Service manual

ManualsBrandsUltima ManualsAutomotiveSHOVELHEAD ENGINES

S&S

Cycle, Inc.

14025 Cty Hwy G PO Box 215

Viola, Wisconsin 54664

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

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

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

Installation and Jetting Instructions for

S&S Super E and G Series "Shorty" Carburetors

IMPORTANT NOTICE:

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



WARNING

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

CAUTION

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

NOTE

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

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

WARRANTY:

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

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

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

ADDITIONAL WARRANTY PROVISIONS:

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



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

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

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

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

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

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

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

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

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

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

SAFE INSTALLATION AND OPERATION RULES:

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

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

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

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

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

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

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

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



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

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



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

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

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

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



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

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



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

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

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



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

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

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

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

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

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



DISCLAIMER:

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

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

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

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

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

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

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

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

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

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



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

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

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

Instruction 51-1012

07-25-12



 





Summary of content (36 pages)

PAGE 1
07-25-12 S&S Cycle, Inc Copyright © 2009, 2010, 2012 by S&S® Cycle, Inc. Phone: 608-627-1497 • Fax: 608-627-1488 Instruction 51-1012 ® . 14025 Cty Hwy G PO Box 215 Viola, Wisconsin 54664 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
INTRODUCTION S&S® Super E and G Shorty carburetors are designed for and Harley-Davidson® big twin and Sportster® models as well as other American v-twin engines. They are butterfly type carburetors with fully adjustable idle mixture and changeable air bleed and mid range and high speed jets. Both carburetors also feature an adjustable accelerator pump and variable enrichment/fast idle device for improved throttle response, engine starting and warm ups. The Super E has a 17⁄8" (47.6mm) bore and 19⁄16" (39.
PAGE 3
THROTTLE REQUIREMENTS NOTE: S&S Super E and G carburetors require the use of a two cable, pull open - pull closed throttle assembly. All 1980 and earlier stock H-D® models equipped with a single cable throttle mechanism must be converted to the two cable, pull open-pull closed type. S&S offers these throttle assemblies but does not include them with any carburetor kit because of the multitude of chassis designs and fitment requirements.
PAGE 4
1996 to 2002 Buell® Models 1996 and 1997 Buell models require special S&S butterfly style throttle cables, which are compatible with the stock 1996-1997 throttle assembly. 1998-'02 carbureted Buell models require installation of stock 1996-‘97 throttle grip and the special S&S throttle cables for Buell models when installing Super E or G carburetors. S&S THROTTLE KITS S&S throttle kits fit 1" handlebars and can be used on most chassis.
PAGE 5
Picture 3 Picture 4 CAUTION Extreme care must be taken to prevent metal chips from entering engine when elbow is removed. S&S® recommends packing breather fitting with grease before removing elbow. Metal chips inside engine will cause extensive damage. Installer bears all responsibility for containment of chips and other debris. 2- Prepare Air Cleaner Backplate NOTE: Fast idle lever screws must not be over tightened.
PAGE 6
3- Shovel, 1980 to 1984 and Sportster® models 1980 to 1985 - Screw crankcase breather vent elbow fitting into hole in air cleaner backplate and angle downward as shown in Picture 7. 4- On 1983 and 1984 shovel engines press plug into other hole on left. 5- Assemble fast idle mechanism as shown in Figure A. On current backplates the pivot point for the enrichener does not have a screw holding it; a boss has been cast onto the backplate to replace this.
PAGE 7
3- Throttle Preparation NOTE: Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation. Throttle must snap closed when released. Cable routing must be free of tight bends to minimize friction between cable and housing. WARNING If throttle does not work freely, it may inadvertently stick open possibly causing loss of control of motorcycle and personal injury to operator or others.
PAGE 8
A- All models: Clean intake ports on cylinder heads to insure proper manifold to head seal. NOTE: Cylinder heads for knucklehead engines 1936-'47 and panhead engines 1948-'54 must be converted to o-ring style manifold and seals. Conversion kits are available from S&S®. See the Flathead Power® vintage section of the S&S Catalog. B- All models: Install S&S® intake manifold. If applicable, vacuum advance fitting must point upward.
PAGE 9
5- Install Carb A- Check idle mixture and idle speed screw settings. 1- Check setting of idle mixture screw on top of carb body. See Picture 15. Turn screw clockwise to close screw, counting number of turns to fully closed position - setting should be 11⁄2 turns. Reset by turning screw counterclockwise to 11⁄2 turns open. After engine is started, screw must be reset as explained in "Adjusting Idle Mixture" section of instructions.
PAGE 10
CAUTION If insulator block is not installed, lower manifold bolt may damage carburetor bowl causing possible gasoline leak. WARNING Gasoline is extremely flammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic when inhaled. Any gasoline leak or spill constitutes a health and fire hazard. D- Adjust throttle cables 1- Turn threaded throttle cable adjusters to remove excessive freeplay. 2- Test throttle to insure that it opens and closes freely.
PAGE 11
6- Install Air Cleaner Backplate NOTE: Air cleaner backplate screws supplied with kit have thread locking compound on threads. If screw without thread locking compound is used, a thread locking product such as Loctite® 242 must be applied, and screws properly tightened. CAUTION Failure to apply thread locking compound or properly tighten screws may cause screws to loosen and fall into engine, causing engine damage not covered under warranty.
PAGE 12
2- Mount the air cleaner backplate on carb using three 1⁄4"-20 x 9⁄16" screw/washer assemblies. Confirm that enrichment device lever, engages enrichment device plunger. See Picture 20. Tighten backplate mounting screws to 5-7 ft-lbs (60-84 in-lbs). 3- Fill gap between backplate mounting ears and cylinder heads with shims provided in S&S shim kit. 4- Bolt backplate to cylinder heads with 5⁄16"-18 x 11⁄4" bolts, flat washers and lock washers. See Picture 24.
PAGE 13
5- Fill gap between backplate mounting ears and cylinder heads with correct shims. Install screws to attach backplate to breather fitting. Torque to 8-12 ft-lb with no Loctite. See Picture 29. D- Buell® models 1994-’02 1- Place washer on breather screw. 2- Roll 5⁄8" O.D. o-ring into large diameter o-ring groove closest to head of breather screw. 3- Roll 1⁄2" O.D. o-ring into small diameter o-ring groove of breather screw. Apply thin film of light grease to o-rings.
PAGE 14
10- For street use, insert 11⁄4" steel tubing provided into short "tee" of T-hose and place 3⁄8" O.D. x 2.80" hose over other end of tubing. Hose must rest in notch in backplate, with bevel down. Secure with Tie-wraps when correctly positioned. See Picture 32. Picture 32 NOTE: An additional, 36" length of hose is provided for "Race Only" applications. It should be attached to T-hose in place of 2.80" hose, and routed to overflow or "catch can" as required by event organizer.
PAGE 15
L- Install air cleaner element and air cleaner cover using three 3⁄4"-20 x 1" mounting screws provided. Insure that element goes around outside edge of locating tang at 9 o'clock position on backplate. Correctly installed element will remain in place on backplate without support. Filter element supplied with carb kits for Buell® models is foam type. Beveled vent hose in kits for Buell bikes must rest in notch in backplate and go between air cleaner element and chromed outer cover.
PAGE 16
•• G carb using air cleaner assembly without filter element flows approx. 7 CFM (10" test pressure) less than carb with 4" air horn. E carb w/air cleaner assembly, no filter, flows same as with 4" air horn. S&S recommends using air filter element for all street applications. •• S&S has found that trimming approximately 3⁄4" off rim of S&S air cleaner cover has resulted in as much as 3 HP increase on Dynojet® 150 chassis dynamometer.
PAGE 17
5- With throttle closed, kick engine through or engage electric starter. 6- If engine fails to start immediately, crack throttle enough to barely open butterfly and continue to kick or engage starter until engine fires. 7- After engine starts, position lever to maintain rpm at approximately 1000-1200 rpm with throttle closed. Lever may gradually be pushed down to closed position as engine warms.
PAGE 18
9- If engine was running properly before installation of carburetor, no other changes were made and carb settings were confirmed as instructed previously, hard starting is likely caused by incorrect intermediate jet or starting routine. Remain calm and patient while attempting to start motorcycle, and experiment with different starting procedures (throttle and enrichener position, number of squirts from accelerator pump, etc.), especially with kickstart motorcycle.
PAGE 19
B- Troubleshooting Tips - engine will not idle: 1- Improper idle mixture or rpm setting. 2- Intake manifold air leak. 3- Malfunctioning automatic advance mechanism or other ignition problem. 4- Foreign material in air or gas passageway in carb causing gas flow restriction to idle or intermediate circuit. Picture 41 shows intermediate air bleed metering hole. Picture 41 shows intermediate jet metering hole. Clear holes with compressed air. Picture 41 CAUTION Do not use wire or drill to clear hole.
PAGE 20
Intermediate Jetting Procedure: 1- Ride motorcycle several miles to bring engine up to normal operating temperature. 2- Check idle mixture adjustment to be sure setting is correct with fully hot engine. 3- Check throttling characteristics by slowly rolling throttle on from a steady speed. This should be done at rpm levels of approximately 2000, 2500, and 3000 rpm. (Depending upon gearing, vehicle speeds will usually be between 30 and 60 MPH).
PAGE 21
d- If engine runs flat and sluggish or "blubbers" or will not take throttle, decrease or lean main jet size .004" smaller and road test again. Note engine smoothness and how easily engine reaches rpm where gear shift occurs. e- Continue changing main jets until jet which makes engine accelerate or rpm through gears quickest and smoothest is identified. S&S's® experience is that jetting about .006" smaller (leaner) than correct will make engine break up and quit. Jetting about .
PAGE 22
6- No air cleaner used or air cleaner used is brand other than S&S. Some air cleaners restrict air flow so that carb cannot draw air as freely as needed. Also, some air cleaners may obstruct bowl vent hole on inlet end of carb and change bowl air pressure. See Picture 45. Picture 45 NOTE: Bowl vent hole passage leads to cavity above fuel in bowl. Passage equalizes bowl pressure and atmospheric pressure. If high or low bowl pressure relative to atmospheric pressure develops, engine may run erratically.
PAGE 23
NOTES: The standard .040" diameter air bleed is the optimum size for most engine combinations, and should not be changed under most circumstances, regardless of intermediate and main jet selections. Changing the main air bleed size should be done only after determining a mid range driveability problem cannot be corrected by changing the intermediate and main jets. For tuning the main air bleed, S&S® recommends an initial increase from the standard .040" jet to an .048" jet as a starting point.
PAGE 24
CAUTION Closing adjusting screw with excessive force may cause irreversible damage to screw threads in carburetor body. 3- Perform intermediate and high speed jetting tests to determine proper jetting. 4- With engine warm and at idle, blip throttle and note throttle response. 5- Turn pump travel screw outward or counter clockwise about 1⁄4 turn at a time and recheck throttle response until engine no longer hesitates. This is usually about two turns out.
PAGE 25
•• Throttle plate and throttle shaft should be checked annually for signs of wear. Replace if necessary. If carb body throttle shaft bushings are worn, carb must be returned to S&S® for repair. If throttle plate removed, be sure to reinstall correctly. See Figure C. Beveled edges of plate must fit flat against carb throat. Figure C •• If accelerator pump cap is removed, lift cap slowly so small spring checkballs and o-rings are not lost.
PAGE 26
SUPER E & G CARBURETOR BODY AND RELATED PARTS 1. Carb body assembly 17⁄8" Super E . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2381 21⁄16" Super G. . . . . . . . . . . . . . . . . . . . . . . . . . 11-2391 2. Throttle shaft 17⁄8" Super E – Includes two plate screws. . . . . 11-2383 21⁄16" Super G – Includes two plate screws. . . . . 11-2483 3. Throttle plate screw - (two required) each. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0055-S 10 pack. . . . . . . . . . . .
PAGE 27
…Continued: Super E & G Carburetor Body and Related Parts 22 18 13 2 6 16 19 20 17 53 21 3 5 57 15 54 23 17 58 14 4 49 24 1 52 9 10 25 48 26 11 28 12 27 55 9 8 29 22 36 38 31 30 56 41 42 47 40 46 43 37 45 51 32 35 32 50 34 44 27
PAGE 28
REPLACEMENT PARTS FOR S&S SUPER E & G AIR CLEANERS FOR 1936-UP BIG TWINS 1 Air cleaner cover – All (Except shovelhead w/5 gallon tanks & cylinders + .075".) Chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0378 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0384 Slasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0004 Shovelhead w/5 gallon tanks & cylinders +.075" 17-0372 2 Element, pleated carbon .
PAGE 29
…Continued: Replacement Parts for S&S® Super E and G Air Cleaners 36 1999–'06 Harley-Davidson Twin Cam 88 ® ® 34 13c 20 17-0403 8 9 1993–’99 Big Twin 6 17-0404 21b 10 11 7 8 23 35 2 23 5 3 13a 37 1 4 6 3 8 9 10 11 7 8 23 25 27 25 Flatwasher – 5⁄16" x 1⁄16" . . . . . . . . . . . . . . . . . . 26 Support bracket XL 1957-'85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BT 1966-'82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . BT 1983-'84 . . . . . . . . . . .
PAGE 30
REPLACEMENT PARTS FOR S&S® SUPER E AND G AIR CLEANERS FOR 1986-UP HARLEY-DAVIDSON® SPORTSTER® MODELS 1. Air cleaner cover 13. Shims, a. XL 1986-’90 5⁄16" x .018" (each) . . . . . . . . . . . . . . . . . . . . . 50-7038 10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7107 Chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0378 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0384 Slasher . . . .
PAGE 31
Continued...Replacement Parts for S&S® Super E and G Air Cleaners For 1986-Up Harley-Davidson® Sportster® Models 32. Air cleaner assembly (Includes: Chrome cover, backplate, filter element, and hardware kit) XL 1957-’85 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0400 XL 1986-’90 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0399 XL 1991-'03 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0404 33.
PAGE 32
REPLACEMENT PARTS FOR S&S® AIR CLEANERS FOR BUELL® MOTORCYCLES 1. Air cleaner cover Chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0078 Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0075 2. Air cleaner element . . . . . . . . . . . . . . . . 17-0079 3. Air cleaner backing plate Super E & G carburetors . . . . . . . . . . . . . 17-0000 Stock carburetors . . . . . . . . . . . . . . . . . . . 17-0003 4. Cover screw Chrome (each) . . . . . . . . . . . .
PAGE 33
REPLACEMENT MANIFOLD PARTS 1-3- Intake manifold See S&S® Catalog for part numbers. 4- Manifold bolts 3⁄8"-16 x 1" ........................................................................................................50-0161 10 pack.................................................................................................................50-0186 3⁄8"-16 x 11⁄4"......................................................................................................50-0162 10 pack..........................
PAGE 34
NOTES: 34
PAGE 35
NOTES: 35
PAGE 36