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S&S Cycle Crankcase for Harley-Davidson Installation Instructions Manual

S&S Cycle Crankcase for Harley-Davidson Installation Instructions Manual

Crankcase for harley-davidson twin cam 88 engines

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Instruction 51-1255
11-29-11
Copyright®, 2003, 2006, 2008, 2009
by S&S Cycle, Inc.
All rights reserved.
Printed in the U.S.A.
Installation Instructions: S&S
Harley-Davidson
For all S&S Stock Bore, 4" Bore, and 4
DISCLAIMER:
S&S parts are designed for high performance, closed course, racing
applications and are intended for the very experienced rider only. The
installation of S&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
®
all H-D part numbers and model designations are used in reference only.
S&S Cycle is not associated with Harley-Davidson, Inc.
SAFE INSTALLATION AND OPERATION RULES:
Before installing your new S&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.
G Gasoline is extremely flammable and explosive under certain
conditions and toxic when inhaled. Do not smoke. Perform installation
in a well ventilated area away from open flames or sparks.
G If motorcycle has been running, wait until engine and exhaust pipes
have cooled down to avoid getting burned before performing any
installation steps.
G Before performing any installation steps disconnect battery to
eliminate potential sparks and inadvertent engagement of starter while
working on electrical components.
G Read instructions thoroughly and carefully so all procedures are
completely understood before performing any installation steps.
Contact S&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&S part on it.
G 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.
G Use good judgment when performing installation and operating
motorcycle.
Good judgment begins with a clear head.
alcohol, drugs or fatigue impair your judgment. Start installation when
you are fresh.
G Be sure all federal, state and local laws are obeyed with the
installation.
G 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.
G Motorcycle exhaust fumes are toxic and poisonous and must not
be inhaled. Run motorcycle in a well ventilated area where fumes
can dissipate.
® ®
S&S
14025 County Highway G PO Box 215
Viola, Wisconsin 54664
Phone: 608-627-1497 • Fax: 608-627-1488
Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: sstech@sscycle.com
Website: www.sscycle.com
with 1999-2006 and 1984-1999 engine mounts.
, H-D
, Sportster
, Evolution
®
®
®
®
Don't let
Cycle, Inc.
Crankcase for
®
Twin Cam 88
®
/
" Bore Twin Cam 88
1
8
IMPORTANT NOTICE:
Statements in this instruction sheet preceded by the following words
are of special significance.
Means there is the possibility of injury to yourself or others.
Means there is the possibility of damage to the part or motorcycle.
Other information of particular importance has been placed in italic type.
S&S recommends you take special notice of these items.
, and
WARRANTY:
All S&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&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&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 prior authorization from S&S. If it is deemed necessary
for S&S to make an evaluation to determine whether the part was
defective, a return authorization number must be obtained from S&S.
The parts must be packaged properly so as to not cause further damage
and be returned prepaid to S&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&S and the part was found to be
defective, repair, replacement or refund will be granted.
ADDITIONAL WARRANTY PROVISIONS:
(1) S&S shall have no obligation in the event an S&S part is modified by
any other person or organization.
(2) S&S shall have no obligation if an S&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&S part.
(3) S&S shall not be liable for any consequential or incidental damages
resulting from the failure of an S&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&S and
a customer.
(4) S&S parts are designed exclusively for use in Harley-Davidson
other American v-twin motorcycles. S&S shall have no warranty or
liability obligation if an S&S part is used in any other application.
Engines
®
engine cases
®
WARNING
CAUTION
NOTE
®
and

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Summary of Contents for S&S Cycle Crankcase for Harley-Davidson

  • Page 1 ® ® S&S Cycle, Inc. Instruction 51-1255 11-29-11 14025 County Highway G PO Box 215 Viola, Wisconsin 54664 Copyright®, 2003, 2006, 2008, 2009 Phone: 608-627-1497 • Fax: 608-627-1488 Technical Service Phone: 608-627-TECH (8324) by S&S Cycle, Inc. Technical Service Email: sstech@sscycle.com Website: www.sscycle.com All rights reserved.
  • Page 2 Oil Fitting Locations For 1984-’99 Chassis Breather Fitting ® Oil Pressure Switch, H-D 26561-99 Crankcase Breather & Oil Pressure Switch Location Oil Return Fitting Oil Return Fitting Oil Supply Fitting Oil Supply Fitting Oil Supply & Return Fitting Locations Oil Supply & Return Fitting Locations for some ®...
  • Page 3: Additional Features

    Please read these instructions thoroughly before starting work. POLISHING, PAINTING, PLATING, OR POWDERCOATING S&S CASES Proceed with the installation only after they are completely S&S Cycle cautions against modifying these crankcases due to the understood. These instructions should be supplemented by the possibility of damaging or weakening them.
  • Page 4: Preparation And Installation

    PREPARATION AND INSTALLATION To check clearance perform following steps: Assemble case halves using case bolts. Tighten to snug. Inspection Torquing bolts to final specification is not necessary. Inspect crankcases to confirm that they are correct style Clean frame engine mounts and carefully remove any and machined for correct bore size.
  • Page 5 NOTE: Apply thread sealant to all tapered pipe threads. CAUTION Restricted oil flow may result in extensive engine damage not Remove crankcase vent fitting (S&S PN 50-0451) covered under warranty. and set aside for later use. Install supplied vent fitting (S&S PN 50-0449 is for use with 2002-’06 with ⁄...
  • Page 6 Remove cover plate that was shipped on Remove the oil line block from the engine case. crankcase from the bottom surface of the rear Install the supplied clamps (S&S PN 50-8156) on the motor mount. The oil line block will be installed lines between the fittings.
  • Page 7 To Change Engine Oil in the Future Slide hose clamp off of fitting along hose. See Picture 7. Place an oil drain pan under front of oil pan. Remove hose from fitting to drain oil. Reinstall hose and clamp. Continue with recommended oil change procedure. Picture 7 S&S Oil Line Installation Kit Replacement Parts for...
  • Page 8 For 1999-’05 Harley-Davidson ® Dyna ® models CAUTION Oil Line installation is crucial to engine life. If you are not sure that you can properly perform this operation, please contact the S&S ® Tech Department for a referral to a shop in your area. NOTE: Installation instructions are based on an engine and transmission already in the chassis.
  • Page 9 Remove the oil line retention plate, plugs and seals 11- Position oil line assembly on both the transmission from the top of the engine crankcase. Remove seals top cover and crankcase and press down until lines from the plugs. Discard the plugs. are firmly seated in the counterbores in the crankcase and transmission cover.
  • Page 10 S&S ® Oil Line Installation Kit Replacement Parts for Harley-Davidson Dyna Models ® ® Plate ................50-0440 Seal ................50-8271 BHSHCS ⁄ -18 x ⁄ ............50-0438 Washer ..............50-0439 Line, oil supply ............31-0444 Line, oil return............31-0443 Line sssembly, Oil feed..........31-0442 Top cover ..............56-1615 SHC - ⁄...
  • Page 11 Crankcase Cylinder Studs Sprocket shaft bearings: Use 1999-2002 style taper roller bearings, included with the crankcase. They must be S&S ® crankcases for Harley-Davidson ® Twin Cam 88 ® engines used with a 1999-2002 style flywheel assembly, are shipped with cylinder studs installed Before assembling purchased separately.
  • Page 12 Replacement Parts for S&S ® Crankcases for Harley-Davidson ® Twin Cam 88 ® Engines 26.Piston Oiler Jet Kit (H-D® #22371-99) 1. Bolt, stator 10-24 x1" SHC - 4 required (H-D® #2720) 12. Dowel, cylinder deck - 2 required (H-D® #16595-99A) Each..................31-2025B Each..................50-0044 Each..................50-8177...