Instruction Sheet #51-1160 04-28-04 S&S Cycle, Inc. 14025 County Highway G Box 215 Viola, Wisconsin 54664 Copyright®, 2003 Phone: 608-627-2080 • Fax: 608-627-1488 by S&S Cycle, Inc. All rights reserved. Printed in the U.S.A. Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.
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. Do not smoke around gasoline. Perform the installation in a well-ventilated area away from sparks or open flame.
Instruction Contents: A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. Introduction Additional Features Modification Notes Engine to Frame Test Fit Engine Assembly Engine to Frame Assembly Ignition System Fuel System Oil Tank, Fittings and Oil LIne Exhaust System Initial Start-up and Engine Break-In Tuning Guidelines Engine Specs and Torque Values Service Intervals Replacement Parts Please read these instructions carefully before starting work.
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. Additional Features: ● ● ● ● ● 4 Greater overall strength than stock crankcases, especially in the front motor mount, an important consideration in high performance applications.
C. 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.
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 case bolts. Tighten to snug. Torquing bolts to final specification is not necessary. 2. Clean frame engine mounts and carefully remove any irregularities from mounting surfaces. Also inspect crankcase mounting bosses for burrs. 3. Position case assembly in frame. 4.
CAUTION - Failure to observe the above may result in engine damage not covered under warranty. 1. Crankcase preparation before assembly. 2. Install flywheels in crankcase. 1. Thoroughly clean parts according to instructions previously mentioned. Apply coat of assembly lube to bearing surfaces. 2 NOTES - S&S crankcases are sold in matched sets only. Individual case halves are not available.
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. Install drive sprocket spacer and sprocket shaft oil seal in main bearing race of left case. Spring side of seal faces out. See Pictures E11 and E12. NOTE - Drive sprocket spacer is not incuded with S&S engine.
Picture E7 Picture E8 Use tool to guide bearing rollers onto inner race Picture E9 Picture E10 1 4 5 8 7 2 3 6 9 Picture E11 Figure 1 Picture E12 Picture E13 9
Picture E15 Picture E14 in the lower groove to allow the wrist pin to slide in under it. Install wristpin through piston and connecting rod, secure with new retaining clips, two per piston. 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. c. 3. Measure ring end gaps and adjust as necessary. See Pictures E13 and E14 d.
Top View Driveside 1 2 Front Head 2 1 Rear Head 3 6. S&S Reed Valve installation 4 4 3 Camside Stage 1 8 Ft. Lbs. Stage 2 18 Ft. Lbs. Stage 3 Turn additional 90 O Figure 2 5. 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. 2. Before installing heads spin each head bolt down on its respective stud to be sure threads are clean and free of contamination.
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. S&S die-cast Twin Cam style rocker covers or similar rocker covers with a center hole or “chimney” must be used if S&S electric compression releases are to be installed.
H. Fuel system installation and tuning NOTES - S&S Engine assemblies are available with either carbureted or fuel injected systems. Assembled Engines are shipped with the 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. Refer to the included instructions for installation and tuning . 1. Install fuel system. 1.
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. NOTES: ● lnstallations must use supplied S&S oil tank fittings instead of the smaller diameter OEM fittings. ● Use only the supplied oil line to connect the engine to the transmission oil tank.
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. Lamp will go out after engine is started and there is oil pressure at the switch in the crankcase. K.
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 - 240º F. If engine oil temperature stays above 220º F, and correct ignition timing has been verified, S&S Cycle suggests that an oil cooler be installed.
M. Engine Specifications and Torque Values Displacement 124” Cylinder Heads .0012”-.0015” .0018”-.0023” .040”-.062” 2.045”-2.060” Rocker Arms Specification Shaft fit in bushing (loose) .0007”-.0018” Bushing fit in rocker arm (tight) .002”-.004” Hydraulic Lifters Specification Lifter fit in guide (loose) .0006”-.0017” Compression Ratio 10.8:1 Specification Timkin race in case (tight) Pinion race in case (tight) .0015”-.003” .005”-.
N. Service Intervals S&S Recommended Regular Service Intervals Item Interval Engine Oil & Filter ...........................................Change at 50, 500, 2,500 miles, every 2,500 ........................................................................miles thereafter. 1 Air Cleaner .......................................................Inspect at 50 and 500 miles, every 2,500 ........................................................................miles thereafter. 2 Petcock, Lines, & Fittings.
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. 1. 2. Bolt, stator 10-24 x1" SHC - 4 required (HD#2720) (10 Pack). .....................50-0194 Seal, sprocket shaft (HD#12068) ...
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