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Sportster PG 2005

1. Oil feed and oil return systems to and The easiest most cost effective way to Lower compression kits will tolerate from heads match the stock systems increase the performance of your Harley lower quality gasoline and generally last Increased displacement for better longer than higher compression kits l l performance All kits are made to work with stock Er Cast pistons generally allow tighter components and come complete so it Maximum running life through running clearances for extended life is not necessary to buy other innovative design features and and quieter operation aftermarket parts HEH Forged pistons are noted for strength needs um appearance applications Minimal installation problems Engine Size Smaller displacements retain stock like engine life while EASE OF INSTALLATION providing significant additional KIT SELECTIONS horsepower Larger higher MI kits can be installed by any There is kit available to match nearly any compression kits provide greater ge dee eh Geer bor riding style for touring riding double horsepower gais with some ul Ing w Natii 0a aj sidecar or trailer operation and drag strip reduction of engine life SA popen Se machine shop acilities are required Most kits come complete with all parts lronhead Sportster 72 or 74 p p necessary to make the conversion Sportster Vie from 74 to 103 Buells 74 to 79 VISIT US AT WWW SSCYCLE COM 9 SPORTST
2. Desperado Air Cleaner Cover 17 0004 PATRIOT AND DESPERADO AIR CLEANER COVERS ARE AVAILABLE FOR S amp S SUPER E amp SUPER G SHORTY CARBURETORS ONLY VISIT US AT WWW SSCYCLE COM 19 E get SEO MA NS AIR FILTERS S amp S HIGH FLOW AIR FILTER AND ADAPTER KIT With larger and larger street engines becoming more common S amp S has developed a high flow air filter kit for Super E and G carburetors The new S amp S high flow filter is 1 taller than our standard filter and features a low restriction pre oiled filter element The low restriction element combined with the larger surface area provided by the 1 filter taller adds up to an airflow increase of 37 percent over our standard filter the ultimate free breathing set up for your engine The filter and filter adapters extend the teardrop housing out 1 The resulting band of exposed filter peeking out from under the teardrop imparts a high performance street racer look Kit installs in minutes no permanent modifications required SPORTSTER amp BUELL PERFORMANCE GUIDE Not for use with S amp S Super B or Super D carburetors or Super E amp G Kits for Buells HIGH FLOW FILTER WITH HIGH PERFORMANCE LOOKS Extended filter kit provides maximum airflow for air hungry engines This free breathing set up looks like it just came from the track Easy to install kit is one inch taller than our standard teardrop filter and features premium filter media Includ
3. rervrnnrrrnrnrvnnnrarennrnnrennsnrvnnnsnvennsnvensnnnrennssvenennnrer 101 95 Air cleaner assembly 1994 2002 Buell w stock CV carD emmeeeureeuseemmeeseeissseeerrernssvenssvvsnnvernsnvenssvesen 158 25 Air cleaner assembly 1984 up V w Super A H 130 35 Air cleaner assembly 1984 up V w stock butterfly type carb cwssversavarnrernnnvensnvennsrernnnvensnvennsvernnnrensnnesssvernsnrensnnenen 129 15 Air cleaner assembly 1993 up BT V amp TC 1991 2003 XL w stock CV carb aaa aaa aaa a aaa aaaasaaasanasanai 188 45 res vr 113 35 Air cleaner assembly 1966 84 BT 1966 85 XL w L series stock butterfly type camp 103 45 Gover air cleaner Super EGG U S AG avse EE 97 80 Air cleaner assembly Super E G 1984 92 BT 1986 90 XL after 3 94 csccsesssssstecsesssssesseesssneseessenessenssennenes 131 45 Air cleaner assembly Super E G 193083 BT 1957 95 AL eegend EE 113 15 Air cleaner assembly Super E G 1994 2002 BUG E 166 25 Air cleaner assembly Super E G 1993 99 V BT after 2 01 c sscsssssssscsscsevssesscsssssssseussssessserssnevsesespsessesecsesvsensases 148 95 Gearcover kit crankcase bushing style 1986 90 XL uuu iGO AE GACER AE EAC ORAWA 393 10 Gearcover kit crankcase bushing style 1991 99 XL aa AAAA AR AE EAC 393 10 EMAIL US AT SSCUSTOSSCYCLE COM SUGGESTED RETAIL PRICING SUGGESTED RETAIL PRICING IN THE CONTINENTAL UNITED STATES Part No 31 1008 31 1009 31 1013 31
4. Pistons supplied are cast type F Pistons supplied are forged type Denotes kit supplied in Hot Set Up AN ECONOMICAL WAY TO GET MORE OUT OF YOUR 883 SPORTSTER l Use these pistons to convert an 883cc engine to 1200cc Bore the I stock 883cc cylinders out to 34 92 2446 SERIES PISTONS I bore or use 1200cc cylinders A L gt template is included for modifying Oversize Part Number stock 883cc cylinder heads to adjust compression and increase 92 24465 flow It is recommended that q flywheels be rebalanced during Manne 92 2449 the next complete overhaul VISIT US AT WWW SSCYCLE COM 11 SPORTSTER amp BUELL PERFORMANCE GUIDE CARBURETORS Half a million and still going strong THE S amp S SUPER E amp G CARBS were a ground breaking development when they were first introduced in October of 1990 Since then they have become the best selling performance carburetor in the V Twin aftermarket and have remained so to this day in mid 2004 S amp S produced the 500 000th Super Shorty carb The combination of good looks easy tuning exceptional performance and not least of all the technical Support of a manufacturer with as many years of experience aS S amp S made the S amp S Super Shorty carbs the ones to get Today the Super E and G carbs are still top selling carburetors and are standard equipment on all S amp S engines another best selling product Lem gt SPORTSTER am
5. drive train components or charging system Engine builder must supply 1991 and later style 5 speed transmission clutch primary components and charging system Stock or aftermarket 1986 and later Sportster style oil pumps may be used 1986 87 bolt on oil filter mount is also required OPTIONS INCLUDE Natural aluminum or black powdercoat finished cylinders and heads Unfinished polished or chrome plated billet rocker covers Assembled by S amp S technicians or unassembled S amp S COMPLETE ENGINES FOR SPORTSTERS Engine complete 100 Sportster 31 9299 Engine complete 91 Sportster ass1122111 31 9302 S amp S COMPLETE ENGINES FOR BUELLS Engine complete 100 Buell 31 9301 Engine complete 91 Buell 2221112 31 9300 Requires S amp S billet motor mount Frame to exhaust clearancing may be required EMAIL US AT SSCUST SSCYCLE COM MOTOR MOUNTS S amp S BILLET MOTOR MOUNTS FOR BUELLS S amp S billet front motor mounts for 1996 02 V Twin Buell motorcycles are machined from 6061 16 billet aluminum and offer a considerable increase in strength over stock They are available in three versions The first version is intended to be a heavy duty replacement motor mount for Buells with stock height engines The second version is designed to allow the S amp S 100 engine to be installed in a stock Buell chassis
6. the type S amp S cylinder heads are available in natural aluminum black wrinkle powdercoat and polished finish S amp S also has specialized cylinder heads for all out racing engines which can be found starting on Page 11 46 in the Racing section of this catalog 30 STATE OF THE ART MANUFACTURING S amp S cylinder heads are machined from heat treated aluminum castings using state of the art NC machining centers for the best possible dimensional precision at the lowest possible cost This high degree of capability assures that the quality our customers demand and have come to expect from S amp S is consistent in every part we make The efficiency that we gain from automated machining helps to lower our costs and that means that our customers can purchase S amp S quality components at competitive prices EMAIL US AT SSCUSTOSSCYCLE COM r el 23 CYLINDER HEADS EVOLUTION STYLE CYLINDER HEADS FOR SPORSTERS The first cylinder heads S amp S introduced in 1994 were for Evolution 3 and 3 bore Big Twins and Sportsters Then in 1998 L gt S amp S introduced the heads for 4 bore Big Twin and Sportster style engines Both of these types of cylinder heads are available on complete S amp S engines and individually for replacement and custom applications FEATURES 2 000 intake valves and 1 605 exhaust valves Special cast to shape intake ports with a special directional fin for improved air
7. to present have a two cable throttle which can easily be SUPER B CARBURETOR KITS modified to work with the Super B carburetor Application na KE Recommended for Racing Only S amp S carburetors are not legal for use in California on motor vehicles RER A operated on public highways or in other states where Die et similar pollution laws may apply The user shall 1983 83 XL 11 0120 determine the suitability of the product for his or her 1986 90 XL V use and shall assume all risk and liability in No Carb only 11 0111 connection therewith Manifold Carb kit w o manifold 11 0100 lt Polishing and Chrome Plating the Carburetor S amp S does not recommend polishing and chrome plating any S amp S carburetor Proper preparation to achieve a good finish requires polishing using buffing compounds The polishing and plating processes and the materials used invariably plug air and or fuel passageways and feed holes and alter operating tolerances in critical areas regardless of the precautions taken NOTE Many 1979 80 engines may be equipped with either o ring or band style heads Check before ordering 16 EMAIL US AT SSCUST SSCYCLE COM S amp S CARBURETOR REPLACEMENT JETS i For those who need to rejet their carburetor because of engine modifications exhaust modifications or changes in altitude we E have extra jet kits available which are designed to cover most jetting situations Compare your jets with those in the
8. 1014 31 2099 31 4114 3129299 31 9300 31 9301 31 9302 32 3089 32 3 12 32 3774 33 5081 33 5082 33 5083 33 5084 33 5352 33 5353 33 5355 33 5361 33 5362 33 5363 33 5364 33 5365 33 5369 33 5371 33 5372 33 5373 33 5374 33 5375 33 5381 33 5383 33 5385 33 5387 33 5389 50 0333 50 8077 50 8079 50 8087 50 8153 53 0040 53 0452 55 1007 55 6008 55 6031 55 6500 55 6501 90 0324 Description Crankcase assembly stock bore 1991 2003 cam geometry XL Buell ernnverrnnrernnnrrennravennrnnrennrnrennnsrenennnrrennrsreens 2 21225 Crankcase assembly 3 bore 1991 2003 cam geometry XL Buell e aaa aaa aaa aaa aaa aaa anna anaaaaizaaaiana 2 212 25 Crankcase assembly stock bore 1986 90 cam geometry XL Buell e u eau aa aaa aa aan aan aa wanna ata na aazaaanin i 2 212 25 Crankcase assembly 3 bore 1986 90 cam geometry XL Buell AEN 2 21225 Gasket derc over 19660 0 ZIE HE EE 14 95 Seal goarcover cami aS NNN pee som tee een 39 95 Engine Complete 100 S amp S Sportster Style aauaaaaaaaaasanaaasza Price varies with options selected Call for pricing Engine Complete 91 S amp S Buell Style csccesssessesessssscsssessescenses Price varies with options selected Call for pricing Engine Complete 100 S amp S Buell Style rurarrsvvarnerrarvrrnerrarerrserrsrenner Price varies with options selected Gall for pric
9. 5373 33 5363 1991 UP S amp S SPORTSTER STYLE EEC 50 8153 SPECIAL S amp S 1991 UP V2 SPORTSTER STYLE vinn _ 4 eh 27 u TAPPET GUIDE SELECTION CHART DIE A EECHER HD 11167A 10 back 90 8079 1991 Up 1991 Up Ea S amp S Super Stock S amp S Special Application Lower O ring 1 ID x 1 OD x CS Viton LE 1 HD 11168A 10 Pack 90 8087 33 5389 33 5369 EE ee OWCY Se Se Oil Passage O ring ID x i OD x CS 70 Buna Rear Exhuast intake _ 33 5387 HD 11110 10 Pack 50 8077 VISIT US AT WWW SSCYCLE COM 23 SPORTSTER amp BUELL PERFORMANCE GUIDE TAPPETS S amp S HYDRAULIC TAPPETS FOR EVOLUTION SPORTSTER STYLE ENIGNES S amp S Hydraulic Tappets fit all Big Twin V style engines and 1986 90 Sportster engines These tappets feature numerous significant design improvements se Larger inner bearing race reduces stresses to increase axle bearing and roller life The S amp S inner bearing race is 123 larger in diameter than the raceless roller axles currently used by some manufacturers Improved inner race roller design allows use of more and larger bearings to increase load carrying surface area further reducing stress and wear in the Critical roller areach Redesigned plunger assembly better withstands forces associated with heavy duty valve springs and cams typically used in high performance applications SPORTSTER amp BUELL PERFORMANCE GUIDE Revised metering device precisely controls
10. A special order front motor mount is also available The special order front motor mount allows builders to install custom engines which are between 200 shorter and 430 taller than stock Keep in mind that when installing some non stock height engines in a stock Buell chassis exhaust and frame clearance may be a problem F I I I SPORTSTER amp BUELL PERFORMANCE GUIDE A slotted steel top motor mount is also required for taller than stock engines S amp S FRONT MOTOR MOUNTS for 1996 02 V Twin Buells For Stock Height Engmnes aaa aasaaaanina 93 4059 For S amp S 100 ENGINES awa OKI 93 4060 SEET 93 4061 slotted Steel Top Motor Mount 93 4062 VISIT US AT WWW SSCYCLE COM 3 SPORTSTER amp BUELL PERFORMANCE GUIDE MUFFLERS S amp S SLIP ON PERFORMANCE MUFFLERS l One of the most popular and cost effective i performance upgrades you can make to a I Harley Davidson motorcycle is to replace the L e Stock exhaust with a set of low restriction high performance mufflers The stock exhaust pipes and S amp S performance mufflers make a great high performance exhaust system with a low price tag NEW FOR 2005 S amp S HIGH PERFORMANCE EXHAUST FOR 2004 UP SPORTSTERS S amp S introduces a new high performance exhaust for 2004 and later Sportsters These mufflers slip on to the stock header pipes and are similar in design and performance to the S amp S Mufflers for 1987 2003 Sportsters However they are desig
11. Kit for V Sportsters Kit w steel top collars 90 2077 Kit w titanium top Collars 111211121 90 2078 NOTES High lift cams may require the engine builder to obtain additional clearance between the piston and valves the intake and exhaust valves and the upper spring collar and rocker cover Clearance should also be checked between the rocker arm and valve spring collar as well as between the rocker arm and rocker cover It is imperative that the engine builder confirm these clearances and check for spring coil bind even when using parts specifically designed for high performance Most valve train failures can be traced to over revving or failure to confirm correct clearances during assembly Top Collars US Patent 5 322 039 When ordering valve springs please specify engine year 26 EMAIL US AT SSCUST SSCYCLE COM PUSHRODS S amp S QUICKEE PUSHRODS FOR EVOLUTION SPORTSTER STYLE ENGINES S amp S developed a pushrod with a new type of adjuster for use with S amp S Shovelhead style tappet guides This is such a cool idea that we ve also made it available for Evolution and Twin Cam engines The threaded adjuster screws into the pushrod until the threads disengage and the adjuster simply slides into the pushrod making installation or removal a snap Once the pushrod is installed and adjusted the locknut prevents the adjuster from moving The ball ends of the pushrods are drilled so that oil can flow throug
12. S SUPER B CARBURETORS l Since its introduction in 1975 the 1 S amp S I Super B carb has been a favorite of Harley J high performance enthusiasts the world over L gt thas under gone a few changes over the years but it is still true to the original idea A simple no frills high performance carb that works well on the street and the drag strip APPLICATIONS SPORTSTER amp BUELL PERFORMANCE GUIDE The S amp S Super B gas carburetor has a 1 throat and is recommended for use on any displacement H D Big Twin or Sportster engine with any degree of performance modifications This includes stock engines and as well as performance engines Super B carb kits are not available for 1991 later Sportsters 1992 later Big Twin or Twin Cam 88 engines NOTES S amp S SUPER B COMPLETE GAS Two Cable Throttle Required S amp S Super B CARBURETOR KITs carburetors require the use of a two cable pull open include an S amp S Super B gas carburetor an S amp S pull closed throttle assembly Any chassis including Teardrop air cleaner kit manifold mounting 1980 and earlier stock H D models equipped with a bose hardware fuel line and clamps two extra main single cable throttle mechanism requires pull open pull jets and installation and jetting instructions closed type S amp S offers a high quality two cable throttle assembly for this purpose See your local S amp S Dealer for more informaion Stock models from 1961
13. all the major rallies around the continental United States On display were the fabulous 124 VFI Shoot out bikes Built around the S amp S 124 VFI SSW engine these are some of the most beautiful custom bikes you could hope to See but the best part about them is that they were built to ride A successful road trip and heads up drag racing Showed that they could indeed be ridden and ridden fast A celebratory five bike simultaneous burn out on the dance floor of the Broken Spoke Saloon in Sturgis wrapped up the 124 VFI Challenge and a good time was had by all Keep and eye on the coming issues of Hot Bike Magazine for details of a totally new event for the 2005 riding season EVENT SCHEDULE Watch for the S amp S Semi Display at the following events Daytona Bike Week Myrtle Beach Rally Sturgis Motorcycle Rally March 5 12 2005 May 14 21 2005 August 6 13 2005 Daytona International Speedway Broadway at the Beach Myrtle Beach SC 1535 Lazelle Street Sturgis SD Laughlin River Run Laconia Bike Rally April 20 23 2004 June 11 18 2005 Riverside Hotel amp Casino Laughlin NV Meredith Harley Davidson Meredith NH VISIT US AT WWW SSCYCLE COM 43 H U Lu U Z el K O LL K L D I i L m m el K H UI K je A N SUGGESTED RETAIL PRICING SUGGESTED RETAIL PRICING IN THE CONTINENTAL UNITED STATES Part No 11 0100 11 0104 11 0105 TOT 11 0115 11 0120 11 0404 11 0406 11 0408 11 0409 11
14. amp S forged rocker ams 90 4104 Individual BUSHINGS Front exhaust Or rear intake ATEST Eee 90 4065F Current SAS forged rocker arms 7150 long Lee 90 4014 Rear exhaust or front intake as aaaaaannnaaaannn 90 4065R ROCKER ARM SHAFTS EOB EE tege 90 4006 Set Includes 4 each 90 4006 221 1112 1 90 4036 product Dress up your engine with these magnetic chrome head bolt covers Easy installation no tools no messy adhesives A Powerful magnet holds cover in place yet allows easy removal Chrome plated steel looks great on any engine but is a must for polished engines For S amp S head bolts only EON NEW S amp S CHROME HEAD BOLT COVERS I I L Sold in a set of 4 CHROME HEAD BOLT COVER SET SE 50 0333 36 EMAIL US AT SSCUST SSCYCLE COM ROCKER ARMS INTRODUCING S amp S STANDARD FORGED ROCKER ARMS I If are looking for something better than stock Evolution or Twin I Cam style rocker arms but you re application does not warrant l the expense of roller rockers this is it S amp S now offers an l economical solution for stock rebuilds and mild performance l upgrades S amp S standard rocker arms are forged from 4140 L gt steel for greater strength than stock or cast steel rocker arms In addition they feature the same 50 long rocker shaft bushings as our S amp S roller rockers do The longer bushing provides 50 more load bearing area than
15. displacement However in spite of the fact that the Super G s larger 2 52 3mm bore size allows more air to pass and generally provides more peak horsepower slower air velocity at lower rom causes poor throttle response and weaker midrange torque in engines under 100 cubic inches For the vast majority of street engines in the 90 100 cubic inch displacement range we strongly recommend the Super E because of the improved low and midrange response However if maximum peak horsepower is the most important consideration a Super G wm m m carb would be appropriate DYNORUN 016 Max Power 124 6 Max Torque 132 5 DYNORUN 015 Mas Power 125 6 Max Torque 133 5 spunod jooy anbuey JvS RPM x1000 TUNE FOR THOSE DRAG PIPES This dyno chart shows two runs on a 124 SSW engine with a Super G carb and 2 drag pipes The two runs are very similar except in the 2500 to 3500 rpm range One run shows approximately 10 ft lb more torque in this range than the other The curve with increased torque was the result of replacing the standard 040 main circuit air bleed with a larger bleed Note that the maximum torque and horsepower was not changed significantly However the additional 10 ft lb of midrange torque will make this motorcycle feel much more responsive and powerful on the street since this is the rpm range most used in street applications Dyno results from Dyno Jet 150 Chassis dynamometer at S amp S Cycle s Research and
16. e A BEE 299 95 Hot set up kit air cleaner amp exhaust 1987 03 Al css aan EAZA EEC ZAK AA GA AAA 484 95 Hot set up kit air cleaner amp exhaust 2004 up AL ooooas aaa aaa aaa aaa aaa aaa aaa A A AA A AAA AA AR AA AAA PA AWARE 529 95 Top end kit 79 SS 630 lift 11 1GR F 92 1100 1994 98 Buell csccscsssvsssrssccssssevssesssesssevsesvasevsssessersenens 1 799 95 VISIT US AT WWW SSCYCLE COM Suggested Retail Price 45 SPORTSTER amp BUELL PERFORMANCE GUIDE H U Lu U Z el K O LL K L D a i L z m el K H UI K je A N SUGGESTED RETAIL PRICING SUGGESTED RETAIL PRICING IN THE CONTINENTAL UNITED STATES Part No 90 0325 90 0326 90 0327 90 0352 90 0389 90 1302 90 1302F 90 1302R 90 1305 90 1305F 90 1305R 90 1310 90 1310F 90 1310R 90 1802 90 1802 90 1802F 90 1802R 90 1805 90 1805F 90 1805R 90 1810 90 1810F 90 1810R 90 1907 90 1908 90 2077 90 2078 90 4006 90 4014 90 4036 90 4049 90 4050 90 4055 90 4065 90 4065F 90 4065R 90 4080 90 4083 90 4090 90 4091 90 4095 90 4104 90 4119 90 4119F 90 4119R 91 3002 91 3012 91 3014 46 Description Suggested Retail Price girl lr ee 200 NERONA 1 924 95 GE lee 1 869 95 HO Se UPKE Dack E NNN NN d NZD 1 994 95 mot set Up Kil 69 55 46 10 3 TCR F 92 1120 NS 3 444 95 motsel Up kl 09 55 4346 E F 92 1000 1966 2003 A EE 3 444 95 Head kit cylinder Stock pattern oo GO UM
17. flow Precision CNC machined from heat treated aircraft quality aluminum castings Complete assembled heads contain premium valves and S amp S 640 lift valve springs Available as bare sets fully machined but without valves or springs Available in natural aluminum black powdercoat and polished specific models only finish S amp S CYLINDER HEADS FOR 34 amp 3 BORE ENGINES l S amp S heads for stock and 3 bore engines were I originally designed for engines using stock I crankcases and in some cases stock cylinders I Although these heads are machined with the stock I Evolution cylinder stud pattern and may be used on L gt stock crankcases special pistons are required with a pop up dome shape that matches the contour of the S amp S combustion chamber Compression Release US Patent 6 557 510 VISIT US AT WWW SSCYCLE COM Super Stock cylinder head kit shown in optional black finish Specify finish when ordering 90 1802 WHY SPECIAL PISTONS Even though special pistons add to the expense and effort required to install these heads there are several good reasons why we designed these cylinder heads to use special pistons A larger more open combustion chamber presents less resistance to air flow around the valves However in smaller displacement engines like 1200cc Sportsters 80 Big Twins or even a 96 S amp S engine a larger chamber will produce a very low compres
18. gt YOU dig the more you ll find There are little differences like the improved dealer locator You can search for a dealer in your area or find an S amp S VFI tuning center and we will even provide you with a map showing you how to get there But wait there s more The new searchable product catalog makes finding what you want quick and easy Up to the minute online race results an events calendar events photos and videos customer bike photos tech tips and forums are just some of the features that you ll find But that s not all New to the S amp S Website is an E commerce area for apparel items Check out our new apparel line But now if something catches your eye you can order it online Keep in mind that while we sell apparel items direct to consumers engine parts are still available exclusively through S amp S Dealers Anybody can make a shirt work but installing and using high performance equipment successfully requires the qualified personal involvement and support of our dealer network SPORTSTER amp BUELL PERFORMANCE GUIDE Speaking of dealers they have their own area on our website were they can check stock place orders and track orders on line 24 7 365 days a year S amp S TOURS are available Wednesday through Friday 11 00 A M 3 00 RM Schedule a tour by calling 608 627 2080 Ext 1363 or email sscust sscycle com TAKIN IT TO THE STREETS During 2004 the S amp S semi truck display made its way to
19. is fully licensed for use on all city state and federal highways also attest that starting is self contained or by kickstart I requiring no external mechanical devices and that this motorcycle is ridden more often on the street than the racetrack understand I that some risk to rider and equipment is present in all forms of motorcycle racing and do hereby accept all risks and liabilities I associated therewith Signature Date T Shirt Size Please include a few words about yourself and your motorcycle Include the model and year a list of engine and frame modifications displacement compression ratio type of exhuast and tire brand Be sure to mention any S amp S products used send inquiries and membership applications to 11 Second Club Attention Carla Langyel S amp S Cycle Inc 14025 County Hwy G Box 215 e Viola Wisconsin 54664 USA Please allow 4 weeks for processing 48 EMAIL US AT SSCUST SSCYCLE COM H A a ZU d Ea lt F L i S amp S 10 SECOND CLUB Caron 1 ID ILAN UMI ough CONTINUING IN THE SPIRIT OF THE 11 SECOND CLUB The 10 Second Club is for registered and licensed street motorcycles with S amp S carbs No wheelie bars are permitted D O T tires full charging systems lighting and self contained starters are required Any chassis or engine modifications compatible with legitimate street use are permitted Mufflers are between you and the authorities but the motorcycle must
20. it picks up additional fuel The new replaceable main system air bleed accepts readily available S amp S main jets which allows a wide range of adjustment Installing a larger air bleed jet causes the main jet to come in at a higher rpm and can help eliminate the transient midrange rich condition when tuning engines with radical cams and exhaust systems 12 will cause the main circuit to come in at a lower rpm A larger air bleed causes the main jet to come in at a higher rpm The air bleed installed at the factory is the same size as we have always used because it works best in the majority of applications However the ability to change the size of the air bleed can be very useful when tuning This causes a transient rich condition at that specific rpm Since this usually occurs at the same rpm at which the main circuit comes in the rich condition can often be reduced and midrange performance improved by making the main jet come in at a slightly higher rpm This can be done by installing a larger main circuit air bleed jet EMAIL US AT SSCUST SSCYCLE COM DO I NEED A SUPER E OR SUPER G CARBURETOR As a general rule we recommend a Super E carb for street engines up to about 100 cubic inches in displacement The Super E s smaller 1 47 6mm bore size creates higher air velocity which results in better low and midrange response and power The Super G is recommended for street engines of no less than 90 cubic inch
21. l l l l l L Ask American V Twin enthusiasts to name one manufacturer of high performance engines and nine times out of ten they ll say S amp S And you gotta wonder about the one guy who didn t S amp S is the largest manufacturer of engines for the V Twin high performance aftermarket S amp S engines power more custom V Twins than anyone else s and they have always been popular as a high performance upgrade in stock motorcycles What could be simpler Take your old engine out and put a new S amp S engine in It s just that simple and you have a sleeper hog that will run the wheels off the competition The reason that S amp S engines are so popular can be summed up in two words Proven Performance VISIT US AT WWW SSCYCLE COM When you stop and think about it the trophies that company founder George Smith f won at the race track in the late 1940 s early 1950 s were awards that really tell you on the street the answer seems to be Yes what S amp S is all about Proven Performance OVERVIEW BIKE ER PJ kh Ban eussi Prodan S SES Geandrioa cams High Perfarmaare Praduri SAS Mei Malan High Pryjstwaare Pradier SAS I45ci Mater These industry awards pretty much tell the story S amp S engines have been receiving awards from industry magazines for years Some that we are most proud of are the Engine Of The Year awards from both Hot Bike and V Twin magazines for the S amp S 124 an
22. pictures to determine the proper jet series The description given tells what carburetors it fits and the sizes available Also listed are the various groups of sizes offered and their respective part numbers RIDERS amp TUNERS It is often difficult to know exactly what jetting combination is best for a particular engine without actually trying it That is why S amp S offers jet packs with a range of jets that gives the tuner the flexibility to try different jetting combinations to achieve the best performance Intermediate Jets Series 94 For even more jetting options S amp S offers high range low range and master jet packs for the professional tuner INTERMEDIATE JETS Series 94 fits all Super 1 26 2 gas carburetors sizes available 025 0265 028 0295 031 032 033 036 040 Sold in packages of 3 jets 1 each 025 0265 028 11 7100 1 each 0265 028 0295 11 7101 1 each 028 0295 031 11 7102 1 each 0295 031 032 11 7103 e 1 each 031 032 033 11 7104 1 each 032 033 036 11 7105 Low RANGE JET PACK 1 each 033 036 040 11 7106 For jetting most stock and moderate performance engines Includes 1 each intermediate jets 025 0265 028 0295 and 1 each main jets 062 064 066 068 070 072 074 E 11 7270 MASTER J
23. rssrvernvvrrnnvensnneensvernnnvensnvennsrernsnvensnvesnnrensnnvensnensnnvensnnvsnsnvnsnnrer 19 90 Intermediate jet 1 each 031 032 033 all Super gas eessasvennvernnnvnnnnnesnnvennnnvnnnnnesnnvernnnennsnnesnnvennnnvsnsnvnsnnvennnnesnnnensnnver 19 90 Intermediate jet 1 each 032 033 036 all Super GAS cece ccesscccsseessseecesseceseeecseeecssecessesesseecesneccauesesseeesnesetesenss 19 90 Intermediate jet 1 each 033 036 040 all Super oa 19 90 Main jet 1 each 062 064 066 068 070 DI 11 40 Main jet 1 each 066 068 070 072 074 Op 11 40 Main jet 1 each 072 074 076 076 080 UI 11 40 Main jet 1 each 078 080 082 084 086 U88 ccc cccceccssesesseeccseeccseeseseeeccsneeceeesesescestessseesessuesentessieneesneens 11 40 Main jet 1 each 090 092 094 096 siscicsevctiensvnsas ncdusiantsanisapnaiuie samenunnansinndhdiaeaitidn rit yisidueiuansanieiihaddedsminnraiabetawediabannns 9 50 WEIER Cae 100 102 104 106 100 ou GE ORA 9 50 Jet kit LOW range engines up to 937960 uma RAGE ENO GE O AA EECC RACK 39 80 Jel KIG Man ANE engines EH 39 80 JOT UE il PSEC AN LE AGA A RADA RAERD AAE ai 68 65 Cover air cleaner Super E amp G Slotted SSW mmmmmmmnrerursrrerrrareerranrernrsreenssareensavresnsnreenssnveenssvenssssresnssrenersnresssnrresessrenernne 82 35 ME KIL talt clement ana EE 41 15 Feie 15 40 Air cleaner assembly 1955 84 BT 1957 85 XL w GBL GAL Super B
24. sake of safety all S amp S carbs are designed to use a and in carbs manufactured after 10 1 03 a replaceable main two cable pull open pull closed throttle system Super Shorty carbs for Sportsters are compatible with stock circuit air bleed The main jet meters fuel for high rom and full throttle conditions while the air bleed can be used to control 1981 87 throttle cables Due to inadequate frame clearance the rom at which the main system comes into play Adjustment the taller throttle bracket can not be used on Sportsters of the air bleed is normally not needed with standard engine Therefore late model Sportsters and Buells require the configurations but can be very useful when tuning engines with installation of earlier butterfly style throttle cables radical cams and exhaust systems EMAIL US AT SSCUST SSCYCLE COM Continued S amp S Super E amp G Carburetors These S amp S Super E amp G carburetor kits contain everything you need for a complete installation PERFORMANCE BY DESIGN The S amp S Shorty carbs do not use a traditional choke plate for starting enrichment Instead a separate adjustable enrichment circuit is used for cold starts The enrichment circuit is activated by pulling the enrichment lever on the air cleaner to the up position Once the engine starts the lever can be moved downward to function as an adjustable fast idle to keep a cold engine running until the bike is underway or the engine i
25. the racetrack understand I that some risk to rider and equipment is present in all forms of motorcycle racing and do hereby accept all risks and liabilities associ I ated therewith Signature Date T Shirt Size NZ Slam Please include a few words about yourself and your motorcycle Include the model and year a list of engine and frame modifi cations displacement compression ratio type of exhuast and tire brand Be sure to mention any S amp S products used Send inquiries and membership applications to I1 Second Club Attention Carla Langyel S amp S Cycle Inc 14025 County Hwy G Box 215 Viola Wisconsin 54664 USA Please allow 4 weeks for processing f51 1503 S amp S Cycle 2005 L p S amp S Cycle Inc 14025 County Hwy G Viola Wisconsin 54664 Phone 608 627 2080 Email sscustesscycie com Website www sscycle com
26. the world today One of course makes motorcycles in Milwaukee Another is S amp S Cycle Inc Founded in 1958 S amp S has been building high performance engines and engine components for the heavyweight cruiser market without interruption for over forty five years Quality performance and dependability are the values that S amp S is famous for and the legendary S amp S teardrop air cleaner cover is a symbol to all that its owner feels the Same way we do second best is not good enough r l l SPORTSTER amp BUELL PERFORMANCE GUIDE To celebrate the rich heritage of S amp S and its place in the American motorcycle industry we are offering for a limited time only this Patriot version of the famous teardrop air cleaner cover An American flag on an American Patriot Air Cleaner Cover 17 0385 carburetor on an American motorcyle S amp S DESPERADO AIR CLEANER COVER A second design the Desperado is also now available The Desperado had its beginnings in much more down to earth circumstances While developing the new Super Sidewinder Plus series of engines we found that their increased L gt performance called for a better breathing intake tract and of course the air cleaner cover is the first part in that tract During dyno testing a 1 2 horsepower gain was realized and as with the Patriot air cleaner cover it does not require any jetting changes to a properly jetted carburetor Good looks and better performance
27. them ideal for stock and high performance applications They are available in stock and special lengths Most S amp S pushrods are made of UD chrome moly steel tubing with pressed in heat treated ends This provides maximum Strength and durability regardless of the application SPORTSTER amp BUELL PERFORMANCE GUIDE All pushrods are listed by length in terms of their relationship to stock Pushrod length varies directly with effective cylinder lenght Adjustable Pushrod Conversion Kits Include four adjustable V2 style steel pushrods These pushrods can be used in place of the stock non adjustable pushrods in stock as well as high performance applications Compatible with hydraulic and solid lifters 1991 amp 03 V gt SPORTSTERS 1986 90 V SPORTSTERS PUSHROD SELECTION CHART Displacement PartNo Cylinder Length 883cc 1200cc 79 93 5033 650 Stock 93 5022 437 93 5025 5 750 1 100 Special Order 93 5036 Specify PUSHROD SELECTION CHART Displacement Part No Cylinder Length fer 995089 5007 L 93 5030 S amp S PUSHROD KITS FOR IRONHEAD SPORTSTERS 1957 85 IRONHEAD SPORTSTERS 900cc AND 1OOOcc Zell STEEL l l i 1957 85 Sportster Includes four non L gt adjustable pushrods S amp S pushrods are a direct replacement for stock HD 17904 57 1957 85 IRONHEAD SPORTSTERS PUSHROD SELECTION CHART PartNo Cylinder Length 93 5037 5 330 Stock 93 5038 Special
28. to 89 with S amp S ported the functional design The Super E amp G s are butterfly style heads Ann loves to go fast but she also enjoys going carbs and have only two fuel circuits not counting the starting on trips system or accelerator pump In addition idle mixture idle speed and accelerator pump adjustments are easily accessible when the carburetor is installed on a motorcycle The low speed circuit which handles engine speeds from idle up to about 2500 rpm is controlled by a changeable intermediate EASY INSTALLATION jet which meters fuel to the intermediate system as well as the Installation is easy because carbs are sold in complete kits that contain everything needed to install the carb on the specified model motorcycle All kits include a comprehensive step by step installation instruction booklet and tuning guide that takes the rocket science out of installation and tuning idle mixture control needle The intermediate jet is selected to provide the best performance and fuel economy in the lower rpm range and the idle mixture screw allows for precise adjustment of the air fuel mixture at idle The adjustable accelerator pump eliminates off idle hesitation and can be adjusted to provide the correct amount of fuel for a wide variety of engine displacements and styles The accelerator pump is also very useful as a Starting aid THROTTLE CABLE COMPATIBILITY The main or high speed system features a replaceable main jet For the
29. vast majority of street applications using S amp S Super Stock or H D cylinder heads either style rocker covers can S amp S die cast rocker covers offer an attractive alternative to billet covers at a be used according to the builder s preference much lower price and budget NOTE In spite of the similarities between different S amp S rocker covers not all parts are interchangeable See Replacement Rocker Cover Parts for correct part numbers SPECIAL DESIGN FEATURES S amp S rocker covers fit all engines that accept stock H D V Sportster rocker covers regardless of year and whether the engine vents through the crankcase or cylinder heads OEM style umbrella fittings are included with billet rocker boxes for 1991 and up Sportsters engines with cylinder head venting Cast rocker boxes use an exclusive one way valve which is built into the rocker cover gasket to control oil carry over in head breathing engines S amp S cast rocker covers and billet rocker covers for V style engines include all parts required for installation S amp S rocker covers are available in three finishes show quality chrome polished or raw machined Raw machined is ideal for powdercoating and other custom appearance treatments Installation on stock and most comparably sized engines can be performed without removing the engine from the frame Extremely tall engines such as the 4 stroke 98 and 5 stroke 103 may require removal from the fr
30. 0424 11 0426 11 0428 11 0429 11 0448 11 0449 11 7100 11 7101 11 7102 11 7103 11 7104 11 7105 11 7106 11 7200 11 7201 11 7202 11 7203 11 7204 11 7205 11 7270 11 7271 11 7272 17 0004 17 0045 17 0055 17 0099 17 0105 17 0107 17 0108 17 0117 17 0198 17 0199 17 0385 17 0399 17 0400 17 0402 17 0404 31 0302 31 0303 44 Description Suggested Retail Price Carokit w ocmanitold oupe r B aa EE EE 374 95 Blog kii Super KE EE 384 95 Blog lee lee KE O MANANA tissues EE ARA 398 60 Eer Se RS A A 289 10 AE A EE 420 05 Blogen FOS EE 401 65 EO 416 65 TE HE RR 427 75 Blog lee nt NNN 446 20 GarO KE SUP E 19 MS A beem 454 70 ET SENE EE EE 427 75 ET KR SUpor GD LO BK EEE EN 438 85 Garb KE Super ECK EEN 457 75 Garb KL Super G 1991 2003 A EEN 466 15 Carb kit Super E 1994 2002 BUA EE 517 50 Caro kit Super G 1994 2002 BUOlkocaak GAGA EE GEAR io RA ZE dok 524 65 Jet intermediate 3 pack all Super gas series 94 ccsccccsesssssscressssessesseevssnesseevsenessenssaneaseessveessnessenepersseneasenserenaseesas 19 90 Intermediate jet 1 each 0265 028 0295 all Super gas meeersvvrranvenrnneensvernnnvensnnennsvernnnvensnvesnnrenssnrenssensnnvenssnesnsnensnnter 19 90 Intermediate jet 1 each 026 0295 031 all Super gas rsanvernvvrnnnvenrnneensvernnnvensnnesnsvernnnvensnvesnnrensnnrensnensnnvenssnrsnsnensnnrer 19 90 Intermediate jet 1 each 0295 031 032 all Super gas
31. 5 Piston set 005 4 125 T 37e NS SN 236 45 Piston set 3 010 TSN AS NNN 236 45 Piston set 3 020 4 12 5 1 3 e 10 5 1 SSFDF 1984 up VP rnennrvennnvensavennnvernnnvnnsnvennsvesnnvvnnsnvenssvesnnvenssnrenssenenn 236 45 Piston set 3 030 4 12 5 1 3 e 10 5 1 SSFDF 1984 up VP rresnrvennnvnnsavenrnvernnvennsnvenssvesnnvenssnvenssvessnvenssnrenssveeenr 236 45 Piston set 3 std 4 10 9 1 3 6 9 2 1 SSRDF 1984 up NEEN 244 60 Piston set 31 005 883 10 5 1 SSFDF 1986 up Alana nich kn Gda 288 70 Piston set 31 std 883 10 5 1 SSFDF TIR d ET 288 70 Piston set 32 010 883 10 5 1 SSFDF 1986 up AL uoacaicacanoci a ciii N G ara 288 70 Piston set 34 020 883 10 5 1 SSFDF 1986 up AT 288 70 Piston set 3 030 883 10 5 1 SSFDF 1986 up ET 288 70 Piston kit 31 std 9883 9251 RDC 1986 Up ET 214 15 Piston kit 3 005 683 9 25 1 RDC 1986 up Al 214 15 Piston kit 3 010 683 9 25 1 RDC 1986 up Al 214 15 Piston kit 3 020 683 9 25 1 RDC 1986 up Al 214 15 Piston kit 3 030 683 9 25 1 RDC 1986 up Al 214 15 Piston set 3 e 010 4 6 4 e 25 1 9 1 F 102 DA 226 55 Piston set 3 e 020 4 6 4 e 25 1 9 1 F 1972 85 XL rnnrrrrrerrarenrsverssvrerssresenverssvresssresssvessrvvesssresesverssrensssresssvenen 226 55 Piston set 3 e 030 4 4 25 1 9 1 F 1972 85 XL avrrrnvrnranvnnanvennnvnnnanennsnvensnennnnvenns
32. 79 SW 3 13 16 9 2 1 or 11 0 1 CR F 92 1940 1986 2003 XL rraerernersareranerrarersnesrannsrnvrvsrnssrerrsrersneesnn 668 40 Cylinder kit 3 x 3 13 16 10 5 1CR 4 650 SSF 92 2056 1986 2003 883 AL oa sosna ona 759 10 Cylinder kit 3 x 3 13 16 10 5 1CR 4 650 SSF 92 2016 1986 2003 XL i rreravvrnovrrnvennnvnrsovsrsversvensvvrnnessssvnssvensnnennn 712 80 EMAIL US AT SSCUSTOSSCYCLE COM SUGGESTED RETAIL PRICING SUGGESTED RETAIL PRICING IN THE CONTINENTAL UNITED STATES Part No 91 3204 91 3206 91 3504 91 3506 91 3906 91 3908 92 2016 92 20165 92 2017 92 2018 92 2019 92 2036 92 20565 92 2056 92 2057 92 2058 92 2059 92 2446 92 24465 92 2447 92 2448 92 2449 92 3701 92 3702 92 3703 92 3704 92 3705 92 3706 92 3707 92 3708 93 4059 93 4060 93 4061 93 4062 93 5022 93 5025 93 5033 93 5036 93 5037 93 5038 93 5088 93 5089 93 5130 93 5131 93 5132 93 5133 93 5135 Description Suggested Retail Price Sv kt eo EE Dien LE ts NNN NNN NNN 1 774 95 SV Kit 69 Je Oo Forio ICR 92 1940 NNN EE 1 774 95 OW Kites SOS or iho WG Rum NNN NNN 1 784 95 OW Kite gs E GNR NENNE 1 784 95 Cylinder kit Black 34 x 3 10 5 1CR 4 650 SSF 92 2056 1986 2003 883 AL uo oaza zaawan zaa 844 10 Cylinder kit Black 34 x 3 10 5 1CR 4 650 SSF 92 2016 1986 2003 XL isvrravrvnvvnsvensnvvnsvnnssvnenvensnsnsnsenrsesnsvennn 797 80 PISTON Sel oo en KE WOO ILO RT NE 236 4
33. Development facility in Viola Wisconsin VISIT US AT WWW SSCYCLE COM CARBURETORS SPORTSTER amp BUELL PERFORMANCE GUIDE NOTES lt gt lt gt Throttle cable guides 5 amp S Super E and G carburetors require the use of a two cable pull open pull closed throttle assembly Throttle cables for Sportsters Any 1980 or earlier stock H D Sportster chassis including models equipped with a single cable throttle mechanism requires conversion to a two cable pull open pull closed type S amp S offers high quality two cable throttle assemblies for this purpose The long throttle cable guide for use with CV style throttle cables on Big Twins can not be used on Sportster chassis due to clearance problems As a result Sportster models 1988 up fitted with a constant velocity CV carb require conversion to 1981 1987 butterfly style throttle cables See Throttle Assemblies section of this catalog for more information 1998 and later carbureted Buells require the use of 1996 Buell throttle assembly and S amp S throttle cables when installing a Super E or G carburetor Super E and G carbs cannot be used on Ironhead Sportster engines equipped with vertical magnetos due to clearance problems Recommended for Racing Only This carburetor is not legal for use in California on motor vehicles operated on public highways or in other states where similar pollution laws may apply The user shall determine the suitability of the product fo
34. ELL PERFORMANCE GUIDE SPORTSTER amp BUELL PERFORMANCE GUIDE E get SEO MA NS VALVE SPRING KITS HIGH PERFORMANCE VALVE SPRING KITS l l S amp S valve spring kits are designed to simplify high lift cam installation and reduce the risk of valve float They eliminate most of l the complicated procedures and specialized tools required to prepare cylinder heads for high lift cams While confirming critical L Clearances remains the responsibility of the engine builder most Evo street cams will require no additional modification of the cylinder head when S amp S valve spring kits are used In some instances S amp S valve spring kits serve as excellent replacements in stock rebuild applications All kits include detailed instructions VALVE SPRING KITS FOR 1986 UP SPORTSTERS 640 Lift Triple Valve Spring Kit Fits S amp S Super Stock H D and other V or Twin Cam type heads that require Stock 0 D outer spring Includes 4 top collars 4 bottom collars 4 each outer middle and inner springs 8 shims 4 each 015 4 each 030 and 8 keepers Use with shoulderless style valve guides Special keepers included fit valves with stock stems and S amp S collars only Patented steel top collars are drilled for lightness and to increase cooling of valve springs Spring seat pressure is 170 Ibs at stock 1 800 installed height Open pressure is 390 Ibs at 560 lift 415 Ibs at 630 lift 640 Lift Triple Valve Spring
35. ER amp BUELL PERFORMANCE GUIDE STROKER KITS Continued S amp S Sidewinder Big Bore and Stock Bore Stroker Kits S amp S SIDEWINDER BIG BORE AND STOCK BORE STROKER KITS GENERAL INFORMATION The S amp S stock bore stroker kits described and pictured in this section are available for Ironhead Sportster engines S amp S big bore Sidewinder kits are available for Evolution Sportster engines All kits include complete installation instructions which detail the model specific modifications sometimes required Additional information pertaining to basic engine assembly procedures and recommended running clearances is available in the appropriate Harley Davidson Factory Service Manual MAKING IT ALL WORK Sidewinder and stroker kits create large displacement engines which can be difficult to start This should be kept in mind when considering one of these kits Using an appropriate cam with longer duration and later intake closing time to reduce cranking compression will make starting easier Not only will the appropriate cam make starting easier but it is necessary in order for the engine to achieve its full potential We urge you to consider purchasing an S amp S Hot Set Up Kit that includes the recommended camshaft See pages 8 through 10 of this Catalog or see page 25 for help with camshaft selection NOTES Rod length varies for Evolution Sportster kits 79 engines require stock length 6 926 rods 89 require spec
36. ET PACK For jetting all Super B E and G equipped engines Includes 1 each intermediate jets 025 0265 028 0295 031 032 033 and 1 each main jets 062 064 066 068 070 072 074 076 078 080 082 084 Fu 11 7272 HIGH RANGE JET PACK For jetting some stock and all performance engines Includes 1 each intermediate jets 0295 031 032 033 and 1 each main jets 072 074 076 078 080 082 084 EE 11 7271 VISIT US AT WWW SSCYCLE COM MAIN JETS Series 72 fits all Super 17 2 6 2 gas carburetors sizes available 040 to 108 in increments of 002 Sold in packages of 3 to 6 jets 1 each 062 064 066 068 070 072 REENEN 11 7200 1 each 066 068 070 072 074 076 EE EE 11 7201 1 each 072 074 076 078 080 082 EE EE 11 7202 1 each 078 080 082 084 086 088 He 11 7203 1 each 090 092 094 096 098 EE 11 7204 1 each 100 102 104 106 108 EE EE 11 7205 d z MAIN JET TOOL For changing series 472 main jets SPORTSTER amp BUELL PERFORMANCE GUIDE AIR CLEANER KITS THE S amp S TEARDROP AIR CLEANER The S amp S Teardrop Air Cleaner is one of the most recognizable shapes in the industry This is testimony to its distinctive good looks and outstanding performance features features like the uniquely designed backplate wit
37. Engine or any or all defective parts Repair or replacement of defective parts is the sole and exclusive remedy HOW LONG IS THE WARRANTY COVERAGE The warranty coverage remains in force for a period of twelve 12 months from the date that the original Consumer Purchaser buys the Engine However warranty coverage will automatically terminate if the original Consumer Purchaser sells or otherwise transfers all or any portion of the Engine WHAT IS NOT COVERED BY THIS WARRANTY The Company shall not pay or be responsible for the cost of Shipping the defective Engine or part to the Company for service under this warranty nor will the Company pay for the cost of labor to remove and or replace the defective Engine or part Moreover the Company shall have no obligation under this warranty in the event that the Engine becomes defective in whole or in part as a result of improper assembly installation break in maintenance or use or any other misuse or mistreatment of the Engine including without limitation operation of the Engine with fuels oils or lubricants not conforming to specifications published by the Company for use in or with the Engine or continued operation of the Engine after a defect or malfunction occurs or is identified or Suspected The Company shall have no obligation under this warranty for defects in the Engine s black powdercoat finish when that option is Selected if the defects are caused by but not limited
38. L PERFORMANCE GUIDE WARRANTY LIMITED WARRANTY RETURN AUTHORIZATION WHAT ARE THE PROCEDURES TO OBTAIN SERVICE UNDER THIS WARRANTY To obtain service under this warranty the original Consumer Purchaser should immediately contact the dealer where the Engine was purchased The dealer will then contact the Company for a determination as to whether the defect in the Engine or part is covered by this warranty THE DEALER OR SERVICE PROVIDER MUST RECEIVE AUTHORIZATION FROM THE COMPANY BEFORE PROVIDING SERVICE UNDER THIS WARRANTY In the event that the Company determines the Engine or part must be returned to the Company for evaluation or service the Company will provide the dealer with a Return Authorization Number to put on the shipping container for identification The original Consumer Purchaser or dealer must clean and properly package the Engine or part so as not to cause further damage and return the Engine or part shipping costs prepaid to the Company The Return Authorization Number must be clearly visible on the outside of the shipping container If the Engine or part must be cleaned prior to warranty inspection the cost of cleaning will be charged to the original Consumer Purchaser or dealer The original Consumer Purchaser or dealer must also send to the Company a detailed explanation of the relevant facts concerning the nature of the problem the specific use of the Engine and the circumstances giving rise to the defect o
39. N NN 1 003 00 Head assembly front cylinder stock pattern SS 630 lift 1986 90 Al 601 80 Head assembly rear cylinder stock pattern SS 630 lift 1986 90 XL ENEE 601 80 Head kit cylinder Stock pattern SS 630 lift 1994 2002 Bell 997 20 Head assembly front cylinder stock pattern SS 630 lift 1994 2002 Buell Al 598 30 Head assembly rear cylinder stock pattern SS 630 lift 1994 2002 Buell a 598 30 Head kit cylinder stock pattern SS 630 lift 1991 2003 XL EE 1 003 00 Head assembly front cylinder stock pattern SS 630 lift 1991 2003 Al 601 80 Head assembly rear cylinder stock pattern SS 630 lift 1991 2003 XL amp Buell 601 80 Head kit cylinder Black stock pattern SS 630 lift 1986 90 XL rrvrnrnrvnernavennnnrrennsarennsnnvnnnnnvennnssvresesrennssnensnsnrennnne 1 073 00 Head kit cylinder Black stock pattern SS 630 lift 1986 90 XL rrvrnrnrvnernavennnnrrennssrennrsnvnnnnnvesnnsarrenesrnnnsssensnnnresenne 1 073 00 Head assembly front cylinder Black stock pattern SS 630 lift 1986 90 Al 643 80 Head assembly rear cylinder Black stock pattern SS 630 lift 1986 90 AL 643 80 Head kit cylinder Black stock pattern SS 630 lift 1994 2002 Buell lss 1 067 20 Head assembly front cylinder Black stock pattern SS 630 lift 1994 2002 Buell cssc 640 30 Head assembly rear cylinder Black stock pattern SS 630 lift 1994 2002 Buell 640 30 Head kit cy
40. Order 28 EMAIL US AT SSCUST SSCYCLE COM CYLINDER HEADS S amp S SUPER STOCK CYLINDER HEADS Over the last ten years S amp S Cycle has become the leading aftermarket manufacturer of high performance cylinder heads for Harley Davidson and other American V Twin motorcycles Old timers will remember that when the S amp S Evolution L Style heads became available they were the final piece that allowed S amp S to offer a relatively complete engine assembly Time marches on and today we see S amp S engines powering the majority of the custom V Twins being built today That s because of reliability and power S amp S quality make our engines reliable but it s our cylinder heads that make the power It s pretty fundamental more air in more power out PERFORMANCE BY DESIGN S amp S cylinder heads are the result of years of design and research work Using the latest in computer aided design techniques all S amp S parts are designed and built first as 3 D models on the computer Using our laser rapid prototyping capability dimensionally correct parts can be produced in plastic from the 3 D model This allows S amp S engineers to solve the majority of dimensional problems before we are committed to tooling and hard parts By using these cutting edge design methods we fast forward the development of our cylinder heads and are way ahead of the game when it comes time for real world testing We already know how a cylinder hea
41. Purchaser sells or otherwise transfers all or any portion of the purchased parts WHAT IS NOT COVERED BY THIS WARRANTY The Company shall not pay or be responsible for the cost of Shipping the defective parts to the Company for service under this warranty nor will the Company pay for the cost of labor to remove and or replace the defective parts Moreover the Company shall have no obligation under this warranty in the event that the parts become defective in whole or in part as a result of improper assembly installation break in maintenance or use or any other misuse or mistreatment of the parts including without limitation operation of the parts with fuels oils or lubricants not conforming to specifications published by the Company or continued operation of the parts after a defect or malfunction occurs or is identified or suspected The Company shall have no obligation under this warranty for defects in parts with a powdercoat finish when that option is selected if the defects are caused by but not limited to negligence of parties other than the Company an accident ordinary wear and tear assembly or disassembly power washing natural occurrences like stone chips bead blasting improper maintenance including the use of any harsh cleaning agent chemical or solvent and salt or other substances used on streets and highways for maintenance and safety VISIT US AT WWW SSCYCLE COM The Company provides touch up paint with
42. Sportster chassis with only L gt minor modifications This kit is for the serious street performance and competition rider Our Hot Set Up 69 has galned a hard earned reputation as the Giant Killer KL w i DE wi SPORTSTER amp BUELL PERFORMANCE GUIDE Stock crankcases must be bored to accept the 3 big bore cylinders Sportsters 1991 up require conversion to the 1986 90 style pushrod cover assemblies Pushrod adapters are included 89 XL HOT SET UP Kolomea 32 3089 89 XL HOT SET UP yields 89 cubic inches with a compression ratio that is determined by the extent of modification to stock cylinder heads Hot Set Up includes an 89 Sidewinder kit with 4 stroker flywheels assembled with mainshafts and connecting rods S amp S 3 bore Sidewinder cylinders and pistons complete a valve spring kit an HLoT kit head bolts pushrod cover keepers front and center engine mounts a SuperE carb kit and installation instructions on ETER RENEE Renee started riding dirt mini bikes when she as 10 years old Growing up on a dairy and quarter horse I farm she snuck her first mini bike home in the back l of a friend s boat kept it hidden in the woods and L Stole chainsaw gas from her dad However her secret only lasted a month or two After selling her horses i four legged kind she purchased a new 883 XL in 1987 and that bike now has 55 000 miles on it Also in her stable i
43. a matter of unplugging the connection between the transmission sensor and speedometer and plugging the two connectors into the S amp S Calibrator The Calibrator can then be used to correct the difference between actual and indicated speeds and mileage oS FEATURES Fits all Harley Davidson Big Twins and Sportsters equipped with O E M electronic Speedometer Allows precise adjustments in 1 increments between 29 and 69 Compact size 2 25 x 1 50 x 1 10 permits a neat simple installation sensitive components are sealed in epoxy for protection from vibration and weather EMAIL US AT SSCUST SSCYCLE COM pt E WARRANTY LIMITED WARRANTY STANDARD PARTS WHO IS COVERED BY THIS WARRANTY This warranty covers only the original Consumer Purchaser of these parts and is not transferable WHAT DOES THIS WARRANTY COVER S amp S Cycle Incorporated the Company warrants these parts to be free from defects in material and workmanship If the parts become defective during the warranty coverage period the Company will at its option repair or replace any or all defective parts Repair or replacement of defective parts is the sole and exclusive remedy HOW LONG IS THE WARRANTY COVERAGE The warranty coverage remains in force for a period of twelve 12 months from the date that the original Consumer Purchaser buys the parts However warranty coverage will automatically terminate if the original
44. ame for rocker cover installation NOTE Minor clearancing of the front motor mount is required to install S amp S rocker covers on Buell motorcycles 34 EMAIL US AT SSCUST SSCYCLE COM ROCKER COVERS Continued S amp S Rocker Covers for 1986 03 V Style Sportsters and Buells S amp S V ROCKER COVERS AND RELATED PARTS BILLET ROCKER COVERS FOR 1986 03 V SPORTSTERS AND 1994 02 BUELLS SPORTSTER amp BUELL PERFORMANCE GUIDE EE 90 4050 Rose 90 4080 DEE 90 4055 Gasket hit 90 4049 DIE CAST ROCKER COVERS FOR 1986 03 V SPORTSTERS AND 1994 02 BUELLS lier 90 4095 FOR ene 90 4090 SE GE EE A EO 90 4083 S amp S billet rocker covers are the ulitmate in quality Strength and beauty are EE EO ZO 90 4091 combined in our finest Evolution style rocker covers NOTE NOTE In most instances only minor clearancing is required to use SAS rocker covers with valve springs larger than 1 660 O D Kits include front and rear cover assemblies with base and top cover rocker shaft supports gaskets and o rings and instructions 03 0040 The performance oriented design of the billet rocker boxes permits valve lifts up to 710 with stock H D or S amp S Super Stock heads and up to 810 with S amp S Special Application heads using stock H D or S amp S roller rocker arms Cast rocker boxes may require some minor clearancing and it is recommended that they be ordered either polished or raw machined so that clearancing may be d
45. ankcases Pages 21 22 S amp S Super Stock Sportster and Buell style crankcases are an excellent choice for stock replacement for 1991 and later engines and other high performance engine upgrades Tappet Guides amp Tappets Pages 23 24 Tappet Guides for 1986 up V Sportster style engines and Hydraulic Tappets for 1986 90 style Sportsters Camshaft Kits Page 25 Meeting the needs of high performance engines Valve Spring Kits Page 26 S amp S valve spring kits are designed to simplify high lift cam installation Adjustable Pushrod Kits Pages 27 28 Pushrods for V Sportsters and Ironhead Sportsters Super Stock Cylinder Head Kits Pages 29 33 One of the most important things that needs to be done to get more horsepower out of any engine is to get more air into it S amp S can help Rocker Covers Pages 34 35 S amp S manufactures two types of rocker covers for V style engines billet and die cast Rocker Arms and Rocker Shafts Pages 36 37 S amp S forged roller rocker arms or new forged standard rocker arms Speedometer Calibrator Page 38 The S amp S Speedometer Calibrator allows the rider to correct Harley Davidson electronic speedometers easily S amp S Warranty Information Pages 39 42 S amp S Website and Show Schedule Page 53 We ve just updated our website Suggested Retail Price List Pages 44 47 S amp S 10 Second amp 11 Second Club Page 48 Are you fast enough to join AMERICA S ENGINE BUILDER l l
46. be street ridden on a regu lar basis SPORTSTER amp BUELL PERFORMANCE GUIDE HERE S WHAT WE NEED TO WELCOME YOU IN 1 Proof that your street ridden motorcycle is equipped with one of our carburetors and hopefully other S amp S products as well has turned a 10 999 or quicker quarter mile Send either the original or a good photocopy of an official timing slip from a sanctioned dragstrip it must be dated after 01 01 99 and signed by the timekeeper The registered owner must ride the motorcycle for the qualifying pass 2 Your t shirt size and a photograph of yourself and the motorcycle The carburetor must be in plain view 3 Asigned and dated copy of the statement below Please tell us a little about yourself and your motorcycle Included the model and year a list of all engine and frame modifications the type of exhaust and tire brand and model Be sure to mention all S amp S products used Submitted materials may be used for promotional purposes Members will receive a certificate club patch and t shirt but no payment or other considerations i do hereby attest that have fulfilled all membership requirements of the S amp S Cycle 10 Second Club as outlined above and that my I motorcycle is fully licensed for use on all city state and federal highways also attest that starting is self contained or by kickstart I requiring no external mechanical devices and that this motorcycle is ridden more often on the street than
47. brator corrects the I reading of stock H D electronic speedometers when using I oversized rear tires or when other drive train modifications have been done that effect final drive ratio L gt The accuracy of electronic speedometers provided on late Harley Davidsons can be greatly affected by the installation oversized tires non stock wheel or transmission sprockets and by the replacement of certain transmission gears These modifications are often made for appearance to improve acceleration decrease engine RPM at highway speeds or to reduce mechanical noise S amp S ELECTRONIC SPEEDOMETER CALIBRATOR NOTES Calculating the difference between actual and indicated speeds mileage requires only that the rider compare odometer readings to a known distance Highway mile markers are usually accurate enough to use for calibration although the test should be repeated between several different markers for confirmation The S amp S Speedometer Calibrator can then be adjusted to increase or decrease the speed and mileage indicated by the speedometer In most cases it is possible to achieve accuracy within 5 The S amp S speedometer calibrator will not work with Rev Tech transmissions 38 5 SPEEDOMETER CALIBRATOR 55 1007 00117 THE S amp S SPEEDOMETER CALIBRATOR allows the rider to correct H D electronic speedometers easily and without special tools or expensive test equipment Installation is simply
48. cams S amp S Al 55 10 Tappet guide assembly RI 1986 90 cams S amp S SL 55 10 Tappet guide set 1986 90 cams S amp S Al 220 20 Tappet guide set 1991 2003 cams S amp S Al 220 20 Tappet guide assembly FE 1986 90 XL HIDS OpT1p 2p1 aaa aaa aaa azaa az aaa aazazaiaaazinaei 55 10 Tappet guide assembly Fl 1986 90 XL il RE ACHEN EEN 55 10 Tappet guide assembly RE 1986 90 XL HD 1861 8 86 ccccsesssesscsesssssscssseesssresstesseressersseneaseessorsastessenessnesseneas 55 10 Tappet guide assembly RI 1986 90 XL HD 18619 86 EEN 55 10 Tappe guide Sers 1996 Ne 220 20 Tappet guide assembly FE FI 1991 2003 cams S amp S XL AE 55 10 Tappet guide assembly RE RI 1991 2003 cams S amp S Al 55 10 Eege er El WEE GENEE 55 70 Tappet guide assembly RE RI 1991 2003 XL EE 55 10 Tappei NNN EE 220 20 Cover sei S amp S head Dolt Tu EE 49 95 O ring ID x 4 OD x 6 CS 70 Buna cylinder vent fitting upper tappet block 1986 90 XL 10 pack 5 40 O ring 1 ID x 1 e OD x CS Viton HD 11167A upper tappet block 1986 90 XL 10 pack 14 95 O ring 1 ID x 1 OD x CS Viton HD 11168A lower tappet block 1986 90 XL 10 pack 9 40 AO ONN aA A ite BELCE 11 90 EG GA EE EEE E 77 20 Ge PE GATE EEE E eT eer 10 85 Calibration unit electronic speedometer all models w electronic speedo aaa aaa aa aaa aaa aaa aaa aaa ania anan za 9123 55 ENN e BE 249 95 IER MUNET ln 0 OE ET
49. cluding but not limited to a turbocharger Supercharger or nitrous oxide is used with the Engine Further the Company shall have no obligation under this warranty for any Engine that includes a Competition Package Option since the Package is for use in racing and similar competitive activities THE COMPANY SHALL NOT BE LIABLE FOR AND DISCLAIMS ALL CONSEQUENTIAL INCIDENTAL PUNITIVE OR SPECIAL DAMAGES ARISING OUT OF THE USE OF OR INABILITY TO USE THE ENGINE some states do not allow the exclusion or limitation of incidental or consequential damages so the above exclusion may not apply to you WHAT MUST THE ORIGINAL CONSUMER PURCHASER DO TO QUALIFY FOR WARRANTY COVERAGE Within thirty 30 days after the date of purchase of the Engine the Original Consumer Purchaser must return a completed Owner s Registration Card along with a copy of the invoice evidencing such purchase to the Company at the following address S amp S Cycle Incorporated Attention Technical Services 14025 County Highway G PO Box 215 Viola WI 54664 0215 Phone 608 627 8324 Fax 608 627 0773 Email sstech sscycle com Direct Phone 608 627 TECH 8324 THIS WARRANTY IS VOIDABLE AT THE COMPANY S OPTION IF THE ORIGINAL CONSUMER PURCHASER DOES NOT RETURN TO THE COMPANY THE OWNER REGISTRATION CARD AND A COPY OF THE INVOICE WITHIN THIRTY 30 DAYS FROM THE DATE OF PURCHASE OF THE ENGINE 41 SPORTSTER amp BUELL PERFORMANCE GUIDE SPORTSTER amp BUEL
50. d Tribute 145 engines PERFORMANCE AND RELIABILITY Everybody knows that S amp S engines make a lot of power What you may not be aware of is that because of our innovative designs and premium materials they last a lot longer than you might think was possible for a high performance engine Let s face it the stroker engines of the late 1960 s and early 1970 s were pretty crude by today s standards and they gave high performance motors a bad reputation as far as engine life is concerned But keep in mind that the high performance industry has come a long way in the last 35 years or so and S amp S has been a leader in the quest not only for more power but also for greater dependability and improved engine life So if you could double your horsepower and still get near stock engine life wouldn t that be a fair trade off Judging from the number of large displacement S amp S engines GLEN SPORTSTER amp BUELL PERFORMANCE GUIDE SPORTSTER amp BUELL PERFORMANCE GUIDE S amp S 91 amp 100 SPORTSTER amp BUELL STYLE ENGINE S amp S complete Engines for Sportsters and Buells are available in 91 and 100 displacements The 91 engines have 3 stroke with a 4 bore Cylinder length is stock So the engine fits in all frames with little or no modification Compression ratio of the 91 engine is 95 1 he 100 engine has 4 stroke with a 4 bore Cylinder length is 260 taller than stock The 100 engine will genera
51. d will flow and what the chamber volume will be before we make the real parts in metal VISIT US AT WWW SSCYCLE COM 29 SPORTSTER amp BUELL PERFORMANCE GUIDE SPORTSTER amp BUELL PERFORMANCE GUIDE CYLINDER HEADS PROVEN PERFORMANCE S amp S TESTING The S amp S company motto is Proven Performance and it is not just something we say It s what we do S amp S cylinder heads have been subjected to a comprehensive testing program to insure that the performance will be there every time you twist the throttle We ve proved it Flow testing dyno testing many thousands of simulated miles on our engine durability stand and of course many more thousands of miles of real world road miles and countless passes at the race track have proven that S amp S cylinder heads do perform h o APPLICATIONS S amp S cylinder heads for Shovels Evolution Big Twins Evolution Sportsters and Twin Cams are recognized as the best in terms of performance and value They are designed to be easy to install and to be compatible with stock components whenever possible Stock like outer dimensions eliminate most clearance issues often associated with high performance cylinder heads However all S amp S heads for Evolution and Twin Cam style engines have larger than stock intake ports for increased air flow This requires that a special S amp S intake manifold be used that matches the diameter of the S amp S intake port Depending on
52. es a Super Stock cylinder head kit with valves and springs installed manifold with o rings and flanges required hardware top end gaskets 500 lift cams adjustable chrome moly pushrods an HL gt T kit a Super E carb kit and installation instructions S amp S pistons must be ordered separately NOTE Pistons are available for 883 and 1200 cc engines that do not require rebalancing of the stock flywheels Flywheels for the 1100cc engines should be rebalanced ORDER THE CORRECT PISTON OVERSIZE FROM THESE CHARTS 92 2016 SERIES PISTONS 74 XL S amp S Heads 10 5 1 Compression No rebalancing for 1200cc Oversize SC Part Number 92 2016 tandard 005 92 20165 010 92 2017 010 92 2018 020 92 2019 030 Cylinder amp Piston Kit Natural Cylinder amp Piston Kit Black 91 3908 92 2056 SERIES PISTONS 883 to 1200XL V S amp S Heads 10 5 1 Compression No rebalancing for 883cc GO OT 92 2036 Series Piston Part Number 92 2056 92 20545 92 2057 92 2058 92 2059 91 3014 Cylinder amp Piston Kit Natural 91 3012 Cylinder amp Piston Kit Black 91 3906 EMAIL US AT SSCUST SSCYCLE COM HOT SET UP KITS 89 XL HOT SET UP KIT SIDEWINDER STROKER KIT 89 FOR EVOLUTION SPORTSTERS WITH STOCK H D CYLINDER HEADS l i l The 89XL Hot Set Up is based on the l S amp S 89 XL Sidewinder which is the l largest practical motor that will fit into l the stock
53. es filter and three plated steel air cleaner extensions HIGH FLOW FILTER KIT CONTAINS 1 High flow filter for S amp S Super E or G Teardrop air cleaner One inch taller than the standard S amp S filter 3 1 Tall plated steel filter adapters AIR FILTER amp ADAPTER KIT For S amp S Super E and G Carburetors 20 EMAIL US AT SSCUST SSCYCLE COM CRANKCASES S amp S EVOLUTION SPORTSTER AND BUELL STYLE CRANKCASES I l We ve made some changes to our Sportster and Buell I style crankcases By making a couple of small 31 1008 I machining changes we ve made one crankcase that fits both 1986 03 Sportsters and 1994 03 Buell chassis REP It should be noted that although these cases will fit the 1986 90 four speed style Evolution Sportster chassis they require a 1991 03 style five speed transmission clutch alternator and flywheel assembly For this reason they are not stock replacement crankcases for 1986 90 four speed engines Although S amp S can supply crankcases with 1986 90 four speed or 1991 03 five speed cam chest geometry S amp S recommends using the 1986 90 cam chest tappets and cover This style of tappet which is the same one used in Evolution Big Twin engines has a larger roller and has proven to be more reliable in high performance applications In addition four speed style cam covers are more readily available to complete scratch built engines Crankcases machined for five speed cam geo
54. es subject to EPA noise regulations constitutes tampering and is a violation of federal law unless it can be shown that use does not cause the motorcycle to exceed applicable federal standards EMAIL US AT SSCUST SSCYCLE COM HOT SET UP KITS AIR CLEANER AND EXHAUST HOT SET UP KITS I l Okay so maybe your budget isn t ready for a l new big inch S amp S engine yet But better l performance is still within your reach I Consider the NEW S amp S Muffler and Air Cleaner L gt Hot Set Up Kits For under 500 you can gain more than 10 horsepower Dollar for dollar that s about as good as it gets The big motors will be there when you re ready but in the mean time why not pick some low hanging fruit and get more power right now SPORTSTER amp BUELL PERFORMANCE GUIDE S amp S EXHAUST AND AIR CLEANER HOT SET UP KITS are the perfect way to balance the performance budget Kits include a set of S amp S performance mufflers and a high flow S amp S air cleaner that will fit on either a stock carburetor A jet kit is also included for maximum power gains and improved drivability 1987 Up Sportsters 55 6500 AIR CLEANER AND EXHAUST HOT SET UP KITS 1987 03 Sportsters 1 11111 99 6900 2004 up Sportsters NENNEN 99 6901 DYNORUN D Max Power 74 1 Max Torque 75 6 rei DE SMaxPower 67 8 Max Torque 72 7 8 2 2004 Up Sportsters 55 6501 g 8 8 i S 3 S This dyno compar
55. exclusion may not apply to you WHAT MUST THE ORIGINAL CONSUMER PURCHASER DO TO QUALIFY FOR WARRANTY COVERAGE Within thirty 30 days after the date of purchase of the Engine the Original Consumer Purchaser must return a completed Owner s Registration Card along with a copy of the invoice evidencing such purchase to the Company at the following address S amp S Cycle Incorporated Attention Technical Services 14025 County Highway G PO Box 215 Viola WI 54664 0215 Phone 608 627 8324 Fax 608 627 0773 Email sstech sscycle com Direct Phone 608 627 TECH 8324 THIS WARRANTY IS VOIDABLE AT THE COMPANY S OPTION IF THE ORIGINAL CONSUMER PURCHASER DOES NOT RETURN TO THE COMPANY THE OWNER REGISTRATION CARD AND A COPY OF THE INVOICE WITHIN THIRTY 30 DAYS FROM THE DATE OF PURCHASE OF THE ENGINE EMAIL US AT SSCUST SSCYCLE COM pt E WARRANTY LIMITED WARRANTY UNASSEMBLED ENGINES WHO IS COVERED BY THIS WARRANTY This warranty covers only the original Consumer Purchaser of the Unassembled Engine the Factory Assembled Basic Engine or the Factory Assembled Basic Engine With Options the Engine and is not transferable WHAT DOES THIS WARRANTY COVER S amp S Cycle Incorporated the Company warrants this Engine to be free from defects in material and workmanship If the Engine or any part thereof becomes defective during the warranty coverage period the Company will at its option repair or replace the
56. h the pushrod This is the stock oiling system for Evo s and Twin Cams but this allows Shovelhead engines to be set up with 1984 and later style top end oiling via the pushrods provided S amp S Shovel style tappet guides and roller rocker arms are also used r l l SPORTSTER amp BUELL PERFORMANCE GUIDE NOTE S amp S Quickee pushrods are designed for use with Evolution and Twin Cam style hydraulic tappets They are not compatible with stock or aftermarket Shovelhead hydraulic tappets or most solid style tappets R Quickee Pushrods Pending S amp S EASY INSTALL PUSHRODS our seer sm men Le nm 1986 90 V XL 88300 89 93 5130 mem 1986 90 V XL 108 Special Order Specify EVOLUTION PUSHROD COVER ADAPTER FITS 1991 O3 SPORTSTER I l S amp S Evolution Sportster pushrod cover adapters are designed to convert 1991 03 L gt Sportster crankcases to accept 1986 90 style pushrod cover assemblies to allow access to adjustable pushrods Four are required for each engine Adapter Set of Tour 33 5355 VISIT US AT WWW SSCYCLE COM 27 PUSHRODS S amp S PUSHROD KITS I I Pushrod flex costs horsepower by preventing the I valves from following the cam profile This problem a is most common in high performance applications with heavier than stock valve springs S amp S pushrods are designed to remain rigid and provide positive valve action at all engine speeds which makes
57. h air horn style radiused entryway and the dimpled cover with air directional cone on the inside Both features help maximize air flow by giving intake air an efficient easy path to follow into the carburetor And the beauty of it all is that the S amp S Teardrop air cleaner is also available to fit stock Tillostson Bendix and Keihin butterfly CV carbs or any carb with the same air cleaner mounting bolt pattern SPORTSTER amp BUELL PERFORMANCE GUIDE om WHEN ORDERING To ensure that the correct air cleaner kit is shipped to you please specify the type and year of the engine carburetor to be used and part numbers of the air cleaner kit and mounting S amp S Air Cleaner Kit for 1991 up carbureted Evolution Sportsters hardware when applicable ER AIR CLEANER SELECTION CHART SAS L Model Year Ar H D Tillostson Super B Super E amp G and EFI f weg Bendix Keihin 1991 up Sportster 17 0117 17 0404 1988 90 Sportster PP 47 0107 17 0399 17 0198 1986 87 Sportster P 17 0108 17 0107 17 0399 17 0198 1966 85 Sportster P 17 0199 17 0099 17 0400 17 0198 1994 amp Up Buell wows 1 1 17000 Must be used with thick insulator block 16 0497 or 16 0498 18 EMAIL US AT SSCUST SSCYCLE COM AIR CLEANER COVERS S amp S PATRIOT FLAG AIR CLEANER COVER There are only a handful of companies that have been around long enough to claim to have helped shape the industry and lifestyle that is so popular around
58. ial 7 113 rods 96 and larger Evolution Sportster engines require 7 440 rods IRONHEAD SPORTSTER STOCK BORE STROKER KITS 74 Kit for 1972 85 Sportsters includes a set of Stroker flywheels a pair of stroker pistons complete with rings wristpins buttons and installation instructions A NUMBER OF OPTIONS MAKE IT EASY to build big bore and stroker engines to achieve your Specific goals Do your own flywheel assembly and balancing or allow S amp S to do it for you 4 These kits are available with or without sprocket and pinion shafts and are shipped unassembled or completely assembled and ready to install into the cases However Evolution Sportster engines must use S amp S mainshafts since stock mainshafts are not reusable EXTRA COST OPTIONS Compression Piston Piston Piston a Sa Kit Part Sprocket Connecting Flywheels oe eee mme em fr for e e e e ojojo o Order stroker pistons separately Refer to page listed in chart for correct oversize 10 EMAIL US AT SSCUSTOSSCYCLE COM SIDEWINDER KITS S amp S V SPORTSTER amp BUELL BIG BORE SIDEWINDER KITS l S amp S Offers several Sidewinder Kits for Evolution Sportsters The 79 Kit is a top end kit with stock length cylinders and can be used with stock XL flywheels Rebalancing is neccessary The 89 Kit is the biggest kit that will fit in a stock frame and inlcudes a set of 4 stroke S amp S flywheels The 103 Kit requ
59. ift cams adjustable chrome moly pushrods an HLoT kit head bolts pushrod cover GER keepers pushrod tube adapters 1991 up kit only front and center engine mounts a Super E carb kit and This dyno chart shows the performance gains of an 89 installation instructions Select kit with desired XLSS Hot Set Up over a stock 1200cc Sportster compression ratio and specify model year and Dyno results from Dyno Jet 150 Chassis dynamometer E at S amp S Cycles Research and Development facility in SS Viola Wisconsin se 8 EMAIL US AT SSCUSTOSSCYCLE COM SIDEWINDER amp STROKER KITS S amp S SIDEWINDER BIG BORE AND STOCK BORE STROKER KITS S amp S stock bore stroker kits and Sidewinder 3 big bore kits are designed to increase the displacement of an existing Stock engine More cubic inches means more power but in addition to horsepower L m gt gains reliability ease of installation and compatibility with stock components are also important considerations to our customers With an S amp S kit you can build a performance street engine with confidence Our years of experience add up to proven performance DL KK bk di w 3 AMU Ae SPORTSTER amp BUELL PERFORMANCE GUIDE Shown here is the 89 V2 Sportster Kit Typical Sidewinder stroker kits include everything necessary for a complete installation 91 3204 FOR ALL OHV BIG TWINS SELECTION STOCK COMPATIBILITY AND SPORTSTERS CONSIDERATIONS
60. ing Engine Complete 91 S amp S Sportster Give Price varies with options selected Call for pricing Hot Setup 89 4 e F 92 1900 1986 2003 XL ssccssssssssevscsevsscvsesssveevsessassevsssusstesserevsseuseneususvavsusnecnassevsnnscaseasnns 2 194 95 Stroker kit 72 4 8 1GR F 92 3700 1972 85 Xl nnniversvvvrnnrnsersanvrrsverssevsnsenrnnsnssessasvnressserssrensnvenssesrsvrssvnsssvrnnvnenneen 368 00 Stroker kit 74 4 9 1GR F 92 3700 E E TEEN 368 00 Gam set 500 Andrews V6 1986 90 XL ssssscsssssssesssesssensessaseevsvssescevsssesssevsesessessaecasensussesssessesevsseuseneusnseueresenss 280 75 Gam set 500 Andrews V6 1991 2003 XL ccsccssssssessesssssnsesssssevsvsseseesssssvsscuscuersessavecaseevsssnssnessesevsseuseneusnssannenterss 280 75 Cam set 555 Andrews V9 1986 90 XL wcciesesecescssecnecctacexnavnasnscicaciendndsoiedladaiadationnivacchsecedndincteclavidessebanneiivantareerinueaoead 280 75 Cam set 555 Andrews V9 KREE 280 75 Tappet set hydraulic 1984 99 BT 1906 GO A aa wok WRC kad CEC 199 95 Tappet set hydraulic wi Biel 1984 99 BT 1986 90 XL ssisivsinitsanisinasuisnipeeednsnnaiiasbiinesiticapaubadwndwiubsaivatnbrviemiemainiundieiieties 214 95 Adapter pushrod cover 1991 2003 XL set of 4 NEEN 24 95 Tappet guide assembly FE 1986 90 cams S amp S XL E 55 10 Tappet guide assembly Fl 1986 90 cams S amp S AL 55 10 Tappet guide assembly RE 1986 90
61. ires extensive frame modificatons due to the increased engine height and includes a set of S amp S 5 stroke XL flywheels V SPORTSTER amp BUELL BIG BORE SIDEWINDER KIT SUMMARY CHART Compression Compression Piston Cylinder Kit Part 9 2 10r11 0 1 F Stock Stockelike 1986topresent 91 3002 437 1986 to 1990 91 3204 4 3 9 5 1 or 10 2 1 F gt Very good EMODE 5 087 1991 to present 91 3206 i e 1 100 1986 to 1990 91 3504 5 3 10 5 1 or 11 8 1 F gt Poor wm s sw osionsa 5 750 KE 1991 to present 91 3506 NOTES C Pistons supplied are cast type F Pistons supplied are forged type Denotes kit supplied in Hot Set Up Compression ratio depends on cylinder head type used If stock heads are used extensive cylinder head modifications must be performed making compression ratios completely dependent on final combustion chamber volume 1991 and later engines using adjustable pushrods require conversion to 1986 90 style pushrod tube assemblies S amp S kits for 1991 and later engines include a special pushrod tube adapter Pushrod tube assemblies are not included and must be purchased separately This kit has stock height cylinders and will fit Buell motorcycles PARTS INCLUDED IN V SPORTSTER amp BUELL BIG BORE SIDEWINDER KITS SE 2D os o EE gt 8 LL et Displacement Cylinders Sprocket Shaft Connecting Rod Assembly Center Head Mount Front Head Mount NOTES C
62. ison show the gains in horsepower and torque that can be had with these simple bolt on kits ae E Tests were conducted on a DynoJet 250 chassis dynamometer at the S amp S Research and Development facility in Viola Wisconsin 2 4 0 RPM x1000 2004 Sportster VISIT US AT WWW SSCYCLE COM 5 SPORTSTER amp BUELL PERFORMANCE GUIDE HOT SET UP KITS 74 XLSS HOT SET UP KIT INCLUDES S amp S SUPER STOCK CYLINDER HEADS FOR EVOLUTION SPORTSTERS i This Hot Set Up puts some sport in your I Sportster Turns any 883cc 1100cc or 1200cc I Sportster into a potent 74 inch street bike The i combination of S amp S Super Stock heads and an aggressive cam profile produce a power curve that is ideal for the light weight of the Sportster All components are carefully selected for performance and dependability Flywheel rebalancing is not required in stock 833cc and 1200cc engines EN Max Power 61 1 Max Torque 664 Max Power B06 Max Torque 736 3 d 45 50 RPM x1000 Dyno results from Dyno Jet 150 Chassis dynamometer at S amp S Cycle s Research and Development facility in Viola WI S amp S 74 HOT SET UP KITS FOR EVOLUTION SPORTSTER ENGINES Kit Number Kit Number 1980 90 90 0326 90 0324 1991 up 90 0327 90 0325 THIS KIT REQUIRES SPECIAL S amp S PISTONS THE 74XLSS HOT SET UP yields 74 cubic inches and is available in compression ratios of 9 2 1 and 10 5 1 Kit includ
63. linder Black stock pattern SS 630 lift 1991 2003 Al 1 073 00 Head assembly front cylinder Black stock pattern SS 630 lift 1991 2003 Al 643 80 Head assembly rear cylinder Black stock pattern SS 630 lift 1991 2003 XL 6 Buet 643 80 CSE ER EE EEE EEE 26 35 Gasket kit e Une ORNE 26 35 Spring kit valve 640 lift steel top collar 1984 up V 1999 up TC ICRRI aaa aaa aaa aaa aaa anna anaana 111 45 Spring kit valve 640 lift tit top collar 1984 up V 1999 up TC TOB BT eeeaa aaa aaa aaa anna aaa aaa aaaaaaiannaaei 164 30 Shaft rocker arm all V HD 17611 83 EEE annas 7 35 SUS EG EE LU eene 2 50 MAN Sel rocker EE EEE EE asa 29 20 Gasket set rocker cover Dillet 1984 Up V aoc GOGO OWA Gadka 44 85 Kit rocker cover chrome billet LE TEE 866 85 Kt rocker cover piain pillet LEE 624 25 MENN EE 389 95 Arm assembly roller rocker FE RI 1984 up V Lane ka GOGHA WO ba d Gie 116 95 Arm assembly roller rocker RE FI VIe 116 95 Kit rocker cover polished Dillet 1184 Ettel 735 75 Kit rocker cover plain die cast 1984 99 KE 281 65 Kit rocker cover polished die cast 1984 99 Mt geet Er LEA 387 05 Gasket set rocker Ee EN e A 48 65 Kit rocker cover gt chrome die cast 1964 E 559 95 Kit rocker arm rebuild 90 4065 EE 102 95 MN 174 95 Arm assembiy rocker FE RI 1984 Up RE 52 50 Armi assembDiy rocker REFI REE NE 52 50 Cylinder kit
64. lly fit in stock Sportster frames with no modification but due to the increased cylinder length requires the S amp S billet motor mount to fit in the Buell chassis Exhaust modifications may also be required to gain frame clearance when installing a 100 engine ina Buell frame Compression ratio of the 100 engine is 10 3 1 Crankcases have 1986 90 four speed style cam geometry 1991 up five speed style driveside and are available only in natural aluminum finish Primary components charging system ignition system oil pump and transmission components are not included KO wim COMPLETE SPORTSTER AND BUELL ENGINES INCLUDE Special Application XL or Buell style crankcases Complete S amp S flywheel assembly S amp S Super Stock cylinder heads S amp S cylinders and pistons S amp S 555 camshaft set and required gearcase components Adjustable pushrods and pushrod cover assemblies S amp S billet tappet guides with hydraulic tappets Super G carburetor kit S amp S gear billet XL style cover kit S amp S billet aluminum rocker covers and roller rocker arms NOTES The S amp S billet motor mounts are required for installaton of the 100 Buell style engines due to the increased engine height Although the 91 engine can be installed with a stock Buell motor mount we recomend the S amp S billet mounts to be used for the increased strength The S amp S Sportster and Buell style engines do not include
65. metry require 1991 2003 Style cams and 1991 96 gearcover Unlike stock five speed crankcases S amp S cases with 1991 03 style cam chests feature Special removable billet aluminum tappet guides which allow the use of 1986 90 style pushrod covers These tappet guides provide a replaceable wear area for tappet travel and two piece pushrod covers allow access to adjustable pushrods normally used in high performance applications Pushrods can not be accessed with the Stock five speed style one piece pushrod tubes All S amp S Sportster Buell style crankcases can be used with any stock 1986 up Sportster oil pump and require a 1986 90 style oil filter assembly In addition to the complete compliment of hardware and fittings that are provided with all S amp S crankcases Sportster Buell Style cases also include an S amp S heavy duty transmission access door The S amp S transmission door provides a seal between the primary case and the transmission allowing the use of different lubricants in each section A simple modification allows the primary case and transmission to share the same oil The transmission door is complete with required bearings and bushings installed Right side transmission case bearings are also installed and ready for assembly S amp S Sportster Buell style crankcases for 5 speed 1991 2003 cam geometry include billet tappet guides designed to accept 5 speed tappets Case with four speed cam geometry do not include tappet g
66. ned to be a direct replacement for stock 2004 up XL style mufflers and connect to the crossover pipe built into the stock muffler Support bracket DYNORUN 01 Max Power 66 5 Max Torque 68 8 DYNORUN 001 Max Power 59 4 Max Torque 63 2 E D z e Q 2 EE Ww lt Kei spunod joo enbio JyvS 3 5 4 0 RPM x1000 This dyno chart compares the performance of a 1200 XL with stock exhaust and S amp S Super E carburetor with the same bike after installing the S amp S Slip On Performance Mufflers Seven more horsepower and over five more ft lb of torque That is a very cost effective increase in performance Dyno results from Dyno Jet 150 chassis dynamometer at S amp S Cycle s Research and Development facility 1987 03 Sportster Style Chrome 55 6008 2004 up Sportster Style Chrome 55 6031 S amp S SLIP ON MUFFLER KITS 1987 03 Sportster Style Chrome 11 1 99 6008 2004 up Sportster Style Lhromge 99 6031 NOTES It may be necessary to rejet the carburetor or recalibrate the fuel injection system for best performance when a change is made in the exhaust system Dyno results are from tests performed on a DynoJet 150 dynamometer at the S amp S Research and Development facility in Viola Wisconsin S amp S performance mufflers are designed for closed course competition motorcycles only and do not conform to U S EPA noise emission standards Use on motorcycl
67. nnenenene 86 95 Pushrod set adjustable Special Order steel 1986 up XL ersnrenrnvernnvvnrnnvenrnvnrnnvensnnrensnvnsnnrenssnvensnvnssnvenssvessnvenssnrenssvennn 103 40 Pushrod set non adjustable std steel 1957 85 XL mea an aaa aan aan aaa zaawan anawa anna zaawan zazaaaanzzaa au 38 55 Pushrod set non adjustable Special Order steel 1957 85 XL rmmrvrsvrvvrrrervernververvresversvesvervresverveesvervesvverresveesrerseesvenveenee 55 00 Pushrod set adjustable 1 100 steel 1991 up AL ososa swa a awa saw n a w osa aaa wa a A a A A AA A AAA A AA AAA KA AAAA KASA KA 86 95 Pushrod set adjustable s steel 199 UP A 86 95 Pushrod set quickee 883 89 1991 up VF E 169 95 Pushrod set quickee 883 89 1989 90 V XL 1 unnvnnvvrnanvrnrnnvnnnvennnnvnnsnnennrernsnennsnvennsvernnnennsnvennsvnsnnnennnnvennsvnsnnnennsnvennneeenn 169 95 Pushrod set quickee 103 1984 99 V BT 1986 90 V2 dE 169 95 Pushrod set quickee 103 1991 up A E 169 95 Pushrod set quickee special TE 199 95 VISIT US AT WWW SSCYCLE COM 47 SPORTSTER amp BUELL PERFORMANCE GUIDE SPORTSTER amp BUELL PERFORMANCE GUIDE S amp S 11 SECOND CLUB imvites yow to Jo HERE S HOW YOU CAN JOIN SOME FAST COMPANY First go fast after breaking in your engine according to the manufacturer s instructions Next provide the documentation listed below Then toss everything in an envelope and
68. nvensnennsnvennsnesnsnennnnvennnnenen 226 55 Piston set 3 e 040 4 6 47 e 25 1 9 1 F 1972 85 XL avrrrnvvnranvnnanvensnennsanennsnvensnennnavennsnesnsnennsnvennsnesnsnennnnvennnnenen 226 55 Piston set 3 e 050 4 4 25 1 9 1 F 1972 85 XL avrrrnvvnranvnnanvrnnnennsnnennsnvensnennnavennsnvsnsnenssnvennsnesnsnennsnvennnnenen 226 55 Piston set 3 e 060 4 4 25 1 9 1 F 1972 85 XL iavrrrnvvnranvnnanvennnennranennsnvensnennnavennsnvsnsnennsnvennsnesnsnennsnvennnnenen 226 55 Piston set 3 e 070 4 4 25 1 9 1 F 1972 85 XL avrrrnvnnranvnnanvennnennsanennsnvensnennnnvennsnernsnennsnvennsnesnsnennsnvennnnenen 226 55 Piston set 3 e 080 Aide 4 e 25 1 9 1 F 1972 85 XL uvrrrnvnnranennanvnnnnennsnnennsnvensnennnnvennsnesnsnennsnvennsnesnsnennsnvennnnenen 226 55 Mount isolator to head stock engine height 1996 2002 Buell EEN 321 45 Mount isolator to head S amp S 100 engine height 1996 2002 Buell ceecee 321 45 Mount isolator to head special order 1996 2002 Buell EEN 321 45 Mount top motor slotted steel 1996 2002 Buell lisa kk GLAGOW 83 65 Pushrod set adjustable steel 4s 1986 90 XL std 1991 up XL oossa aaa nana waaan aaa aaa ana aaa AAAA AAAA AA AAAA 86 95 Pusnrod set adjustable 1100 steel 1980 90 AL EE 86 95 Pushrod set adjustable std steel 1986 90 XL uursavernrrnnnvennnnnnnvennnnnnvnennnnnvnvennnnnenennnnnneennnnnnveensnnnnenensnnnennensnnennenn
69. oil delivery to top end insuring rapid lifter pump up and reducing possibility of oil starvation to bottom end 4 Each lifter body and plunger assembly is hand fit and then pressure tested to insure correct operation NOTE Because of close tolerances tappet in set 33 5353 S amp S HYDRAULIC TAPPET ASSEMBLY may require slightly longer bleed down time than conventional tappets At temperatures of 65 F and Without HLoT Kit Set of Tout 33 5352 above however bleed down should take 20 minutes witi ALT RESA TOU aieri 33 9393 or less using 20W50 engine oil ROBIN I l This 2004 Sportster owned by Robin Smith L wife of S amp S company President Brett Smith is equipped with the new S amp S Air Cleaner and Muffler Hot Set Up kit 24 EMAIL US AT SSCUST SSCYCLE COM CAMS FOR V SPORTSTERS 1986 UP EVOLUTION SPORTSTER STYLE S amp S SOO CAM FOR MODIFIED 1200S amp UP TO 89 SPORTSTERS WITH NO MORE THAN 9 5 1 COMPRESSION Bolts in and works with stock or ported heads valve spring spacing not required other normal clearancing checks recommended See Camshaft Specification Chart for overall cam timing information ae elles Rian S amp S 500 Camshaft for 1986 up Evolution Sportsters 33 5081 S amp S 555 CAM FOR 79 AND LARGER SPORTSTERS WITH COMPRESSION RATIOS FROM 9 5 TO 11 5 1 L gt Works better with ported heads broad torque NOTE range from 3500 to 6500 rpm valve spring 2000 up Sp
70. one without disturbing chrome plated surfaces S amp S billet rocker covers accept valve springs up to 1 660 O D without modification Cast rocker boxes may require minor clearancing Cylinder heads must be set up correctly for high lift cams and it remains the builders responsibility to confirm all clearances S amp S ROCKER WRENCH SET I l Lo m m m The S amp S rocker wrench set 53 0040 speeds installation and is recommended for professional use Installation can also be accomplished with shortened allen wrenches AN VISIT US AT WWW SSCYCLE COM 35 ROCKER ARMS S amp S FORGED ROCKER ARMS AND ROCKER SHAFTS FOR 1986 03 V SPORTSTERS Our forged steel roller rocker arms were designed for l superior strength and to eliminate the failure prone I stress areas found in some other rockers S amp S roller I rockers are forged from 4140 steel heat treated and L gt then shot peened for additional strength and protection from fatigue Our rockers also utilize long bronze bushings compared to the more common long bushings or needle bearings and feature a modified lubrication system with unrestricted roller oiling SPORTSTER amp BUELL PERFORMANCE GUIDE The end result is what we believe to be the finest rocker arm available anywhere for any price 90 4065 ROLLER ROCKER ARM SET REBUILD KITS FOR S amp S ROCKER ARMS Includes 2 each front and rear rocker arms 90 4065 Current S
71. onsible for the cost of Shipping the defective Engine or part to the Company for service under this warranty nor will the Company pay for the cost of labor to remove and or replace the defective Engine or part Moreover the Company shall have no obligation under this warranty in the event that the Engine becomes defective in whole or in part as a result of improper installation break in maintenance or use or any other misuse or mistreatment of the Engine including without limitation operation of the Engine with fuels oils or lubricants not conforming to specifications published by the Company for use in or with the Engine or continued operation of the Engine after a defect or malfunction occurs or is identified or suspected The Company shall have no obligation under this warranty for defects in the Engine s black powdercoat finish when that option is Selected if the defects are caused by but not limited to negligence of parties other than Company an accident ordinary wear and tear assembly or disassembly power washing natural occurrences like Stone chips bead blasting improper maintenance including the use of any harsh cleaning agent chemical or solvent and salt or other Substances used on streets and highways for maintenance and Safety This warranty does not cover consumables that is those parts consumed in the normal operation of the Engine The Company provides touch up paint with each powdercoated Engine It is the c
72. ortsters and Buells with stock flywheel assemblies Spacing and other normal clearancing checks require a 1991 99 style pinion gear if S amp S cams are to be must be done See Camshaft Specification installed Engines with S amp S flywheels require 1986 87 style Chart for overall cam timing information pinion gear available from Harley Davidson or S amp S 1986 UP EVOLUTION SPORTSTER CAM SPECIFICATION CHART Camshaft Valve Timing Valve Duration Lift TDC Application Near RI Open Close 9 e uran tt Intake Exhaust Intake Exhaust 74 to 89 with 9 1 to 10 5 1 GR 1986 90 33 5081 S amp S 89 to 100 with less than 9 5 1 CR 1988 90 34 50 56 28 264 2649 Fe or Good torque easy installation 1991 Up 1991 Up 33 5082 ydraullc s ee E 1986 90 33 5083 33 53 53 33 266 266 pe 240 240 e etter mid range and top end 1991 Up 33 5084 Hydraulic 1 Timing designation is function of zero lash 053 off base circle 2 TDC lifts are measured at the valve and are for reference only Overlap valve lifts must be checked on assembled motor Minimum valve to valve clearance of 040 is recommended 3 Cams specified for solid tappets may be used with modern high performance hydraulic tappets with V style hydraulic mechanism Stock hydraulic tappets are not recommended 4 1980 81 engines require conversion to late style valve guides VISIT US AT WWW SSCYCLE COM 25 SPORTSTER amp BU
73. p BUELL PERFORMANCE GUIDE SO HOW DO YOU IMPROVE ON THAT A fairly simple design change has given the Super Shorty carbs an even higher degree of tunability which improves compatibility with some of the more radical cams and exhaust systems For the vast majority of our customers this new design will not change the way they dial in our carbs but for our customers who use extreme cams and exhaust systems designed for maximum performance the change will make life a lot easier HOW DOES IT WORK The design change involves the main fuel circuit air bleed In the past S amp S Shorty carburetors have had a fixed air bleed for the main circuit that was sized for the best all around performance However starting October 1 2003 all Super E and G carbs have a replaceable jet in place of the fixed main circuit air bleed This allows for fine tuning of the main circuit The main circuit air bleed determines the rpm at which the main fuel circuit begins to feed fuel A smaller air bleed engines with high performance exhaust systems which often exhibit some harmonic reversion problems Harmonic reversion usually inhibits exhaust flow at a Specific rom In extreme cases aggravated by very aggressive cam timing the reversion pulses can actually push air back out of the intake valve This pulse of air picks up fuel as it goes out past the main discharge tube of the carburetor and is then drawn back through the carburetor where
74. powdercoated parts It is the customer s responsibility to repair minor finish damage to prevent or inhibit further deterioration It is the responsibility of the original Consumer Purchaser to cease operation as soon as a defect or malfunction is identified or Suspected The failure to cease operation once a defect or malfunction exists can cause substantial damage to the Company s parts that could otherwise be avoided In addition the Company shall have no obligation under this warranty for parts defects caused by alteration including but not limited to polishing powdercoating painting removing or reconfiguring any components modification repair or unauthorized service The Company shall have no obligation under this warranty if the parts are used in racing or similar competitive activities The Company shall have no obligation under this warranty when a competition application including but not limited to a turbocharger supercharger or nitrous oxide is used with the Engine Further the Company shall have no obligation under this warranty for any parts that are included in a Competition Package Option offered by the Company since the Package is for use in racing and similar competitive activities THE COMPANY SHALL NOT BE LIABLE FOR AND DISCLAIMS ALL CONSEQUENTIAL INCIDENTAL PUNITIVE OR SPECIAL DAMAGES ARISING OUT OF THE USE OF OR INABILITY TO USE THESE PARTS some states do not allow the exclusion or limitation of inciden
75. r FW A4 AL dfs A na ORMAL Sportster amp Buell S amp S Performance Guide 2005 Performance is in stock at your local S amp S Dealer d gt U H U Z lt K O LL 19 H D z I H S m el K H O K je d OU zt SE Sa ZEIEN TABLE OF CONTENTS S amp S Sportster amp Buell Style Engines Pages 1 3 Using cutting edge technology to provide a better power plant for V style Sportsters amp Buell style motorcycles Slip On Performance Mufflers Pages 4 5 S amp S performance mufflers make a great high performance exhaust system with a low price tag Hot Set Up Kits Pages 6 8 Proven combinations fo components that offer the best perform ance value Sidewinder amp Stroker Kits Pages 9 11 S amp S Sidewinders have always been a good way to increase dis placement of an existing engine Stock bore strokers are still the most economical and cost effective way to make more power because the existing stock cylinders are used Carburetor Kits Pages 12 16 The most popular performance carbs for Harleys in the world Also get our new air cleaner covers and air filter elements for your Super E amp G Carb Jets Page 17 Carburetor replacement jets and a handy tool for changing main jets Cleaner Kits amp Air Filter Elements Pages 18 20 Get our new air cleaner covers and air filter elements for your super E amp G Carb Also find new air cleaner cover designs Cr
76. r G and Super D carburetors as well as the more popular CV carbs STEP 4 PISTONS FOR S amp S 34 amp 3 BORE S amp S V SPORTSTER STYLE CYLINDER HEADS Select the correct piston for our application Your S amp S dealer can help you select the correct piston for your engine whether it is a stock 883 or 1200 or if the displacement has been increased with a 3 big bore kit NOTE AAAA S amp S Super Stock Evolution style cylinder heads must be used nn g ff with S amp S Super Stock pistons Use with stock flat topped pistons will result in very low compression and poor performance VISIT US AT WWW SSCYCLE COM 33 SPORTSTER amp BUELL PERFORMANCE GUIDE ROCKER COVERS S amp S ROCKER COVERS FOR 1986 03 V STYLE SPORTSTERS AND 1994 02 BUELLS S amp S manufactures two types of rocker covers for V style engines billet and die cast Billet covers are manufactured from aluminum billet using computer controlled machining centers Cast covers are also made of aluminum but using the more economical die casting process All S amp S rocker covers include formed Viton gaskets and o rings for leak free operation our proven two piece design makes for a simple installation l Which is better billet or die cast Both work equally well for most applications The billet covers will allow the use of larger diameter valve springs and valves with extra long stems without additional clearancing However in the
77. r backplate provides a radiused inlet similar to an air horn or velocity stack This provides a smooth path for air to follow while traveling into the carburetor inlet This results in less turbulence which allows more air to flow into the carb The flow of air is also enhanced by a directional cone inside the air cleaner cover which also directs the air smoothly into the inlet of the carburetor since the radiused inlet and directional cone are contained within the filter element air flowing into the carb is not effected by turbulent air flowing past the carburetor when the motorcycle is traveling at high speeds So the air cleaner cover and the filter element also play an important role in eliminating turbulence and increasing flow While installing an S amp S Super E or G carburetor on a stock engine will result in more power the addition of a performance cam and exhaust system will result in even more power gains Take a look at the S amp S Hot Set Up kits on pages 8 10 of this catalog for more information 1957 78 XL 11 0404 11 0424 1979 85 XL 11 0406 11 0426 1986 90 XL 11 0408 11 0428 1991 up XL 11 0409 11 0429 The Super E amp G Shorty carburetors are designed for Buell 1994 up 11 0448 11 0449 American V Twin applications and are protected by US Does not fit engines equipped with vertical magneto Patent 9 128 071 which covers thirteen specific design elements VISIT US AT WWW SSCYCLE COM 15 CARBURETORS S amp
78. r his or her use and shall assume all risk and liability in connection therewith Polishing and Chrome Plating the Carburetor S amp S does not recommend polishing and chrome plating the Super E or G carburetor Proper preparation to achieve a good finish requires polishing using buffing compounds The polishing and plating processes and the materials used invariably plug air and or fuel passageways and feed holes and alter operating tolerances in critical areas regardless of the precautions taken 13 SPORTSTER amp BUELL PERFORMANCE GUIDE RE AE SSRFOR MA NS CARBURETORS WHAT MAKES THE S amp S SUPER E amp G SO POPULAR I I The popularity of the S amp S Super E amp G Shorty carburetors is I largely because of results Ease L of installation easy tuning pm em gt excellent performance and the technical support of a company with over 45 years of experience in the high performance V Twin industry are all factors in the popularity of the Super Shorty carbs It can be best summed up by the S amp S company motto Proven Performance THEM CHANGES Ann pictured at right has been with S amp S for eleven years and currently works as a Current Product Engineering Test Technician Formerly the supervisor of the cylinder head finishing department Ann ports a S amp S SHORTY CARBS EASY TUNING eet kn Si ma bd The S amp S Shorty carbs are easy to tune due to the simplicity of changes from 883 to 1200
79. r problem If it is not practicable to contact the dealer for warranty service the original Consumer Purchaser may contact the Company at the following address telephone number fax number or e mail address S amp S Cycle Incorporated Attention Technical Services 14025 County Highway G PO Box 215 Viola WI 54664 0215 Phone 608 627 8324 Fax 608 627 0773 Email sstech sscycle com Direct Phone 608 627 TECH 8324 42 ARE THERE OTHER WARRANTIES THE WARRANTIES STATED IN THIS WARRANTY REPLACE ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY OTHER OBIGATIONS OR LIABILITIES ON THE PART OF THE COMPANY WHETHER IN CONTRACT WARRANTY NEGLIGENCE OR OTHERWISE TO THE EXTENT NOT PROHIBITED BY LAW some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you How DO STATE LAWS RELATE TO THIS WARRANTY This warranty gives you specific legal rights You may also have other rights that vary from state to state EMAIL US AT SSCUST SSCYCLE COM BE ON THE LOOKOUT FOR S amp S WE VE JUST UPDATED OUR WEBSITE If you haven t visited our website recently you re in for a pleasant surprise Direct your web browser to www sscycle com and i get ready for an all new S amp S web experience The difference will be apparent immediately with an all new look but the further L
80. s a 1989 heitage softail with an S amp S carb Renee has been at S amp S Cycle for 6 years and works in the Sales Department selling horsepower VISIT US AT WWW SSCYCLE COM 7 HOT SET UP KITS 89 XLSS HOT SET UP KIT SIDEWINDER STROKER KIT 89 FOR EVOLUTION SPORTSTERS INCLUDES S amp S SUPER STOCK CYLINDER HEADS Adding S amp S Super Stock heads to the popular 89XL kit takes performance to the next level This is the biggest Hot Set Up kit we Offer for Sportsters Not for the faint of heart Stock crankcases must be bored to accept the 3 big bore cylinders Sportsters 1991 up require conversion to the 1986 90 style pushrod cover assemblies using adapters provided Some frames may require minor clearancing SPORTSTER amp BUELL PERFORMANCE GUIDE r ma m ma EN ma 89 XLSS HOT SET UP KITS 9 5 1 Compression Ratio 90 0389 10 2 1 Compression Ratio 90 0352 Max Powers 617 1 Max Torque 66 4 Max Power 924 Max Torque 89 0 THE 89 XLSS HOT SET UP yields 89 cubic inches at 9 5 1 or 10 2 1 compression and includes 4 s stroker flywheels assembled with l mainshafts and connecting rods 3 bore Sidewinder l cylinders and pistons complete a Super Stock cylinder head kit with valves and springs installed manifold with O rings and flanges required hardware top end SAE Horsepower spunod jooy anbioy avs Kon L gt gaskets 500 or 550 l
81. s warm enough to idle normally By using an enrichment circuit instead of the usual choke mechanism the bore of the carburetor is not restricted by hardware that is only used on cold starts That means that the carb can supply more air to the engine at full throttle and that equates to more power Another reason the Shorty carbs are capable of making more power is the design of the air cleaner This design takes into account two of the most significant factors that can improve air flow into a carburetor The most important factor is a filter element that does not restrict the flow of air and almost as important is the elimination of turbulence at the inlet of the carburetor The filter area of the Shorty carbs is maximized by an ingenious backplate design that wraps slightly around the carb to allow room for a wider filter element than a straight back plate would allow The pleated S amp S filter element looks like paper but is actually a special resin impregnated cellulose fiber media that provides excellent filtration as well as superior flow That makes for improved performance and better engine protection SUPER E amp G CARBURETOR COMPLETE KITS SELECTION CHART Seat Year 8 Type Super E Garb Kit Super G Carb Kit CARBURETORS SPORTSTER amp BUELL PERFORMANCE GUIDE Reducing turbulence is almost as important as finding a filter media that allows air to pass with a minimum of restriction The shape of the S amp S air cleane
82. send it to SAS We ll send you an official 11 Second Club patch for your leathers or denims a certificate authorizing braggin rights and a free 11 Second Club T shirt HERE S WHAT WE NEED FROM YOU 1 Proof that your street ridden motorcycle D O T tires full charging system no wheelie bars or air shifts equipped with one of our carburetors and hopefully numerous other S amp S products has turned an 11 99 or quicker quarter mile time We ll need an official timing slip from a sanctioned dragstrip dated after June 1 1997 and signed by the timekeeper A good photocopy will do We don t care if you trailer the bike to the track so long as it sees more action on the street than off 2 A photograph of yourself anyone else you d care to include and the motorcycle Action shots are preferred if sharp and clear but the carburetor MUST be in plain view 3 A signed copy of this statement Please tell us a little about yourself and your motorcycle Included the model and year a list of all engine and frame modifications the type of exhaust and tire brand and model Be sure to mention all S amp S products used Submitted materials may be used for promotional purposes Members will receive a 11 Second Club certificate patch and T shirt but no payment or other considerations d do hereby attest that have fulfilled all membership requirements of the S amp S Cycle 11 Second Club as outlined above and that my I motorcycle
83. sion ratio with a stock style flat topped piston We wanted the improved flow of a larger chamber but we also wanted compression ratios slightly higher than stock The solution of course was to use a larger chamber for the flow with a domed piston to increase compression We then went a step further and designed a specially shaped combustion chamber and a piston dome shaped to match the contours of the chamber Due to the increased squish area of this design the interaction between the cylinder head and piston dome at TDC sets up a controlled turbulence in the combustions chamber That turbulence improves flame travel for a more efficient burn and reduced detonation Pistons are available to achieve various compression ratios 31 SPORTSTER amp BUELL PERFORMANCE GUIDE CYLINDER HEADS ORDERING NOTES I Your S amp S dealer can help you put the correct package together for your engine Following these simple steps will make it easy and ensure that you have everything you need dl select the cylinder head kit that is correct for your application See chart below 2 select a cylinder head gasket installation kit for the bore size of your engine Select a manifold for the cylinder length of your engine and carburetor you intend to use See your S amp S dealer for more information 4 Select a set of pistons for your bore size engine displacement and desired compression ratio Your S amp S dealer can help you selec
84. t the correct piston for your application SPORTSTER amp BUELL PERFORMANCE GUIDE STEP 1 CYLINDER HEAD KITS select a cylinder head kit for your engine style ASSEMBLED HEADS FOR 3 AND 3 BORE EVOLUTION STYLE ENGINES Bolt Pattem Bore Set From Rem Sel From mer V XL 1986 90 90 1302 90 1302F 90 1302R 90 1802 90 1802F 90 1802R V XL 1991 03 90 1310 90 1310F 90 1310R 90 1810 90 1810F 90 1810R Buell 1994 02 90 1305 90 1305F 90 1305R 90 1805 90 1805F 90 1805R 32 EMAIL US AT SSCUST SSCYCLE COM CYLINDER HEADS STEP 2 GASKET KITS FOR S amp S EVOLUTION STYLE CYLINDER HEADS S amp S has convenient cylinder head installation gasket kits that contain high quality S amp S head and base gaskets as well as gaskets for the exhaust pipes Whether your engine is stock 3 bore or if it has a 3 big bore kit the correct gaskets are available See your S amp S dealer for full details GASKET KITS FOR S amp S V SPORTSTER STYLE CYLINDER HEADS Engine and Bore Size Part Number 3 Bore V Sportster Buell 90 1907 3 Bore V Sportster Buell 90 1908 SPORTSTER amp BUELL PERFORMANCE GUIDE STEP 3 MANIFOLDS FOR S amp S V SPORTSTER STYLE CYLINDER HEADS select the correct S amp S manifold for your engine Your S amp S dealer can help you select a manifold that is the correct length for your engine and the correct size for the carburetor you intend to use S amp S offers manifolds for S amp S Super E Supe
85. tal or consequential damages so the above exclusion may not apply to you 39 SPORTSTER amp BUELL PERFORMANCE GUIDE H U Lu U Z el K O LL K L D a i L m m el K H Un K je A N WARRANTY LIMITED WARRANTY COMPLETE FACTORY ASSEMBLED ENGINES WHO IS COVERED BY THIS WARRANTY This warranty covers only the original Consumer Purchaser of the Complete Factory Assembled Super Stock Engine the Engine and is not transferable WHAT DOES THIS WARRANTY COVER S amp S Cycle Incorporated the Company warrants this Engine to be free from defects in material and workmanship If the Engine or any part thereof becomes defective during the warranty coverage period the Company will at its option repair or replace the Engine or any or all defective parts Repair or replacement of defective parts is the sole and exclusive remedy How LONG IS THE WARRANTY COVERAGE The warranty coverage remains in force for a period of twelve 12 months from the date that the original Consumer Purchaser buys the Engine Engines specifically designed for and sold with the S amp S Intelligent Spark Technology ignition system are covered by a special twenty four 24 month warranty However warranty coverage will automatically terminate if the original Consumer Purchaser sells or otherwise transfers all or any portion of the Engine WHAT IS NOT COVERED BY THIS WARRANTY The Company shall not pay or be resp
86. the 500 long bushings used in stock and other aftermarket rocker arms The valve contact tips are induction hardened for extended durability Thousands of hours of engine testing have proved them to be superior to any non roller rocker arm on the market Fits Evolution Sportster style engines Recommended for cams of 585 lift or less S amp S STANDARD ROCKER ARMS FOR V SPORTSTER STYLE ENGINES Set Includes 2 each front and rear rocker arms 90 4119 Individual Front exhaust or rear intake cccceccccccceueeeceecceeseeneees 90 4119F Rear exhaust or front intake cccecccccceceeeececeeeeeeneess 90 4119R VISIT US AT WWW SSCYCLE COM Each HD 17611 83 Set Includes 4 each 90 4006 90 4119 NOTES gt long bushings provide 50 more bushing support area than 4 long bushings They eliminate the risk of engine damage associated with failed needle bearings Adjustable pushrods must be used with S amp S roller rocker arms to obtain proper valve clearance New rocker arm shafts are recommended for maximum performance and rocker life ROCKER ARM SHAFTS S amp S rocker arm shafts can be used for stock replacement as well as with S amp S roller rockers or standard rocker arms 37 SPORTSTER amp BUELL PERFORMANCE GUIDE SPORTSTER amp BUELL PERFORMANCE GUIDE SPEEDOMETER CALIBRATOR S amp S SPEEDOMETER CALIBRATOR I I l The electronic speedometer cali
87. to negligence of parties other than Company an accident ordinary wear and tear assembly or disassembly power washing natural occurrences like Stone chips bead blasting improper maintenance including the use of any harsh cleaning agent chemical or solvent and salt or other Substances used on streets and highways for maintenance and Safety This warranty does not cover consumables that is those parts consumed in the normal operation of the Engine VISIT US AT WWW SSCYCLE COM The Company provides touch up paint with each powdercoated Engine It is the Consumer Purchaser s responsibility to repair minor finish damage to prevent or inhibit further deterioration It is the responsibility of the original Consumer Purchaser to cease Operation as soon as a defect or malfunction is identified or Suspected The failure to cease operation once a defect or malfunction exists can cause substantial damage to the Engine that could otherwise be avoided In addition the Company shall have no obligation under this warranty for defects in the Engine caused by alteration including but not limited to polishing powdercoating painting removing or reconfiguring any components modification repair or unauthorized service of the Engine The Company shall have no obligation under this Warranty if the Engine is used in racing or similar competitive activities The Company shall have no obligation under this warranty when a competition application in
88. uides since stock can be used S amp S SUPER STOCK SPORTSTER BUELL STYLE CASES S amp S SUPER STOCK SPORTSTER BUELL STYLE CRANKCASE SELECTION CHART Cam Geometry Stock Bore 1991 2003 31 1008 31 1009 1986 1990 31 1013 31 1014 NOTES All S amp S XL crankcases use 5 speed transmission and primary components These cases will not accept 4 speed transmissions or flywheel assemblies are available for stock bore and 3 bore engines For bore sizes larger than 3 and for deck heights taller than stock S amp S special Application SA Sportster Buell style crankcases are available By special order S amp S SA crankcases can be machined for Deck heights as much as 1 taller than Stock and for cylinders with spigots up to 4 635 in diameter see your S amp S Dealer for more information on S amp S Special Application Sportster Buell Style crankcases SPORTSTER amp BUELL PERFORMANCE GUIDE Requires use of S amp S cam cover gasket S amp S 31 2052 1991 amp later cases require 1991 97 gear covers Includes lifter blocks VISIT US AT WWW SSCYCLE COM 21 SS RFORMANS GEARCOVERS S amp S SPORTSTER BILLET GEARCOVERS BUSHING SYLE S amp S billet Sportster gearcovers are intended for S amp S 31 0302 Sportster style crankcases only These gearcovers are DOT recommended for engines with stock 1986 90 crankcases as they have no provision for the four speed style crankcase breather Kits come with hard
89. ustomer s responsibility to repair minor finish damage to prevent or inhibit further deterioration 40 It is the responsibility of the original Consumer Purchaser to cease operation as soon as a defect or malfunction is identified or Suspected The failure to cease operation once a defect or malfunction exists can cause substantial damage to the Engine that could otherwise be avoided In addition the Company shall have no obligation under this warranty for defects in the Engine caused by alteration including but not limited to polishing powdercoating painting removing or reconfiguring any components modification repair or unauthorized service of the Engine The Company shall have no obligation under this warranty if the Engine is used in racing or similar competitive activities The Company shall have no obligation under this warranty when a competition application including but not limited to a turbocharger Supercharger or nitrous oxide is used with the Engine Further the Company shall have no obligation under this warranty for any Engine that includes a Competition Package Option since the Package is for use in racing and similar competitive activities THE COMPANY SHALL NOT BE LIABLE FOR AND DISCLAIMS ALL CONSEQUENTIAL INCIDENTAL PUNITIVE OR SPECIAL DAMAGES ARISING OUT OF THE USE OF OR INABILITY TO USE THE ENGINE some states do not allow the exclusion or limitation of incidental or consequential damages so the above
90. ware and special S amp S gearcover gasket SPORTSTER amp BUELL PERFORMANCE GUIDE KOS mmm 000000000 31 0303 IIIIIIIT i H S amp S BILLET GEARCOVERS 00000 00000000 BUSHING STYLE VPN 31 0303 VPN 31 0302 Replacement Gasket 5 Pack 31 2099 Replacement Seal 5 Pack 221112 31 4114 22 EMAIL US AT SSCUST SSCYCLE COM TAPPET GUIDES TAPPET GUIDES AND O RINGS FOR V SPORTSTER STYLE ENGINES S amp S Evolution Sportster style tappet guides are machined from billet aluminum Assemblies and kits designated as stock style fit stock style Sportster style crankcases including S amp S Super Stock cases Assemblies and kits designated as SA are designed for S amp S Special Application crankcases with cam chest offset Special S amp S 1991 up tappet guides are designed exclusively for S amp S Super Stock and Special Application Sportster style crankcases with 1991 up cams These cases are machined for removable tappet guides similar to 1986 90 engines However these Special tappet guides are designed to be used with the 1991 99 stock style Sportster tappets S amp S 1986 90 V2 SPORTSTER Sportster tappet guide assembly set 33 5375 TAPPET GUIDE SELECTION CHART 1986 90 1986 90 Stock Style S amp S Special Application Se RER EE Front Intake _ 33 5372 33 5362 Front Exhaust 335371 33 5361 TAPPET GUIDE O RING KIT 33 5364 1986 90 SPORTSTER AND Rear Exhaust 33

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