Super E - Nightrider.com
Contents
1. Part 50 0075 6 Fast idle friction washer Part 50 7035 7 Fastidle steel washer Part 50 7037 8 Fast idle nylon washer Part 50 7036 9 Fast idle lever Part 17 0329 10 Fast idle brass washer Part 50 7007 11 Fast idle lever screw Part 50 0041 12 Shim kit V2 FL 1984 1992 amp XL 1986 1990 includes 2 ea x 020 x 030 Pre V Air Cleaner 33 Yo X 040 s x 100 amp 4 ea x 125 and Mounting Hardware O EEE EEA Part 17 0314 FL 1993 up amp XL 1991 up includes 2 ea 4 x 020 x 030 x 040 y x 100 amp 4 ea x 125 EEEN E A T Part 17 0464 13 Shim V FL 1984 1992 amp V XL 1986 1990 Me K O20 seccwssinavvinainansnacesioiinnweast Part 50 7038 Tie BANOO EE ES A Part 50 7039 Vie KOKO coceswsavvenaencpaesiorsewatweand Part 50 7040 Tie RN OO N EE NA ET Part 50 7041 Ve NED EEE use on pre Vs when insulator block is installed dai E E OE E E Part 50 7042 V FL 1993 up amp V XL 1991 up Ye X 020 sersnwivcuwtnnewasucnesmadadanwrent Part 50 7085 Ve ANDO aa Part 50 7086 AE o eeeeeseeseseseeeeeeeeeeee Part 50 7087 Yee AOU EE EEE E Part 50 7089 A X20 errie Part 50 7090 1984 1991 FL V2 and 14 Backplate mounting bolt 1986 1990 XL V Air Cleaner All pre V2 Ye 18 X 1 Lo eeeeee eee Part 50 0108 i and Mounting Hardware Vie S E E SE Part 50 0107 15 Elbow fitting2. 000 Part 50 8110 4G Breatherecrew 20 Breather fitting 26 Support bracket Standard Length cccccccssssseeeeee Part 17 0338 FL 1993 up amp XL 1991 up Part 17 0337 SHOVE sestindesontceursemsastiuiesomeeved Part 17 0392 1 longer use with 1 spacer block 21 Crankcase breather hose 57 85 XL orrae Part 17 0393 E E Part 17 0343 Fi 1304 1992 8 XE 19861930 Part1 7 0113 17 Breather screw o ring O D FL 1993 up FL amp XL 1991 up Part 17 0339 27 Mounting bracket bolt E Part 50 8032 22 Vent hose connector Part 50 8111 Shovel 6 18 X 0 2 Part 50 0106 18 Breather screw o ring O D 23 Backplate plug Part 50 8312 FL 84 92 amp 57 90 XL s 18 x 1 SC Part 50 8006 24 Locknut beveseueseueessaessecesseesessesseessseesseseee Part 50 0110 i Breather screw washer Part 50 7119 s 18 use with 16 0471 Part 50 5021 28 Lockwasher 0 Part 50 7032 25 Flatwasher 76 X ee Part 50 7034 29 Flatwasher 3 X 2 0 eee Part 50 7033 Super E and G Air Cleaner Parts and Mounting Hardware 30 Thread insert 13 to 18 Part 50 8151 31 Wire tie Not shown Part 50 8003 32 Hose clamp Not shown Part 50 8002 33 Air cleaner assembly All pre V includes 1 ea 17 0330 17 0378 17 0379 17 0441 oe Part 17 0400 All Shov w 5 gal tanks amp c
3. 008 Lb a een ene eee E ns Part 50 8016 ii A E ian Part 50 8015 Bellows seal 005 Part 11 2266 Bowl vent plug Part 50 0105 Main discharge tube Part 11 2085 Main jet state size see jet section Intermediate jet state size see jet section Bowl gasket Part 11 2386 FOA esra Part 11 2187 Float pin o ae Part 11 2369 Bowl screw 10 24 XH ieee e en ena Part 50 0034 MOOR eee eee Part 50 0040 Carb bowl assembly Part 11 2388 Bowl plug sscssscsisesscssestsasseeascves Part 11 2090 Seat bowl plug o ring Part 50 8009 Needle 1 E amp 2 G Street needle use with 11 1465 seat Part 11 2195 Racing needle use with 11 2466 seat Part 11 2197 Seat 1 E amp 2 G Street seat use with 11 2195 needle Part 11 2465 Racing seat use with 11 2197 needle Part 11 2466 Part 50 8011 Part 11 2373 Ejector nozzle oring Pump pushrod 40 41 42 43 44 45 Ball check ee Part 50 8090 Ball check spring Part 11 2374 Pump cap oring Part 50 8012 Pump cap assembly Part 11 2389 Overflow hose per ft Part 19 0262 Pump cap screw Part 50 0042 46 47 48 49 Diaphragm spring Part 11 2275 Diaphragm c0 Part 11 2282 Fuel line with 90 bend i eee er een eee P
4. 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 C Replace throttle cables all models equipped with constant velocity CV type carb 1 Carefully remove existing cables noting how they are routed 2 Install replacement cables using same routing as stock cables 3 Loosen cable 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 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 or air horn rigidly to engine CAUTIONS 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 WARNING Improperly mounted carburetor may break free in event of collision or other vehicle accident creating a fire hazard with potential personal injury to operator and others A All models Clean intake ports on cylinder heads to insure proper manifold to head seal NOTE Cylinder heads for Knuckles 1
5. 1993 and Later Shovels 1966 1978 with 5 gallon tanks amp 075 taller cylinders Shovels 1979 1982 with 5 gallon tanks amp 075 taller cylinders Shovels 1983 1984 with 5 gallon tanks amp 075 taller cylinders Shovels 1966 1984 11 0438 with 5 gallon tanks amp 075 taller cylinders without manifold lronhead XL s 1957 1985 11 0439 without manifold except magnetos FL V2 s 1984 1992 11 0444 XL V2 s 1986 1990 FL V2 s 1984 1992 11 0440 XL V2 s 1986 1990 without manifold FL V2 s 1993 and Later 11 0446 without manifold XL V2 s 1991 and Present 11 0447 without manifold 11 0449 1994 Present Buell Throttle cables on 1981 to 1989 models are compatible with S amp S carburetors and stock 1981 1995 throttle assemblies 1996 and later throttles require a different style cable S amp S can supply correct cables for all applications See Step 3 Throttle Preparations Throttle cables can be ordered separately See below 11 0435 11 0436 11 0437 S amp S THROTTLE CABLE APPLICATION CHART Length Length Part Number Part Number Total Housing Vinyl Housing Open Side Close Side 19 0430 19 0431 For Buell with 7 8 handlebars 36 32 19 0432 19 0433 Also pre 81 w 2 cable throttle housing replaced For Buell with 1 diameter handlebar 19 0436 19 0437 96 Up 883 1200 XL i ji To 95 Softail FXSTC FXST FLSTC FLSTF i i 96 Up Softail FXSTS FXSTC FLSTC FLSTF To 95 81 85 FX an
6. Champion Racing Division for its very informative booklet Write Champion Spark Plug Co PO Box 910 Toledo OH 43601 f bike is used exclusively on drag strip where engine temperatures vary slightly richer jets may be necessary to obtain best performance Larger jets and richer mixtures will enable one to run colder engine which is sometimes desirable This is best determined by experimentation Cams and exhaust systems can make some engines difficult to carburate S amp S has found that certain cams and exhaust systems cause poor performance at a specific rom and attempts to correct problem with carb tuning usually upset carburetion elsewhere A combination of cam overlap reversion and back pressure or even lack of back pressure can cause mixture dilution at certain RPM This will result in loss of power engine roughness or misfiring Drag pipes For Knucklehead Panhead Shovelhead and lronhead Sportster engines 1 O D drag pipes with straight cutoff end 28 to 30 long will work well with almost any camshaft or other performance modification 2 O D drag pipes are not recommended for any application except very large competition engines The use of drag pipes is not recommended for Evolution motors in street application Mufflered exhaust systems A good economical street exhaust system for V and earlier engines consists of stock header pipes with cross over tube and low restriction mufflers such as Scream
7. 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 tyoe 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 All stock chassis 1980 and earlier or any motorcycle equipped with single cable throttle system must be converted to two cable system Kits with 36 39 42 48 or 52 length cables are available Figures refer to overall cable length Vinyl covered outer housing is 4 shorter than overall length Throttle assembly kits may be ordered separately See descriptions below Stock models from 1981 to 1989 have two cable throttle system designed for butterfly type carburetors Cable fittings on these models can be installed on S amp S Super E or G throttle linkage without modification Throttle cables on 1990 and later models or any other motorcycle equipped with a constant velocity CV carburetor will not work with S amp S Super E or G carb S amp S Super E Carb Kit Application Chart CARB PART YEAR GROU
8. See Picture 32 is reached by removing bowl plug part 11 2090 See Jetting Chart Page 20 1 Drag strip dynamometer procedure a Sufficiently warm engine to begin testing b Make run noting engine RPM and final Picture 32 speed or horsepower c Richen main jet by increasing jet size 004 and make second run Again note RPM and final soeed or horsepower d Continue procedure until MPH horsepower falls off e Decrease or lean main jet size by 002 to gain best RPM and MPH When making runs on drag strip strive for consistent miles per hour not lowest ET 2 Street Procedure S amp S uses RPM method to determine main jet size Under racing conditions this level is where horsepower peaks and begins to taper off and is where gear shifts occur Main jet that makes engine accelerate strongest or RPM through gears quickest Is correct NOTE Placing engine under load by accelerating uphill may make result of jet change more pronounced and easier to interpret a Warm engine to operating temperature b Accelerate rapidly through gears noting how quickly and smoothly engine reaches RPM level where pull of engine begins to fade and gear shift occurs c If engine backfires in carburetor and sputters or breaks up and or dies during acceleration increase or richen main jet size 004 larger and road test again Note engine smoothness and how easily engine reaches RPM level where gear shift occurs d I
9. and oil breather banjo bolt assemblies See Picture 21 and refer to Step D 5 above NOTE At least one thick spacer will be required between breather banjo fittings and heads Breather fitting O rings are easily damaged It is suggested that Picture 22 they be lubricated with light grease before installation If possible replacement o rings should be obtained beforehand if banjo assemblies are removed in future 2 Rotate bracket to align hole in bracket with hole in backplate Mark position of bracket with pencil mark on cylinder head to act as guide for final installation Remove backplate 3 Place ends of rubber T hose 17 0339 over breather fittings for trial fit See Picture 22 Temporarily install backplate using correct number of spacers Hose must be routed so as to be free of kinks and not interfere with operation of fast idle lever 4 Remove backplate shorten hose ends as needed for correct fit reinstall and secure with Tie wraps 50 8003 Tighten breather screws 5 Install backplate for final assembly Confirm that fast idle lever has properly engaged enrichment plunger and secure backplate to support 17 0309 with 1 bolt flat washer and locknut provided Securely tighten three backplate screws 50 0075 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
10. be plugged as oil leakage and engine damage may result Same applies to crankcase vent in case breather type engine 2 Fill gap between backplate mounting ears and cylinder heads with shims provided in S amp S shim kit part 17 0314 3 Bolt backplate to cylinder heads with 18 x 1 bolts flat washers and lock washers See Picture 19 4 Final tighten all mounting bracket bolts and manifold clamps 5 Connect crankcase breather hose to air cleaner backplate hose fitting See Pictures 16 and 17 C Shovels 1966 to 1982 and Ironhead XL s 1 Bolt carb mounting bracket to air cleaner backplate Head of 18 x 1 bolt should rest in hex recess on inside of backplate with threaded portion extending through backplate two shims and bracket Secure with 7 flatwasher and locknut provided 2 Final tighten all mounting bracket bolts and manifold clamps 3 Shovels Sportsters 1980 to 1985 Connect crankcase breather hose to air cleaner backplate hose fitting See Pictures 16 and 17 Picture 19 D FL V2s 1993 and up and XL V2s 1991 and up 1 2 Place washer 50 7119 on breather screw 17 0338 Roll O D o ring 50 8032 into large diameter o ring groove closest to head of breather screw Roll O D o ring 50 8006 into small diameter o ring groove of breather screw Apply thin film of light grease to o rings Repeat for other breather screw Fill gap between backplate mounting ears and cylinder
11. of Allen ball end drivers These tools are available at most automotive and tool supply houses See Picture 9 Additionally Performance Plus of Evansville Indiana produces a hex wrench specially modified for accessibility of V manifold bolts Call 812 963 8854 for further information As alternative standard hex wrench can be shortened for convenience NOTE Some Buell motorcycles have a breather fitting with 90 elbow on rear head Due to proximity of frame elbow must be removed before fitting can be taken off engine Loosen fitting and rotate to position convenient for cutting elbow Secure fitting by tightening against cylinder head Elbow may be inaccessible to hacksaw In most instances a die grinder with cutoff wheel will remove elbow with little difficulty If die grinder is unavailable grasp elbow firmly with pliers and snap off then remove fitting CAUTION Extreme care must be taken to prevent metal chips from entering engine when elbow is removed S amp S recommends packing breather fitting with gease before removing elbow Metal chips inside engine will cause extensive damage Installer bears all responsibility for containment of chips and other debris Picture 5 2 Prepare Air Cleaner Backplate NOTE Fast idle lever screws part 11 2384 must not be overtightened Loctite or other thread locking compound may be used sparingly on threads to prevent screws from vibrating loose CAUTION Overtightening fast i
12. points or condenser defective coil or solid state module improper ignition timing loose wire faulty circuit breaker or ignition switch Many ignition electrical problems occur repeatedly at same RPM because of vibration specific to that RPM 3 Incorrect intermediate and or high speed jetting See Adjusting Carb Intermediate System and High Speed Circuit or Main Jet 4 Foreign material in air or gas passageway in carb causing flow restriction Picture 30 shows intermediate air bleed metering hole Picture 33 shows main discharge air bleed metering hole Use compressed air to clear holes Picture 33 17 CAUTION Do not use wire or drill to clear hole If size of hole is altered starting system will be altered and carburetor bowl irreversably damaged WARNING 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 5 Filter oil applied to S amp S air cleaner element NOTE Engine oil deposited upon air cleaner element by crankcase or cylinder head vent should not cause problem Otherwise element is to be run dry 6 No air cleaner used or air cleaner used is brand other than S amp S Some air cleaners restrict air flow so that carb cannot draw air as freely as needed Also some air cleaners may obstruct bowl vent hole on inlet end of carb Se
13. rich at idle and at low speeds also prevent jet change from correcting mixture Float setting too low will cause poor off idle response and may cause mixture to lean out at high speed or when motorcycle leaned over in curve due to insufficient fuel reserve in bowl See General Information on Page 19 for float setting instructions and specifications Fuel standoff Occasionally fuel may be seen misting out carburetor when air cleaner is removed Because carburetor is simply a conduit through which air and fuel enter engine it does not cause fuel standoff Usual cause is cam timing INTERMEDIATE AND HIGH SPEED NOTES Carburetor jetting and spark plug color While spark plug color may be used to help determine carburetor jetting S amp S recommends that our instructions be used as primary jetting guide and that plug color indications be used only as secondary aid Different brands of gasoline gasoline additives engine heat due to ignition timing and type of plugs and heat range used distort plug color drastically making plug reading difficult for average tuner Also new plugs usually require road test of 10 miles or more to properly develop color which means that quarter mile tests may not be long enough and hence not always a good indication of carb jetting tis best to use proven spark plug combinations and to consult spark plug manufacturer with questions To 12 become more proficient at plug reading contact
14. underway Because of displacement compression ratio cam timing exhaust design and other related factors many engines will stumble or bog if throttle is abruptly cranked fully open with engine at idle If correct carburetor E or G is installed and engine properly tuned and equipped with appropriate exhaust and cam stumble should disappear under normal riding conditions GENERAL INFORMATION NOTES Carburetor body has six drilled passages that are permanently sealed with drive plugs CAUTION 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 and 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 Normal float setting on all carbs is with edge of float opposite needle and seat assembly 4 to below bowl gasket part 11 2386 with fuel inlet needle fully closed and spring in needle fully compressed See Picture 36 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 Highest part of float should be to below bowl gasket surface Float must not contact bowl gask
15. 1 2339 from carb body 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 190 3 Repeat step 2 for closing side throttle cable Closing side cable has a spring around inner cable wire See Picture 12 4 Apply drop of Loctite 242 or equivalent to threads of cable bracket screw and reinstall bracket on carburetor C Install carb on manifold 1 Bolt carb and insulator block to intake manifold o ring side of block faces manifold using two Picture 12 7 7 16 x 1 socket cap screws provided in kit Knuckle Pan and 1983 84 Shovel kits include one 1 screw and one 1 screw 1 screw is longer to compensate for thickness of support bracket part 16 0096 for Pan Knuckles or 16 0471 for 1983 84 Shovels and must go in bottom hole See important note and caution below concerning insulator block NOTE If insulator block is not installed manifold bolts supplied in kit will be too long and may bottom in holes Shorter manifold bolts must be used if insulator block is not installed CAUTION If insulator block is not installed lower manifold bolt may damage carburetor bowl causing possible gasoline leak WARNING Gasoline is extremely flammable and explosive under certain conditions Do not smoke around gasoline Gasoline fumes are toxic when inhale
16. 18 1 Aluminum spacer blocks For 174 E includes ea 1 spacer block amp 16 0056 o ring ccccceeeeeeees Part 16 0057 For 2 lt G includes 1ea 1 spacer block amp 16 0356 o ring ccccceseeeeees Part 16 0357 Insulator blocks Insulator block for 174 E includes 1 ea ins block amp 16 0387 o ring Part 16 0491 Insulator block for 2 G includes 1 ea ins block amp 16 0356 o ring Part 16 0492 Manifold orings For 174 E carb body amp insulator block E EE EE E Part 50 8016 For 17 spacer block Part 50 8013 For 2 4 G carb body insulator block amp spacer block n Part 50 8015 VOES tubing per ft Part 19 0395 NOTE All manifold part numbers shown are for stock length manifolds Longer than stock manifolds are available from S amp S See catalog for part numbers of special sizes 22 Super E and G Air Cleaner Parts and Mounting Hardware 1 Air cleaner cover All except Shovel w 5 gal tanks amp cyls 075 ne E ee nC ee a ee Part 17 0378 Shovel w 5 gal tanks amp cyls 075 ee One er ret ne eee ae Part 17 0372 2 Element 0 ccceeeees Part 17 0379 3 Backplate Alpe VP secs te ct ote ect Part 17 0330 V FL 1984 1992 amp XL 1986 1990 E E E E A eee Part 17 0380 1993 up amp XL 1991 up Part 17 0336 4 Cover SCrew i oa Part 50 0072 5 Backplate screw
17. 2 turn setting without fine tuning 4 With RPM screw reset engine idle to approximately 800 1000 RPM Lower idle speed can cause hard starting erratic idle and unnecessary engine wear 5 After engine and oil have reached normal operating temperature repeat Steps 2 through 4 IDLE CIRCUIT NOTES f idle adjustments are made before engine is fully warmed idle mixture will be rich when engine reaches operating temperature This is especially true for engines with aluminum cylinders such as V2 s If ambient temperature is below 60 degrees engine may require 30 45 minutes to reach operating temperature To avoid overheating ride motorcycle during this time Whenever intermediate jet change is made idle mixture screw must be readjusted f idle mixture screw is turned completely in engine should not run If engine continues to run with idle mixture screw seated contact S amp S Technical Services Dept B Troubleshooting Tips engine will not idle 1 Improper idle mixture or RPM setting 2 Intake manifold air leak 3 Malfunctioning automatic advance mechanism or other ignition problem 4 Foreign material in air or gas passageway in carb causing gas flow restriction to idle or intermediate circuit Picture 30 shows intermediate air bleed metering hole Picture 31 shows intermediate jet metering hole Clear holes with compressed air CAUTION Do not use wire or drill to clear hole If size of hole is altered star
18. 936 1947 and Pans 1948 1954 must be converted to o ring style manifold and seals Conversion kits are available from various aftermarket sources B All models Install S amp S intake manifold If applicable vacuum advance fitting must point upward For V2 style 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 C Panheads Loosen center crankcase stud nut between tappet blocks Bolt bracket part 16 0096 in place to connect bottom carb manifold mounting bolt to crankcase stud and reinstall nut Picture 9 Picture 10 D Shovelheads 1966 to 1982 Bolt bracket part 1 7 0392 to front rocker cover using 18 x bolt flatwasher and 3 4 lockwasher provided in kit Do not tighten at this time End of bracket with sharp bend goes toward rocker cover E Shovelheads 1983 to 1984 Loosen center crankcase stud nut between tappet blocks Install bracket 16 0471 to connect lower carb manifold mounting bolt to crankcase stud and reinstall nut F IH XL s 1957 1982 Bolt bracket part 1 7 0393 to front tappet block using 18 x 1 bolt 6 flatwasher and 7 lockwasher provided in kit Do not tighten End of bracket with sharp bend goes toward tappet block NOTE E and G carb will not fit IH XL models equipped with OEM sty
19. Instruction Sheet No 400 Revised 8 2 00 Copyright5 1997 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tue 14025 County Hwy G PO Box 215 Viola Wisconsin 54664 Phone 608 627 1497 4 PROVEN Fax 608 627 1488 PERFORMANCE Customer Service sscust sscycle com Technical Assistance sstech sscycle com Installation and Jetting Instructions for S amp S Super E and G Series Shorty Carburetors SAFE INSTALLATION AND OPERATION RULES Before installing your S amp S carburetor it is your responsibility to read and follow the installation and maintenance procedures in these instructions and to follow the basic rules below for your personal safety Gasoline is extremely flammable explosive under certain conditions and the fumes toxic when inhaled Do not smoke around gasoline Perform the installation in a well ventilated area away from open flames or sparks 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 the air stream away from yourself and others nearby Some solvents degreasers and other chemicals are harmful especially to skin and eyes Many chemical compounds such as lacquer thinner are also flammable and present a fire hazard Read the manufacturer s instruction label for precautions and proper use Use in a well ventilated area and wear protective clothin
20. Loctite 242 must be applied and screws properly tightened 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 B FL V2s 1984 to 1992 and XL V2s 1986 to 1990 1 1992 FL models with crankcase breather vented from cases to air cleaner backplate Install thread sert part 50 8151 in each cylinder head air cleaner mounting bolt hole This converts stock 13 thread to 18 thread Surface of thread sert should be just below surface of cylinder head See Picture 18 NOTES Most 1992 FL s have crankcase breather routed from case to air cleaner backplate However some are Picture 18 routed from heads to air cleaner backplate through air cleaner mounting bosses Those routed from cases must follow Step 1 immediately above Those routed through heads must use 1993 and later carb kit installed according to Step D below Thread serts may be suppled with or without thread locking compound on threads Loctite 242 or equivalent should be applied to threads of thread serts not suppled 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 CAUTION Cylinder head vent passages in head breather type engine must not
21. P Pans 1955 1965 11 0401 Knuckles and Pans 1936 1954 with O ring head modifications 11 0402 11 0403 lronhead XL s 1957 1978 11 0405 11 0406 11 0407 11 0408 11 0409 11 0410 11 0411 FL s 1955 1984 lronhead XL s 1957 1985 11 0414 without manifold except magnetos Shovels 1966 1978 with 5 gallon tanks amp 075 taller cylinders Shovels 1979 1982 with 5 gallon tanks amp 075 taller cylinders Shovels 1983 1984 with 5 gallon tanks amp 075 taller cylinders Shovels 1966 1984 11 0418 with 5 gallon tanks amp 075 taller cylinders without manifold 11 0419 FL V2 s 1993 and Later Carb Only 11 0420 ALL Models FL V2 s 1984 1992 11 0440 XL V2 s 1986 1990 without manifold FL V2 s 1993 and Later 11 0442 without manifold XL V2 s 1991 and Later 11 0443 without manifold 11 0448 1994 Present Buell The braided wire inner cables designed for constant velocity carbs are approximately 1 longer than those for butterfly carbs resulting in excessive free play and incorrect cable adjustment These throttle cables must be exchanged for cables designed for butterfly carbs 11 0415 11 0416 11 0417 S amp S Super G Carb Kit Application Chart CARB PART YEAR GROUP Carb Onl 11 0422 11 0423 lronhead XL s 1957 1978 11 0425 lronhead XL s 1979 1982 11 0426 11 0427 11 0428 11 0429 11 0430 11 0431 FL s 1966 1984 11 0432 without manifold 11 0434 FL V2 s
22. S amp S products often offer substantially more power than the stock items they replace It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use The user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith S amp S parts are intended for the very experienced rider only Important Notice Statements in this instruction sheet preceded by the following words are of special significance WARNING Means there is the possibility of injury to yourself or others CAUTION Means there is the possibility of damage to the motorcycle or a component NOTE Other information of particular importance has been placed in italic type S amp S urges you to take special notice of these advisories 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 six 6 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 S amp S by the purchaser within the 6 month warranty period or within 10 days thereafter In the event warranty service is required the original purchaser must notify S amp S of the problem immediately Some problems can be rectified by a telephone call and need no further action A part that is suspected of
23. S sets screw for maximum volume to aid during initial start up after installation Turning screw inward or in clockwise decreases delivered pump volume Turning screw outward or counterclockwise increases delivered volume 1 Warm engine to operating temperature 2 Turn pump travel adjusting screw inward or clockwise until screw contacts pump actuator arm part 11 2377 This limits actuator arm travel and shuts off pump CAUTION Closing adjusting screw with excessive force may cause irreversible damage to screw threads in carburetor body 3 Perform intermediate and high speed jetting tests to determine proper jetting 4 With engine warm and at idle blip throttle and note throttle response 5 Turn pump travel screw outward or counter clockwise about turn at a time and recheck throttle response until engine no longer hesitates 6 Road test motorcycle noting throttle response at idle and at levels in 500 rom increments from idle to 83000 3500 rpm 7 Set pump travel screw at point where best throttle response is noted with minimum pump travel Minimum pump travel is recommended to conserve fuel prevent spark plug fouling and curtail black smoke from pipes when blipping throttle Black smoke from pipes is usually an indication of a rich condition or excessive accelerator pump travel NOTE Final accelerator pump adjustment should be confirmed by riding motorcycle and noting throttle 19 response with motorcycle
24. applied to threads and screws properly tightened If screws are removed in future Loctite 242 or equivalent must be applied before reinstallation CAUTION 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 6 For street use insert 1 steel tubing provided into short tee of T hose and place OD x 2 80 hose over other end of tubing Hose must rest in notch in backplate with bevel down Secure with Tie wraps when correctly positioned See Picture 23 NOTE An additional 36 length of hose is provided for Race Only applications It should be attached to T hose in place of 2 80 hose and routed to overflow or catch can as required by event organizer Breather hose should be routed in upward direction as much as possible Because crankcase oil air mist exits from hose hose and catch can must be mounted securely and well away from hot or moving parts as well as tires and brakes WARNING Oil on tire or brakes can result in loss of control of motorcycle resulting in possible serious injury or death to operator and others Picture 23 7 Final assembly and checks A Check carb to manifold mounting bolts B Check carb to air cleaner backplate mounting SCrews C Check each of following that is applicable Carb mounting bracket to head bolts Mounting bracket to air cleaner backpl
25. arburetor Body 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Idle mixture screw Idle mixture screw spring Idle speed screw Pump adjustment screw Idle speed pump adjuster spring and Related Parts Carb body assembly As ee eee ee eee Part 11 2381 2 dl ee ee ee EE Part 11 2390 Throttle shaft 1 E includes 2 ea 11 2045 Stich MAEAEA EN I NE PEETA Part 11 2383 2 G includes 2 ea 11 2045 Part 11 2483 Throttle plate screw Part 50 0029 Throttle plate 1g T AE E Part 11 2055 Pye E Part 11 2355 Throttle return spring Part 11 2382 Throttle spool 06 Part 11 2385 Throttle shaft lock washer Part 50 7031 Throttle shaft nut Part 11 2350 Throttle shaft nylon washer Part 50 7050 Pump actuator lever Part 11 2376 Actuator spring Part 11 2375 Pump actuator arm Part 11 2377 Part 11 2354 Part 11 2052 Part 50 0038 Part 50 0039 Part 11 2048 Part 11 2344 Plunger spring Part 11 2340 Enrichment plunger Part 11 2343 Enrichment device use with air horn only NOt SHOWN sgcevteecpoeieeieesenceyhcsiaed Part 11 2084 Cable guide assembly Part 11 2339 Cable clamp float pin screw Part 50 0041 Mainfold o ring Plunger nut
26. art 19 0474 iS EE EE ee eee ee ener ree Part 19 0475 Hose clamp not shown Part 50 8002
27. art 50 0075 38 Enrichment device Used in place of std fast idle mechanism if starting device is required when air horn is used Part 11 2084 39 4 Air horn conversion kit includes 1 ea 16 0063 11 2084 16 0105 17 0333 16 0471 0 Part 17 0485 40 41 42 43 1991 amp Up XL V and 1993 amp Up FL V Air Cleaner and Mounting Hardware 4 Air horn assembly includes 1 ea air horn 3 ea 17 0391 IPTEN TEE EAEE S ET Part 17 0333 Carb mounting bracket assembly includes 1 ea 2 pc bracket 17 0104 17 0245 17 0321 0 0 Part 16 0471 Manifold bolts 16 x 17 use in bottom hole with 16 0471 bracket without insulator block Part 50 0162 16 x 1 Use in bottom hole with 16 0471 bracket with insulator DOCK eeeeeeeeees Part 50 0163 Support bracket bolt TONS KA E E Part 50 0108 Air Horn Assembly For Super E amp G 39 Carburetors IMPORTANT NOTE When an air horn is used on a Super E or G a 16 0471 style bracket which connects the center crankcase stud to the bottom carburetor manifold mounting screw must be used This Style bracket is also recommended for those applications where the cylinder heads have had the intake ports raised causing misalignment problems with the normal carburetor mounting hardware These engines are unusual situations and are handled on a special order basis 24 Super E and G C
28. ate 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 Check fuel line connections and routing Avoid hot surfaces Check vacuum operated ignition advance connections if applicable Check crankcase to backplate vent hose connections if applicable Check fuel overflow hose routing Avoid hot surfaces 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 carb installation Consult authorized H D service manual for installation of parts not covered in S amp S carb 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 carb 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 r o m mM oO 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 Picture 24 CAUTION Gasoline leakin
29. being defective must not be replaced 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 it must be packaged properly to avoid 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 lf after an evaluation was made by S amp S the part was found to be defective repair replacement or refund will be granted ADDITIONAL WARRANTY PROVISIONS 1 No part shall be returned to S amp S without first contacting the company and obtaining a Return Authorization RA number 2 S amp S shall have no obligation in the event an S amp S part is modified by any other person or organization or if another manufacturer s part is substituted for one provided by S amp S 3 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 break in or maintenance improper use abnormal operation or any other misuse or mistreatment 4 S amp S shall not be liable for any consequential or incidental damages resulting from the failure of an S amp S part the breech 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 c
30. cture 7 2 Assemble fast idle mechanism as shown in Figure A E Buell motorcycles 1994 and up 1 Assemble fast idle mechanism as shown in Figure A 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 Figure B WARNING 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 Install new throttle assembly Motorcycles not equipped with two cable pull open pull closed type throttle assembly 1 Remove existing throttle cables and throttle grip assembly Note routing of stock cables 2 Install new throttle assembly and throttle cables Position grip and cables similar to stock position so cables can be angled back toward carb for easy adjustment and free operation 3 Apply light coat of cable lubricant to cables and fittings 4 Loosen cable freeplay adjustment locknuts and thread adjusting screw so half of threads are exposed See Picture 8 B Prepare existing throttle assembly 1981 1989 chassis equipped with two cable pull open pull closed type throttle assembly and butterfly type carb 1 Loosen cable freeplay adjustment locknuts and thread adjusting screw so half of threads are exposed
31. d Perform installation in a well ventilated area away from open flame or sparks Any gasoline leak or spill constitutes a health and fire hazard D Adjust throttle cables 1 Turn threaded throttle cable adjusters to remove excessive freeplay 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 freeplay in cables Tighten adjusting screw locknuts after making final adjustments NOTES Throttle must not bind and must snap shut to fully closed position when released Cables for OEM CV carb lack sufficient adjustment for use with S amp S carb 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 E Slip fuel overflow hose onto fitting on carb bowl and neatly route behind pushrod tubes On Big Twins hose should go toward back of engine On Sportsters hose should go toward front of engine Exit end of overflow hose must extend down below engine and away from exhaust pipes See Pictures 13 and 14 WARNING Overflow hose must not contact hot surface such as exhaust pipe where it could melt and catch fire F Slip hose clamp over end of fuel line with 90 bend Apply thin coat of oil to carb fuel inlet
32. d FL All 81 85 XL 19 0440 19 0441 96 Up custom application 19 0446 19 0447 To 95 custom application 4 3 19 0462 19 0463 To 95 All FLT Models 19 0464 19 0465 96 Up All FLT Models 19 0444 19 0445 To 95 custom application 19 0442 19 0443 96 Up custom application Picture 2 Optional S amp S Two Cable Throttle Conversion Kits For chassis not equipped with two cable throttle S amp S throttle kits fit 1 handlebars and can be used on most chassis An adapter sleeve is available for use with earlier OEM handlebars originally equipped with internal throttle cable Barrel fittings on cables readily plug in to S amp S Super E G or stock H D 1981 and later butterfly type carb throttle linkage Kits include one opening and one closing side cable left and right grips and handlebar clamps Throttle kit with 36 cables 0 Part 19 0450 Throttle kit with 39 cables 0 Part 19 0448 Throttle kit with 42 cables Part 19 0482 Throttle kit with 48 cables Part 19 0449 Throttle kit with 52 cables Part 19 0483 7 8 to 1 Adapter sleeve Part 19 0235 NOTE 1981 90 stock style cables also fit above throttle kits Carb Installation and Operation Refer to Super E and G Carb Kit Application Chart to confirm that carb kit is correct one for your motorcycle Read instructions thoroughly to familiarize yo
33. dle screws may damage backplate A All engines except Vs 1 Knuckles amp Pans 1936 to 1965 Press plugs part 50 8312 into holes in air cleaner backplate See Picture 2 2 Shovels 1966 to 1979 and lronhead IH XLs 1957 to 1979 Press plug part 50 831 2 into hole in air cleaner backplate See Picture 3 3 Shovels 1980 to 1984 and IH XLs 1980 to 1985 Screw crankcase breather vent elbow fitting part 50 8110 into hole in air cleaner backplate and angle downward as shown in Picture 4 On 1983 and 1984 Shovels press plug part 50 8312 into other hole on left 4 Assemble fast idle mechanism as shown in Figure A B FL Vs 1984 to 1992 1 Press plug part 50 8312 into hole on left in air cleaner backplate as shown in Picture 5 Figure A Picture 6 Picture 7 2 Screw vent hose elbow fitting part 50 8110 into remaining hole at right See Picture 5 3 Assemble fast idle mechanism as shown in Figure A C XL V s 1986 to 1990 1 Press plug part 50 8312 into hole on right in air cleaner backplate as shown in Picture 6 2 Screw vent hose nipple fitting part 50 8111 into remaining hole at left See Picture 6 Elbow fitting part 50 8110 supplied in kit may also be used in this location if required 3 Assemble fast idle mechanism as shown in Figure A D FL V s 1993 and up and XL V s 1991 and up 1 Press plugs part 50 831 2 into both holes in air cleaner backplate as shown in Pi
34. e Picture 34 and change bowl air pressure NOTE Bowl vent hole passage leads to cavity above fuel in bowl Passage equalizes bowl pressure and atmospheric pressure If high or low bowl pressure relative to atmospheric pressure develops engine may run erratically 7 Insulator block between carb and manifold not used Heat transfer from manifold to carb may cause temporary rich condition at idle and low RPM when engine is restarted after being shut off for 10 to 20 minutes Install insulator block to reduce heat transfer 8 Aircleaner without element or air horn used without removing bowl vent screw part 50 0105 located in downward facing boss on throttle cable side of carburetor body See Picture 26 9 Valve train defect Leaking or sticky valves weak or broken springs pushrod flex improper clearances for high lift cam or defective camshaft with improper valve timing 18 et Picture 35 10 Inappropriate exhaust system NOTE S amp S has found that long large diameter exhaust pipes either baffled or unbaffled may present insurmountable tuning problems when combined with S amp S carburetor If engine equipped with such pipes does not respond to normal tuning procedure contact exhaust manufacturer for his tuning suggestions or call S amp S for exhaust recommendation 11 Too much gear Horsepower insufficient to pull gearing Incorrect float setting Setting float too high will cause engine to run
35. e fuel filter is required use S amp S part 19 0456 where room permits filter is 3 long or S amp S part 19 0457 where space is limited filter is 112 long For additional information on these products contact Pingel Enterprise Inc 2076 C 11th Avenue Adams WI 53910 Phone 608 339 7999 Fax 608 339 9164 IMPORTANT NOTE 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 1497 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 S amp S SUPER E JETTING Stock Mild Strokers 74 to 84 Strokers 86 to 98 1 to 1 1 2 Turns Stockers 55 to 74 Displacement Idle Mixture Screw Part 11 2354 1 to 1 1 2 Turns 1 to 1 1 2 Turns Bevels must be at angles shown when installing plate Figure C 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 an
36. ediately open throttle slightly and continue to kick or engage starter until engine fires Picture 29 C Troubleshooting Tips engine will not start 1 2 Fuel supply exhausted Weak or no spark discharged battery worn points faulty condenser ignition module coil spark plug wires or magneto 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 Improper ignition timing Worn or poorly maintained mechanical advance units sometime stick in advanced position causing hard starting kick back and erratic idle Tight tappet adjustment Improper idle mixture and or engine idle RPM setting See Adjusting Carburetor Idle Circuit Enrichment device feed hole See Picture 29 in bowl plugged Clear with compressed air CAUTION Do not use wire or drill to clear hole If size of hole is changed starting system will be altered and carburetor bowl irreversably damaged WARNING 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 carb mixture is usually lean and engine must be reprimed If there is no response after three kicks or if engine pops
37. et When motorcycle is not running fuel shutoff valve should always be turned off to prevent possible leakage should needle and seat not seal completely CAUTION Gasoline leaking past inlet needle may flood engine causing contamination of oil supply and damage to engine WARNING Any gasoline leak constitutes a fire and health hazard Throttle plate part 11 2055 or 11 2355 and throttle shaft part 11 2383 or 11 2483 should be checked annually for signs of wear Replace if necessary If carb body throttle shaft bushings are worn carb must be returned to S amp S for repair If throttle plate removed be sure to reinstall correctly See Figure C Beveled edges of plate must fit flat against carb throat f accelerator pump cap is removed lift cap slowly so small spring part 11 2374 checkballs part 50 8090 and o rings part 50 8012 are not lost For racing S amp S offers two air horn conversion kits which include appropriate mounting hardware and a substitute enrichment device Part 17 0485 includes a 27 air horn part 17 0486 includes a 4 air horn 20 f fuel delivery from stock petcock appears insufficient S amp S recommends a Pingel petcock S amp S part 19 0453 which fits most Big Twins or S amp S part 19 0454 requires S amp S part 19 0455 which fits most Sportsters Tests conducted at S amp S have shown Pingel petcocks to provide more than adequate fuel supply for most engines If in lin
38. f engine runs flat and sluggish or blubbers or will not take throttle decrease or lean main jet size 004 smaller and road test again Note engine smoothness and how easily engine reaches RPM level where gear shift occurs e Continue changing main jets until jet which makes engine accelerate or RPM through gears quickest and smoothest is identified S amp S s experience is that jetting about 006 smaller leaner than correct will make engine break up and quit Jetting about 006 larger richer will make engine blubber and miss NOTES Correct jets are essential for optimum performance on street strip and dynamometer Most common causes of poor performance in modified engine are poor carb tuning inappropriate exhaust and incorrect ignition timing S amp S special main jet tool part 53 0452 Is extremely handy for changing main jets Try it youll like it E Troubleshooting Tips for Intermediate and High Speeds Engine will not run at steady speed or RPM or quits for no apparent reason 1 Restriction in fuel supply system Gas tank vent plugged needle and seat not working properly See General Information or gas petcock too small Stock H D petcock is often adequate but may require running on reserve to provide sufficient fuel for big inch engines If fuel delivery to carb is questionable S amp S recommends Pingel brand high flow petcock 2 Faulty ignition electrical system Fouled plugs worn
39. fitting and slip end of fuel line with 90 bend on fitting Position fuel line in such a way as to avoid contact with cylinders and other hot engine parts Tighten hose clamp Slip stock H D protective fuel line covering over fuel line and position where contact with engine parts could occur On models equipped with fuel line support guide use guide if possible Connect other end of fuel line to gas tank petcock using hose clamp provided Picture 15 Picture 17 Picture 16 NOTE Some early Super E and G carbs were equipped with a swivel type fuel inlet This inlet is no longer available lf swivel inlet requires repair it must be replaced with straight inlet 11 2465 o ring 11 2027 and 90 fuel line 19 0474 or 19 0475 See carburetor parts list and line drawing on page 24 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 A All Models except Buells Mount air cleaner backplate on carb using three 4 20 x screw washer assemblies Mounting screws must be tight Confirm that enrichment device lever part 17 0329 engages enrichment device plunger 11 2343 See Picture 15 Tighten backplate mounting screws to 10 12 ft lbs 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
40. g past inlet needle may flood engine causing contamination of oil supply and damage to engine WARNING Any gasoline leak represents a health and fire hazard L Install air cleaner element and air cleaner cover using three 20 x 1 mounting screws provided On Buell beveled vent hose must rest in notch in backplate and go between air cleaner element and chromed outer cover Hose bevel should angle down toward element See Picture 24 NOTE Air filter element goes on dry DO NOT APPLY OIL OR ANY OTHER SUBSTANCE TO AIR FILTER SUPPLIED BY S amp S M Fill gas tank INSTALLATION NOTES In designing the S amp S Super E and G carbs S amp S has made every effort to keep overall assembled length as short as possible On four speed Shovelheads the air cleaner cover may contact the gas tank In such instances an optional chromed notched cover part 17 0372 that Picture 25 will provide additional clearance can be ordered See Picture 25 If anew undamaged Super E G cover is shipped to S amp S prepaid it will be exchanged for part 17 0372 for the difference in cover prices Call for Return Authorization RA number before shipping cover An optional 1 spacer block can be installed between carb and manifold as an alternative or existing air cleaner cover modified to provide minimum clearance Bowl vent screw part 50 0105 See Picture 26 should be removed for any all out racing application which includes use of air h
41. g to avoid personal injury f the motorcycle has been running wait until the engine and exhaust pipes have cooled before performing any installation steps to avoid getting burned Before performing any installation steps disconnect and remove the battery to eliminate potential sparks and inadvertent engagement of the starter while working on the motorcycle Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps Contact an authorized H D service manual for correct disassembly reassembly and installation procedures for any parts that need to be removed to facilitate the installation Use good judgment during assembly installation and when operating the motorcycle Good judgment begins with a clear head Don t let alcohol drugs or fatigue impair judgment Perform the assembly and installation when fresh For optimum performance and safety and to minimize potential damage to the carburetor or other componenis use correct hardware and follow procedures outlined in S amp S instructions and an authorized H D service manual Be sure all fuel lines are routed correctly with clamps in place and tightened Lines must not contact exhaust pipes or other extremely hot surfaces where they could melt or leak and catch fire Motorcycle exhaust fumes are toxic and must not be inhaled Run motorcycle only in a well ventilated area where fumes can dissipate
42. heads with shims provided in S amp S shim kit part 17 0464 Thread breather screw into cylinder head through backplate ear breather fitting and shims Breather fitting 17 0337 mounts directly behind backplate ear with larger diameter hole toward backplate See Picture 20 Repeat for other backplate ear 7 Align breather fitting outlets and tighten breather screws NOTE Breather fitting o rings are easily damaged It is suggested that replacements be obtained prior to removing breather fittings in future 8 Slip hose clamp 50 8002 over short tee of vent hose 1 7 0339 and push hose tee Picture 21 Picture 20 onto nipple fitting on rear of backplate with long hose runner toward rear cylinder breather fitting Trim ends of vent hose as required making sure hose does not kink or restrict enrichment handle movement Push hose ends onto breather fittings Secure hose ends on breather fittings with small Tie wraps 50 8003 supplied in kit secure short Tee of breather hose to backplate with hose clamp 50 8002 supplied with kit 9 Final tighten all mounting bracket bolts and manifold clamps E Buells 1994 to present Installation of breather hardware and backplate is same as procedure described in Step D above However position of 17 0309 backplate support bracket must be determined before backplate can be permanently installed 1 Loosely install bracket on front head using Spacers
43. ial E XL Yn eae Part 16 1600 IA E FL ee eee Part 16 1608 2ye G XL V2 na Part 16 2500 ay ag GFLV enian Part 16 2508 Manifold bolts AT ern mere wernt Part 50 0161 16 x 1 use in bottom hole with 16 0096 or 16 0471 bracket or in top and bottom holes with 16 0491 or 16 0492 insl block PE E E PA E T AT Part 50 0162 16 x 1 use in bottom hole with 16 0096 or 16 0471 bracket and 16 0491 or 16 0492 insulator block sicssseecscescasseecinass Part 50 0163 PIGA riipi Part 50 0164 PIG 4 anaiei renee Part 50 0165 Uo NO Mee anasi Part 50 0166 10 Super E and G Manifold and Related Mounting Hardware 5 10 11 12 13 14 Manifold O ring 55 to 78 FL amp XL PENER nd E EE E E Part 16 0237 Manifold rubberband 79 to 85 FL amp XL PEE EENET EPEE OET Part 16 0238 Manifold O ring V Part 16 0236 Manifold clamps O ring pre 7S co soe vccdenciceccepsctetvse Part 16 0230 Band 7910 B5 isisisi Part 16 0231 V Manifold Flanges Front mounting flange Part 16 0232 Rear mounting flange Part 16 0233 Carb mtg bracket Pan Part 16 0096 Carb mtg bracket assembly includes 1 ea 2 pc bracket 17 0104 17 0245 17 0321 008 Part 16 0471 Support bracket bolt She VB X 1 aaan Part 50 0108 Flat washer 5 6 X t auiii Part 50 7034 Lock nut c 18 eee Part 50 5021 15 16 17
44. iate jet See Picture 31 is reached by removing float bowl assembly Size of metering hole in intermediate jet is stamped in thousandths of an inch on end or side of jet Size of intermediate jet installed in new carburetor from S amp S is indicated on tag attached to carb and or on printed label on carburetor packing box Keep this information handy for future reference especially when contacting S amp S Technical Servces Dept for assistance 16 1 Ride motorcycle several miles to bring engine up to normal operating temperature 2 Check idle mixture adjustment to be sure setting is correct with fully hot engine 3 Check throttling characteristics by slowly rolling throttle on while maintaining steady speed This should be done at RPM levels of approximately 2000 2500 and 3000 RPM Depending upon gearing vehicle speeds will usually be between 30 and 60 MPH Popping or spitting backfiring in air cleaner indicates lean condition requiring that intermediate jet be changed to next larger size size is stamped on end or side of jet See NOTES below 4 Change jet accordingly adjust mixture screw and repeat road test Smallest intermediate jet that eliminates this condition should provide best gas mileage INTERMEDIATE SYSTEM NOTES It is helpful to shut off accelerator pump while fine tuning intermediate circuit as fuel supplied by pump can mask jetting symptoms Consult Accelerator Pump section of inst
45. in Eagle Cycle Shack with CycleShack XP baffles This system typically produces 10 horsepower more than drag pipes in midrange where vast majority of normal riding Occurs Some 2 into 1 collector type exhausts such as SuperTrapp and Rich Products Thunderheader deliver even more midrange power Carl s Speed Shop staggered duals and KhromeWerks AR 100 s work extremely well for riders who prefer a more traditional style exhaust Contact S amp S for current exhaust recommendations Forany all out racing application which includes use of air cleaner without element or use of air horn bowl vent screw part 11 2161 See Picture 26 should be removed to insure atmospheric air pressure exists in bowl If high or low bowl pressure relative to atmospheric pressure develops engine may run erratically Modifying S amp S carburetor While it is not S amp S s intent to discourage purchase of other manufacturers products they should be approached with the understanding that some alter the S amp S carburetor s design and function In such cases manufacturer of installed item must be contacted for tuning guidelines not S amp S Picture 36 F Adjusting Accelerator Pump Function of accelerator pump is to improve throttle response when rapidly opening throttle at low RPM and to aid cold starts Pump travel screw part 50 0039 See Picture 35 regulates volume of fuel delivered by accelerator pump During assembly S amp
46. in exhaust pipes mixture is probably too rich Leave switch on and slowly open throttle 4 turn with each successive kick until engine fires If engine was running properly before installation of carburetor no other changes were made and carb 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 Carb tuning and ignition tuning and maintenance are critical for kick start motorcycles 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 turn turn ignition on and kick until engine starts 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 If not increase accelerator pump setting by turning adjustment screw out in counterclockwise direction Replace air cleaner cover and attempt to start motorcycle according to procedure previously described If more than 2 3 squirts from accelerator pump are required to start motorcycle w
47. ing a potential health and fire hazard 2 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 carb jet size 3 Pull fast idle lever part 17 0327 or part 17 0329 to fully raised position 4 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 5 With throttle closed kick engine through or engage electric starter 6 If engine fails to start immediately crack throttle enough to barely open butterfly and continue to kick or engage starter until engine fires 7 After engine starts position lever to maintain RPM at approximately 1000 1200 rom with throttle closed Lever may gradually be pushed down 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 If engine fails to start imm
48. ith temperature 60 or above larger intermediate jet may be required Refer to following sections for additional information on tuning 2 Adjusting Carburetor A Adjusting Idle Circuit Idle mixture screw part 11 2354 See Picture 10 regulates air fuel mixture at idle speeds and has been angled forward for greater accessibility Throttle stop engine RPM adjustment screw part 50 0038 See Picture 11 is located on boss on rear side of carburetor body During assembly S amp S adjusts both screws to settings that should work for first start up after installation 1 2 3 Start engine and run until slightly warm approximately 1 to 2 minutes Turn RPM adjustment screw 50 0032 to obtain idle of approximately 800 1000 RPM Turn idle mixture screw 11 2354 clockwise slowly leaning mixture until engine starts to die Next turn screw counterclockwise slowly richening mixture until engine RPM fall off Mixture adjustment is correct when screw is positioned about halfway between these points or approximately 1 4 to 2 turn out from lean side of adjustment range NOTE Turning screw out counterclockwise makes idle mixture richer Turning screw in clockwise makes Picture 30 mixture leaner Normally correctly adjusted screw will be between 1 and 1 turns out from bottom if intermediate jet correct size Note that mixture screw must be adjusted according to Step 3 above Do not leave screw at initial 1
49. le magneto due inteference between magneto and carb fuel inlet fitting S amp S manufactures no adapters or other components for installing E or G carb on magneto Sportster G IH XLs 1983 to 1985 and all V s Connect vacuum operated advance ignition switch VOES to manifold using 8 piece of black tubing supplied in kit Cut tubing to shorter length if necessary 5 Install Carb A Check idle mixture and idle speed screw settings 1 Check setting of idle mixture screw part 11 2354 on top of carb body See Picture 10 Turn screw clockwise to close screw counting number of turns to fully closed position setting should be 1 turns Reset by turning screw counterclockwise to 1 turns open After engine is started screw must be reset as explained in Adjusting Idle Mixture section of instructions NOTE Turn idle mixture screw in only far enough to contact seat Do not overtighten CAUTION Overtightening idle mixture screw may cause irreversible damage to carburetor body 2 Check setting of idle soeed adjusting screw part 50 0038 See Picture 11 Turn screw counterclockwise until it no longer contacts throttle linkage spool part 11 2385 Next turn screw clockwise until it just contacts spool Then turn additional 12 turn clockwise to slightly open throttle plate part 11 2055 E carbs or part 11 2355 G carbs B Install throttle cables on carburetor 1 Remove throttle cable housing bracket part 1
50. ompression engines If there is doubt as to which carburetor to use S amp S suggests the Super E IMPORTANT NOTE Recommended for Racing Only S amp S carburetors are not legal for use in California on motor vehicles operated on public highways or in other states where similar pollution laws apply The user shall determine the suitability of the product for his or her use and shall assume all risk and liability in connection therewith Picture 1 Kit Contents Each complete carb kit includes One S amp S Super E or Super G gas carburetor One S amp S teardrop air cleaner assembly One manifold Mounting hardware Fuel line clamps and overflow line One extra intermediate jet and two main jets VOES tubing and additional hardware when applicable Installation and jetting instructions Chrome Plating the Carburetor NOTE S amp S does not recommend chrome plating the Super E or G carburetor Preparation requires polishing with abrasive buffing compounds These materials invariably plug air and or fuel passages and other orifices regardless of precautions taken CAUTION 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
51. orn or air cleaner without filter element Exposed passage in carb body maintains equal pressure between float bowl and atmosphere On any application where air horn is used instead of air cleaner S amp S carb mounting bracket part 16 0471 must be used to securely fasten carb to engine See line drawing on page 23 CAUTION Improperly mounted carburetor may loosen from engine resulting in gas or air leaks poor performance and possible damage to carburetor or other components WARNING Any gasoline leak represents a potential health and fire hazard Picture 26 Picture 27 Picture 28 G carb using air cleaner assembly without filter element flows approx 7 CFM 10 test pressure less than carb with 4 air horn E carb w air cleaner assembly no filter flows same as with 4 air horn S amp S recommends using air filter element for all street applications S amp S has found that trimming approximately 2 off rear of air cleaner cover often results in 3 HP increase on Dynojet 150 chassis dynamometer This increases exposure of filter element to weather and contamination so filter should be inspected regularly and washed or replaced as needed Carb Operation 1 Starting Procedure S amp S Super E amp G 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 pa
52. ructions Whenever intermediate jet is changed idle mixture screw must be readjusted Elevation changes A simple readjustment of idle mixture screw will often compensate for changes in elevation of several thousand feet S amp S test riders have ridden through changes upwards of 7000 feet without changing jets In other cases and depending upon accuracy of initial jetting a change in intermediate and or main jet may be required Higher elevation makes engine run richer meaning that smaller jets may be required to correct overly rich condition Lower elevation nearer sea level makes engine leaner so larger jets may be required While rich condition can cause fouled spark plugs and poor performance lean condition can result in engine damage If smaller jets are installed for higher elevation remember to install larger jets for operation at lower elevation Intermediate jet provides majority of fuel under average operating conditions While it is tempting to change main jet because it is more accessible in most cases intermediate jet should be changed to properly address elevation altitude related problem D Adjusting High Speed Circuit or Main Jet High speed circuit begins around 3000 3500 rpm or 65 70 mph and operates to maximum attainable speed Main jet size is best determined by testing at drag strip or dynamometer because maximum miles per hour RPM and horsepower are most reliable indicators of correct jetting Main jet
53. ssageways and is engaged by pulling fast idle lever part 17 0329 upward See Picture 27 E amp G carburetors also feature a fully adjustable accelerator pump which is actuated by quick throttle movements at partial throttle openings and can be used as an additional starting aid ENRICHMENT DEVICE NOTES Enrichmentfast idle pickup tube located directly below fast idle plunger part 11 2343 is pressed into carburetor body and must not be removed See Picture 28 CAUTION Removal of enrichment fast idle pickup tube from carburetor body may cause irreversible damage to carburetor Plunger nut part 11 2344 plunger spring part 11 2340 and plunger part 11 2343 may be removed for cleaning purposes f air cleaner backplate is removed be sure fast idle lever and enrichment plunger are engaged properly when backplate is reinstalled See Picture 15 S amp S enrichment system operates on manifold vacuum If throttle is opened while starting engine 13 vacuum will be reduced and enrichment system will not function normally A Cold Starts 1 Open fuel petcock 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 CAUTION Gasoline leaking past inlet needle may flood engine causing oil contamination and engine damage WARNING Gasoline leaking past inlet needle may flood engine and surrounding area creat
54. ting system will be altered and carburetor bowl irreversably damaged Picture 31 WARNING 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 5 Enrichment ast idle plunger part 11 2348 not seated causing excessively rich mixture Be sure enrichment lever part 17 0329 is fully disengaged in down position allowing plunger to bottom and seal passageway Remove air cleaner backplate Lift and release plunger several times letting it snap closed to fully seat against carb body When backplate is reinstalled on carb be sure lever is engaged in plunger properly and plunger not lifted as mounting screws tightened See Picture 15 6 insulator block between between carb and manifold omitted Heat transfer from manifold to carb may cause temporary rich condition at idle and low rom when engine restarted after being shut off for 10 to 20 minutes Install insulator block to minimize heat transfer C Adjusting Intermediate System See Jetting Chart Page 20 Intermediate range is used most often under normal riding conditions It controls fuel delivery from just off idle to approximately 3000 3500 rom or 60 to 70 mph depending on gearing Close attention must be paid when selecting intermediate jet to achieve optimum performance and best gas mileage Intermed
55. urself with all procedures before beginning installation NOTE Installation of S amp S Super E and G carb 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 H D service manual for additional information as necessary 1 Remove Old Carburetor WARNINGS Gasoline is extremely flammable and explosive under certain conditions Do not smoke around gasoline Gasoline fumes are toxic when inhaled Picture 3 Picture 4 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 petcock and disconnect battery B Remove air cleaner assembly Drain fuel from existing carburetor Remove carburetor manifold choke cable and any carburetor mounting hardware NOTE Removing and tightening hard to reach Allen bolts such as carb manifold mounting bolts and V manifold flange bolts can be greatly simplified by the use
56. ustomer 5 S amp S parts are designed exclusively for use on Harley Davidson motorcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application Introduction S amp S Super E and G Shorty carburetors are designed for Harley Davidson Big Twin and Sportster engines They are butterfly type carburetors with fully adjustable idle mixture and changeable mid range and high speed jets Both also feature an adjustable accelerator pump and variable enrichment fast idle device for improved throttle response 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 The Super E is recommended for use on any displacement Big Twin or Sportster NOTE Because S amp S carburetors are significantly larger than OEM units unmodified small displacement engines such as 883 and Iron Head Sportsters may experience sluggish low speed response when equipped with S amp S carburetors This can often be minimized with careful tuning The Super G has a 2 52 3mm bore and 1 44 5mm venturi It is identified by a Q cast into the carb body See Picture 1 The Super G is recommended for use on modified engines of 74 cubic inches or more While both carburetors can be made to work on most engines the Super G is not recommended for small low c
57. y problems or repairs needed Thanks for using S amp S products S amp S SUPER G JETTING Stock Mild Strokers Strokers Strokers 74 to 84 86 to 93 96 amp Up 1 to 1 1 2 1 to 1 1 2 1 to 1 1 2 Turns Turns Turns Displacement Idle Mixture Screw Part 11 2354 Intermediate Jet 883 s 0265 to 028 All Others 028 to 0295 Part 11 7101 883 900 1000 062 to 068 All Others 066 to 072 Part 11 7200 lronhead XL s 0295 to 032 All Others 028 to 031 Part 11 7102 or 11 7103 74 80 FL s 066 to 074 All Others 068 to 076 Part 11 7201 lronhead XL s 032 to 033 All Others 030 to 033 Part 11 7104 072 to 082 Part 11 7202 Stockers 028 to 0295 Intermediate All Others Jet 0295 to 031 Part 11 7102 Stockers 066 to 074 All Others 068 to 076 Part 11 7201 lronhead XL s 031 to 033 All Others 0295 to 033 Part 11 7103 or 11 7104 072 to 080 Part 11 7202 032 to 036 Part 11 7105 lronhead XL s 078 to 088 All Others 074 to 086 Part 11 7202 or 11 7203 21 Intake manifold Pan 1 4 E O Nng eee errr ree ete Part 16 1100 Intake manifold Shovhead amp lronhead XL 1 4 BOG ssccscsosrcaccimseoninans Part 16 1200 We E Band l a Part 16 1300 1 E VOES band l a Part 16 1400 2ye GONIN errien Part 16 2200 Biter G Band tees este ge aneaee Part 16 2300 2 G VOES band 06 Part 16 2400 Intake manifold V2
58. yls 075 longer than stock includes 1 ea 17 0330 17 0372 17 0379 17 0441 Part 17 0440 V FL 84 92 amp XL 86 90 includes 1 ea 17 0380 17 0378 17 0379 HY OA OG eteeisapxesssevtansesersageede Part 17 0399 FL 93 up amp XL 91 up includes 1 ea 17 0336 17 0378 17 0379 PUAI spcasssosseninehsuctarennnetecees Part 17 0401 34 Mounting hardware package Not shown Pre V includes 3 ea 50 0072 50 0075 1 ea 50 0110 50 5021 50 7032 50 7033 50 0108 50 7034 50 7007 50 7035 50 0106 50 7037 17 0329 2 ea 50 831 2 50 7036 50 0041 peje ieee NE ETE E A T T Part 17 0441 V FL 84 92 amp V XL 86 90 includes 3 ea 50 0072 50 0075 1 ea 50 8110 50 8111 17 0314 50 7007 50 7035 50 7037 17 0329 2 ea 50 0110 50 8312 50 7034 50 7036 50 0041 00 Part 17 0458 V FL 93 up amp V XL 91 up includes 3 ea 50 0072 50 0075 2 ea 50 0041 50 831 2 50 7036 17 0338 50 7119 17 0337 50 8082 50 8006 50 8003 1 ea 50 7007 50 7035 50 7037 17 0329 17 0339 17 0464 50 8002 Part 17 0439 Super E and G Air Horns 35 2 Air horn conversion kit includes 1 ea 16 0063 11 2084 16 0105 17 0331 16 0471 Part 17 0484 36 24 Air horn assembly includes 1 ea air horn 3 ea 17 0391 POENE EEE E Part 17 0331 37 Air horn mounting screw P
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