Manual

ManualsBrandsS&S Cycle ManualsFor motorcycles49-State Certified X-Wedge Engines

S&S

Cycle, Inc.

235 Causeway Blvd.

La Crosse, Wisconsin 54603



Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

IMPORTANT NOTICE:





WARNING



CAUTION



NOTE





WARRANTY:

            

















    

            

     













ADDITIONAL WARRANTY PROVISIONS:











           

      





 





SAFE INSTALLATION AND OPERATION RULES:







 





           

         



 





         

      







 

   



        

           

         



 

         





           

           



DISCLAIMER:





    

 















           





Emission-Related Installation Instructions for

S&S® 49-State Certied X-Wedge™ Engines

Instruction 106-3353

7-31-08



 .





Because every industry has a leader

Summary of content (20 pages)

PAGE 1
Instruction 106-3353 7-31-08 S&S Cycle, Inc Copyright © 2008 235 Causeway Blvd. La Crosse, Wisconsin 54603 by S&S® Cycle, Inc. ® . 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 All rights reserved. Printed in the U.S.A.
PAGE 2
Installation Overview This S&S® 49-State Certified X-Wedge™ Engine is approved for use in assembled highway motorcycles and conforms to USEPA exhaust emissions 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 given requirements is considered a certified vehicle by the EPA.
PAGE 3
Label 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 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.
PAGE 4
Prior to installing the mounting bolts, the 4 lower engine mounts must be checked to verify the engine is sitting flat on all 4 mounts. This can be checked by using a feeler gauge between the mount and the frame. If the engine is not sitting flat on any of the mounts shims must be installed. Failure to properly shim the mounts could results in damage to the engine case not covered under warranty. After the engine is shimmed, the lower mounting bolts can be installed and torque to 70-80 ft-lbs.
PAGE 5
3- Install Wiring and Engine Control Module WARNING ••The safety of the motorcycle rider is dependent on proper installation of this product. If you are not certain of your capabilities or do •• not have the correct tools for this installation, please consult a shop to have it done for you. Improper installation of this product could result in injury or death to the rider. Do not connect the battery until completing the installation of the wiring and control system of the motorcycle.
PAGE 6
3- Use an appropriate size drill to achieve a 3⁄4” hole in each of the head pipes. See Picture 3. Flange Picture 3 CAUTION If exhaust mounting flanges are installed on head pipes, make sure the flange is above the weld-in boss before it is welded in place. 4- If exhaust mounting flanges are installed on the head pipes, make sure the flange is above the weld-in boss before it is welded in place. See Picture 3. 5- Weld the boss in place using stainless-steel filler rod. When it cools, run an M 18x1.
PAGE 7
- Install the head pipes on the motorcycle. 8- Route the S&S® closed loop sub-harness to allow the Deutsch® connectors for the oxygen sensors to be in position to be plugged in. Verify that the sub-harness will not rub against any moving or hot parts. When you connect the Deutsch connector for each oxygen sensor to the subharness plugs, listen for an audible click to confirm the connection. See Picture 6.
PAGE 8
11- Gently release the clips on each side of the clear plastic cover on the 36-position connector by pressing on each clip with a small flat screwdriver. See Picture 9. Picture 9 12- Remove the socket plugs in terminal positions #8 and #23. See Picture 10. Picture 10 13- Using a Sealed Electrical Tap from the supplied hardware kit, open the cover and position it over the wire coming out of pin #26 (black with a white stripe).
PAGE 9
14- Use a pair of pliers to firmly press the metal connector into place over both wires. See Picture 12. Note: You can put a small amount of pressure on the connector as you position the wires to make sure they are in the correct position. Once the connector is pressed in, close the blue plastic cover and listen for a click to confirm it is seated. Picture 12 15- Insert the white wire with the orange stripe into position #8. Next insert the white wire with the blue stripe into position #23. See Picture 13.
PAGE 10
18- Connect the ground wire from the S&S® closed loop sub-harness to a suitable chassis ground. See Picture 17. Picture 17 Knock Control The knock sensor comes installed on the rear cylinder head of the engine. This mounting location is critical for the operation of the system and it cannot be relocated. Included with the engine is a knock sensor wiring harness to connect the knock sensor to the ECU. To install this harness follow the steps below.
PAGE 11
6- Confirm the terminals are all in proper alignment and reinstall the clear plastic cover. Next, close the cover of the 36-position connector, making sure to get all the clips back in place. Finally, reinstall a wire tie at the base of the 36-position connector. See Picture 20. Picture 20 Bank Angle Sensor A bank angle sensor input to the ECU is required for the engine to run. It is recommended a Harley-Davidson® bank angle sensor be used.
PAGE 12
Vehicle Speed Sensor (VSS) and Speedometer A properly connected and calibrated VSS and speedometer is important for proper engine operation as the ECU uses the vehicle speed input for idle control and engine history data. Listed below are the recommended VSS and speedometers for proper input of the vehicle speed to the ECU.
PAGE 13
Adjusting Wheel Speed Gear Factor: 1- To access the Wheel Speed Gear Factor in ProTune 2 select "ECU Basic Setup". 2- The Select Data Source dialog box will appear. The dialog box will list the current active data sources; i.e. the ECU if it is connected, the demonstration data built into the software, and any calibration files that you accessed since starting the software. To select a data source, click on it to highlight it and then click "OK" or press "Enter".
PAGE 14
4- Fuel System WARNING Fuel hose must be clamped securely with proper clamps and can not contact any hot surfaces where it could melt or catch fire, causing serious injury or death. The X-Wedge engine requires a fuel supply of 58 psi to the fuel injectors. A fuel pump and regulator assembly is available from S&S® (PN 55-5089) that is designed for being mounted inside the fuel tank. Other pumps may be used as long as the supply is regulated to 58 psi and it provides a minimum supply of 45 L/hr.
PAGE 15
A- Install new throttle assembly. I- Install new throttle assembly and cables. Position grip and cables so cables can be angled towards throttle body for easy adjustment and free operation. II- 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. Throttle/Cable Assembly A- Install throttle cables on the throttle body. I- Remove throttle cable housing bracket, PN 11-2339.
PAGE 16
8- Troubleshooting Tips The following is a list of common issues found during a new installation. Included with the ECU is also a CD and instructions for running the Pro Tune 2 software. This will allow access from a computer connected to the ECU to read engine trouble codes and sensor outputs for troubleshooting problems. See the instructions included with the Pro Tune 2 CD for installing the software on a PC.
PAGE 17
PAGE 18
PAGE 19
PAGE 20
Because every industry has a leader 20