PDF Instructions
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1. orfollowinstructions included with S amp S Cylinder Torque Plate Kit Torque plates must be used to simulate compressive stress in an assembled engine Cylinders will distort if torque plates are not used d Repeat this procedure 3 or 4 times Each successive time it should take slightly longer to warm up and you can increase the temp slightly each time 10 You can be more liberal each time with the rpm gently vary rpm continuously from A CAUTION A idle up to 2500 rpm in the final cycle Don t be too concerned with final carb settings at this time because idle speed and mixture cannot be correctly set until the motor reaches full operating temperature The motor should not reach that temperature during these cycles Do not allow engine temperature to become excessive After the motor has cooled to room temperature for the final time you are ready to start the 1000 mile engine break in process e 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 engine riding in hot weather or in stop and go traffic Vary the engine speed but do not lug the engine We recommend changing the oil at 50 miles PISTON FIT SPECIFICATIONS A PART DESCRIPTION CLOSE FIT LOOSE FIT NUMBERS Failure to follow instructions and perform required clearancing installation and or break in procedures may result in damage to pis2. 4 next page Compression ring end gap should be between 016 to 026 Oil ring rail end gap should be between 010 to 050 If there is insufficient ring end gap file the end of the piston ring to achieve the desired gap Ends of piston ring must be deburred after filing Thoroughly clean the piston rings after filing and deburring and install on pistons Install Oil rings See Figure 4 page 4 1 Expander gap must be in center of thrust face front of piston or 90 from wristpin 2 Bottom rail gap should be approximately 1 5 or 45 to right of expander gap 3 Top rail gap should be approximately 1 5 or 45 to left of expander gap NOTE Confirm that ends of expander do not overlap during installation Properly installed expander will appear larger than piston but will compress when cylinder installed In some cases same expander is used for several bore sizes Oversize rings will not necessarily have a larger expander icture 2 Picture 3 d Install compression rings observing the following e Second compression ring is cast iron regular or reverse torsion type This ring has a darker charcoal gray finish and slight bevel along inner surface e Top compression ring is moly faced ring This ring has a gray finish that is relatively light in color e Any identifying pip marks dots or oversize marks go to top of piston e If ring has dot and inside diameter bevel dot goes to top of piston See F
3. 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 1 Remove the cylinder heads cylinders and pistons according to the procedures in the Harley Davidson service manual 2 For 2004 up models prior to installing the new S amp S pistons and cylinders move tappet covers as far as possible to toward the outside of the engine away from the cylinders to ensure adequate clearance between the tappet covers and cylinder bases a Remove tappet covers from crankcase b Clean tappet covers reusable gaskets crankcase gasket surface and hardware with solvent and a clean rag c Apply blue thread locking compound to tappet cover screws d Reinstall tappet cover gaskets covers and screws but do not final tighten e Hold the tappet cover as far away from the cylinders as possible See Picture 1 below f Torque screws to 120 In lb in a criss cross pattern 3 Install S amp S Pistons NOTES e These S amp S piston scan be used in either the front or rear position However when purchased in a kit with cylinders each piston must be kept with the cylinder it was delivered in as each cylinder is individually honed to fit a specific piston e Rebalancing is not required when installing this kit a Clean pistons and wrist pins with solvent NOTE Wristpin must be thoroughly cleaned before installation paying particular attention to bore
4. Instruction 510 0087 01 07 13 Copyright 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 1200cc Piston and Cylinder Kits for Harley Davidson 883cc and 1200cc Sportster Models 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 associ
5. Pass clean lint free cloth back and forth through wristpin bore several times to insure removal ofall contaminants b Apply assembly lube to connecting rod bushings wristpins and piston wristpin holes Install pistons with the FWD arrow mark pointing toward the front of the engine See Picture 2 below Ensure that wristpin clip groove in piston is free of burrs and foreign matter Install wire clips using procedure recommended in a Harley Davidson service manual End of clip must rest over notch in piston below wristpin hole to allow removal of clip in future Be sure clip is fully seated in groove NOTE Round wire style clips supplied with this kit are identical to and interchangeable with stock clips in Harley Davidson Evolution engines Picture 1 Top 2nd Suggested ring end gaps Ring Gap Tolerance inches Target Gap 0 016 0 022 0 017 0 016 0 026 0 021 Oil ring rails 0 010 0 050 0 010 to 0 050 5 Install Piston Rings NOTE Ring widths on some piston series may change from time to time Part numbers of rings originally supplied with pistons should be recorded for future reference in the event replacement rings are required a Measure ring end gap by pushing ring about 1 inch into the cylinder bore from the head end of the cylinder using the piston to insert the ring squarely in the bore See Picture 3 next page Measure the gap between the ends of the ring with a feeler gauge See Picture
6. ated with Harley Davidson 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 y
7. eration h After 1000 miles verify carburetor jetting and adjustment Change the engine oil Motorcycle can now be operated normally i Have Fun A TOP COMPRESSION SECOND COMPRESSION RING GAP RING GAP Additional Information The following information is provided in case pistons must be replaced as in the event of an engine overhaul or if the engine is niaar ial to be set up for immediate severe duty such as drag racing or other TOP RAIL GAP BOTTOM RAIL GAP competition application See Piston Fit Specification chart below 1 For maximum piston and ring life fit pistons using close fit dimensions Close fit requires absolute adherence to new engine aes a break in as described in Step 5 on pages 3 4 2 Forimmediate drag strip use fit pistons using loose fit dimensions Break in rings and pistons with 50 easy miles if possible Piston and ring life will be reduced with loose fit dimensions 3 Measure all pistons at widest point across thrust face TOP COMPRESSION SECOND COMPRESSION perpendicular to wristpin hole Several measurements should be BEE RING GRE taken to locate widest point Typically this will be at bottom of piston skirt and approximately 12 below level of wristpin hole 4 S amp S recommends 220 280 grit stone for final honing of S amp S Figure 4 GAP PLACEMENT ILLUSTRATION bore cylinders 5 Follow procedure recommended in Harley Davidson service manual for boring and honing S amp S cylinders
8. esigned for high performance and as such are not as tolerant of inadequate break in as a stock engine 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 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 that oil is returning to the oil tank and that no leaks exist b Shut off engine and thoroughly check for any leaks or other problems Let engine cool to the touch c After engine has cooled start up again and allow the motor to build some heat Engine should be run no 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 SaNa Figure 1 Figure 2 Figure 3 EAP NODER GAP g For the balance of the first 1000 miles the motor can be TOP RAIL GAP ONE 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 i e excessive speed trailer towing or sidecar op
9. igure below e If ring has no dot but does have inside diameter bevel bevel goes to top of piston See Figure 2 below e Ifring has no dots and no bevel it can go either way See Figure 3 below e Second compression ring gap should be 135 or approximately 4 2 to right of oil expander gap See Figure 4 next page e Topcompressionring gap should be 135 or approximately 4 2 to left of oil expander gap See Figure 4 next page A CAUTION A Failure to remove burrs from piston ring ends after filing to size may cause engine damage Incorrect installation of rings may result in poor performance excessive oil consumption or engine damage 4 Reassemble cylinders cylinder heads pushrods and fuel system according to procedures in the Harley Davidson service manual or in instructions included with any aftermarket components used If high performance cams are installed valve to piston clearance must be checked Picture 4 NOTE 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 higher compression pistons and high lift camshafts In addition to clearances mentioned 060 valve to piston clearance must be confirmed A CAUTION A Failure to establish proper clearances can result in severe engine damage not covered under warranty 5 Engine Break In Procedure NOTE S amp S engine kits are d
10. ou are fresh Be 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
11. that 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 other
12. tons and or other engine components not covered under warranty A CAUTION Lugging or punning epams prematare ey eusranen high rpm 06 8 STD 883 TO 1200 CONVERSION PISTON 0025 T0 0030 0035 10 0045 f 1 554 1 WW i LLI n n may r it in dam istons an her engin mponents Ay PESMI da AJE rO pIstans S d other e JME component 106 5549 010 1986 UP XL 3 BORE DISHED S amp S voids its guarantee if engine is not broken in properly 106 5550 020 DOME 920 0061 STD 1200CC PISTON 1986 UP XL 312 0025 T0 0030 0035 10 0045 920 0063 010 12 3CC RAISED DOME 920 0065 STD 1200CC PISTON 1986 UP XL 312 0025 T0 0030 0035 10 0045 920 0067 010 3 6CC RAISED DOME NOTE FIT WRISTPINS AT 0007 TO 0014 f The next 500 miles should be spent running engine no faster than 3500 rpm or 60 mph Avoid continuous steady speeds and do not lug the engine Vary engine rom We recommend changing the oil again at 500 miles
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