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Instruction Sheet #51-1160
04-28-04
Copyright®, 2003
by S&S Cycle, Inc.
All rights reserved. Printed in the U.S.A.
Assembly and Installation Instructions
For all S&S Twin Cam style Engine Assemblies with Twin Cam style or
S & S Cycle, Inc.
14025 County Highway G Box 215
Viola, Wisconsin 54664
Phone: 608-627-2080 • Fax: 608-627-1488
Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: sstech@sscycle.com
Website: www.sscycle.com
S&S Twin Cam Style Engine
optional Evolution style engine mounting.
All S&S Twin Cam style Engine Assemblies are
Type "A" style (non-counterbalanced).
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Table of Contents
Related Manuals for S&S Cycle Motorcycle Accessories
Summary of Contents for S&S Cycle Motorcycle Accessories
- Page 1 Instruction Sheet #51-1160 04-28-04 Copyright®, 2003 by S&S Cycle, Inc. All rights reserved. Printed in the U.S.A. Assembly and Installation Instructions For all S&S Twin Cam style Engine Assemblies with Twin Cam style or S & S Cycle, Inc. 14025 County Highway G Box 215 Viola, Wisconsin 54664 Phone: 608-627-2080 •...
- Page 2 SAFE INSTALLATION AND OPERATION RULES: Before installing any S&S engine part, it is your responsibility to read and follow all instructions. The rules below are for your personal safety, and must be kept in mind at all times. Gasoline is extremely flammable and explosive under certain conditions, and toxic when inhaled.
- Page 3 Instruction Contents: A. Introduction B. Additional Features C. Modification Notes D. Engine to Frame Test Fit E. Engine Assembly F. Engine to Frame Assembly G. Ignition System H. Fuel System Please read these instructions carefully before starting work. Proceed with the installation only after the instructions are completely understood.
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Page 4: Additional Features
Torque Horsepower Dynomometer chart showing typical horsepower and torque curves for S&S 124” Twin Cam style engine. Horsepower and torque curves will vary, dependant on the engines state of tune, and the ignition and fuel systems used on the completed engine. B. - Page 5 C. Modification Notes S&S Cycle cautions against crankcases due to the possibility of damaging or weakening them. Modifying S&S crankcases in any fashion voids all manufacturer warranties. Should the customer elect to modify the crankcases regardless, it is imperative that they and the information tag attached to them be inspected beforehand to confirm that the correct model, style, bore size, etc.
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Page 6: Engine Assembly
CAUTION - Improper alignment of engine and frame mounts may cause abnormal stresses resulting in damage to crankcases or other parts. 2. Test-fit instructions for Twin Cam style cases with Evo Style motor mounts. 1. Assemble case halves using Tighten to snug. Torquing bolts to final specification is not necessary. - Page 7 CAUTION - Failure to observe the above may result in engine damage not covered under warranty. 1. Crankcase preparation before assembly. NOTES - S&S crankcases are sold in matched sets only. Individual case halves are not available. S&S Twin Cam style engines are shipped with cylinder studs installed Before assembling engine, verify that the lower collar of each stud is contacting the case deck, and that the studs are torqued to 10 ft.-lbs.
- Page 8 Picture E3 3. Coat right main bearing and race with assembly lube. , then join left and right crankcase halves. 4. Tighten 5⁄16" case bolts to 18 ft-lbs, tighten 1⁄4" center bolt to 120 in-lbs. in the sequence shown. See Figure 1. 5.
- Page 9 Picture E7 Picture E9 Picture E11 Picture E12 Picture E8 Use tool to guide bearing rollers onto inner race Picture E10 Figure 1 Picture E13...
- Page 10 Picture E14 2. Inspect pistons, especially areas around machined surfaces such as ring grooves and wristpin holes. De-burr as necessary, taking care to remove particles that could become dislodged inside engine. 3. Measure ring end gaps and adjust as necessary. See Pictures E13 and E14 a.
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Page 11: Top View
Top View Driveside Front Head Rear Head Camside Stage 1 8 Ft. Lbs. Stage 2 18 Ft. Lbs. Stage 3 Turn additional 90 Figure 2 Install cylinder heads 1. Place head gasket on top of cylinder. Locate on dowels installed in cylinder. NOTE - Head gaskets should be installed clean and dry. - Page 12 9. Compression releases and rocker cover installation. Refer to the included instructions to install the compression releases and rocker covers NOTES: If S&S compression releases will be installed, it is much easier to install them before the rocker covers are installed and the engine is installed in the frame.
- Page 13 H. Fuel system installation and tuning NOTES - S&S Engine assemblies are available with either carbureted or fuel injected systems. Assembled Engines carburetor or fuel injection system installed. Refer to the included instructions for operation and tuning . Unassembled Engines are shipped with the fuel system packaged separately.
- Page 14 NOTE - S&S oil line, oil tank fittings, and oil conduit block fittings have a larger diameter than OEM components. CAUTION - Do not use the existing OEM oil tank fittings with S&S oil line #50-8157. The OEM fittings are not large enough diameter for the S&S oil line.
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Page 15: Exhaust System
NOTES: If oil fails to appear at oil sender hole within 30 seconds of starter operation, allow the starter to cool. verify that oil line routing is correct and that the oil tank is full to the proper level Oil pressure indicator lamp should light when ignition is turned on. -
Page 16: Tuning Guidelines
2. Engine break-in 1. Closely monitor engine for excessive heat build-up. Do not allow the engine to idle for long periods of time. Be especially watchful when air temperatures exceed 90 degrees. Slow speed operation in urban areas during the summertime is especially hard on engines.. Temperature for engine oil should be between 180º... - Page 17 M. Engine Specifications and Torque Values Displacement 124” Cylinder Heads Specification Valve guide in head (tight) .0015”-.003” Valve seat in head (tight) .005”-.0075” Valves Specification (Fit in guide.) Intake .0012”-.0015” Exhaust .0018”-.0023” Seat Width .040”-.062” Stem Protrustion 2.045”-2.060” Rocker Arms Specification Shaft fit in bushing (loose) .0007”-.0018”...
- Page 18 N. Service Intervals Item Engine Oil & Filter ...Change at 50, 500, 2,500 miles, every 2,500 ...miles thereafter. Air Cleaner ...Inspect at 50 and 500 miles, every 2,500 ...miles thereafter. Petcock, Lines, & Fittings. Vacuum Lines...Inspect at 50 and 500 miles, every 2,500 ...miles thereafter.
- Page 19 O. Replacement Engine Assembly Parts Use the line drawings to identify replacement parts. Parts designed to fit as direct stock replacements are listed with corresponding H-D part number. If no H-D part number is shown, S&S part cannot be used in stock application and vice versa Parts not shown in this diagram, are detailed by other instruction sheets accompanying the Engine.
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