- S&S Cycle
Contents
1. Install noise reducer on backplate over supports See Picture 27 3 Flat side of pleated filter element goes against noise reducer Insure that element goes around outside edge of locating tang at 9 o clock position on backplate Rounded side of element with S amp S part number goes toward outside Correctly installed element will remain in place on backplate without support 4 Install cover using the three 1 4 20 mounting screws provided Picture 26 B j Picture 27 i NOTE Pleated air filter element supplied in carburetor kits for big twins and Harley Davidson Sportster models goes on dry Do not apply filter oil to pleated filter Foam filter element may be installed dry or foam type filter oil may be applied Foam filter elements may be washed and reused but pleated elements must be replaced when they become dirty or clogged M Fill gas tank INSTALLATION NOTES In designing the S amp S Super E carburetor S amp S has made every effort to keep overall assembled length as short as possible Due to the short installed length of the carburetor assembly the air cleaner cover may contact the gas tank of four speed shovelhead chassis In such instances an optional chromed notched cover that will provide additional clearance can be ordered If a new undamaged Super E G cover is shipped to S amp S prepaid it will be exchanged for the difference in cover prices See your authorized S amp S dealer for this service An optional 1 s2. S amp S enrichment system operates on manifold vacuum If throttle is opened while starting engine vacuum will be reduced and enrichment system will not function normally 13 A Cold Starts 1 Open fuel petcock 2 NOTE When motorcycle is not running fuel petcock shutoff valve should be turned off to prevent possible leakage should needle and seat not seal properly Gasoline leaking past inlet needle may flood engine causing oil contamination and engine damage Gasoline leaking past inlet needle may flood engine and surrounding area creating a potential health and fire hazard 3 Prime engine with one or more squirts from accelerator pump Ambient temperatures below 60 may require increased priming up to 6 7 squirts depending upon exact temperature and carburetor jet size 4 Lift fast idle lever to fully raised position 5 Turn on ignition NOTE Some engines especially those equipped with magnetos will start easier if given two prime kicks BEFORE ignition is turned on For reliable starting magneto should be equipped with kill button to disable ignition for prime kicks 6 With throttle closed kick engine through or engage electric starter 7 If engine fails to start immediately crack throttle enough to barely open butterfly and continue to kick or engage starter until engine fires 8 After engine starts position lever to maintain rom at approximately 1000 1200 rpm with throttle closed Lever may gradually be pushed d
3. Total Housing Vinyl Housing Open Side Close Side 19 0430 19 0431 For Buell with 7 handlebars 36 32 19 0432 19 0433 To 1995 1981 85 FX and FL All 1981 85 XL Also pre 1981 w 2 cable throttle housing replaced For Buell with 1 diameter handlebar 19 0436 19 0437 1996 up 883 1200 XL 39 35 19 0434 19 0435 To 1995 Softail FXCTC FXST FLSTC FLSTC FLSTF 1986 94 FXR 1993 95 Dyna 39 ao 19 0438 19 0439 1996 up Softail FXSTS FXSTC FLSTC FLSTF 1996 Up Dyna 19 0465 1996 up All FLT Models Chart 1 S amp S THROTTLE KITS S amp S throttle kits fit 1 handlebars and can be used on most chassis An adapter sleeve is available for use with earlier 2 OEM handlebars originally equipped with internal throttle cable Barrel fittings on S amp S cables readily plug in to S amp S Super E G and stock H D 1981 90 butterfly type carburetor throttle linkage Kits include one opening and one closing side cable left and right grips and handlebar clamps Kits with 36 39 42 or 48 length cables are available Length specified refers to overall cable length Vinyl covered outer housing is 4 shorter than overall length NOTE Cables supplied with above kits are interchangeable with 1981 90 stock H D butterfly style throttle cables S amp S Throttle Cables for 1996 and Later Chassis These throttle cables feature the plug in cable fastener to fit 1996 and later throttle grips and the correct length inner ca
4. VE PAI O IIIS AENEON AAEN ENE E A eee 17 0337 14 Crankcase breather hose TUV 1970 84 sesssessessesssesseeseossessseseeosessscsseeseossessceseessesserssesseeseessesse 17 0113 TOV TSF UD ence nem ne ne enan a 17 0339 1970 84 T V Big Twin 9 r 10 a 15 Backplate plug e 27 10 PACK sussssssssssssssssssssssssssssssssssssssssesees 50 1015 a i ae 1 16 Flatwasher 6 X Yio 10 PACK scssssssssssssssssssscsssscsssscsssecsssscacees 50 7069 oN 17 Mounting bracket bolt S amp S 4 Bore me NVA GOPI ssia 50 0148 18 Screw vent fitting BT 1993 99 oo ssessessssessecsesssseesseseeseees 17 0347 19 Screw air cleaner to head sesessesssesesesecoseseseseeosessesorossseseroeosssss 17 0346 20 Washer silicone coated steel 520 10 Pack BI T99 A ainar E 50 7057 21 Plate air cleaner noise reducer csscessesessecssseccsececsecsesecsees 17 0389 22 Rubber isolator mounts 3 PACK scsccsscsscsesseesssscsesscscsessensesees 50 8511 23 Shim spacers 2 OD x 1 4 ID x 080 BPG EE EE E 50 7970 24 Shim 850 x 325 x 400 S amp S 4 Bore VPE PEA AIOE ONI A OA E ene A ects eee ee 50 7027 25 Lockwasher 46 10 Pack ss sssesssseessseessseessseesssecssssesssecssseessseessss 50 7077 26 Locknut HH 6 18 10Pack s ssssssssssssssseseesssessceresssssecorsssss 50 5020 27 Spring clamps NS 10 Pack s essssessssessssessssessssessssessssessssessssesss 50 8088 NOTE The line drawing is used for ill
5. 48 49 50 Intermediate jet state size oe ssscssscsssecssseesesecees See Dealer Catalog DOV gasket 10 Pari mnuniesonmann neh a 11 2387 E E AE A EE I NO E AE TA E OT 11 2187 Float pin 5 Pack s sssssssesssesssessseesseesseesseessecosecosecsseseseesscoseeoseeesecesessseosseesee 11 2370 Bowl screw 10 Pack 10 24 x Za 3 required onnon 50 0034 10 24 x 2 1 required ceecccecsssccccssssssecssssssesssesesessssessensssetsessseetesseseese 50 0061 Carb bowl assembly esisisisissisisinisieseiiinneinineinsaniniiniii 11 2388 Bowl plug a Pack sneep N 11 2092 Seat o ring Required w 11 2465 and11 2466 only when replaces 360 style fuel inlet 5 Pack sssss ssssseesssssessssseesssseeessssseesssseesss 50 8095 Needle Wk 220 E eee ee 11 2195 Racing ONY eai A O 11 2197 Seat 1A ERI GS Replaces 11 2347 Uses 11 2195 Needles siicnmnniiinumiieaniianninimndanmadne 11 2465 Racing only Replaces 11 2348 USES 1722197 NEEGER 11 2466 Racing only threaded fuel inlet 157 ID for Super E or G USES 11 2195 needle ssssssseseseseresesosessseccossseserorosssssecoossssssrosossssesessse 11 2395 Racing only threaded fuel inlet 235 ID for Super E or G Uses 11 2197 needle usssissssssssesessosssscosossessicnssossesssrons svovusnsssersssssasstssss 11 2396 Ejector nozzle o ring 10 Pack ssssssssessseessseessseessseessseeesseeesseeenseeesseeesseee 50 8096 Pump pushrod 5 Pack es ssssssseesseesssesssesssessscsseeessces
6. SAFE INSTALLATION AND OPERATION RULES Before installing your new S amp S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed Do not smoke Perform installation in a well ventilated area away from open flames or sparks If motorcycle has been running wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps Contact S amp S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S amp S part on it Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation Use good judgment when performing installation and operating motorcycle Good judgment begins with a clear head Don t let alcohol drugs or fatigue impair your judgment Start installation when you are fresh Be sure all federal s
7. SUPER E amp G AIR CLEANERS 1 Air cleaner cover CHOME geostatistics caursucsimnseredneteencsn omen 17 0378 2 Element pleated carbon TOV iiscescssssssssssssssssssssssssssesssseessees 17 0375 3 Backplate OA EE AA nieces 17 0860 1984 99 Big Twin T V TUV 1984 99 356 and 4 BOLE eesssssssssssssssssssssesssssesssssseesssssees 17 0388 3 and 4 Bore 13 20 TUV SC 8 DOTE caan 17 0395 20 4 Cover screw chrome 10PaCk ss sssesrsessersssssesessseeesssscesssseesss 50 0347 17 0430 12b be Sy A 14 5 Backplate screw 10 PACK vsccssscssssssssssssssesssscssssssssesessssesescscssees 106 2105 6 Fast idle friction washer 10 PACK ssesssssssessesssesssessescsseseesssscses 50 7058 7 Fast idle steel washer 10 Pack ssscsssssssssssssessssscsssecssseesseesees 50 7061 8 Fast idle nylon washer 10 Pack sss ssssessssessssessssessssessssessssesss 50 7060 9 Fast idle lever o2 25 seers pinne annie ewasennaieccnnis 17 0329 10 Fast idle brass washer 10 Pack scicsisssisissacodstncasssasissbeasesansnoeivs 50 7010 11 Fast idle lever screw 10 PACK scsssssssssssssssssssssssscsssseacsecassscaeees 50 0062 12 Shims 10 Pack a S amp S 4 Bore A6 A BO asir EAEE 50 7107 EE e OO E E A N OE N A 50 7070 Te O p a a A 50 7068 Pe KaAOS oea heen te ea ae 50 7062 b 1984 99 354 amp 4 bore T V DS E E eee ees 50 7110 Te HCHO a A 50 7111 H KOTI ee E E EE eee 50 7112 13 Breather fitting BT 1993 99 amp XL 1991 up
8. may also be used in this location if required 3 Assemble fast idle mechanism as shown in Figure A Picture 6 C 1993 up big twin amp 1991 up Harley Davidson Sportster 1 Press plugs into both holes in air cleaner backplate as shown in Picture 7 2 Assemble fast idle mechanism as shown in Figure A Picture 7 3 Throttle Preparation NOTE Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation Throttle must snap closed when released Cable routing must be free of tight bends to minimize friction between cable and housing If throttle does not work freely it may inadvertently stick open possibly causing loss of control of motorcycle and personal injury to operator or others A Prepare existing throttle assembly 1981 1989 Harley Davidson Sportster and 1981 and later big twin chassis equipped with two cable pull open pull closed type throttle assembly 1 Loosen cable freeplay adjustment locknuts and thread adjusting screw so half of threads are exposed See Picture 8 2 Clean grease and dirt off cables cable housings and cable fittings 3 Apply light coat of cable lubricant to cables and fittings B Replace throttle cables all 1988 and later Sportster models equipped with constant velocity CV type carburetor 1 Carefully remove existing cables noting how they are routed 2 Install replacement cables using same routing as stock cables 3 Loosen c
9. noise restrictor is not installed engine damage will result due to lean condition e If insulator block is not installed lower manifold bolt may damage carburetor bowl causing possible gasoline leak A WARNING Gasoline is extremely flammable and explosive under certain conditions Do not smoke around gasoline Gasoline fumes are toxic when inhaled Any gasoline leak or spill constitutes a health and fire hazard C Adjust throttle cables 1 Turn threaded throttle cable adjusters to remove excessive free play 2 Test throttle to insure that it opens and closes freely Turn handlebars to extreme left and open and close throttle then turn bars to extreme right and open and close throttle If throttle binds loosen cable adjusters to put more free play in cables Tighten adjusting screw locknuts after making final adjustments NOTE Throttle must not bind and must snap shut to fully closed position when released A WARNING If throttle does not return to fully closed position when released it may inadvertently stick open causing possible loss of control of motorcycle and personal injury to operator or others D Install Overflow Hose 1 Slip fuel overflow hose onto fitting on carburetor bowl and neatly route behind pushrod tubes On a big twin model hose should go toward back of engine On a Harley Davidson Sportster model hose should go toward front of engine Exit end of overflow hose must extend down below engine and away from ex
10. not be replaced by a Dealer without prior authorization from S amp S If it is deemed necessary for S amp S to make an evaluation to determine whether the part was defective a return authorization number must be obtained from S amp S The parts must be packaged properly so as to not cause further damage and be returned prepaid to S amp S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem how the part was used and the circumstances at the time of failure If after an evaluation has been made by S amp S and the part was found to be defective repair replacement or refund will be granted ADDITIONAL WARRANTY PROVISIONS 1 S amp S shall have no obligation in the event an S amp S part is modified by any other person or organization 2 S amp S shall have no obligation if an S amp S part becomes defective in whole or in part as a result of improper installation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the S amp S part 3 S amp S shall not be liable for any consequential or incidental damages resulting from the failure of an S amp S part the breach of any warranties the failure to deliver delay in delivery delivery in non conforming condition or for any other breach of contract or duty between S amp S and a customer 4 S amp S parts are designed exclusively for use in Harley Davidson and other American v twin motorcycles S amp S s
11. 0096 or 16 0471 bracket or in top and bottom holes with 16 0491 or 16 0492 insulator block 3 3 16 X Va 5 Pack eesssssessssessesessessesessosseseseeseeseseoseseoseoseseosessosessesessessesoseeseoseseosesee 50 0178 Use in bottom hole with 16 0096 or 16 0471 bracket and 16 0491 or 16 0492 insulator block De AD 5 Pack sessiicssissssissscsiissisisesisrerieseisesressseritiitisisea seoir a stonscrsieracnceest 50 0185 Te VOM 21 4 5 PaCk sessssssssssssssssceesssssseecccessssssseceessossseccceesssssssceroosssssceceessssssseceessssss 50 0180 Ss 16 X272 5 Pack craisnaiicnotiararaloniniaiaraeieacundntannunannil 50 0188 5 Manifold o ring 1955 78 BT amp Sportster OOO ores E EEO A E anor nes Ganon eee 50 8132 6 Manifold rubberband 1979 85 BT amp Sportster 10 Pack r sesssesseesseerees 16 0245 Manifold o ring 1984 up big twin amp 1986 up Sportster STOCK cylinder heads 10 PACK eczsyscxstsssvcsswssndtuacsnsasentieaucssscannaneaiesneateutnesteenains 16 0236 S amp S cylinder heads 10 Pach ccscecse tes cecesasectccesvctresastetecteveccoteestnesteeniannensdeceeeece 16 0235 8 Manifold clamps REVO pre 1D 7D ccsssscescesccte casastets tate cdpacezusdeaseaicascesecessaceatuaetteaseuaotecl becesusescbcceees 16 0230 Band T7910 D jenaeere emer mare ae a er ere cee ener eae 16 0231 9 Manifold Flanges 1984 06 BT amp 1986 06 Sportster Front MOUNTING flange 5 PACK eccsescssssssssssssssssssscssesssecsscsssscsscsssccssceseccs
12. Instruction 106 2469 3 20 08 Copyright 2008 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tue 235 Causeway Blvd La Crosse Wisconsin 54603 Phone 608 627 1497 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Website www sscycle com Fax 608 627 1488 Because every industry has a leader Installation Instructions TUV Approved Super E Carburetor Kits DISCLAIMER S amp S parts are designed for high performance off road racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely affect your factory warranty In addition such installation and use may violate certain federal state and local laws rules and ordinances as well as other laws when used on motor vehicles used on public highways especially in states where pollution laws may apply Always check federal state and local laws before modifying your motorcycle It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use and the user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith The words Harley Harley Davidson H D Sportster Evolution and all H D part numbers and model designations are used in reference only S amp S Cycle is not associated with Harley Davidson Inc
13. able freeplay adjustment locknuts and thread adjusting screw so half of threads are exposed See Picture 8 4 Apply light coat of cable lubricant to cables and fittings Picture 8 4 Install New Manifold and Mounting Hardware NOTE When applicable all carburetor mounting brackets and hardware supplied in kit must be installed to secure carburetor and air cleaner backplate assembly rigidly to engine Improperly mounted carburetor could loosen unexpectedly resulting in air leak poor performance and possible damage to engine or carburetor Incorrect combinations of mounting hardware may cause mounting bolts to bottom out in holes or inadvertently contact other parts possibly causing damage to engine or carburetor components Improperly mounted carburetor may break free in event of collision or other vehicle accident creating a fire hazard with potential personal injury to operator others A All models Clean intake ports on cylinder heads to insure proper manifold to head seal B All models Install S amp S intake manifold If applicable vacuum advance fitting must point upward For manifold flange and seal assembly order See Figure B Note that bevel side of seal goes toward recess in manifold flange flat side of seal against head Do not completely tighten manifold clamps or flange bolts at this time Figure B C Harley Davidson Sportster models 1983 later and all 1984 up big twins Connect vacuum operated advanc
14. and maintenance are critical for kick start motorcycles NOTES e If severe flooding is suspected turn ignition off slowly roll throttle to wide open position and kick 6 8 times to clear engine Then close throttle to approximately 1 turn turn ignition on and kick until engine starts e If insufficient fuel is suspected remove air cleaner cover and confirm accelerator pump operation by snapping throttle open from closed position Fuel should exit accelerator pump nozzle directly behind main discharge tube in carburetor bore No more than 2 3 squirts from accelerator pump should be required to start motorcycle with temperature 60 F or above This may also be caused by incorrect idle mixture adjustment or a manifold leak Refer to following sections for additional information on tuning 2 Adjusting Carburetor The carburetor comes preset from S amp S It is illegal to adjust the carburetor to settings other than those provided in the documentation included with the engine In the case maintenance is needed the idle emissions and idle speed may be reset to the specification in the documentation by the following procedure A Adjusting Idle Circuit for idle emission The idle mixture screw regulates air fuel mixture at idle speeds and has been angled out for greater accessibility See Picture 30 Engine rpm adjustment screw is located on boss on rear side of carburetor body See Picture 31 During assembly S amp S adjusts both screws to se
15. ble for use with S amp S butterfly style carburetors with the shorter cable bracket These cables must be used in 1996 and later Sportster installations These cables may be used on 1996 and later big twin installations if the S amp S carburetor is equipped with the short cable guide bracket CARB INSTALLATION Read instructions thoroughly to familiarize yourself with all procedures before beginning installation NOTE Installation of S amp S Super E carburetor kits on certain models is easier with gas tanks removed Some owners may elect to perform installation without removing gas tanks This is left to individual discretion If installer elects to remove tanks or other stock parts S amp S recommends referring to appropriate Harley Davidson service manual for correct removal procedure as necessary 1 Remove Old Carburetor A WARNING Gasoline is extremely flammable and explosive under certain conditions Do not smoke around gasoline Gasoline fumes are toxic when inhaled Perform installation in a well ventilated area away from open flames or sparks Any gasoline leak or spill constitutes a health and fire hazard If motorcycle has been running wait until engine and exhaust have cooled to avoid getting burned during installation Electrical sparks can ignite explosive gasoline fumes Failure to disconnect battery while working on motorcycle can also result in inadvertent engagement of starter and personal injury A Shut off fuel pet
16. buretor In spite of the differences in throttle cables for these year groups stock throttle cables on all 1981 to present big twin models can be installed on the S amp S Super E throttle linkage with no cable modification S amp S Super E carburetor kits for 1936 to 1989 big twins contain a throttle cable guide designed for butterfly type throttle cables and kits for 1990 and later big twins contain a taller throttle cable guide designed for CV type throttle cables See Picture 2 The two throttle cable guides are interchangeable on the carburetor body and can be changed very easily to update older carburetors or to accommodate custom throttle cables which are not stock for a particular year chassis 1990 and later BT 1936 1989 BT Picture 2 1981 to Present Harley Davidson Sportster Models Stock Sportster models from 1981 to 1987 have two cable throttle system designed for butterfly type carburetors 1988 to present models have a two cable throttle system designed for use with the stock constant velocity CV type carburetor Since the taller cable guide bracket can not be used on a Sportster chassis due to insufficient frame clearance throttle cables on motorcycles originally equipped with a CV type carburetor must be changed to butterfly style cables S amp S can supply the correct style throttle cables See S amp S Throttle Cable Application Chart 1 S amp S Throttle Cable Application Chart Length Length Part Number Part Number PERA
17. cock and disconnect battery B Remove air cleaner assembly Drain fuel from existing carburetor Remove carburetor manifold choke cable and any carburetor mounting hardware NOTES Removing and tightening hard to reach Allen bolts like carburetor mounting bolts and manifold flange bolts can be greatly simplified by using some special tools The S amp S rocker cover wrenches work very well for this application See Picture 3 Allen ball end drivers are also very helpful and are available at most automotive and tool supply houses See Picture 4 As an alternative a standard hex wrench can be shortened for convenience Picture 3 2 Prepare Air Cleaner Backplate NOTE Fast idle lever screws must not be over tightened Loctite or other thread locking compound may be used sparingly on threads to prevent screws from vibrating loose AX CAUTION Over tightening fast idle lever screws may damage backplate A 1984 92 Harley Davidson Evolution big twin engines 1 Press plug into hole on left in air cleaner backplate as shown in Picture 5 2 Screw vent hose elbow fitting into remaining hole at right See Picture 5 3 Assemble fast idle mechanism as shown in Figure A Elbow Fitting Figure A Picture 5 B 1986 to 1990 Sportster models 1 Press plug into hole on right in air cleaner backplate as shown in Picture 6 2 Screw vent hose nipple fitting into remaining hole at left See Picture 6 Elbow fitting supplied in kit
18. e ignition switch VOES to manifold using 8 piece of black tubing supplied in kit Cut tubing to shorter length if necessary D Twin Cam 88 1999 up engines Install stock map sensor in S amp S manifold See Picture 9 Secure sensor to manifold with stock clip and screw See Picture 10 Install manifold on engine with stock hardware Connect fuel petcock vacuum hose to manifold fitting and connect wiring harness to map sensor See Picture 11 a Picture 9 Picture 10 Picture 11 5 Install Carburetor A Install throttle cables on carburetor 1 Locate throttle cable housing bracket on carburetor or in kit 2 Install opening side throttle cable barrel fitting and throttle cable in throttle linkage and appropriate side of throttle cable housing bracket Opening side cable housing outside diameter is smaller and measures 0 190 3 Repeat step 2 for closing side throttle cable Closing side cable has a spring around inner cable wire See Picture 12 Picture 12 4 Apply drop of Loctite 242 or equivalent to threads of cable bracket screw and reinstall bracket on carburetor B Install carburetor Install the two 3 16 socket cap screws through mounting holes in manifold from back side Install insulator block onto cap screws with O ring side of block facing manifold Install noise restrictor onto cap screws with the gasket side facing manifold See Picture 13 Install carburetor and tighten cap screws Se ae Picture 13 If
19. ections if applicable Check fuel overflow hose routing Avoid hot surfaces raAammyD Test throttle to be sure it opens and closes freely Turn handlebars to extreme left and open and close throttle then turn bars to extreme right and check throttle When released throttle should snap closed in all positions Reassemble components that were removed or disassembled for carburetor installation Consult authorized Harley Davidson service manual for installation procedure for stock parts not covered in S amp S carburetor instructions J Check fuel needle and seat assembly Fill gas tank with just enough fuel to test system Lean motorcycle over towards carburetor side turn on fuel petcock and wait 20 seconds If gas runs out end of carburetor or out overflow hose turn off petcock and check needle and seat See General Information K Check fuel inlet fitting and fuel line connections for leaks Hose clamps must be tight NOTE Fuel needle and seat assembly must completely shut off fuel supply to carburetor bowl Fuel inlet fittings and fuel line connections must not leak Gasoline leaking past inlet needle may flood engine causing contamination of oil supply and damage to engine Any gasoline leak represents a health and fire hazard L Install air cleaner element noise reducer and air cleaner cover 1 Install three cover mounts and washers on backplate cover supports Use Loctite 242 or equivalent on threads See Picture 26 2
20. eed screw in order to maintain idle speed This reduces manifold vacuum and makes the enrichment circuit less effective See Adjusting Carburetor Idle Circuit on page 15 7 Ifthe enrichment device feed hole in bowl is plugged then clear with compressed air Do not use wire or drill to clear hole If size of hole is changed starting system will be altered and carburetor bowl irreversibly damaged Compressed air and particles dislodged by compressed air are potentially harmful to eyes and body Wear protective goggles when using compressed air and always direct air stream away from yourself and others nearby 8 Improper diagnosis of rich or lean mixture condition If engine backfires in carburetor mixture is usually lean and engine must be reprimed If there is no response after three kicks or if engine pops in exhaust pipes mixture is probably too rich Leave switch on and slowly open throttle turn with each successive kick until engine fires 9 If engine was running properly before installation of carburetor no other changes were made and carburetor settings were confirmed as instructed previously hard starting is likely caused by incorrect intermediate jet or starting routine Remain calm and patient while attempting to start motorcycle and experiment with different starting procedures throttle and enrichener position number of squirts from accelerator pump etc especially with kickstart motorcycle Carburetor tuning and ignition tuning
21. hall have no warranty or liability obligation if an S amp S part is used in any other application INTRODUCTION S amp S Super E Shorty carburetors are designed for big twin and Harley Davidson Sportster models as well as other American v twin engines They are butterfly type carburetors with an accelerator pump for improved throttle responses and a variable enrichment fast idle device for improved engine starting and warm ups The Super E has a 1 47 6mm bore and 1 39 6mm venturi It is identified by an E cast into the throttle linkage side of the body below the letters S amp S SUPER Picture 1 NOTE S amp S carburetors are jetted at the factory to meet noise and exhaust emissions when properly installed It is illegal to run the bike without the noise reducers installed Operating the motorcycle without the noise reducers will also cause engine damage The user shall determine the suitability of the product for his or her use and shall assume all risk and liability in connection therewith Kit Contents Each complete carburetor kit includes One S amp S Super E gas carburetor One S amp S teardrop air cleaner assembly with noise reducer One manifold with noise restrictor Mounting hardware Fuel line fuel line insulator clamps and overflow line VOES tubing and additional hardware when applicable Installation instructions and TUV documentation CHROME PLATING THE CARBURETOR NOTE S amp S does not recommend chr
22. haust pipes See Pictures 14 and 15 A WARNING Overflow hose must not contact hot surface such as exhaust pipe where it could melt and catch fire E Install fuel line 1 Slip hose clamp over end of fuel line with 90 bend 2 Apply thin coat of oil to carburetor fuel inlet fitting and slip end of fuel line with 90 bend on fitting 3 Position fuel line in such a way as to avoid contact with cylinders and other hot engine parts Tighten hose clamp 4 Slip protective fuel line covering over fuel line and position to protect fuel line where contact with engine parts could occur On models equipped with fuel line support guide use guide if possible 5 Connect other end of fuel line to gas tank petcock using hose clamp provided A WARNING Fuel line must be clamped securely and not contact hot surfaces such as exhaust pipes where it could melt and catch fire 6 Install Air Cleaner Backplate NOTE Air cleaner backplate screws supplied with kit have thread locking compound on threads If screw without thread locking compound is used a thread locking product such as Loctite 242 must be applied and screws properly tightened AX CAUTION Failure to apply thread locking compound or properly tighten screws may cause screws to loosen and fall into engine causing engine damage not covered under warranty A Harley Davidson Evolution big twin 1984 to 1992 and Sportster models 1986 to 1990 1 1992 big twin models with crankcase breat
23. her vented from cases to air cleaner backplate Install thread sert in each cylinder head air cleaner mounting bolt hole This converts stock 2 13 thread to s 18 thread Surface of thread sert should be just below surface of cylinder head See Picture 16 Picture 16 NOTES Most 1992 big twins have crankcase breather routed from case to air cleaner backplate However some late 1992 engines have breather routed from heads to air cleaner backplate through air cleaner mounting bosses If crankcase breather is routed through heads 1993 and later carburetor kit must be installed Follow instructions for installation on 1993 engine Thread serts may be supplied with or without thread locking compound on threads Loctite 242 or equivalent should be applied to threads of thread serts not supplied with thread locking compound Thread serts should be installed in desired position and left in place Installing thread sert in hole activates thread locking compound making it difficult to change position of thread sert after installation Cylinder head vent passages in head breather type engine must not be plugged as oil leakage and engine damage may result Same applies to crankcase vent in case breather type engine 3 4 5 6 Mount the air cleaner backplate on carburetor using three 4 20 x 6 screw washer assemblies Confirm that enrichment device lever engages enrichment device plunger See Picture 17 Tighten backplate
24. idie mixture screw C PAC esrara RN A 11 2378 Idle mixture screw spring 10 PACK ssssessseessseessseessseessseeesseeesseeesseeesseee 11 2060 Idle speed screw 10 PACK sssssssesssesssessseesseesscessereseesssessecoseessecessessseesseesee 50 0150 Pump adjustment screw 10 PaCk sss sssssessseessssessssessseessseseeeeeeeessssssssssses 50 0146 Idle speed PUMP adjuster spring 10 Pack sssssssssessssessssessseessseeessee 11 2053 Plunger n t 10 Paci ssensirissienninnriini n innate 11 2372 Plunger spring 10 Pack ssssessssessssesssessssesesseessseeesseeesseeesseeesseeesseeesseeesseee 11 2359 Fast idle OLIGO ossimori A 11 2343 Cable guide assembly For use with butterfly style cableS ssssssssessssssseeressssssesesssssseesesssss 11 2339 For use with CV cables Constant velocity style ssssssssssssssssesss 11 2338 Cable clamp float pin screw 10 Pack rscsessssessssersssessssessesessesessesesseseeees 50 0062 O ring1 E 10 Pack sssrin 50 8094 Dhe G 10 Paek numica onii 50 8093 Bellows seal 5 Pack seunisinenenananiea an 11 2279 B wl vent plug 10 Pad anrssoennncnntnennnoninnnninnn naaa 50 0151 Main discharge TUG sssssssssessssvesseseserivossenstsssrassosisseinssrsssvorcsseiosriosssnsiresss 11 2085 Main jet State SIZC ssssessssessssessssessssessssessssessssessssessssess See Dealer Catalog 18 28 29 30 31 32 33 34 3D 36 37 38 39 40 41 42 43 44 45 46 47
25. mounting screws to 10 12 ft lbs Fill gap between backplate mounting ears and cylinder heads with shims provided in S amp S shim kit Bolt backplate to cylinder heads with 346 18 x 114 bolts flat washers and lock washers See Picture 18 Final tighten all mounting bracket bolts and manifold clamps Connect crankcase breather hose to air cleaner backplate hose fitting See Pictures 19 and 20 d mal Picture 18 Picture 19 Picture 20 B Harley Davidson Evolution big twin engines 1993 99 Sportster models 1991 03 and all Twin Cam 88 engines 1999 up 1 Install breather fittings in heads See Picture 21 Apply red Loctite to threads and torque to 15 20 ft lb See Picture 22 for component placement Install breather hose between breather fittings with long hose runner toward rear cylinder breather fitting Position hose in such a way that it is not kinked and does not interfere with travel of the enrichment lever Trim ends of vent hose as required Secure hose to fittings with small wire ties Install backplate and gasket Connect the short T of the breather hose to the steel nipple fitting on the back of backplate See Picture 23 Secure hose to backplate fitting with hose clamp Confirm that fast idle lever has properly engaged enrichment plunger See Picture 17 Tighten screws holding backplate to carburetor to 10 12 ft lbs Determine which of the provided shims correctly fills the gaps between backplate a
26. nd breather fittings See Picture 24 Fill gap between backplate mounting ears and cylinder heads with correct shims Install screws to attach backplate to breather fitting Torque to 8 12 ft lb with no Loctite See Picture 25 Picture 22 10 rr 5 Ti hel l a EL ef Picture 23 Picture 24 Picture 25 NOTE Backplate screws supplied with kit have pre applied thread locking compound on threads If screw without thread locking compound is used a thread locking compound such as Loctite 242 must be applied to threads and screws properly tightened If screws are removed in future Loctite 242 or equivalent must be applied before reinstallation Failure to apply thread locking compound or properly tighten screws may cause screws to loosen and fall into engine resulting in engine damage not covered under warranty Final assembly and checks A Check carburetor to manifold mounting bolts B Check carburetor to air cleaner backplate mounting screws C Check each of following that is applicable Carburetor mounting bracket to head bolts Mounting bracket to air cleaner backplate Mounting bracket to center case stud Mounting bracket to tappet guide bolt Mounting bracket to head breather vent fitting Air cleaner backplate to head mounting bolts E a ee ES Check fuel line connections and routing Avoid hot surfaces Check vacuum operated ignition advance connections if applicable Check crankcase to backplate vent hose conn
27. ome plating the Super E carburetor Preparation requires polishing with abrasive buffing compounds These materials invariably plug air and or fuel passages and other orifices regardless of precautions taken The chrome plating process can alter critical operating tolerances in several areas Additionally chrome may obstruct fuel passages possibly altering the fuel mixture and causing engine damage All manufacturer warranties become void if any part of the carburetor is polished chrome plated or otherwise altered THROTTLE REQUIREMENTS NOTE S amp S Super E and G carburetors require the use of a two cable pull open pull closed throttle assembly All 1980 and earlier stock H D models equipped with a single cable throttle mechanism must be converted to the two cable pull open pull closed type S amp S offers these throttle assemblies but does not include them with any carburetor kit because of the multitude of chassis designs and fitment requirements WARNING Single braided wire cable throttle mechanisms cannot mechanically close the throttle If throttle inadvertently sticks in open position loss of control of motorcycle and personal injury to operator or others may result 1981 to Present Big Twin Models Stock big twin models from 1981 to 1989 have two cable throttle system designed for stock butterfly type carburetors Big twins from 1990 to present have a two cable throttle system designed for the stock constant velocity CV type car
28. own to closed position as engine warms Engine should be warmed sufficiently to idle with fast idle lever off in 1 to 4 minutes or after a few miles of riding NOTE Operating engine with fast idle lever up for excessive time will result in fouled spark plugs Push lever completely down as soon as engine will run smoothly without enrichener B Hot Starts 1 Open fuel petcock 2 Turn on ignition 3 With throttle closed kick engine through or engage electric starter 4 lf engine fails to start immediately open throttle slightly and continue to kick or engage starter until engine fires C Troubleshooting Tips engine will not start 1 Fuel supply exhausted 2 Weak or no spark discharged battery worn points faulty condenser ignition module coil spark plug wires or magneto 3 Plug gap too wide S amp S uses 025 to 030 plug gap on engines with points type ignition and stock coil Electronic ignitions and high output coils can run wider plug gaps 4 Improper ignition timing Worn or poorly maintained mechanical advance units sometime stick in advanced position causing hard starting kick back and erratic idle 5 Tight tappet adjustment If solid tappets are adjusted too tightly valves may not seat properly and the loss of compression may prevent the engine from starting 6 Improper idle mixture and or engine idle rpm setting If idle mixture is set incorrectly throttle plate must be opened farther with the idle sp
29. pacer block can be installed between carburetor and manifold as an alternative or existing air cleaner cover modified to provide 18 minimum clearance Improperly mounted carburetor may loosen from engine resulting in gas or air leaks poor performance and possible damage to carburetor or other components A WARNING Any gasoline leak represents a potential health and fire hazard 12 CARB OPERATION 1 Carburetor Starting Procedure S amp S Super E carburetors do not have a conventional choke Instead a mixture enrichment fast idle device is used for starting and engine warm ups The enrichment device utilizes separate air and fuel pickup passageways and is engaged by pulling fast idle level upward See Picture 28 Super E carburetors also feature an accelerator pump which is actuated by quick throttle movements at partial throttle openings and can be used as an additional starting aid Picture 28 ENRICHMENT DEVICE NOTES Enrichment fast idle pickup tube located directly below fast idle plunger is pressed into carburetor body and must not be removed See Picture 29 Picture 29 Removal of enrichment fast idle pickup tube from carburetor body may cause irreversible damage to carburetor Plunger nut plunger spring and plunger may be removed for cleaning purposes If air cleaner backplate is removed be sure fast idle lever and enrichment plunger are engaged properly when backplate is reinstalled See Picture 17
30. scesseeses Rear MOUNTING flange 5 PACK seccsessssssssssssssssesssssssecssccsscsssccsscsssccsscssscesscesseesss 20 10 11 12 13 14 15 16 17 Carb mounting bracket 1948 65 BT not SHOWN sssssssssssssssssssssssssss Carb mounting bracket assembly sssssssssssssesssssssssssssssessssssssssssssssssssssess Includes 1 each 2 piece bracket 17 0104 17 0245 17 0321 Support bracket bolt 16 18 1 ssssssscecsssssssssecesssssseeccceesssssssereessssss Flat washer 7 16 X i6 sssessesessessesesseseeseseeseseeseoseseosessosesseseseseoseseoseososeosesee lock nut ire 18 ea ka E ESENE a sE 1 Aluminum spacer blocks For 17 Super E sessesssesssessessesssesseeseessesscessessesseesseoseeseesseossesseoseossesseeseessessee Includes 1 each 1 spacer block amp 50 8013 o ring For Fie SUPON Qosssesiississeseststreosessesstsrtsvs sste aketa s Ssa SEE ESEESE EEEa Includes 1 each 1 spacer block amp 50 8015 o ring Insulator blocks 14s Super E All big tWiNnS sese sssessssesssssessseessssessseeosssessssessssessseessss Includes 1 each insulator block amp 50 8016 o ring 2 6 Super G All big tWinS s sssesssseessseessssessseessseessssessssessseessseessss Includes 1 each insulator block amp 50 8015 o ring 1 s E for Sportster Manufactured after 6 15 01 ween Includes 1 each insulator block amp 50 8016 o ring 2 16 for Spor
31. scsssessseessseosecoseees ceseeese 11 2393 Ball Check 2 required 10 PACK ssscscscssssssessssscsssssssssesssesesessssseseseseseaes 50 8125 Ball check spring 5 Pach erenersnoiciraniii danin 11 2392 Pump cap o ring 2 required 10 Pack sssscsssscsssscssssssses seeesseesssecesseee 50 8100 Pump cap assemDIy enaieeniia aar E ener nt er eee 11 2389 Overflow hose per 24 5 PACK s cscssssssssssssssssesses sosssssessesseessseeseseesesseseseess 19 0263 Pump Cap Screw 8 32 2 required 10 PACK esssessssssesessssssesessesesseseees 50 0098 Diaphragm spring 10 PACK sxscvsssenssssenssivescsacssiensesxactivassenthareisbentneonaeen 11 2278 DE NU E e a Vacs ca tr ATEEN E A A T AE O E TA 11 2282 Gasket back plate 10 Pack es sssessseessessseesssesssessecssserssesscssseesesenscesseosseesse 17 0383 Enrichment device Use with air horn only ss sssssessssessssessseessseesssee 11 2084 Fuel line w 90 bend 19 Use w 11 2465 or 11 2466 s s s 19 0475 19 REPLACEMENT MANIFOLD PARTS 1 Restrictor plate not SHOWN ccsssssssssssesssssssssssssescscssssssesssacscssesesescsseseaceseseaes 16 0489 2 Intake manifold for 1986 2006 Harley Davidson Sportster 16 1620 3 Intake manifold for 1990 2005 DII DNI iassa anina ap aaa eaa enn 16 1718 1984 1999 DIO IWIN onesna a 16 1628 4 Manifold bolts 10 Pack PAON T a EEA E EAE 50 0186 IEE al ly E EN E A ere wre ee eee en ere ee 50 0177 Use in bottom hole with 16
32. tate and local laws are obeyed with the installation For optimum performance and safety and to minimize potential damage to carb or other components use all mounting hardware that is provided and follow all installation instructions Motorcycle exhaust fumes are toxic and poisonous and must not be breathed Run motorcycle in a well ventilated area where fumes can dissipate IMPORTANT NOTICE Statements in this instruction sheet preceded by the following words are of special significance A WARNING Means there is the possibility of injury to yourself or others CAUTION Means there is the possibility of damage to the part or motorcycle NOTE Other information of particular importance has been placed in italic type S amp S recommends you take special notice of these items WARRANTY All S amp S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve 12 months from the date of purchase Merchandise that fails to conform to these conditions will be repaired or replaced at S amp S s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter In the event warranty service is required the original purchaser must call or write S amp S immediately with the problem Some problems can be rectified by a telephone call and need no further course of action A part that is suspect of being defective must
33. tster Manufactured after 6 15 01 s sssssesssssee Includes 1 each insulator block amp 50 8015 o ring Manifold O rings For 1 7 s E carb body amp insulator block 10 PACK ssssssssssssssssssesessens For 17 s spacer block 10 PACK sicassssissacsesssasevesssassatiursaivateinonsssiobecadasvareveds For 2 16 G carb body insulator block amp spacer block 70 Pack
34. ttings that should work for your application ai iH Picture 30 Picture 31 Start engine and allow it to fully warn up Adjust idle speed by turning rpm adjustment screw Adjust idle emissions by turning idle mixture screw Verify idle speed has not changed m T 15 GENERAL INFORMATION NOTES Carburetor body has six drilled passages that are permanently sealed with drive plugs Removal of these plugs may cause irreversible damage to carburetor To insure proper seal so needle completely shuts off fuel supply entering bowl float hinge needle lift and needle must work freely and not bind Float must not contact bowl gasket If problem is suspected remove bowl and check float movement If obvious misalignment binding or sticking occurs remove straighten and reinstall to obtain free movement Reset float level and double check for free movement To check remove bowl not accelerator pump cap and raise float until needle is in closed position and spring in top of needle is compressed The top of the float opposite the needle and seat assembly should be to 6 below the bowl gasket surface Float must not contact bowl gasket See cut away bowl in Picture 32 Br TI Picture 32 When motorcycle is not running fuel shutoff valve should always be turned off to prevent possible leakage should needle and seat not seal completely Gasoline leaking past inlet needle may flood engine causing contamination of oil s
35. upply and damage to engine Any gasoline leak constitutes a fire and health hazard Throttle plate and throttle shaft should be checked annually for signs of wear Replace if necessary If carburetor body throttle shaft bushings are worn carburetor must be returned to S amp S for repair If throttle plate is removed be sure to reinstall correctly Beveled edges of plate must fit flat against carburetor throat faccelerator pump cap is removed lift cap slowly so small spring checkballs and o rings are not lost IMPORTANT NOTES We at S amp S feel we have designed and manufactured a superior product and will stand behind it If you have questions or problems first refer to this instruction manual Answers to nearly all questions can be found herein If your problem cannot be resolved call 608 627 8324 for technical assistance Do not however call until you have become thoroughly familiar with this manual S amp S also has a complete carburetor repair and rebuild service that provides quality work at a fair price If you are not properly equipped to service an S amp S carburetor and do not have a qualified repair shop nearby we recommend that you contact us for a Return Authorization RA number and send the carburetor to us Be sure to include a note with your name and address RA number and a detailed description of any problems or repairs needed Thanks for using S amp S products REPLACEMENT PARTS FOR TUV APPROVED S amp S
36. ustration purposes only Not all of the parts shown are included and used in every carb installation Parts followed by an N A are no longer available Those followed by an NS means parts are not shown 17 S amp S SUPER E AND G CARBURETOR REPLACEMENT PARTS 22 23 24 25 26 27 Carb body assembly gf ANA AAEN S A A 11 2381 Dg a E T E E 11 2390 Throttle shaft 1 E Includes 2 plate SCreWwsS sssesssessseessesssessseessecssecssesosersseessseosecsseees 11 2383 2he G Incluces 2 Plate screws ssessssesssesssessecsseeessesssesssesseeesscessessseesse 11 2483 Throttle plate screw 2 required 10 PACK ssssssssssssesessssesesessesesseeeees 50 0064 Throttle plate TE EEEN EE O E 11 2055 P E A E AT AA AA AE AOAN AA 11 2355 Throttle return spring 5 Pack uniinawoninnnnsnnnnnsmannen 11 3502 Throttle SOOlsssninemenenenionnsiennenn ae 11 2385 Throttle shaft lock washer 2 required 10 Pack sssssessesessessssesssesss 50 7073 Throttle shaft nut 2 required 5 PACK ccecsssessssessesessesesscssssscsseseseeeens 11 2363 Throttle shaft nylon washer 10 PACK s sssssscssssssssssssscsscssessessessessesees 50 7072 Pump actuator lever ooscsssoevscxaedncesssissatonssssacteaniapastatnsedioenanieleiiaroten 11 2376 Actuator spring 5 Pack s sssssesseessessesssesseeseessesseessesseoseessesseoseroseosseseeosesss 11 3501 Pump actuator arM e seesessessessessesseseesessseseosesseesessessesseseosseseeseoseosessesseosesees 11 2377
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