Service manual

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SAFE INSTALLATION AND OPERATION RULES:

Before installing your new S&S stroker kit it is your responsibility

to read and follow the installation 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 compressed air is used during installation, be particularly careful.

Compressed air and particles dislodged by compressed air are

harmful to eyes and body. Wear protective goggles, and always direct

air stream away from body parts such as hands and eyes and other

people near you.

●●

● When using solvents, degreasers and other chemicals during

cleaning and installation, read manufacturer's instruction label for

proper use. Exposure of some chemicals to skin, eyes and/or other

body parts may be harmful. Many items are flammable and present

a fire hazard. Use in well ventilated area and wear protective clothing

when using them to avoid personal injury.

●●

● 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 while working on electrical components.

●●

● 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.

●●

● Consult an appropriate authorized H-D service manual for correct

disassembly and reassembly procedures for any parts other than

those outlined in these instructions.

●●

● 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.

●●

● Be sure all federal, state and local laws are obeyed with the

installation.

●●

● Be sure all fuel lines, supply and overflow, are routed correctly

and fuel line clamps are in place and tightened. Lines must not

contact exhaust pipes or other extremely hot surfaces where they

could melt or leak and catch fire.

●●

● Before starting engine and riding motorcycle, be sure throttle opens

and closes smoothly. Turn handlebars to left and test throttle. Then,

turn bars to right and test throttle. To avoid possible loss of control

of motorcycle and potential personal injury to yourself or others due

to throttle sticking in open position, throttle must work smoothly

and return to a fully closed position when hand is removed from

throttle grip.

●●

● Motorcycle exhaust fumes are toxic and poisonous and must not

be breathed. Run motorcycle in a well ventilated area where fumes

can dissipate

S&S

Cycle, Inc.

Box 215

Viola, Wisconsin 54664

Phone 608-627-1497 Fax 608-627-1488

Instruction sheet No. 3100

Revised 11-28-95

by S&S Cycle, Inc.

IMPORTANT NOTICE:

Statements in this instruction sheet preceded by

the following words are of special significance:

WARNING

Means there is the possibility of injury to yourself

or others.

CAUTION

Means there is the possibility of damage to the

engine or motorcycle.

NOTE

Other information of particular importance has been

placed in italic type.

S&S recommends you take special notice

of these items.

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 six (6) 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 6

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

motorcycles. S&S shall have no warranty or liability obligation if an

S&S part is used in any other application.

Installation of S&S Sidewinder 3

⁄8" Big Bore Cylinders

for Evolution Sportster V

Engines - 1986 and Later

DISCLAIMER:

S&S parts are designed for high performance, off road, 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.

Summary of content (16 pages)

PAGE 2
Introduction Installation Steps: Installation of an S&S Sportster V2 35⁄8" bore stroker Sidewinder Kit is comparatively easy and can be performed by any Harley-Davidson repair shop equipped to do complete engine overhauls. 1. 2. 3. 4. 5. 6. NOTES ● To make installation of S&S Sidewinder series 3 5⁄8" bore kits easier, S&S has designed several Special Tools worth considering. They are: Part #53-0002 - Connecting Rod Checking Pin helps check piston alignment in cylinder bore.
PAGE 3
B. Refer to chart in Figure 1 to determine increase over stock engine height for the kit to be installed. S&S recommends .100" minimum clearance between engine and frame. If increased cylinder height of Sidewinder kit will not leave sufficient room, clearancing will be required. S&S V2 XL style cylinder heads are .062" taller than stock, so additional clearance will be required if S&S heads are to be used. NOTE - S&S recommends there be .100" minimum clearance between engine and frame. Up to .060" or .
PAGE 4
B. Picture 2 4. Bore Crankcases C. NOTE - Boring cylinder spigot holes in cases to accommodate big bore cylinders will machine a notch on center case bolt. This bolt must be replaced with a special stud which is installed into the top crankcase bolt hole in the cam side case half. D. Perform following procedure to bore crankcases: A. In 1986-1990, four speed cases, the center crankcase bolt must be replaced by S&S stud #312046.
PAGE 5
5. Modify Crankcases for Oil Returning from Heads NOTE - Oil return passageways in V 2 Sidewinder cylinders are moved out slightly compared with stock oil return holes to accommodate 3 5⁄8" bore. This creates misalignment between cylinder oil return passage and crankcase oil return passage. Figure 2 CAUTION - Damaged studs may cause stress risers which can lead to stud failure and possible damage to engine components. F. Center boring bar head in cylinder spigot bore in crankcases, not hole in plate.
PAGE 6
Grind four oil grooves on both sides of forked rod Figure 3 recommends that four grooves be ground on each side of both front and rear connecting rods. See Figure 3. Make these grooves .020" to .030" deep and .030" to .040" wide and should be ground 90° from each other. After making grooves, remove all sharp edges and burrs with emery cloth. B. Thoroughly clean all parts to remove dirt, filings, etc. CAUTION - Burrs, dirt, filings, etc.
PAGE 7
Picture 7 CAUTION - S&S warranty is void if flywheel tapers are lapped. C. Check keys in grooves of shafts. Key should be light hand press fit in groove. If key is too tight in groove, sand side key with fine sand paper on a metal plate or other flat surface. Do not hammer key into groove. CAUTION - Hammering tight key into groove may result in irreparable damage to shaft. D. With key in shaft, insert into respective tapered hole in flywheel and check to see that key does not bottom in groove.
PAGE 8
ups are used. Please read this entire section before beginning work. CAUTION - Insufficient clearance between connecting rods and crankcases, pistons and flywheels, and between the two pistons will cause contact and damage to components. Picture 9 J. Finish assembling flywheels and rods. K. Check flywheel assembly for run out by placing ends of mainshafts between centers. Place dial indicators on bearing surfaces of mainshafts. See Picture 9. True wheels as needed. S&S trues flywheel assemblies to .
PAGE 9
operation. For this reason, piston to piston clearancing is done on the front skirt of the rear piston in order to leave the rear skirts of both pistons as long as possible. e. Reassemble and recheck clearance. 2. Piston to Flywheel Clearance a. Perform Steps 1 through 3 in “Connecting Rod Clearance” above. b. Rotate flywheel to position where front piston is closest to flywheel. This is at the bottom of the stroke. See Picture 14. c. Check clearance between piston and flywheel.
PAGE 10
completely rebuilt. Observe pistons for wear spots on sides above top compression ring. If one side near wristpin is worn clean while side opposite is carboned up, then piston was not running straight and true in cylinder bore. Piston will also generally show diagonal wear pattern on thrust faces of skirts and possibly signs of connecting rod to wristpin boss contact inside piston. ● We feel that not enough emphasis is given to checking piston alignment in cylinder bore.
PAGE 11
due to machining variations in cases, cylinders or pistons, top land of piston deck will appear closer to cylinder wall at one point around circumference. This means that piston is cocked in cylinder bore and can be corrected by bending rod in opposite direction. Figure 5 shows an exaggerated side view of this condition. 5. Repeat Steps B to D for other cylinder. Piston Deck Deck Height Wrist Pin Hole 11. Cylinder Head Preparation A.
PAGE 12
just above top compression ring groove), not dome, must be flush with or slightly below gasket surface. 4. If piston deck is higher than cylinder at top dead center, something is wrong and S&S should be notified. If piston deck position is correct proceed to Step B. NOTE - Most stock V 2 and S&S V 2 style engines are designed with .045" to .062" piston to head clearance. This clearance is provided by thickness of head gasket.
PAGE 13
C. Install pistons, rings and wristpin clips per S&S piston instruction sheet #2500. D. Coat piston skirts with engine oil or assembly lube and install cylinders. E. Place o-ring seals over cylinder head alignment dowels. Install head gaskets provided in kit dry. NOTE - Care must be taken to use correct alignment dowel o-rings with V 2 head gaskets. Head gaskets supplied with S&S cylinder heads compress to about .045" thick and require .070" diameter o-rings.
PAGE 14
Manifold Flange O-ring Figure 8 tubes in cup of adapter. Use stock 1986 to 1990 pushrod seals. Rotate S&S pushrod tube adapters so that cup surface is as close to perpendicular with pushrod tube as possible. Install pushrod cover clip and final tighten stock pushrod tube retainer bolt. 4. Install rocker covers and gaskets. 5. Install intake manifold, mounting flanges and o-ring seals. Be sure o-rings and flanges are assembled in correct sequence.
PAGE 15
Improper initial engine start-up and break-in procedure may cause head gasket failure. NOTE - Proper first time engine start-up and break-in is critical to achieve permanent and lasting head gasket seal. Prior to initial start-up, a .001" to .005" feeler gauge will fit between head gasket and head and cylinder gasket surfaces stopping at fire ring on head gasket. Warming engine as instructed will tightly close this gap producing a good, lasting seal.
PAGE 16
● Carburetor jetting and spark plug color - While spark plug color may be used to help determine carburetor jetting, S&S recommends that our instructions be used as primary jetting guide and that plug color indications be used only as secondary aid. We have found that different brands of gasoline, gasoline additives, engine heat (due to ignition timing), and brands of plugs and heat range used distort plug color drastically making plug reading difficult for the average tuner.