Service manual

4
1996 to 2002 Buell® Models

        

S&S THROTTLE KITS




  
  
  
  
  
NOTE: Cables supplied with above kits are interchangeable with 1981-'90 stock H-D buttery style throttle cables.
S&S Throttle Cables For 1996 and Later Chassis




CARB INSTALLATION


NOTE: Installation of S&S® Super E and G carb kits on certain models is easier with gas tanks removed. Some owners may elect to perform installation
without removing gas tanks. This is left to individual discretion. If installer elects to remove tanks or other stock parts, S&S recommends referring to
appropriate Harley-Davidson® service manual for correct removal procedure as necessary.
1- Remove Old Carburetor And Manifold
 Gasoline is extremely ammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic
when inhaled. Perform installation in a well ventilated area away from open ames or sparks. Any gasoline leak or spill constitutes a
health and re hazard.
 If motorcycle has been running, wait until engine and exhaust have cooled to avoid getting burned during installation.
 Electrical sparks can ignite explosive gasoline fumes. Failure to disconnect battery while working on motorcycle can also result in
inadvertent engagement of starter and personal injury.
 
 

NOTES:
 Removing and tightening hard to reach Allen bolts like carb-manifold mounting bolts and manifold ange bolts can be greatly simplied by using
some special tools. The S&S rocker cover wrenches work very well for this application. See Picture 3 on next page. Allen ball-end drivers are also very
helpful, and are available at most automotive and tool supply houses. See Picture 4 on next page. As an alternative, standard hex wrench can be
shortened for convenience.
 Some Buell® motorcycles have a breather tting with 90° elbow on rear head. Due to proximity of frame, elbow must be removed before tting can be
taken o engine.
 Loosen tting and rotate to position convenient for cutting elbow. Secure tting by tightening against cylinder head. Elbow may be inaccessible to
hacksaw. In most instances, a die grinder with cuto wheel will remove elbow with little diculty. If die grinder is unavailable, grasp elbow rmly with
pliers and snap o, then remove tting.
WARNING