- S&S Cycle
Contents
1. A WARNING A Some solvents degreasers and other chemicals used for cleaning parts are harmful to skin eyes and other body parts Many items are flammable and present a fire hazard Read manufacturer s instruction label for proper use Use in well ventilated area and wear protective clothing when using them to avoid personal injury All Engines With Two Piece Mainshaft Flywheels Balance shaft assembly used to balance flywheels in all engines with removable mainshaft consists of main balance shaft two tapered spacers and nut to secure flywheels to shaft See Picture 1 next page Shaft with two different angled pressed on tapers is used to do most flywheels with smaller diameter tapers removable tapered spacers can be added to one side of shaft or other to balance all flywheels with larger diameter tapers A Check keyway and oil hole in flywheel taper for burrs and remove if present B Clean flywheel balance shaft and bobweight tapers with solvent C Select taper on shaft and taper spacer if necessary that fits mainshaft taper in flywheel to be balanced Secure assembly in flywheel with balance shaft nut D Bolt bobweight assembly in crankpin hole Owner s name lohw Doe 1234 Viola Street La Crosse W Date Front Piston Weight 04 15 10 Piston 400 Big Twin 5 Wristpin 100 Sportster O Clips Year of Engine 192Z Rings 40 Bore Wristpin 100 SA QU aos Total 545 Stroke 4 5 e Rear Piston Weight Piston 295 Rod2. Not Shown ss sssesssessseessessseess 53 0011 Owner s name Big Twin O Sportster O Year of Engine Notes Front Piston Weight Piston Wristpin Clips Rings Wristpin Total Rear Piston Weight Piston Wristpin Clips Rings Wristpin Total Total of Both Connecting Rods Crankpin Nuts Cages Bearings Nut Locks amp Screws Total Front Rod WP End CP End Total Act Wt Rear Rod WP End CP End Total Act Wt Reciprocating Weight Total of Both Pistons WP End of Front Rod WP End of Rear Rod Total Reciprocating Weight Rotating Weight Total of Crankpin Nuts etc Front Rod CP End of Front Rod CP End of Rear Rod Total Rotating Weigth Total Reciprocating Weight Multiply Times balance Factor Reciprocating Weight Add Total Rotating Weight Total Bobweight for 2 wheels Divide by 2 Total Weight of Bobweight to be used on Each Flywheel
3. be moved up and down and swiveled from side to side so flywheel bob weight assembly when placed with rod side up on table can be drilled around outer rim Support as much of the assembly on drill press table as possible Set drill depth so drill point stops 346 above table Use to 746 dia drill to drill holes in Harley Davidson Sportster model flywheels and 7 6 to 12 dia drill for big twins Before drilling see Figure 4 below right for recommended areas to drill See following notes for drilling rules and additional information F There is no formula to explain how many holes to drill or how deep holes should be Experience is best teacher After several balance jobs you may be able to judge how much material how many holes to drill and how deep must be removed from flywheel by how fast heavy spot rotates downward When first starting and learning drill hole about 1 4 deep then check then drill again Drill first hole at heaviest point to half depth Drill additional holes an equal number to identical depths on each side of first hole When flywheel is close to being balanced 146 depth of material in a 2 diameter hole will make a big difference between assembly rotating or remaining stationary If about Yo is all that s left to remove drill remaining amount from first hole Assembly is in balance when heavy point is placed in three different positions on balance stand 120 apart and flywheel r
4. cap 1 diameter secures bobweight in crankpin hole Shim cap 2 diameter screws into main body to hold shims in place Bobweight without shims has been machined to weigh 1000 grams An assortment of shims in varying thickness and weights is also furnished These are bolted between shim retainer cap and main body to make up a bobweight equal to weight required to balance one flywheel Number of shims furnished and weight of each one is 2 Shims ceescstenues 185 thiCk ssss ss 100 grams each 2 SHIMS 0 092 TRICK sessarssssincen 50 grams each 5 STUNG censceteaccs O25 thick ceccniace 13 4 grams each 5 SHIMS 0 020 MiC Kisii 10 8 grams each 5 SHIMS 00 015 ThilGKasceneies 8 1 grams each 5 ShiMS sensesinvans 010 thick 000 5 4 grams each 5 SIMS senscaseaies 005 THICK axsesscascie 2 7 grams each NOTE If no shims are used a bobweight of as little as 1000 grams can be used Ifas many shims as can be placed on screw of shim retainer cap and still thread retainer in main body a bobweight of slightly over 1400 grams can be made This range from 1000 to 1400 grams should be adequate to cover most engine builder s needs If bob weights of less than 1000 grams are required main bobweight can be lightened by machining material evenly from flat surface A CAUTION A Do not drill holes to lighten bobweight as this will change the center of gravity and cause erratic and inaccurate results A Weigh main b
5. not shown Special adapter sleeve is screwed on shaft to act as bearing surface and counterweight adapter Collar spacer is used on sprocket shaft to space adapter away from flywheel if Timken bearing has been removed Counterweight is screwed in adapter and offsets weight of flywheel and bobweight when assembly is placed on balance stand NOTE Some earlier two piece mainshaft flywheel assemblies may also be balanced using these balancing components in lieu of disassembling them rebalancing them and then reassembling them Big twin driveside A Clean mainshaft bearing surface flywheel crankpin taper inside and outside of collar spacer 53 0097 and sleeve 53 0091 counterweight 53 0099 and bobweight taper with solvent B If Timken bearing assembly has been removed use collar 53 0097 to space sleeve 53 0091 away from flywheel C Slip sleeve 53 0091 on sprocket shaft Screw sleeve on to sprocket shaft until sleeve contacts bearing or 53 0097 spacer Hand tighten Do not overtighten D Lay flywheel down with sleeve shaft facing up and screw counterweight 53 0099 into end of sleeve until hand tight Do not overtighten E Bolt bobweight assembly in crankpin hole Big twin camside A Clean mainshaft bearing surface flywheel crankpin taper inside and outside of sleeve 53 0101 counterweight 53 0099 and bobweight taper with solvent B Slip sleeve 53 0101 on pinion shaft Screw sleeve on shaft until it contacts fly
6. ES Before installing your new S amp S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed Do not smoke Perform installation in a well ventilated area away from open flames or sparks If motorcycle has been running wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps Contact S amp S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S amp S part on it Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation Use good judgment when performing installation and operating motorcycle Good judgment begins with a clear head Don t let alcohol drugs or fatigue impair your judgment Start installation when you are fresh Be sure all federal state and local laws are obeyed with
7. Instruction 51 1037 03 01 13 Copyright 2006 2010 2013 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tue 14025 Cty Hwy G PO Box 215 Viola Wisconsin 54664 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 Installation Instructions S amp S Balancing Kit DISCLAIMER S amp S parts are designed for high performance closed course racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely affect 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 Always check federal state and local laws before modifying your motorcycle It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use and the user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith The words Harley Harley Davidson H D Sportster Evolution and all H D part numbers and model designations are used in reference only S amp S Cycle is not associated with Harley Davidson Inc SAFE INSTALLATION AND OPERATION RUL
8. Type S S 7100 _ __ Wristpin 100 Cage Type Clips Alloy Rings 40 Wristpin Total 540 Total of Both Notes Front Roa WP Wp 2089 29O 208 r 275 DRF 2 587o 209 Picture 1 Connecting Rods Crankpin 550 Nuts LO Cages 30 Bearings 40 Nut Locks amp Screws wot used Total ZOO Front Rod WP End 209 CP End B81 Total 590 Act Wt 590 Rear Rod WP End 204 CP End A amp i 685 685 Figure 2 Reciprocating Weight Total of Both Pistons WP End of Front Rod WP End of Rear Rod Total Reciprocating Weight das Rotating Weight Total of Crankpin Nuts etc Front Rod CP End of Front Rod Z221 CP End of Rear Rod 481 Total Rotating Weigth 1562 Total Reciprocating Weight 1498 Multiply Times balance Factor 60 Reciprocating Weight ZIL Add Total Rotating Weight 1562 0 Total Bobweight for 2 wheels 2460 8 Divide by 2 2 Total Weight of Bobweight to be used on Each Flywheel 1230 4 CP Rear Roa WP CP 27 Wp 2059 205 pect 2 CP 4839 s L 2 B84 ELKo 204 ASL gt Picture 2 Level stand in both axes as shown z Figure 3 All Engines With One Piece Mainshaft Flywheels In 1985 Harley Davidson changed flywheel mainshaft assembly design from multiple piece to single one piece construction S amp S kit components used to balance these flywheels are a set of special adapter sleeves two collar spacers and a counterweight See Picture 2 page 4 one collar spacer
9. assembly to be balanced on balance stand Position assembly with balance shaft installed between and in center of stand edges with bobweight at top See Picture 3 page 5 Bobweight must clear edge when allowed to rotate 360 Assembly with sleeve and counterweight screwed on shaft place outside of stand edges but in center with bobweight at top Counterweight must be perpendicular to parallels and bobweight nut must clear stand throughout 360 of rotation See Picture 6 below NOTE Balance stand and balance shaft should be handled with care so as not to nick or scratch stand edges or other balancing component surfaces A CAUTION A Damaged components will cause unwarranted rolling resistance between parts often resulting in misleading readings and improper balance hole placement B Heavy side of assembly usually counterweight side of flywheel or side opposite bobweight will rotate downward When heavy point on flywheel has been determined mark position on inside connecting rod side of flywheel Check to be sure heaviest spot has been selected by positioning spot 90 to right of downward position and then letting flywheel rotate Recheck Picture 6 The L S Starrett Co Atno Mass U S A I Dms ou 0005 m Foor te Picture 5 by positioning spot 90 to left of downward position and then letting flywheel rotate Note each time how fast flywheel drops to heaviest position Set drill press with table that can
10. counterweight Example If 200 gm is removed from bobweight 100 gm must be added to counterweight Slug size can be estimated using the following 1 000 Diameter X 1 100 long adds about 100gm 500 Diameter X 1 100 adds about 25gm Mallory metal is available from M I Tech Metals 1340 North Senate Ave Indianapolis IN 46202 1 800 624 1895 www mi techmetals com Conclusion We feel that excellent results can be obtained using this kit to statically balance flywheels As proficiency increases actual balancing can be done in a matter of minutes Weighing parts and calculating weight of bobweight to be used will actually take longer Included is a copy of a record form we developed and urge you to use Make copies of this form and use them save the original to make copies It is interesting to review these records from time to time and note similarities and trends The material in this instruction sheet should equip the engine builder with a basic understanding of balancing There are many technical aspects that would fill books on the subject but for the average shop application further discussion is not necessary Balance Kit Replacement Parts EE i Balance stand e sssesssesssessseesseessersseesseesseeoseeoseeoseeosseeseees 53 0088 Balance Shaft sssessssessseessseessseesssessssessserssseesssersssesssseesss 53 0090 Balance shaft nUt sssesssseessseesssessssessseesssersssersssessssessss 53 0092 Tape
11. e until hand tight Do not overtighten D Bolt bobweight assembly in crankpin hole 5 Balance stand Balance stand shown in Figure 3 above left has four mounting lugs so it can be bolted down Bottom of lug pads and two narrow top edges have been surface ground When stand is placed on a perfectly flat and level surface narrow edges should be level in both axes as shown A Select unobstructed work surface or construct separate balancing bench NOTE If many balancing jobs are to be performed it is recommended that a special balancing bench be constructed Building a separate bench cuts down balancing stand setup and leveling time because bench isn t subjected to day to day abuses which can alter stand staying level B Bolt stand to bench Do not tighten bolts If surface plate is used as in Picture 3 above right stand does not need to be bolted down C Shim under four corners as necessary to level stand in both directions as shown in Figure 3 above left If separate bench and surface plate combination is used surface plate can be leveled using three leveling screws located under surface plate See Picture 4 next page Level stand plate by placing level on stand as in Picture 5 next page Turn stand with level on edges 90 and check Picture 4 NOTE Leveling is important and should be done as accurately as possible Recheck before performing each balance job 6 Balancing flywheels A Gently place flywheel
12. emains stationary and does not rotate Do not drill holes deeper than 1 4 in area marked i crankpin holes Q Crankpin Side D Counterweight Side Figure 4 NOTE If heavy spot continually changes position around circumference and flywheel still wants to rotate more than likely balance stand surface plate is not perfectly level or balance shaft or balance stand surfaces are dirty nicked or uneven G Repeat process for other flywheel NOTES e Drill holes in center of face along dotted line in diagram See Figure 4 previous page Leave of material to avoid breaking out of back side of flywheel e Donot drill holes deeper than 14 in areas marked near crankpin hole e When balancing stock Harley Davidson or other cast iron flywheels drill holes 14 minimum from outer edge of rim Space holes 14 apart e amp S forged steel flywheels are stronger Holes can be drilled from outer rim and s apart e Do not accept flywheels for rebalancing with holes drilled in unprescribed areas Have flywheels magnafluxed to check for cracks if any doubt exists about structural integrity A CAUTION A Numerous holes and drilling holes in unprescribed areas may weaken flywheels causing them to break resulting in damage to engine A WARNING A Weakened flywheels from improper balancing and being rebalanced too many times may explode during operation causing personal injury to you or others aro
13. g cages Bearings Small end of front rod See Figure 1 for correct positioning to weigh connecting rod ASST EG al NOTE To get correct weight of each end of rod centerline of rod must be level horizontally when pointer of scale is at zero position Eyeball rod position and adjust rod support stand accordingly A card with horizontal lines placed behind scale makes leveling of rods easier Rest edge of rod that exhibits smoother contours on platform and rod support stand Grinding marks and or forging seam lines may cause unwarranted friction which may distort actual balance weight of rod L Big end of front rod M Complete front rod Centerline of rod must be level horizontally when pointer of scale is at zero Eyeball rod position and adjust rod support stand accordingly Rest edge of rod the exhibits smoother contours on platform and rod support stand Grinding marks and or forging seam lines may cause unwarraned friction which may cause errors in rod weight readings Figure 1 NOTE Purpose of obtaining total weight of each connecting rod is to compare sum weight derived from adding weights of each end to actual total weight of rod and then adjust each end accordingly If actual weight is more or less than sum by 6 or more grams each end of rod must be reweighed If actual weight is more or less than sum by less than 6 grams two thirds of difference is added to or subtracted from crankpin end weight and one third
14. ligation if an S amp S part is used in any other application Introduction The S amp S balancing kit is designed to allow the engine builder to Statically balance each flywheel separately in Harley Davidson engines The static method of balancing uses gravity to cause the heaviest part of the flywheel to rotate downward when placed on the balance stand Weight is then removed from the heavy side by drilling holes When the flywheel no longer rotates it is in balance The object of balancing the flywheels is to minimize engine vibration which improves performance and riding comfort and avoids damage to engine and chassis components Usually the rider is quick to blame engine flywheel imbalance as the cause of the problem We have found that the problem often lies elsewhere Improper engine installation in the frame poor engine and transmission sprocket alignments flywheels not properly trued tires out of balance faulty frame design poorly balanced stator and or clutch hub worn primary drive chain and rigidly mounted handlebars are a few areas that can cause vibrations often blamed on flywheel balance Improper installation of the engine in the frame and other chassis components that are bolted on the frame sometimes form a resonant effect resulting in vibration at certain rpms This explains why an engine which runs smoothly in one frame may vibrate when placed in another frame with different forks Only after investigating all of the
15. motion These are the pistons piston rings wristpins wristpin clips and the wristpin ends of the connecting rods The total weight of the reciprocating parts equals the reciprocating weight Rotating parts Rotating parts are those which move in a circular motion The crankpin crankpin nuts bearings bearing cages nut locks and screws and crankpin end of both connecting rods are rotating parts whose weights when added together equal the rotating weight The balance formula used to calculate the weight of the bobweight that must be bolted into each flywheel is Weight of bobweight 60 xreciprocating weight 100 x rotating weight per flywheel 2 NOTE S amp S uses 60 of the reciprocating weight When we speak of the balance factor we usually refer to the percentage of the total reciprocating weight used in balance calculations Balancing procedure Perform following steps to balance flywheels 1 Weigh Parts All reciprocating and rotating parts to be used must be weighed and recorded to calculate weight of bobweight For greatest accuracy S amp S recommends using gram scale Weigh and record weight of A Front piston B Front piston wristpin C Front piston wristpin clips buttons D Front piston rings E Repeat steps A through D for rear piston NOTE Weighing parts separately allows for direct comparisons of parts in event parts are replaced at some later time Crankpin Crankpin nuts Crankpin key Bearin
16. obweight to be sure it equals 1000 grams B Subtract actual weight of main bobweight from balance weight required to balance one flywheel Difference in weight must be made up of shims to be bolted between shim retaining cap and main body of main bobweight C Select combination of shims to obtain required weight and check actual total weight by adding them one at a time to main bobweight on scales platform Add heaviest weights first Actual total weight should be within one gram of calculated weight NOTE Specific combinations of weights that equal commonly use bobweights i e 4 stroke with cast pistons and S amp S rods with alloy bearing cages should be recorded for future reference If discrepancies in weight from shim to shim exist actual weight of each shim can be stamped on shim to simplify identification Shim weight can be customized by cutting material from O D of extra ready made shims but material must be removed evenly from perimeter to avoid changing center of gravity of shim 4 Assemble Flywheel for Balancing NOTE All balance components and flywheel mating surfaces such as mainshaft and crankpin tapers etc must be clean and free of metal filings and dirt to avoid damage to engine and balance parts A CAUTION A Metal filings dirt or other material caught between flywheel and balance shaft and or bobweight tapers may damage flywheel tapers which may make truing flywheels difficult during final assembly later
17. of the difference is added to or subtracted from wristpin end weight A 2 1 ratio of crankpin end to wristpin end is used because crankpin end is approximately twice as heavy as wristpin end of rod Example Actual weight of rear rod equals 600 grams and sum of each end together equals 605 4 grams Difference equals 5 4 grams and must be subtracted from rod end weights Difference divided by 3 equals 1 8 Subtract 3 6 grams 1 8 grams X 2 from weight of crankpin end of rod Subtract 1 8 grams from weight of wristpin end of rod Now both ends when added together equal actual total weight A CAUTION A Never subtract weight of one end of rod from actual total weight to get weight of other end of rod An incorrect end weight used in this shortcut method can greatly affect balance and reverse final objective N Repeat procedure for rear rod 2 Calculate weight of bobweight All weights required to calculate bobweight to be used should be recorded on record sheet furnished Perform calculations See Figure 2 next page as an example showing calculations of a hypothetical balance job NOTE Figures shown are for purpose of illustration only Do not use these figures in any balance computation Use actual weights of parts to be used 3 Assemble bobweight A multiple piece bobweight composed of three parts is furnished with kit See Picture 1 next page Main body has 234 diameter and is tapered to fit in crankpin hole Bobweight retaining
18. r adapters Taper adapter bt 72 E 81 es sssessesseessesseessesssessesssessees 53 0086 Taper adapter Late 81 up all s sseessosseessesssessesssessees 53 0087 Adapter sleeve counter weight ceseseesessseseeseeees 53 0099 Adapter sleeves Driveside adapter sleeve all Dt eseseeeeeeeeees 53 0091 Camside adapter sleeve bt 1970 1992 sess 53 0101 Camside adapter sleeve bt 1993 Up uu sees 53 0102 Driveside adapter sleeve all XI eeseseceeteeeseseeees 53 0093 Camside adapter sleeve all XI esesesesseseseseeseeees 53 0095 Driveside collar spacers Collar spacer all bt ses sseessossesssesseessessssssesseesserseessesss 53 0097 Collar spacer xl 1986 1990 s ssesssessssssesseesserseessess 53 0098 Collar spacer xl 1991 UP ss ssesssessssssessssssesseesserseessess 53 0085 Bobweight 1000 gr no shims included 53 0094 10 11 12 Bobweight shims A As gece ee rene ete en eer Creme eer eer nmr tee ee ere 53 0105 So rere tr en Ter eee Onn A ey E cnte merry orient ey 53 0110 S IE 2 EAA A A AEA E A 53 0115 oo P E PPIE EE A AE E er ane 53 0120 ic i So EI E E AA A EAE 53 0125 O e EE ne rer omer ee ee 53 0150 LOO Ooennnrenereern ten menrn e EN 53 0100 Bolts for bobweights Mie Se VA aaa EA 50 0201 MBN MOA saat aces scat feteete sas oases ER 50 0200 Adjustable rod support stand esseesseesseesssesseesseesssees 53 0089 Platform gram scales
19. se other areas should the engine be checked The 45 design of the Harley Davidson engine makes it difficult to obtain perfect flywheel balance that will make the motorcycle vibration free at all roms The goal is to make the motorcycle as vibration free as possible and perform the best in the rpm range where the most riding is done If the engine is used exclusively for drag racing it may be desirable to balance for higher rom ranges say 3000 rpm upward Most street riders run their engines in the 2000 rpm to 5000 rpm range most of the time The balance factor we use and recommend is 60 We arrived at this percentage after much experimentation and found it to give the best results over the rom range that riders most commonly use Factors other than 60 will change the direction and amplitude of vibration For example if the balance factor is 50 or less the engine will tend to vibrate vertically As the percentage is increased this vertical motion changes to horizontal motion Horizontal motion from our experiments is more acceptable with less noticeable vibration transmitted to the rider Therefore 60 is the percentage S amp S uses as a compromise for best all around performance and riding comfort Balance formula The components which must be compensated for when balancing Harley Davidson flywheels are placed in two categories Reciprocating parts Reciprocating parts are those parts which travel in a reciprocating up and down
20. t prior authorization from S amp S If it is deemed necessary for S amp S to make an evaluation to determine whether the part was defective a return authorization number must be obtained from S amp S The parts must be packaged properly so as to not cause further damage and be returned prepaid to S amp S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem how the part was used and the circumstances at the time of failure If after an evaluation has been made by S amp S and the part was found to be defective repair replacement or refund will be granted ADDITIONAL WARRANTY PROVISIONS 1 S amp S shall have no obligation in the event an S amp S part is modified by any other person or organization 2 S amp S shall have no obligation if an S amp S part becomes defective in whole or in part as a result of improper installation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the S amp S part 3 S amp S shall not be liable for any consequential or incidental damages resulting from the failure of an S amp S part the breach of any warranties the failure to deliver delay in delivery delivery in non conforming condition or for any other breach of contract or duty between S amp S and a customer 4 S amp S parts are designed exclusively for use in Harley Davidson and other American v twin motorcycles S amp S shall have no warranty or liability ob
21. the installation For optimum performance and safety and to minimize potential damage to carb or other components use all mounting hardware that is provided and follow all installation instructions Motorcycle exhaust fumes are toxic and poisonous and must not be breathed Run motorcycle in a well ventilated area where fumes can dissipate IMPORTANT NOTICE Statements in this instruction sheet preceded by the following words are of special significance A WARNING Means there is the possibility of injury to yourself or others CAUTION Means there is the possibility of damage to the part or motorcycle NOTE Other information of particular importance has been placed in italic type S amp S recommends you take special notice of these items WARRANTY All S amp S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve 12 months from the date of purchase Merchandise that fails to conform to these conditions will be repaired or replaced at S amp S s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter In the event warranty service is required the original purchaser must call or write S amp S immediately with the problem Some problems can be rectified by a telephone call and need no further course of action A part that is suspect of being defective must not be replaced by a Dealer withou
22. und you e Before drilling check opposite side of flywheel for old balance holes Do not drill into old holes If drilling must be done in crankpin side of flywheel and there are holes in counterweight side fill holes in counterweight side first before balancing There are several ways to do this Solder method 1 Tap holes 2 Heat holes with propane torch 3 Fill holes with acid core solder 4 Use punch or chisel to stake threads to insure that solder can not come out of threaded hole during engine operation Threaded rod method 1 Tap holes 2 Screw a bolt or threaded rod into holes Use Loctite or similar thread locking compound to insure that threaded rod can not come out of threaded hole during engine operation 3 Cut threaded rod off and grind or machine flush with surface of flywheel Filling holes makes counterweight side heavier thereby reducing number of holes required to balance flywheel e When balancing flywheels to very heavy bob weights it is sometimes necessary to machine holes in counterweight of flywheel and press in slugs of Mallory metal tungsten alloy sometimes called heavy metal To determine the amount of Mallory to add to counterweight remove weights from bobweight until flywheel could be balanced to the lightened bobweight by normal drilling method Note amount of weight removed and replace weights on bobweight One half amount of weight removed from bobweight must be added to flywheel
23. wheel and hand tighten Do not over tighten C Lay flywheel down with sleeve shaft facing up and screw counterweight 53 0099 into end of sleeve until hand tight Do not over tighten D Bolt bobweight assembly in crankpin hole Harley Davidson Sportster model driveside A Clean mainshaft bearing surface flywheel crankpin taper inside and outside of collar spacer 53 0098 or 53 0085 and sleeve 53 0093 counterweight 53 0099 and bobweight taper with solvent Picture 3 B If Timken bearing assembly has been removed slide collar 53 0098 for 86 90 engines or collar 53 0085 for 91 and up engines on sprocket shaft to space sleeve 53 0093 away from flywheel C Slip sleeve 53 0093 on sprocket shaft Screw sleeve on shaft until it contacts spacer or Timken bearing Hand tighten only Do not overtighten D Lay flywheel down with sleeve shaft facing up and screw counterweight 53 0099 into end of sleeve until hand tight Do not overtighten E Bolt bobweight assembly in crankpin hole Harley Davidson Sportster model camside A Clean mainshaft bearing surface flywheel crankpin taper inside and outside of sleeve 53 0095 counterweight 53 0099 and bobweight taper with solvent B Slip sleeve 53 0095 on pinion shaft Screw sleeve on shaft until it contacts flywheel and hand tighten Do not overtighten C Lay flywheel down with sleeve shaft facing up and screw counterweight 53 0099 into end of sleev
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