® Instruction 106-4500 10-29-08 S&S Cycle, Inc. 14025 Cty Hwy G Viola, Wisconsin 54664 Copyright® 2008 Phone: 608-627-1497 • Fax: 608-627-1488 by S&S Cycle, Inc. 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.
DISCLAIMER: IMPORTANT NOTICE: 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.
Instruction Contents: 123456- Introduction Additional Features Modification Notes Engine to Frame Assembly Ignition System Fuel System 789101112- Oil Line Installation Exhaust System Initial Start-up and Engine Break-In Tuning Guidelines Engine Specs and Torque Values Service Intervals Please read these instructions carefully before starting work. Proceed with the installation only after the instructions are completely understood.
Torque Horsepower Dynomometer chart showing typical horsepower and torque curves for S&S 111” T111 engine. Horsepower and torque curves will vary, dependent on the engines state of tune, and the ignition and fuel systems used on the completed engine. 2 Additional Features: Greater overall strength than stock crankcases, especially in the front motor mount, an important consideration in high performance applications. All oil passages between the crankcase and cam support plate are O-ring sealed.
3- Modification Notes S&S® Cycle cautions against modifying these 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. have been provided.
5- Ignition System Installation 6- A- All Carbureted S&S T111 assemblies come with an S&S IST (Intelligent Spark Technology) ignition. Use of this ignition system is highly recommended. All aspects of ignition timing- advance, retard, and curves are handled automatically by the S&S IST ignition. NOTES - S&S® Engine assemblies are available with either carbureted or fuel injected systems.
- Oil Line Installation 4- Install the vent hose and clamp (S&S PN 50-8156 or 50-8076-S) on the new fitting. A- For 1999-2006 Harley-Davidson® FL models NOTE- The stock vent hose is reused in this step. CAUTION 5- 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.
7- 8- Mount the oil line block on the crankcase using 5⁄1618 x 13⁄4” long screw (S&S® PN 50-0437)—do not final tighten as it will be removed again. The next step is to measure and then cut the oil hoses. The straight hose connects the 90 degree fittings of the oil line block and oil pan. The bent hose runs between the oil return fittings on the oil line block and oil pan. See Picture 4. 10- Install O-Rings (S&S PN 50-8066) in the counter bores of the oil line block.
S&S® Replacement Parts for Harley-Davidson® FL Models 12345- Block, Oil line .........................................................106-1168 BHSHCS, 5⁄16-18 x 13⁄4 (10 pack) .................................106-1169 O-ring (10 pack) .........................................................50-8066 Fitting, Pipe, 90 degree (2 pack)...........................106-1170 Fitting, 7 ⁄16 (2 pack) ............................................................106-1171 3 ⁄8 (2 pack) ...................................
8- 9- Install the transmission top cover screws and washers according to Detail A. Use blue threadlock on the screws, but leave them loose at this time. See Detail A in exploded view of replacement parts for Harley-Davidson® Dyna® on page 11. Remove the oil line retention plate, plugs and seals from the top of the engine crankcase. Remove seals from the plugs. Discard the plugs. Picture 8 Picture 10 Picture 8a 5- 6- 7- Remove the transmission top cover.
12- Press the oil line retention plates into place until they seat. Install the two screws (5⁄16-18 x 3⁄4 button head) through the oil line retention plates. First screw goes in the transmission top cover and the second mounts into the crankcase near the rear motor mount. Treat both screws with blue threadlock and tighten to 18-ft-lbs. 13- Tighten transmission top cover screws to 100-120 in-lbs. 14- Install the vent line (S&S PN 50-8291) with clamps (S&S PN 50-8156). 15- Reconect neutral switch wires.
C- Oil recommendations NOTES S&S® Cycle recommends the use of Mobil 1® V-TWIN 20W50 synthetic oil in our engines. S&S Cycle recommends the use of S&S® oil filters, PN 31-4103 (black), or PN 31-4104 (chrome). All reference to Harley-Davidson® part numbers is for identification purposes only. We in no way are implying that any of S&S® Cycle’s products are original equipment parts or that they are equivalent to the corresponding HarleyDavidson® part number shown.
9- Initial Start-Up And Engine Break-In NOTE - engines are designed for high performance and as such are not as tolerant of inadequate break-in as stock or lower performance engines. Correct break-in will assure longer engine life and will prevent unnecessary engine damage. Engine damage caused by improper break-in is not covered under the S&S® warranty. B. Engine break-in 1- Closely monitor engine for excessive heat buildup. Do not allow the engine to idle for long periods of time.
10- Tuning Guidelines Ignition timing and carburetor jetting are responsibilities of the customer. If not thoroughly familiar with these procedures, contact a professional mechanic. A- Exhaust Systems Muffled exhaust systems. If you have an existing 2-into-2 system that uses slipon style mufflers, whether it is an OEM or an aftermarket system, we recommend the new S&S slipon mufflers. S&S® dyno tests achieve almost 8 more horsepower and 5 ft. lbs.
Torque Values Specification S&S Suggestion Rocker box hardware 1⁄4” Rocker box hardware 5⁄16” Tappet guide fasteners Pushrod locknuts Cylinder head bolts Crankcase fasteners 1⁄4” Crankcase fasteners 5⁄16” Gearcover fasteners Intake manifold-to-head Intake manifold-to-carb Exhaust flange-to-head Spark plug Cylinder studs Piston oiler screws 120 in-lbs. Loctite® 243 18 ft-lbs. Loctite 243 120 in-lbs. Loctite 243 120 in-lbs. See chart on page 11. 120 in-lbs. 15 ft-lbs. 120 in-lbs. Loctite 243 16 ft-lbs.
Replacement Parts for S&S® Crankcases for Harley-Davidson® Twin Cam 88® Engines 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Switch, oil pressure Case with rear motor mount, 1948-’99 big twin (H-D#26561-84) (Not shown) ..............................................31-2016 Bolt, stator 10-24 x1” SHC - 4 required (H-D#2720) (10 Pack) ....................................................50-0194 Seal, sprocket shaft (H-D#12068) ..............................
