- S&S Cycle
Contents
1. bushing with clean 20W 50 oil or assembly lube e Hold the piston over the connecting rod with the piston facing the correct direction and the piston pin bore and upper bushing bores lined up f Install the piston pin through the piston pin bore and through the connecting rod bushing until the pin contacts the clip Install the other piston clip Ensure that both clips are fully seated Repeat procedure for the rear piston gt Q Cylinder Installation Bring the front cylinder to TDC Apply a light coating of oil to the piston and rings Lightly oil the new cylinder base o ring and install on the cylinder Lightly oil the new o rings for the lower cylinder deck alignment dowels and install Verify that the ring gaps are orientated correctly refer to Picture 5a f Remove the rubber tubing from the cylinder studs g Compress ring pack by using a suitable ring compressor If possible position the ring compressor so that you can see the oil expander gap during installation Picture 5b h Install cylinder on piston making sure not to overlap oil ring expander i Remove ring compressor j Remove plastic sheeting covering crankcase k Slide the cylinder down until it seats against the crankcase m Qnoooa Vi M Rotate the engine until the rear cylinder is at TDC Repeat procedure for the rear cylinder 6 Cylinder Head Installation Head Gasket Tightening Torque Specifications Multi layer2. by AO O 2 Setting Ring End Gaps NOTES e Important The gap of the second ring should be larger than the top ring this will help keep the top ring seated for improved performance Each ring should be fitted to the particular cylinder in which they will be installed e Oil rails can be installed without adjusting the end gap The minimum gap should be 0 015 e Never alter the end gap of the oil expander ring e Always install the ends of the expander facing up as shown in Picture 3 next page a Thoroughly wash cylinders with hot soapy water then wash with brake cleaner and wipe with a clean white towel Repeat until towel does not show evidence of debris and apply a light coat of oil immediately b Check the ring end gap by placing the ring into the cylinder Use a piston or caliper to ensure that the ring is placed squarely in the bore See Picture 1 c Measure the ring end gap with a feeler gauge See Picture 2 d See Table 1 for proper end gap measurement If adjustment to the gap must be made use a proper ring end gap filing tool e Always file from the ring face towards the inside diameter to avoid damaging the face coating f Remove material from only one end of the ring g Ensure that ring end gaps are square h Remove sharp edges and burrs i Recheck gap measurement and adjust as necessary j Repeat procedure with the other rings Ring End Gap Application Top Ring Second Ring OilRing o Street H
3. confirmed A CAUTION A Failure to follow instructions and perform required clearancing installation and or break in procedures may result in damage to pistons and or other engine components not covered under warranty The proper break in procedure is in Section 9 of these instructions DISASSEMBLY Refer to the Harley Davidson manual for your specific motorcycle for the correct disassembly procedure The engine should be disassembled to the short block i e induction system exhaust system cylinder heads cylinders and pistons should be removed INSTALLATION AND REASSEMBLY 1 Boring Cylinders If stock Harley Davidson cylinders will be bored to accept these pistons the following procedures must be used a Torque plates must be used during the boring and honing operations Do not use a hand hone Honing Use a 220 grit stone until there is 0 001 of material left from the final bore The bore must be round to 0 0002 checked 360 around the bore from the bottom to the top of the cylinder Use a 280 grit stone at 50 load until there is 0 0002 remaining With the 280 grit stone reduce the load to 20 to achieve the final bore size Final bore size should be 3 937 0 00025 d Use a dial bore gauge to accurately measure the cylinder bore e When finished honing wash the cylinders thoroughly to remove material trapped in the honing grooves Failure to clean the cylinder could lead to premature ring wear and blow
4. steel MLS head gasket PN 106 3714 0 045 thick or PN 900 0216 0 030 thick a Check surfaces for flatness and imperfections an excessively rough finish may cause gasket failure b Check all hardware for defects Clean all threads and lubricate with clean oil Lubricate the underside flange of the head bolts with clean oil wipe away excess c The head bolts are two different lengths The short ones go on the spark plug side the long ones go on the pushrod side d Place the head gasket on the cylinder and locate the gasket using the cylinder head alignment dowels Either face of the gasket can be up there is not a specific top or bottom to the gasket NOTE Do not use the cylinder head alignment dowel O rings with MLS head gasket e Once the gasket is in place make sure that it fits the bore The gasket should not hang into the bore or combustion chamber area f If using cylinder heads other than stock check the brass rivets of the MLS gaskets to ensure the rivets do not interfere with the sealing surface in any way g Important In order to properly seal the head gasket the head bolts must be torqued in the sequence shown in the next step fully loosened then torqued again a 2 time Follow the head tightening sequence in the next step then fully loosing the head bolts turn at a time in the sequence shown in Picture 6 until fully loose Repeat the tightening sequence in step h below a second time h Tighten the he
5. Instruction 510 0260 03 06 14 Copyright 2014 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 98 and 107 Piston and Big Bore Kits for 1999 06 and 2007 14 Big Twins 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 Da
6. ad bolts according to the following procedure start with the front head then the rear head i Tighten each bolt finger tight using the sequence in Picture 6 ii Tighten each bolt to 10 12 ft lbs using the sequence iii Tighten to 15 17 ft lbs using the sequence iv Finally tighten the bolts an additional turn 90 Top View Drive Side Picture 6 7 Final Assembly Assemble the remaining items according to the Harley Davidson service Manual specific for your motorcycle 8 Tuning S amp S big bore kits increase the displacement and compression ratio of your engine The fuel and ignition systems must be calibrated for these changes before the engine is driven and break in is attempted It is recommended that a performance carburetor such as the S amp S Super E or G be used with the correct jetting for the engine size for carbureted models Fuel injected engines must be tuned using a replacement ECU such as the S amp S VFI module or an aftermarket tuner such as the DynoJet Power Vision tuner NOTE The S amp S VFI module is not compatible with 2008 up Touring models with electronic throttle control S amp S recommends the Dynojet Power Vision tuner for these applications 9 Break in Procedure NOTES e S amp S engines and parts are designed for high performance and are not as tolerant of inadequate break in Correct break in will assure longer engine life and will prevent unnecessary engine damage Engine damage c
7. aused by improper break in is not covered under the S amp S Warranty e Proper engine tuning will be required in order for your engine to run correctly and to prevent damage Carbureted engines must be rejetted and a larger carburetor is recommended EFI calibration can be changed with the use of an S amp S VFI module or other aftermarket tuner It is recommended to start by adding 10 fuel across the map if you do not have a tune file for the set up you are running Check the S amp S website for Power Vision calibration files a Initial start up Run the engine approximately one minute at 1250 1750rpm DO NOT crack the 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 oil is returning to the oil tank and no leaks exist b Shut off engine and inspect for leaks Allow engine to cool to the touch c Start up engine again and allow the engine to warm up for 3 to 4 minutes Again do not crack the throttle or subject the engine to any type of load Shut down the engine and allow to cool Repeat this procedure at least 3 more times d After the engine has cooled to room temperature you are ready to start the 500 mile engine break in process e The first 50 miles are the 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 2500rpm Avoid luggi
8. 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 other American v twin mot
9. i F 0 004 0 008 Minimum 0 015 Performance Bore x 0 005 0 004 0 008 Minimum 0 015 l Bigger than top ring Do not file i 0 004 0 008 Minimum 0 015 Table 1 Drag Racing Nitrous Turbo Supercharged d The top ring must be installed with the N facing up see Picture 4 The top ring will have a chamfer on the inside edge this chamfer will face up Use a ring expander tool to install the ring to the top groove Orient the gap according to Picture 5a TOP RING 2 4 RING ws Picture 4 OPRA ae Top Oil Rail Gap Expander Ring Gap i l CAM SIDE IQIS JAYA Bottom Oil Rail Gap Second Rino Picture 5a Expander Ring Gap Picture 2 3 Piston Ring Installation Order of installation 1 Oil ring expander ends must face up as shown in Picture 3 2 Oil ring rails 3 2nd ring cast iron with a taper underhook groove face letter N faces up 4 Top ring steel compression ring that has been gas nitride letter N faces up a Install the oil ring expander to the bottom groove of the piston The expander ring has a silver finish Make sure the end of the expander ring is butted together and not overlapping Picture 3 below If the tips are overlapped excessive oil consumption will occur Orient the expander gap such that it can be viewed as it enters the cylinder See Picture 5c Incorrect orientation Correctly butted tips facing up Picture 3 b Install oil rails The oil rails are
10. ng the engine riding in hot weather or in traffic Vary the engine speed We recommend changing the oil after the first 50 miles f The next 500 miles should be spent running no faster than 3500rpm or 60mph Avoid running continuous steady speeds and do not lug the engine Vary the rom We recommend changing the oil again at 500 miles g For the balance of the first 1000 miles the engine can be run ina normal but conservative manner You can be more liberal with the rpm range and the 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 side car operation h After 1000 miles change the engine oil Now the motorcycle can be operated normally OIL RECOMMENDATIONS S amp S Cycle recommends the use of S amp S 20W 50 synthetic or petroleum based V Twin Motor Oil Break in can be performed with either synthetic or petroleum based oil Regardless of what type of oil you select be sure to only use oil specifically designated for use in an air cooled motorcycle engine If you prefer not to use a multi viscosity oil utilize the viscosity suggested for the temperature you will be operating your motorcycle in
11. ontain 3 937 bore pistons with 1 265 deck height These kits are intended for stock stroke 4 000 1999 06 big twin engines e Pistons in both kits are the same for the front and rear cylinders and can be used with either cylinder e CAUTION THE PISTONS MUST BE ORIENTED SO THAT THE VALVE RELIEFS MATCH THE CORRESPONDING VALVES THE INTAKE VALVE RELIEF IS LARGER THAN THE EXHAUST VALVE RELIEF THE 107 PISTONS HAVE A NOTCH ON THE BOTTOM OF THE SKIRT THIS NOTCH MUST BE INSTALLED TOWARD THE CENTER OF THE ENGINE THE 98 PISTONS DO NOT HAVE A NOTCH AND MUST BE INSTALLED WITH THE VALVE RELIEFS ORIENTED TO THE APPROPRIATE VALVE e The pistons are machined during manufacturing to provide the correct running clearance when cylinders are bored to nominal size of 3 937 In other words the clearance is built into the piston diameter If you wish to confirm piston diameter measure the diameter 0 5 up from the bottom of the piston skirts see Specification Sheet for details Cylinder measurements must be taken with the cylinder in torque plates with bolts tightened at correct torque value to simulate conditions in an assembled engine e In all cases it is the engine builder s responsibility to confirm proper clearances when assembling an engine This is especially critical with performance components such as larger valve high performance heads and high lift camshafts e In addition to clearances mentioned 0 060 valve to piston clearance must be
12. orcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application Special Tool Requirements e Harley Davidson service manual for the specific model you are working on e Piston ring compressor e Piston ring expander e Piston ring end gap filing tool e Digital or dial calipers e Feeler gauges e Torque Wrench Instruction Contents e General Information e Disassembly e Installation and Reassembly Boring Cylinders Setting Ring End Gap Piston Ring Installation Piston Installation Cylinder Installation Cylinder Head Installation Final Assembly Tuning Break in Procedure Piston Kit Contents e 2 3 937 pistons front and rear pistons are the same e 2 0 927 piston pins e 4 Piston pin clips with installation tool e 2 Ring packs which include the top second oil rail and expander rings Piston and Cylinder Kit Contents e 1 3 937 Piston Kit e 2 3 937 Bore Cylinders e 2 MLS Multi Layer Steel head gaskets 0 045 thick e 2 Cylinder base O rings e 2 Cylinder base dowel O rings e 2 Exhaust gaskets wo emaoewyanrBRWDN General Information e Thoroughly read and understand all the instructions before starting installation e S amp S 107 big bore kits contain 3 937 bore pistons with 1 085 deck height These kits are intended for stock stroke 4 375 2007 14 big twin engines e S amp S 98 big bore kits c
13. 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 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
14. the thinnest of all the rings Either side can be placed up Install the rails into the groove by hand Install one rail above the expander and one below Orient the gaps according to Picture 5a c Install the 2nd ring with the N facing up see Picture 4 Use an expander to install the ring to the 2nd groove in the piston Orient the gap according to Picture 5a Picture 5c 4 Piston Installation NOTES e Pistons are identical and can be installed in either cylinder e CAUTION THE PISTONS MUST BE ORIENTED SO THAT THE VALVE RELIEFS MATCH THE CORRESPONDING VALVES THE INTAKE VALVE RELIEF IS LARGER THAN THE EXHAUST VALVE RELIEF THE 107 PISTONS HAVE A NOTCH ON THE BOTTOM OF THE SKIRT THIS NOTCH MUST BE INSTALLED TOWARD THE CENTER OF THE ENGINE THE 98 PISTONS DO NOT HAVE A NOTCH AND MUST BE INSTALLED WITH THE VALVE RELIEFS ORIENTED TO THE APPROPRIATE VALVE e Check piston pin to connecting rod bushing clearance Clearance should be between 0 0007 and 0 0012 Bushing should be replaced if clearance exceeds 0 002 a Place rubber tubing over the cylinder studs to prevent damage to the pistons and rings during assembly b Place a clean sheet of plastic over the crankcase openings to prevent anything from dropping into the crankcase c Install one of the piston pin clips into each of the pistons according to the instructions included in the piston kit d Lightly oil the piston pin piston pin bore and upper connecting rod
15. vidson Inc SAFE 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 e 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
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