S&S Cycle V series Assembly And Installation Manual

Manual is about: 4 1/8" bore engines

Summary of V series

  • Page 1

    S&s ® cycle, inc. 235 causeway blvd. La crosse, wisconsin 54603 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 because every industry has a leader safe installation and operation rules: before ...

  • Page 2

    Introduction 4 1 ⁄ 8 " bore engine instructions often refer to procedures described in other s&s ® instructions or a harley-davidson ® service manual. These materials should be cross-referenced as necessary. All 4 1 ⁄ 8 " bore engines are designed for frames that accept 1984-'99 big twin engines, an...

  • Page 3

    Failure to observe the previous instructions may result in engine damage not covered under warranty. Flywheels confirm pinion shaft main bearing fit. Correct size bearing is supplied with engine, but must be verified by engine builder. Flywheel assembly can then be prepared for installation. Notes ●...

  • Page 4

    2. Apply coat of assembly lube to timken ® bearing installed in step 1. 3. Place left side crankcase half on sprocket shaft and bearing, insuring that connecting rods are in correct positions. See picture 3. 4. Install included timken ® bearing spacer. See picture 4. 5. Lubricate rollers of remainin...

  • Page 5

    Note - because of sealed, wet primary in harley-davidson ® evolution ® models drive trains, s&s ® installs sprocket shaft seals with spring facing out. See picture 8. 5. Allow crankcase sealant to cure per mfr.’s instructions, then pour four ounces of motor oil over bearing end of connecting rod ass...

  • Page 6

    Note - a dab of hylomar ® or other thin gasket sealer in corners may be used to hold gaskets in place. Otherwise gaskets should be installed dry. 4. Install driveshaft gear key and snap ring. Note - be sure drive shaft key and snap ring are installed properly, paying particular attention to snap rin...

  • Page 7

    Install breather gear, camshaft, and gear cover 1. Thoroughly clean and dry all parts including camshaft lockwasher and thrust washer. Carefully inspect breather gear for burrs and remove as necessary. Inspect edges of crankshaft breather “window” for burrs and smoothness. Cam thrust washer and brea...

  • Page 8

    Install lifters and lifter guides note - s&s® installs hl2t (hydraulic lifter limited travel) kit in lifters in assembled and unassembled 4 1 ⁄ 8 " bore engines. Install lifters and guides as follows: 1. If installed, remove oil pressure sending unit behind rear lifter guide opening. 2. Identify gas...

  • Page 9

    D. Install the oil ring support rail in the lower ring groove of piston. See picture 21. E. Install the oil ring separator in the lower ring groove, then install one oil ring rail on either side of the separator. S&s ® recommends covering cylinder studs with 3⁄8” i.D. Fuel line to protect piston and...

  • Page 10

    4. Insert pushrod tube o-ring washers in lifter blocks. See picture 23. 5. Install o-rings in lifter blocks 6. Install thick pushrod tube o-rings in cylinder heads. 7. Determine pushrod placement by comparing lengths of each pushrod (not including adjuster). Longest pushrod is for front exhaust, nex...

  • Page 11

    4. Check rocker arm endplay by sliding rocker arm to one side as far as possible and measuring gap between rocker arm and support at opposite end. The specification for endplay is .001”-.012”. If endplay is insufficient, carefully remove material from end of rocker arm to achieve correct endplay. Le...

  • Page 12

    S&s ® recommends that the primary drive and housing be removed when installing this engine in order to ensure all components are in proper alignment. Note - install the charging system to the crankcase as per the appropriate service manual according to the specifications for the particular model. Us...

  • Page 13

    B. Refer to the appropriate service manual for the torque specifications of the inner primary housing transmission mounting fasteners. 6. Tighten the four lower engine mounting fasteners to 35 ft-lbs. 7. Install the upper engine mounting bracket. Tighten bracket to head to 35 ft-lbs. Refer to specif...

  • Page 14

    Carburetor 1. Install carb a. Check idle mixture and idle speed screw settings. 1. Check setting of idle mixture screw, part #11-2354, on top of carb body. See picture 29. Turn screw clockwise to close screw, counting number of turns to fully closed position - setting should be 1 1 ⁄ 2 turns. Reset ...

  • Page 15

    If throttle does not return to fully closed position when released, it may inadvertently stick open, causing possible loss of control of motorcycle and personal injury to operator or others. E. Slip fuel overflow hose onto fitting on carb bowl and neatly route behind rear cylinder pushrod tubes. Exi...

  • Page 16

    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 ® 243 must be applied, and screws properly tightened. Failure to apply thread locking compound or properly tighten...

  • Page 17

    Note - s&s ® cycle recommends the use of harley-davidson ® oil filters, part numbers 63805-80a (black), or 63796-77a (chrome),or equivalent. The use of an oil filter designed for a twin cam 88 ® is not recommended. All reference to harley-davidson ® part numbers is for identification purposes only. ...

  • Page 18

    Note - if oil fails to appear at tappet screen port, verify that oil line routing is correct and that the oil tank is full to the proper level. Remove the check-ball spring from under the cap of the shorter tower on the oil pump. Replace cap to avoid losing oil from pump. 5. Once oil is seen at the ...

  • Page 19

    Pinging or ignition knock is an early sign of detonation and possible impending engine damage. Should pinging occur, the throttle must be backed off and the cause determined and corrected. Excessive retard is less obvious but equally destructive. For that reason, final timing should be confirmed wit...

  • Page 20

    Specifications for 4 1 ⁄ 8 ” bore engines displacement bore stroke compression ratio 111” 4 1 ⁄ 8 ” 4 1 ⁄ 8 ” 9.7:1 117” 4 1 ⁄ 8 ” 4 3 ⁄ 8 ” 10.2:1 124” 4 1 ⁄ 8 ” 4 5 ⁄ 8 ” 10.8:1 cylinder heads specification valve guide in head (tight) .0015” - .003” valve seat in head (tight) .005” - .0075” crankc...