act and will make the manufacturer of the motorcycle kit manufacturer or assembler subject to penalties and fines INSTALLATION REQUIREMENTS No changes may be made to the engine that could reasonably be expected to increase its exhaust emissions for any pollutant This includes changes to the fuel metering system changes to the ignition system changes to the camshaft and modifying recalibrating removing or failing to properly install any other specified component The following requirements
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