51-1160 Twin Cam Long Block 2
Contents
1. 4 pack areir ch acta a aa iae iaa 106 1185 5 Eine oil 10 en a aiant 31 0447 6 Line oil PETULN A cece eecseseeeeseseeeeseseeeesseeessseeeeeeee 31 0048 7 Line assembly oil FECC cceseseessssessssesseesseaeees 31 0449 B TOP COVED vis caeaincvaccceccvacenscenevssusctasttanacsbaeasiesntvinesuatunne 9 SHC 20 x 14 10 pack 10 SHC 20 x 24 10 pack 11 SHC 20 x 1 10 pack 12 SHC 20 x 1 10 pack 13 Gasket tranny tOP COVED eeeeeeeeeeeeetettetteeieeaee See Detail A for screw assignment 14 Drill Template cece eeeeeeeeeeeeeeeeeeeeeeeeeeaees 106 1188 15 Fitting G pack i es ora a leaserteeangeteese 106 1182 16 Hose 90 degree bend ceccceceeeeeeeeeeeeeeeeeeeeeees 50 8292 17 Clamp 10 Pack cccccccesccecessceseeceeeeseeeeeeseeeeeeeeeeeeeeneees 50 8156 18 Plug pipe 10 Pack ceccecccesceecesseeeseeseeeeetireseeeees 106 1175 19 Oring 10 Pack ai a ad adane dea ddenai 106 1183 20 Fitting 2 pack cadita aeiae 106 1173 Detail A 11 12 C Oil recommendations NOTES S amp S Cycle recommends the use of Mobil 1 V TWIN 20W 50 synthetic oil in our engines S amp S Cycle recommends the use of S amp S oil filters PN 31 4103 black or PN 31 4104 chrome All reference to Harley Davidson part numbers is for identification purposes only We in no way are implying that any of S amp S Cycle s products are original equipment2. H D 16595 99 10 Pack ccscceeccscceescecceeceeeeeeecereneeeeeens 50 8179 Nut 4 28 Grade 8 1 required 10 Pack 50 5014 Bolt cam plate 4 20 x 1 SHC 4 required 10 PaCk EE E E E AE E 50 0244 Bolt cam plate 4 20 x 1 4 SHC 2 required 00 PACK a an a o oae aa pe Euan 50 0153 O ring cam plate 9 required H D 11301 10 Pack cccccscceeccecceesceeceesceesneceneeneeeesens 50 8066 Dowel cam plate 2 required H D 16589 99 50 8148 Bearing inner cam H D 9198 ccccseeseeeeeeeeeeeeees 31 4080 Bearing pinion shaft Fits all S amp S and OEM 2000 02 Balanced models only amp all OEM 2003 up H D 24604 00 amp 24604 00C ccceeeeeeeeeeeeeeeeeeeeeeeeee 31 4085 Retaining ring internal spiraloc H D 35114 02 6 DaCK cccccccccseeeeeesessesesssssnsteeaeeaeenees 50 1047 O ring oil pump ec 1 D x 1 6 O D x 4 CS H D 11293 reiii iieiaeie adea iTe 50 8039 34 19 Switch oil pressure Case with rear motor mount 1948 99 big twin H D 26561 84 NOt SHOWN ccccsssesccsessesseeessessesesseseeeeas 31 2016 NOTE Stock style use stock pressure switch 20 Plug magnetic drain 2A Baffle Platene Sateviecdl hive chastesstaacta lads 22 Screw 10 24 x panhead 2 required LO PACK EEE AE OEE E Prien I EA tia uaduacte 50 0139 23 Dowel case alignment 2 required H D 16574 99 10 Pack ccccccceeeeeceeeeeeeeeeeeeeeeeeeee
3. to crankcases or other parts B Test fit instructions for T124V style cases with 1984 1999 mounts 1 Clean frame engine mounts and carefully remove any irregularities from mounting surfaces Also inspect crankcase mounting bosses for burrs 2 Position engine assembly in frame 3 Install engine mounting bolts in motor mounts and check clearance between mounting bosses on cases and frame and any other areas where frame and cases may contact each other Bolts may be difficult to install if contact is severe 4 If engine contact frame remove it and relieve just enough material in offending area to provide clearance 5 Place engine in frame install one rear mounting bolt and snug nut 6 Measure gap between crankcase mounting bosses and frame motor mounts with feeler gauge to determine if shimming is required 7 If gap exists fabricate shim just thick enough to fill gap 8 Install opposite corner shim and mounting bolt and nut and tighten identical to other bolt 9 Check other corners with feeler gauge to confirm thickness required is same as before If not determine cause and correct NOTE S amp S T124V engine installation in 1984 1999 design motorcycle frame is essentially the same as stock although additional clearancing and shimming may occasionally be required When this style of case is solid mounted instead of rubber mounted additional care must be taken in installing the case Main areas of concern
4. two plugs on the that you can properly perform this operation please contact forward face of the oil pan allowing the oil to drain the S amp S Tech Department for a referral to a shop in your area Once the oil is completely drained replace the pipe plug with a 90 degree fitting S amp S PN 50 8288 NOTE Installation instructions are based on an engine and Position barb of fitting toward right side of bike at an angle slightly above horizontal as shown in Picture 2 Next install the oil return fitting S amp S PN 50 0451 with O ring S amp S PN 50 8008 in the drain plug location transmission already in the chassis l Qo fe O a OQ s 4 Ve i eRe om FL Oil Line Install Kit PN 31 0425 NOTE Apply thread sealant to all tapered pipe threads Picture 2 1 Remove the stock oil supply and return fittings 6 Remove cover plate that was shipped on crankcase from the transmission from the bottom surface of the rear motor mount 2 Install two supplied NPT pipe plugs S amp S PN 50 8330 The oil line block will be installed in this location in the oil fitting location Assemble the oil line block by installing the 90 degree fitting S amp S PN 50 8288 and the oil return NOTE Apply thread sealant to all tapered pipe threads fitting S amp S PN 50 0451 with O ring S amp S PN 50 8008 into the block as shown in Picture 3 3 Remove crankcase vent fitting S amp S PN 50 0451 and set aside for later use In
5. FL Models G Fitting 4 2 Pack eececseceeseeceeeeeeeeeeeeeseeeeeeeneeeeteaes 106 1173 a 7 Oting 10pack iriis isiin enian i ipinita 106 1183 ty Bibel OU ME akaniaga ia 10071193 B Hose oil FOOD sirnaa 50 8157 2 BHSHCS 6 18 X 174 10 pack cscscerssseesseeeseeeeeeeees 106 1169 9 Clamp 3 O ring 10 DaCk E E ESTEE 50 8066 Double Wire Spring 10 pack soccesssssssssessesseeeee 50 8156 4 Fitting Pipe 90 degree 2 pack xeicarestintenatte 106 1170 Hose Spring 10 pack cccccccsceeseeeeeeeteeeeeeseeeees 106 1174 oy prng 10 Hose Oil Line 90 degree bend essssssssssssnesnesne 50 8292 he 2 Pack iieiea risaie eraran 106 1171 11 Plug pipe 10 pack cceresssscsssssssessssssesesssssesesssesseeeee 106 1175 DB 2 PACK EE E 106 1172 B For 1999 05 Harley Davidson Dyna models 1 Remove the stock oil supply and return fittings from the transmission 2 Install two supplied NPT pipe plugs S amp S PN 50 8330 A CAUTION in the oil fitting location Oil line installation is crucial to engine life If you are not sure that you can properly perform this operation please contact NOTE Apply thread sealant to all tapered pipe threads the S amp S Tech Department for a referral to a shop in your area 3 Drain the oil from the oil pan see the proper NOTE Installation instructions are based on an engine and factory service manual for instructions and then transmission already in the chassis remove the oil pan from the
6. INSTALLATION AND OPERATION RULES 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 inhaled 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 judgement when performing installation and operating motorcycle Good judgement begins with a clear head Don t let alcohol drugs or fatigue impair your judgement Start installation when you are fresh Be
7. Instruction 51 1160 SES Cycle Tuc 10 26 06 235 Causeway Blvd La Crosse Wisconsin 54603 Copyright 2003 2006 Phone 608 627 1497 e Fax 608 627 1488 by S amp S Cycle Inc Technical Service Phone 608 627 TECH 8324 All rights reserved Technical Service Email sstech sscycle com Printed in the U S A Website www sscycle com Because every industry has a leader Installation Instructions S amp S T124 and T124V Engine Assembly DISCLAIMER S amp S parts are designed for high performance off road racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely effect 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
8. and 1T124V instructions often refer to procedures described in other S amp S instructions or a Harley Davidson Service Manual These materials should be cross referenced as necessary IMPORTANT Before proceeding verify that serial numbers on crankcases match numbers on packing carton and certificate of origin Contact S amp S immediately if numbers do not match NOTE Valid certificate of origin is required for any transfer or sale of longblock assemblies Certificate of origin is required to title and license any motorcycle which is to be driven on public streets and highways 3 Modification Notes S amp S Cycle cautions against modifying these crankcases due to the possibility of damaging or weakening them Modifying S amp 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 The customer must confirm that crankcases and related parts are correct before assembling them or having them modified in any manner and assumes all liability for modifications Under no circumstance will S amp S be held responsible for expenses related to the modification of any S amp S part in the event warranty service is required Modified parts will not be accepted for credit or exchange This will apply regardless
9. are between cases and frame motor mounts Checking clearance around and between case mounting bosses and frame is necessary to insure that crankcase rests squarely on motor mount pad and no stress is applied to crankcases when mounting bolts are tightened Shimming may be required to compensate for variances between frames Replace all other motorcycle components removed for engine installation Consult authorized Harley Davidson service manual for installation procedure for stock parts not covered in S amp S instructions NOTE On certain models it may be necessary to switch the shift linkage to the outside of the shift lever Make certain that there is clearance between the shifter rod and the engine crankcases 5 Ignition System Installation A All Carbureted S amp S T124 and T124V assemblies come with an S amp S IST Intelligent Spark Technology ignition Use of this ignition system is highly recommended All aspects of ignition timing advance retard and curves are handled automatically by the S amp S IST ignition B Once the IST ignition has been installed per the included instruction sheet 51 1155 no other adjustments are necessary NOTES f the S amp S IST ignition is not used S amp S recommends using electronic ignition with adjustable advance curve in S amp S T124 and T124V engines Adjustable curve permits slowing rate of advance to control or eliminate pinging under heavy load or when elevated temperatures or po
10. ative manner The first 50 miles are most critical for new rings and piston break in Engine damage is most likely to occur during this period Keep heat down by not exceeding 2500 rpm Avoid lugging the motor riding in hot weather or in traffic Vary the engine speed Do not lug the engine Change the oil at 50 miles This will remove the heavy accumulation of break in residue from the oiling system 3 The next 500 miles should be spent running engine no faster than 3500 rpm or 60 mph Correct any obvious ignition or fuel problems if present Avoid continuous steady speeds and do not lug the engine Vary engine rpm change the oil again at 500 miles A CAUTION Lugging or running engine prematurely at sustained high rpm may result in damage to pistons and other engine components S amp S voids it s guarantee if engine is not broken in properly 4 For the balance of the first 1000 miles the motor can be run in a normal but conservative manner You can be more liberal with the rom range and motorcycle can be operated at normal highway speeds Avoid overheating or putting any hard strain on the engine no drag racing dyno runs excessive speed trailer towing or sidecar operation 5 After 1000 miles verify Ignition and fuel system settings and adjustments Change the engine oil The break in process is complete 13 14 10 Tuning Guidelines Ignition timing and carburetor jetting are responsibilities of the customer If no
11. better feel of its potential and can change gearing accordingly The following formula will determine final drive gear ratio Engine Revolutions Per One Revolution of Rear Wheel Clutch Sprocket x Rear Wheel Sprocket Motor Sprocket x Transmission Sprocket Number of teeth on each sprocket 11 Engine Specifications amp Torque Values Stroke 4 Bore 4 Displacement 124 Cylinder Heads Valve guide in head tight Valve seat in head tight Crankcase Specification 001 003 001 003 Timkin race in case tight Pinion race in case tight Valves Fit in guide Intake Exhaust Seat Width Stem Protrusion Specification 0012 0015 0018 0023 040 062 2 045 2 060 Rocker Arms Shaft fit in bushing loose Compression Ratio 10 8 1 Specification 0015 003 005 0075 Service Wear Limit less than 0025 less than 0025 Service Wear Limit 0025 0035 2 080 Specification Service Wear Limit 0007 0018 0035 Bushing fit in rocker arm tight 002 004 Hydraulic Lifters Specification Lifter fit in guide loose 0006 0017 Flywheels Specification Runout shaft at flywheel 0005 001 End play 001 005 Pistons Specification 002 0025 017 025 Fit in cylinder End gaps Top two compression Oil control rails 016 035 Connecting Rods Specificatio
12. eeees 50 8109 24 O ring case alignment 6 1 D x 1 6 O D x 6 CS 2 required H D 26432 76A 10 Pack sscccssseeeeeees 50 8102 25 Piston oilers Kit Of 2 H D 22371 99 cceeeeees 31 2026 26 Hardware kit oil line PlUQS cceeceeeesteeeeeeeees 50 1081 27 Fitting crankcase vent 1999 00 2 Pack csccscceecseccesceesceneeecceseeeaeeeeeneetenes 106 1172 2001 060 2 Pack sirce nannies ee a 106 1171 28 Plate oil line COVEN ccecccseseseeesssssssrseeeeeeeeeeeeens 106 1184 29 BHSH CS 6 18 x 10 Pack ccccscceseseeseeeeeteeseeees 106 1178 30 O ring 10 Pack ceccceccessceceeseceseeeeeeseeeeeeeeeeeeneeseeees 106 1183 These parts are for crankcases manufactured before 8 1 06 31 Plug SUMP H D 765 0 cc c ccceeseeeeeeeeeeseeeeseneeeeseneees 50 8330 B2 Oil CONCUIt bl ck a i anaona raas eneen 31 2076 33 Washer flat 4 chrome 12 Pack ccccccccsscseessseseeees 50 7013 34 Bolt 4 20 x SHCS 1 required 12 Pack 50 0144 35 Hose oil inlet outlet c cccecesssesssseeeeeeeeeeeeeeees 50 8157 36 Spring clips 10 Pack cccccesccecsseceeseeeeessteeeeseteeeeseees 50 8156 37 Oil line fittings inlet outlet 2 required 50 8158 38 Oil line fitting vent H D 25259 93A ccsceeees 50 8146 All reference to H D part numbers is for identification purposes only We in no way are implying that any of S amp S Cycle s product
13. en ignition is turned on Lamp will go out after engine is started and there is oil pressure at the switch in the crankcase A CAUTION Avoid excessive time of starter engagement Overheating of starter motor will result in damage Oil pump should prime and deliver oil to the oil sender hole within 30 seconds 8 Exhaust System NOTE The engine must be correctly mounted into the frame before the exhaust system is installed 1 Place new woven metal gasket into exhaust ports of cylinder heads 2 Inspect the exhaust pipe header flanges and retaining rings Replace if distorted warped or otherwise damaged 3 Apply a high temp anti seize lubricant to threads of exhaust studs at cylinder heads 4 Install exhausts to cylinder heads Hand tighten exhaust stud nuts 5 Attach exhausts to lower mounting bracket Shim if necessary Hand tighten mounting hardware 6 Tighten exhaust flange nuts at head to 60 80 in lbs In some instances brake master cylinder must be spaced out from frame to clear crankcase UNDER NO CIRCUMSTANCES SHOULD MASTER CYLINDER OR BRAKE LINE BE ALLOWED TO CONTACT EXHAUST PIPE IN FINAL INSTALLATION Heat transferred to brake fluid may expand and cause brakes to seize resulting in possible fire hazard and loss of control of motorcycle with injury or death to rider and others NOTE Make certain that the exhaust system is not pre loaded or in a bind at the lower mounting points Make all spacing adj
14. every 2 500 miles thereafter Spark Plugs Champion RA8HC or equiv Inspect every 5 000 miles Replace every 10 000 miles or as needed Ignition Timing 28 deg total advance max Inspect every 5 000 miles Engine Mounts Inspect every 500 miles and every 5 000 miles thereafter External Fasteners except cyl head bolts Re torque at 500 miles and every 5 000 miles thereafter 1 S amp S recommends that petroleum based oil not specifically formulated for air cooled motorcycles should be changed every 1 000 miles 2 Replace more frequently if required or if engine is operated in a dusty environment Replacement Parts for S amp S Crankcases for Harley Davidson Twin Cam 88 Engines 1 ba oo 10 11 12 13 14 15 16 17 18 Bolt stator 10 24 x1 SHC 4 required H D 2720 10 Pack ccccecccscceescecceescucceesceseeeeeeeeneeeeeens 50 0194 Seal sprocket shaft H D 12068 cccsccsssesseeesees 31 4035 Bearing Timken sprocket shaft H D 9028 31 4013 Bolt case 6 24 x 2 HHC 8 required S PACK Sis coke a E N E teens E 50 0190 Washer flat 6 x Ye x 6 8 required 10 PACK EEEE E tie EAE AE ES 50 7069 Bolt center case 4 28 x 6 HHC Grade 8 5 Pak AE E AE maetasease 50 0221 Washer flat 4 x 474 x 050 10 Pack 50 7076 Cylinder studs H D 16834 99 8 Pack cccsssee0e 31 2340 Dowel cylinder deck 2 required
15. is suspect of being defective must not be replaced by a Dealer without 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 othe
16. motorcycle 4 Place the supplied template 53 0080 over the oil pan baffle and use a scribe to mark the location of the 4 hole as shown in Picture 8 Use a drill press to machine the hole as marked in Picture 8a Use a small file or deburring tool to make sure no chips or pieces are left on the 4 hole and then clean the oil pan and baffle with a solvent before reinstalling the pan with a new gasket on the motorcycle Dyna Oil Line Istall Kit PN 31 0424 Picture 8a Remove the transmission top cover Remove the neutral indicator switch vent line and fitting from the transmission top cover Install the neutral indictor switch vent line and fitting on the new S amp S transmission top cover S amp S PN 56 1615 Slide the oil feed line S amp S PN 31 0449 through the hole in the top cover closest to the oil filler dipstick boss Place a new top cover gasket S amp S PN 56 1261 on the transmission case and position the new S amp S top cover on it Rotate the oil feed line so it will pass through the hole in the baffle Be sure the bend in the oil feed line orientation is to the rear of the motorcycle See Picture 9 Picture 9 10 11 Install the transmission top cover screws and washers according to Detail A Use blue threadlock on the screws but leave them loose at this time See Detail A in exploded view of replacement parts for Harley Davidson Dyna on page 117 Remove the oil line retention
17. n Crankpin bearing 001 0012 Running clearance Piston pin fitment in rod Connecting rod side play 0005 001 015 035 Service Wear Limit 003 Service Wear Limit 003 exceeds 005 Service Wear Limit 005 028 050 Service Wear Limit 002 002 040 Torque Values Specification S amp S Suggestion Rocker box hardware 120 in lbs Loctite 243 Rocker box hardware 18 ft lbs Loctite 243 Tappet guide fasteners 120 in lbs Loctite 243 Pushrod locknuts 120 in lbs Cylinder head bolts See chart on page 11 Crankcase fasteners 4 120 in lbs Crankcase fasteners 15 ft lbs Gearcover fasteners 120 in lbs Loctite 243 Intake manifold to head 16 ft lbs Loctite 243 Intake manifold to carb 18 ft lbs Loctite 243 Exhaust flange to head 60 80 in lbs Anti seize Spark plug 11 18 ft lbs Anti seize Cylinder studs 10 ft lbs Loctite 262 Piston oiler screws 35 in lbs Loctite 243 12 Service Intervals S amp S Recommended Regular Service Intervals ee ee Change at 50 500 2 500 miles every 2 500 miles thereafter 1 Inspect at 50 and 500 miles every 2 500 miles thereafter 2 Petcock Lines amp Fittings Vacuum Lines Inspect at 50 and 500 miles every 2 500 miles thereafter Fuel Filters Every 5 000 miles Engine Idle Speed Adjust as required Throttle amp Enrichment Device Control Inspect and lubricate throttle cables at 500 miles and
18. of cause or fault customer retailer manufacturer or other For further information contact S amp S Technical Services at 608 627 8324 FAX 608 627 1488 or e mail sstech sscycle com NOTE Modification includes but is not limited to appearance changes such as painting powdercoating plating and polishing Proper preparation for these procedures as well as the processes themselves may require the use of polishing compounds chemicals or procedures that are potentially harmful to crankcases A CAUTION Passages and internal cavities may become obstructed by residues from materials used to polish paint plate or powdercoat surfaces Additionally surface finishing processes can damage critical machined surfaces Any of the above may cause premature wear damage or failure of other engine components as well as the crankcases themselves Glass bead and polishing residues are abrasive and can be difficult to remove from recesses and small passages Abrasive residues can cause oil contamination and extensive engine damage Engine damage caused by powder coating polishing glass bead blasting or other modification will not be covered under warranty Powder Coating Subjecting heat treated alloys such as those used in S amp S crankcases to excessive heat can drastically alter their strength and their critical properties The degree of change depends upon the temperatures reached and the duration of exposure When powder coating or
19. or quality gasoline encountered All other ignition systems other than the included S amp S IST ignition install per manufacturers instructions S amp S recommends setting the total ignition advance to 28 degrees Timing degree recommendations given by S amp S take precedence over the ignition manufacturers instructions A CAUTION Timing that is too advanced will result in detonation and engine damage Timing that is too retarded will result in engine over heating and engine damage This caution applies only to installations other than the S amp S IST Ignition A CAUTION If S amp S determines that engine damage was caused by improper ignition timing repair will not be covered under warranty Excessive ignition advance will cause engine to kick back against the starter during start up and buck when ridden at steady speed with partial throttle An advanced condition can also cause pinging or ignition knock and possible piston damage These symptoms may not be noticed if electronic ignition with soft advance curve is used Excessive ignition retard causes sluggish performance and severe overheating with possible subsequent damage to the engine and must also be avoided Immediate or rapid exhaust pipe discoloration is usually a sign of retarded ignition timing 6 Fuel system installation and tuning NOTES S amp S Engine assemblies are available with either carbureted or fuel injected systems Assembled Engines a
20. otherwise processing alloy parts S amp S exposes them to a maximum temperature of 370 F for no longer than 20 minutes Under no circumstances should parts be heated past 400 F S amp S strongly recommends trial fitting every engine before frame is painted or powdercoated 4 Engine To Frame Assembly The engine should be installed into the frame before the ignition fuel exhaust and oil system components are installed Follow the engine to frame fitting below Engine to Frame Test Fit NOTE The engine must be fitted to the frame it is installed into It must rest squarely on its attachment points and bolted solidly to the frame without stressing the engine case at any point A CAUTION Failure to correctly mount the engine can cause problems not covered under warranty including but not limited to excessive vibration driveline mis alignment and broken castings A Test fit instructions for T124 style cases with stock 1999 up engine mounts 1 Clean frame engine mounts and carefully remove any irregularities from mounting surfaces Also inspect crankcase mounting bosses for burrs 2 Position engine in frame check for clearance at frame and alignment to transmission It is a good idea to replace rubber engine mounts at this time Old mounts deform over time and can induce unwanted stresses on the engine case A CAUTION Improper alignment of engine and frame mounts may cause abnormal stresses resulting in damage
21. parts or that they are equivalent to the corresponding Harley Davidson part number shown If not using Mobil 1 V TWIN 20W 50 Ambient Temperature F Above 20 100 Viscosity SAE 20W50 SAE 50 Above 60 100 Above 80 100 D Verify oiling system operation before starting A CAUTION If engine is run with foreign material in the oil tank engine damage will occur Engine damage caused by foreign material in the oil tank is not covered under the S amp S warranty A CAUTION Restricted oil flow may result in extensive engine damage not covered under warranty A CAUTION Improper installation of oil lines or fittings may result in parts damage not covered under warranty 1 Fill the oil tank to the proper level 2 Remove spark plugs Ground plug wires to cylinder head with either a jumper wire or through a test plug 3 Remove oil sender unit 4 Turn ignition on and turn the engine over with the starter motor until engine oil appears at the oil pressure sender hole 5 Re install and re connect oil sender unit 6 Verify that engine oil is returning to oil tank 7 Start motorcycle Verify oil pressure by watching oil pressure light NOTES f 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 wh
22. plate plugs and seals from the top of the engine crankcase Remove seals from the plugs Discard the plugs Picture 10 To install the oil lines S amp S PN 31 0447 and 31 0448 orient the ends and openings so they are parallel Insert the lines through the oil line retention plates then the included washers S amp S PN 50 0439 and last the seals S amp S PN 50 8271 on each line end The ends of the lines should protrude through the seals about inch Position oil line assembly on both the transmission top cover and crankcase and press down until lines are firmly seated in the counterbores in the crankcase and transmission cover Picture 11 12 Press the oil line retention plates into place until they seat Install the two screws 18 x button head through the oil line retention plates First screw goes in the transmission top cover and the second mounts into the crankcase near the rear motor mount Treat both screws with blue threadlock and tighten to 18 ft lbs 13 Tighten transmission top cover screws to 100 120 in Ibs 14 Install the vent line S amp S PN 50 8291 with clamps S amp S PN 50 8156 15 Reconect neutral switch wires 16 Check function of neutral switch S amp S Replacement Parts for Harley Davidson Dyna Models Te Plate nnn n nei ee a 106 1176 2 Seal 4 pack mirrata ietie Deke eke BN 106 1177 3 BHSHCS 6 18 X 34 10 Pack cccccsccsscescesscesecseeesseseee 106 1178 4 Washer
23. r American v twin motorcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application Instruction Contents 1 Introduction Additional Features 8 Modification Notes 9 Engine to Frame Assembly Ignition System Fuel System Exhaust System 7 Oil Line Installation Initial Start up and Engine Break In 10 Tuning Guidelines 11 Engine Specs and Torque Values 12 Service Intervals Please read these instructions carefully before starting work Proceed with the installation only after the instructions are completely understood These instructions should be supplemented by the appropriate OEM service manual for your motorcycle Follow all safety information 1 Introduction S amp S T124 Engines are available in two versions The first version is designed and intended for installation in a stock Harley Davidson Twin Cam 88 chassis It will bolt directly to the stock transmission and engine mounts of chassis designed for stock Twin Cam 88 engines The second version the T124V is machined with an 1984 1999 rear motor mount It may be installed in a stock or Harley Davidson Evolution chassis Both versions are available in natural aluminum or black powder coat finish The oil lines for the T124V engine connect to the engine on the rear of the cam chest The top fitting is oil return The lower fitting is oil supply Installation can be performed by any Harley David
24. r other problems Let engine cool to the touch 4 After engine has cooled start up again and allow the motor to build some heat Engine should not be run longer than three to four minutes When the cylinders become warm hot to the touch approximately 150 shut the motor down and let it cool to room temp Follow the same cautions as for the initial start up and continue to watch for problems 5 Repeat this procedure 3 or 4 times Each successive time it should take slightly longer to warm up and you can increase the temperature slightly each time You can be more liberal each time with the rpm gently vary rpm continuously from idle up to 2500 rpm in the final cycle The motor should not reach full operating temperature during these cycles Do not allow engine temperature to become excessive B 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 180 240 F If engine oil temperature stays above 220 F and correct ignition timing has been verified S amp S Cycle suggests that an oil cooler be installed Do not run engine under conditions where oil temperatures continue to remain high 2 For the first 50 miles ride the motorcycle in a very conserv
25. re shipped with the carburetor or fuel injection system installed Refer to the included instructions for operation and tuning A Install fuel system 1 Engine assemblies supplied with Super G carburetors refer to included instruction sheet 51 1012 2 Engine assemblies supplied with Super D carburetors refer to included Special Application Racing Carburetor Supplement for additional information 3 Engine assemblies supplied with fuel injection refer to included Induction System instruction Sheet B Re install and connect fuel tank 1 Refer to appropriate service manual Inspect fuel lines and clamps replace as necessary 2 Check fuel line connections and routing Avoid hot surfaces Make certain that the protective cover has been placed over fuel line and that it is clear from sharp edges and abrasive surfaces 3 Fill the fuel tank with a sufficient quantity of gasoline for the initial start up procedure 4 Double check that all fuel line connections have been made correctly and there is no gas leakage at any point in the system 7 Oil Line Installation 4 Install the vent hose and clamp S amp S PN 50 8156 or 50 8076 S on the new fitting A For 1999 2006 Harley Davidson FL models NOTE The stock vent hose is reused in this step A CAUTION 5 Position a drain container in front of the oil pan Oil line installation is crucial to engine life If you are not sure Next locate and remove the
26. s are original equipment parts or that they are equivalent to the corresponding H D part number shown
27. son repair shop equipped to do complete engine overhauls No special tools other than those used in normal engine building operations are required NOTES Installation of a fuel injected engine in a motorcycle that was originally equipped with a carburetor is fairly difficult and expensive This conversion requires a fuel pump equipped gas tank as well as wiring harness All S amp S T124 assemblies are for Twin Cam 88 non counterbalanced engine applications and are not for use in Twin Cam 88B counterbalanced applications DYNORUN 010 Max Power 129 2 a 2 f ae W lt L 79 70 60 Horsepower 50 40 H H H 20 25 30 35 40 RPM x10 4 5 00 Max Torque 137 0 spunod joo enbio ays 5 0 5 5 6 0 Dynomometer chart showing typical horsepower and torque curves for S amp S 124 T124 engine Horsepower and torque curves will vary dependent on the engines state of tune and the ignition and fuel systems used on the completed engine Additional Features Greater overall strength than stock crankcases especially in the front motor mount an important consideration in high performance applications All oil passages between the crankcase and cam support plate are O ring sealed Compatible with stock components Use stock oil pump cam support plate gear cover etc Uses 1999 2002 Timken style sprocket shaft bearing Uses 2003 up pinion shaft bearing S amp S T124
28. stall supplied vent fitting S amp S PN 50 0449 is for use with 2002 06 with s ID vent hose or 50 0454 for use with 1999 01 with ID vent hose with O ring installed on fitting See Picture 1 Picture 3 Picture 1 2002 06 Shown 7 Mount the oil line block on the crankcase using 18 x 1 long screw S amp S PN 50 0437 do not final tighten as it will be removed again 8 The next step is to measure and then cut the oil hoses The straight hose connects the 90 degree fittings of the oil line block and oil pan The bent hose runs between the oil return fittings on the oil line block and oil pan See Picture 4 Picture 4 9 Remove the oil line block from the engine case Install the supplied clamps S amp S PN 50 8156 on the lines between the fittings See Picture 5 f a f e Picture 5 10 Install O Rings S amp S PN 50 8066 in the counter bores of the oil line block Position the oil line block on the engine case and tighten the screw to 18 ft Ibs of torque with blue threadlock on the threads See Picture 6 Picture 6 11 Position hose clamps over the fittings To Change Engine Oil in the Future Slide hose clamp off of fitting along hose See Picture 7 Place an oil drain pan under front of oil pan Remove hose from fitting to drain oil Reinstall hose and clamp Continue with recommended oil change procedure Picture 7 S amp S Replacement Parts for Harley Davidson
29. sure all federal state and local laws are obeyed with 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 inhaled 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 A 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
30. t thoroughly familiar with these procedures contact a professional mechanic A Exhaust Systems Muffled exhaust systems If you have an existing 2 into 2 system that uses slip on style mufflers whether it is an OEM or an aftermarket system we recommend the new S amp S slip on mufflers S amp S dyno tests achieve almost 8 more horsepower and 5 ft Ibs of torque on a stock Harley Davidson Twin Cam 88 engine using stock header pipes and S amp S slip on mufflers and S amp S Super Sidewinder engines have produced 1 1 1 horsepower per cubic inch using stock style exhaust and S amp S slip on mufflers These mufflers will allow your engine produce more horsepower and torque than straight through drag pipes in street and highway driving and work equally well on both stock and large displacement engines Drag pipes While drag pipes can be used with good results to achieve top end horsepower they are generally not recommended for street applications Carburetor adjustment and jetting is generally easier for engines with muffled exhaust systems Gearing Gearing depends on the total weight of the machine and rider the size of the engine cam exhaust system and type of riding Most high performance engines and particularly those with larger displacements are capable of pulling more gear We suggest you break the engine in with stock gearing to minimize the load on the engine After the engine is broken in you will have a
31. ustments prior to final tightening of the upper exhaust mounting hardware at the cylinder heads Failure to follow this procedure may cause excessive vibration and result in failure of exhaust pipes or mounting hardware 9 Initial Start Up And Engine Break In NOTE engines are designed for high performance and as such are not as tolerant of inadequate break in as stock or lower performance engines Correct break in will assure longer engine life and will prevent unnecessary engine damage Engine damage caused by improper break in is not covered under the S amp S warranty A Initial start up 1 For the initial start up the fuel and ignition systems should be adjusted to their baseline settings Baseline settings allow the bike to start and run and are the starting point for tuning This is adequate for the initial start up and heat cycling of the engine NOTE Because there are several ignition and fuel system combinations possible with the S amp S T124 and T124V engine baseline settings are not listed here Refer to the appropriate ignition or fuel system instruction sheet 2 Run engine approximately one minute at 1250 1750 rom DO NOT crack throttle or subject to any loads during this period as head gaskets are susceptible to failure at this time During this time check to see that oil pressure is normal and that oil is returning the oil tank 3 Shut off engine and thoroughly check for any oil leaks fuel leaks o
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