Owners Manual
Contents
1. e S OPTIONAL OIL PRESSURE CASE BREATHING VENT POINT TO AIR CLEANER OPTIONAL LINE ROUTING SUPPLY FROM OIL TANK OPTIONAL LINE ROUTING RETURN TO OIL FILTER A RELOCATE FITTING RELOCATE FITTING Q OIL TANK ALT GEN OIL FILTER MOUNT OR OTHER OIL Ufo FILTER MOUNT A OE B FILTER HLIER RECOMMENDED 1 FRONT CHAIN OILER ADJUSTMENT OIL PUMP CASE BREATHING VENT TO AIR CLEANER TURN CHAIN OILING SCREW IN TO DISABLE CHAIN OILING IF FRONT CHAIN OILING IS NOT NEEDED OWNERS MANUAL 585 KN P AND SH SERIES ENGINES VENT TANK B TANK TO PUMP IN C RETURN TO FILTER D VENT TO TANK E FILTER IN FILTER OUT H CAM CHEST OIL LINE HOOK UP P AND SH SERIES FILTER TO TANK TO AR CLEANER CASE BREATHING VENT A lt a o D Ka M A lt x il CASE BREATHING VENT TO AIR CLEANER OIL PUMP RECOMMENDED J SUPPLY FROM TANK K PRIMARY CHAIN OILER L RETURN TO CASE M RETURN FROM PRIMARY FUEL REQUIREMENTS The gasoline used in your engine should have a US octane rating of 91 The United States uses the RM method of octane rating In many countries outside the United States2. P AND SH SERIES ENGINES 23 OWNERS MANUAL NOTES 24 OWNERS MANUAL 585 P AND SH SERIES ENGINES 25 26 OWNERS MANUAL 585 P AND SH SERIES ENGINES 27 SES Cycle Tuc 14025 County Hwy G Viola WI 54664 Phone 608 627 1497 Fax 608 627 1488 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com www sscycle com 510 0364 02 28 15 Copyright 2015 by 585 Cycle Inc All rights reserved Printed in the U S A
3. Owners Manual S amp S KN P and SH Series Engines m ai eS AAA N 5 a V DISCLAIMER S amp S parts are designed for high performance closed course racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely effect your factory warranty In addition such installation and use may violate certain federal state and local laws rules and ordinances as well as other laws when used on motor vehicles used on public highways especially in states where pollution laws may apply Always check federal state and local laws before modifying your motorcycle It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use and the user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith The words Harley Harley Davidson Sportster Evolution and all H D part numbers and model designations are used in reference only S amp S Cycle is not associated with Harley Davidson Inc SAFE 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 a
4. SERIES ENGINES With engine idling turn accelerator adjustment screw clockwise until it lightly seats Snap throttle open engine should stumble Turn screw counter clockwise or of a turn at a time until engine responds to throttle twist with smooth quick response Ride motorcycle in various RPM ranges and then try to maintain a consistent 40 to 50 MPH If the engine has a flat spot or is popping sneezing in the air cleaner it can indicate a lean condition If you notice stumbling or sputtering it can indicate a rich condition Low RPM operation is controlled by the intermediate jet 11 If sneezing or popping is experienced below approximately 3000 RPMs the intermediate jet must be replaced with a larger sized richer jet If the engine does not run smoothly at low speeds fouls plugs blows black smoke or gets bad gas mileage a smaller leaner intermediate jet needs to be installed Always readjust the idle mixture 2 and idle speed 1 screws after making a jet change To test the main jet do a roll on from 50 MPH to 70 MPH in 3rd gear If the engine backfires or breaks up in the carb increase the main jet size 004 If the engine is flat or will not accelerate decrease the main jet by 004 Since 2004 S amp S shorty carbs have been fitted with an adjustable main jet air bleed 13 Changing this jet to a larger size will delay the signal to the main jet therefore aiding with high speed tuning as described in step 8
5. This also aides with tuning an engine that is fitted with an exhaust system that is not intended for high performance The air bleed uses main jets the stock size is 40 If it needs to be changed the range is normally 50 to 60 11 10 11 12 12 NOTE Drag or straight pipes especially large diameter or long designs can prevent you from obtaining optimum carburetor performance Ifthe S amp S teardrop air cleaner is being replaced with an aftermarket air cleaner be sure to remove the auxiliary bowl vent screw 14 Never use a velocity stack on a street driven motorcycle Poor throttle response will be experienced Always be sure to attach the hose to the overflow tube fitting 6 and route it toward the back of the engine OWNERS MANUAL 585 P AND SH SERIES ENGINES Approximate Jetting For 585 Super E amp G Carburetors Dum oe or or ore These jetting recommendations are a starting point only Re jet carb for best performance 1 Idle Speed Screw 2 Idle Mixture Screw 3 Accelerator Pump Adjustment Screw 4 Enrichment Device 5 Serial Number 10 Accelerator Pump Pushrod 6 Overflow Tube Fitting 11 Intermediate Jet 7 Fuel Inlet 12 Main Jet 8 Bowl Vent Hole 13 Main Jet Air Bleed 9 Bowl Plug 14 Auxiliary Bowl Vent Plug 14 OWNERS MANUAL 585 P AND SH SERIES ENGINES ENGINE SERVICE INTE RVALS Engine Oil amp Filter Change at 50 500 2 500 miles 80 8
6. breathed Run motorcycle in a well ventilated area where fumes can dissipate 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 5855 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 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
7. engine RPM below 3 500 RPM but do not lug the engine The dyno must be operated so the engine runs under a load roughly equal to the power needed to move the bike down the road this would be about 12 hp at 55 MPH Keep engine head temperatures below 200 F at the temp sensor or surface of the head Stop and cool the engine if needed Allow the engine to cool down to room temperature Run the bike for 25 more miles 50 miles total under varying speeds loads gears as before Make sure there is some load on the engine Keep engine speed below 4 250 RPM but do not lug the engine Limited short bursts of throttle can aid in ring seating as long as the calibration tune keeps the AFR in control Keep engine head temperatures below 225 F at the temp sensor or surface of the head 5 After the first 50 miles on the dyno it is recommended the normal break in schedule be followed under normal riding conditions on the street See Step 5 on the previous page The oil filter used on an S amp S KN P or SH Series engine should be rated at 24 microns Spin on filters should not have an anti drain back valve S amp S filters are available to replace Harley Davidson 63805 80A and 63796 77A The S amp S part numbers 31 4101 and 31 4102 TUNE UP INFORMATION S amp S KN P and SH Series engines come from the factory with Champion RN12YC 14mm long reach spark plugs S amp S PN 55 1321 that should be gapped between 038 and 042 inch If yo
8. load operation and high heat conditions From 1 000 miles on Break in is complete enjoy NOTES FOR COMPLETING INITIAL 50 MILE BREAK IN AND INITIAL TUNING ON A CHASSIS DYNO When running the bike on the dyno it is critical that engine temperatures are monitored AFR is kept between 12 5 14 7 and the engine is not overheated Fans must be used to keep the engine cool When tuning under higher loads stop regularly and allow the engine to cool A load must be placed on the engine to properly seat the rings Running a new engine continually with no load will result in cylinder glazing and poor ring seal The engine should be loaded to simulate close to the weight of the bike a load of 10 15 on a Dyno jet 250i is usually sufficient It is not recommended to use an inertia only dyno to break in an engine as no load can be placed on the engine OWNERS MANUAL S amp S AND SH SERIES ENGINES Initial tuning on the engine can be completed during the initial 50 miles of dyno break in It is recommended the engine be run on the street for a minimum of 500 miles prior to completing tuning at full power Monitor engine temperature during tuning to ensure the engine is not overheated DYNO BREAK IN PROCEDURE FIRST 50 MILES 1 Follow the same procedure outlined above for initial start up and heat cycling the engine Run the bike for 25 miles on the dyno under varying speeds and loads while going up and down through the gears Keep
9. the RON Research Octane Number is used which will result in a higher octane requirement of about 96 GENERAL BREAK IN NOTES Remember that these are air cooled engines Sufficient air movement is required to keep engine temperatures within safe operating limits Avoid heavy traffic and congestion or extended idle periods whenever possible 585 v twin performance engines are designed for and happiest when running between 2750 3500 at normal highway speeds Today s heavier bikes and taller gearing can easily push a high performance engine into a lugging condition which increases loads on engine components causes detonation builds excessive heat and increases fuel consumption If the engine does not accelerate easily when given some throttle downshift to a lower gear 585 engines benefit from a warm up period any time they are started to get to operating temperature before being subjected to heavy loads or quick throttle revs BREAK IN OIL CONSIDERATIONS Either petroleum or synthetic oil designed for air cooled v twin engines can be used during the break in period and during normal use If preferred petroleum oil can be used for the break in period after which the engine can be changed over to synthetic oil BREAK IN PROCEDURE 1 Initial start up Run engine approximately one minute at 1250 1750 RPM DO NOT crack throttle or subject to any loads during this period as head gaskets are susceptible to failur
10. 00 4 000 kilometers every 2 500 miles 4 000 kilometers thereafter1 Air Cleaner Element Inspect at 50 and 500 miles 80 and 800 kilometers every 2 500 miles 4 000 kilometers thereafter2 Replace every 5 000 miles 8 000 kilometers Tappet Oil Screen Inspect every 2 500 miles 4 000 kilometers Replace every 5 000 miles 8 000 kilometers Petcock Lines amp Fittings Inspect at 50 and 500 miles 80 and 800 kilometers every 2 500 miles 4 000 kilometers thereafter Vacuum Lines Fuel Tank Filter Screen amp Inspect every 5 000 miles 8 000 kilometers In Line Fuel Filter If used Engine Idle Speed Adjust as required Operation of Throttle amp Inspect at 500 miles 800 kilometers and every 2 500 miles 4 000 kilometers thereafter Enrichment Device Controls Spark Plugs Inspect every 5 000 miles 8 000 kilometers Replace every 10 000 miles 16 000 kilometers or as needed Ignition Timing Inspect every 5 000 miles 8 000 kilometers Engine Mounts Inspect at 500 miles 800 kilometers and every 5 000 miles 8 000 kilometers thereafter External Fasteners Except Re torque at 500 miles 800 kilometers and every 5 000 miles 8 000 kilometers thereafter Engine Head Bolts 1 S amp S recommends that petroleum based oil not specifically formulated for motorcycles should be changed every 1 000 miles 1 600 kilometers after the break in period 2 Replace more frequently if required or if engine is operated in a dusty en
11. AL S amp S KN P AND SH SERIES ENGINES Ambient Temperature F SAE 20W50 Above 30 100 SAE 50 Above 60 100 SAE 25W60 Above 80 SAE 60 Above 80 OIL RECOMMENDATIONS S amp S recommends synthetic engine oil such as S amp S Premium Synthetic 20W50 However a premium petroleum based engine oil such as S amp S Heavy Duty 20W50 25W60 is acceptable S amp S recommends using S amp S oil as it has been designed specifically for our engines S amp S motor oil has higher concentrations of anti wear and corrosion additives along with high quality base stock oils that work well in the high load and high temperature environment Optimum oil temperatures are between 180 230 F if temperatures exceed 250 F on a regular basis the addition of an oil cooler is recommended Regardless of what type of oil you select be sure to only use oil specifically designated for use in an air cooled motorcycle and select the viscosity suggested for the temperature range you will be operating your motorcycle in OIL LINE HOOK UP GEN KN KONE AND 5 5 VENT TO TANK 0 OIL TANK SUPPLY TO OIL PUMP RETURN PRIMARY OIL PUMP RETURN TO OIL FILTER TO OIL FILTER B CHAIN C OIL FILTER TO OIL TANK 8 E D VENT TO OIL TANK w TEE TO PRIMARY 5 E PRIMARY CHAIN OILER TO PRIMARY PRIMARY RETURN CASE PRIMARY RETURN TO CASE ial ey Y VACUUM INTO CASE FROM OIL F
12. Engine Dimensions nsesnseosssnssnssenssnussunsenssnussnnssnsssussnssenssnusssussnsssusnnne 14 Torque Specifications Specifications and Wear Limits esee eerte nnns 18 INTRODUCTION The S amp S engine you have purchased is an air cooled v twin It is designed to offer Proven Performance and reliability Specifications for both the 3 s and 3 bore engines are found in this manual We have covered the most popular configurations 74ci 80ci 93ci 93ci high compression and 103ci based on their original S amp S production designs Some changes may have been made over time as these engines have been in production for a number of years The specifications in this manual are based on the most recent production specifications ENGINE INSTALLATION The procedure for installing an S amp S engine is basically the same as outlined in the factory service manual for the model of motorcycle the engine is being installed in However S amp S engines are sometimes taller then a stock engine so the installer must check to make sure there is adequate clearance between the engine and all chassis components include the frame and fuel tanks An upgraded clutch should also be considered since the S amp S engine will produce more power than the stock engine it is replacing OIL LINE HOOK UP These diagrams show how the oil lines should be hooked up for S amp S KN Series engines P Series and SH Series engines OWNERS MANU
13. d Center To find an S amp S dealer in your area go to the S amp S Dealer Locator at www sscycle com dealer locator 18 IMPORTANT INFORMATION S amp S engines are not recommended for inexperienced riders because the increased performance requires a higher level of riding skill not lug your S amp S engine This is a high performance engine designed to produce excellent horsepower at higher RPM It was not well suited to pull heavy loads at low RPM We recommend that the engine not be operated below 2500 RPM for extended periods of time Shift to a lower gear to keep the engine speed up when traveling at lower speeds Your S amp S Engine is air cooled which means that it depends on air moving across the cooling fins to keep it from over heating Do not allow your engine to idle for extended periods of time Avoid stop and go traffic or any other situation where the motorcycle is not moving while the engine is running avoid engine damage do not operate the engine above 6200 RPM SERVICE SPECIFICATIONS FOR S amp S ENGINES Forthe most part if an S amp S engine requires service a qualified mechanic who services Harley Davidson engines can do the work However the specifications for S amp S engines are somewhat different These charts are provided for reference For more detailed information about any specific S amp S component installation instructions are available for free download from the S amp S website
14. e at this time During this time check to see that oil pressure is normal that oil is returning the oil tank and that no leaks exist 2 Shut off engine and thoroughly check for any leaks or other problems Let engine cool to the touch 3 After engine has cooled start up again and allow the motor to build some heat Engine should be run no longer than three to four minutes When the cylinders become warm hot to the touch approximately 150 F shut the motor down and let it cool to room temp Follow the same cautions as for the initial start up and continue to check for problems 4 First 50 Miles a Street Ride normally do not lug the engine Avoid high heat conditions and vary the RPM while riding No stop and go traffic extended idle periods or high load or high RPM conditions Max of 3 500 RPM or 60 MPH b Dyno chassis dynamometer can be used to put the first 50 miles on a new engine See the notes and procedure below for chassis dyno break in 8 50 100 Miles Ride normally do not lug the engine Avoid high heat conditions no stop and go traffic or extended idle periods Limited short bursts of throttle can aid in ring seating from this point forward during the break in but avoid continuous high speed or load conditions Max of 4 250 RPM 70 MPH 100 500 Miles Avoid lugging the engine and high heat conditions Max of 5 000 RPM Change oil at 500 miles 500 1 000 miles Ride bike normally but avoid continuous high
15. 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 shall have no warranty or liability obligation if an S amp S part is used in any other application OWNERS MANUAL 585 KN P AND SH SERIES ENGINES Table of Contents A A 2 Engine Installation iisssccscassisscscccssesccisssasassasacesnssesoacasseiseosssensosecsestectbases 2 Oil Line Hook up Oil Recommendations I asss 2 General Break in Procedure I saa 5 Tune Up Information Super Stock Ignition System a 7 Super E amp G Carburetors a 7 Engine Service Intervals Engine Specifications 13
16. nd 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 sure all federal state and local laws are obeyed with the installation For optimum performance and safety and to minimize potential damage to carb or other components use all mounting hardware that is provided and follow all installation instructions Motorcycle exhaust fumes are toxic and poisonous and must not be
17. ne through If the engine does not start after several kicks or five seconds of cranking shut the ignition off for 15 seconds to let the starter cool Open the throttle slightly and press the starter button or kick the engine through again It may be necessary to re prime the engine If the engine kicks back the throttle may be opened too far Once the engine is running use the fast idle lever to maintain the proper engine speed required during warm up When the engine has warmed up enough to idle without the enrichment system disengage the fast idle lever The fast idle lever is not required to restart a hot engine SUPER E amp G CARBURETOR TUNING GUIDE 1 Verify carburetor is set to stock settings Idle mixture screw 1 turns from lightly seated b Idle speed screw Y turn clockwise from engagement point C Accelerator adjustment screw two turns counter clockwise from seated Start bike bring to operating temperature Set idle speed adjusting screw clockwise to increase RPM counter clockwise to decrease RPM Idle RPM range should be 950 to 1050 RPMs Adjust idle mixture by turning idle mixture screw slowly clockwise until the engine runs poorly Note position Slowly turn the screw counter clockwise until it starts to stumble Note position Set the idle mixture screw halfway between the positions or at the strongest idle Inconsistent idle may indicate a manifold leak OWNERS MANUAL 585 KN P AND SH
18. u are not using S amp S Super Stock ignition refer to your ignition manufacturer for any additional recommendations SUPER STOCK IGNITION SYSTEM S amp S KN P and SH Series engines come from the factory with an S amp S Super Stock ignition system installed S amp S Super Stock ignition modules are factory programmed for the specific engine they are intended for In addition the module is installed and timed to S amp S specified timing Changing the timing or removing the Super Stock ignition may void your warranty If you choose to install another after market ignition module make sure that the ignition advance is set according to these specifications If the ignition system has a rev limiter make sure it is set no higher than 6200 RPM 10 RPM Max Advance WOT Total Advance Max Advance VOES Grounded Wide Open deg BTDC Throttle WOT START UP ENGINES EQUIPPED WITH S amp S SUPER E OR G CARBURETOR 1 S amp S Super amp G carburetors have a mixture enrichment fast idle lever used to aide in cold starts and help during the warm up period Do not ride the motorcycle with the lever engaged 2 Turn the fuel supply valve on wait a moment to make sure the carburetor bowl is full and twist the throttle twice to prime the carburetor starting in extremely cold weather may require additional priming 3 Pull the fast idle lever up turn on the ignition and press the start button or kick the engi
19. vironment 15 ENGINE SPECIFICATIONS The following chart contains information about a number of S amp S engines covered by this owners manual Ignition Displacement Bore Tappets Fuel System ETT stem 3 smo 1 jo 71 1900 HydrauicwHLzT w HL2T SuperG G Super Stock Stock ho Jw Je ez se Hyerauicwnatzr suere SuperStock ox 600 SuperStock 16 OWNERS MANUAL 585 KN P AND SH SERIES ENGINES ENGINE DIMENSIONS Some S amp S engines are taller than stock engines These diagrams show the dimensions of various S amp S engines This information will be most useful to customers building custom motorcycles with after market frames Note that KN Series engines may be used in 1948 99 style frames if the provided spacer is installed under the front motor mount 2 1 750 SH93 15 479 19 668 5 480 SH80 15 419 19 611 P103 15 891 19 675 15 625 19 46 KN93 15 031 19 057 15 572 19 397 KN74 14 943 18 985 17 SERVICES SPEED CENTER Nothing lasts forever and despite the superior materials and design of the components in your 585 engine some day it will need to be serviced Who better to repair your engine than the technicians at the company where it was made To obtain factory service for your 585 engine have your S amp S dealer contact the S amp S Service amp Spee
20. www sscycle com OWNERS MANUAL 585 KN P AND SH SERIES ENGINES TORQUE SPECIFICATIONS P amp SH SERIES ENGINES Rocker arm shaft retaining screws Loctite 243 Rocker arm shaft plug Loctite 243 Crankcase fasteners 12 15 ft lbs 4 Flywheel crankpin nuts 495 ft lbs Green Loctite 609 18 20 ft lbs 49 749090100006 nis Oi pump sono Forpumprepmountngi some 19 TORQUE SPECIFICATIONS KN SERIES ENGINES Mieris _ ___ approwzorieel Crankcase fasteners 18 20 ft lbs FPushrodiodmuts J ig hole pita 12010 65 pump cover mounting bolts 90 120 in Ibs DIE Oil pump top mounting 2 60 in Ibs Intake manifold to head 16 ft lbs Loctite 243 Intake manifold to carb 18 ft lbs Loctite 243 20 OWNERS MANUAL 585 KN P AND SH SERIES ENGINES SPECIFICATIONS amp WEAR LIMITS P amp SH SERIES ENGINES Description Specification Weartimie Description Specification Wear Limit Proc am O emigra re amme A meer SA FPSS Ca A Dia 21 SPECIFICATIONS AND WEAR LIMITS KN SERIES ENGINES Description Specification wear Description specication Wear Limit_ mam es cin dear cover 0007 0023 0006 Compression ring gap 3 Oil pump shaft 0005 0025 0035 Lifter fit in guide 0006 0017 0022 OWNERS MANUAL 585
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