S&S Worldwide Air Cleaner for Stock Tillotson, Bendix, and KeihinCarburetors User's Manual
Contents
1. Backplate screws supplied with this kit have thread locking compond on threads If screw without thread locking compound is used a thread locking compound such as Loctite 242 must be applied and screws properly tightened 8 Align the mounting brackets with the head breather bolts and secure with backplate screw 17 0346 Do not tighten completely at this time Position mounting brackets A On all carbureted models align backing plate and brackets then tighten all mounting hardware B On single runner fuel injected models align and tighten all hardware except backplate screw Fill gap between mounting bracket and breather screw with supplied shims 50 7113 50 7114 50 7115 as needed Shims are only used on fuel injected models See Picture 3 Item B A B C D 10 11 12 Picture 3 Breather T hose in backplate notch Breather fitting and support bracket 200 Shim used on 93 and up Big Twins only Position of shims used on fuel injected models Place wire tie or metal clamp over tee of T hose insert 2 steel tube 50 8121 part way into tee and tighten clamp Then slide short length of beveled hose 1 7 0365 over steel tube with beveled end out and facing down Tighten clamp See Picture 1 Apply a few drops of Loctite 242 blue or equivalent to threads install nuts and lockwashers Tighten all mounting hardware NOTE Torque specifications flat vent fittings 15 20 ft2. lb with red Loctite 262 Air Cleaner mounting screw 8 12 ft lb with no Loctite 13 14 Install filter element and air cleaner cover Secure with three air cleaner cover screws 50 0072 to complete installation Start motorcycle inspect for leaks and test ride Engine should run smoothly after proper warm up Surging or misfire may indicate lean carburetion If necessary consult professional mechanic regarding possible need to install correct carburetor jetting Picture 4 Buell Vent Fitting A 50 7120 Spacer B 125 Spacer required minimum C Vent hose in notch in backplate INSTALLATION KIT 17 0105 See line drawing on page 7 1 Remove existing air cleaner assembly and related hardware including cylinder head breather fittings if applicable Refer to authorized Harley Davidson Service Manual as needed NOTE Hose barb on rear cylinder head breather fitting must be removed To remove fitting from cylinder head a cut off wheel or similar tool is used to cut barb oft Care must be taken that no metal chips get into the breather fitting S amp S recommends packing fitting with grease An alternative is to grasp barb with pliers and snap off 2 Place head vent shim 50 7120 over breather cap screw 1 7 0338 and roll O D o ring 50 8032 into large diameter o ring groove closest to head of breather screw See Picture 4 Item A 3 Roll 2 O D o ring 50 8006 into small diameter o ring groov
3. screw crankcase breather vent elbow fitting 50 8110 into hole B See Figure A 3 Mount air cleaner support bracket 1 7 0311 two required from air cleaner support holes in cylinder heads with 18 x 1 bolts and lockwashers Do not tighten bracket completely at this time NOTE Backplate screws supplied with this kit have thread locking compond on threads If screw without thread locking compound is used a thread locking compound such as Loctite 242 must be applied and screws properly tightened 4 Attach backplate to carb and determine number of shims or washers required to fill gap between backplate and mounting bracket 5 Insert 18 bolts of appropriate length through backplate shims mounting bracket and lockwasher 6 Tighten all mounting hardware 7 Insert vent hose connector 50 8111 into end of existing crankcase vent hose place S amp S crankcase vent hose 17 0113 over other end of connector and secure with hose clamp Place second clamp over vent hose and attach end of hose to elbow fitting 50 8110 in backplate Secure with clamp See Picture 1 8 Install filter element and air cleaner cover Secure with three air cleaner cover screws 50 0072 to complete installation 9 Start motorcycle inspect for leaks and test ride Engine should run smoothly after proper warm up Surging or misfire may indicate lean carburetion If necessary consult professional mechanic regarding possible need to in
4. Instruction Sheet 51 1062 Revised 6 26 02 Copyright 1998 1999 2001 2002 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tue 14025 County Hwy G Viola Wisconsin 54664 U S A Phone 608 627 2080 Fax 608 627 1488 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Box 215 Because every industry has a leader Website www sscycle com Installation Instructions for S amp S Air Cleaner for Stock Tillotson Bendix and Keihin Carburetors on all OHV H D s 1994 up Buells and All 2000 up Single Runner Fuel Injected Models INTRODUCTION Installing an S amp S air cleaner on a stock carburetor is simple and straightforward Because this modification increases airflow larger carburetor jets may be required Additionally S amp S air cleaners for stock carburetors have no provision for the emissions canister purge valve required in some areas As a result installing this product may render the motorcycle illegal for street use in California and other areas with similar emissions standards It is solely the owner s responsibility to determine the suitability of this product for his use and application S amp S air cleaner kits for stock carburetors are available for Big Twins Sportsters and 1994 up carbureted Buells Kit 17 0199 fits 1966 1984 Shovelheads and 1966 1985 ale Kit 17 0105 fits 1994 up carbureted Buells Kit 17 0108 fits 1984 1989 Big Twin
5. e of breather screws Apply thin film of light grease to o rings NOTE Breather fitting o rings are easily damaged It is suggested that replacements be obtained prior to removing breather fittings in future 4 Repeat for other breather screw 5 Pass breather screws through breather fittings 17 0337 and OEM support bracket Do not tighten at this time 5 NOTE At least one 125 shim must be installed between breather fitting and cylinder head Otherwise breather screw may bottom out in cylinder head resulting in oil leak and possible damage to head or screw See Picture 4 Item B 6 Install backplate on carb NOTE Backplate screws supplied with this kit have thread locking compond on threads If screw without thread locking compound is used a thread locking compound such as Loctite 242 must be applied and screws properly tightened 7 Remove backplate and breather screw assemblies then install shims and reinstall breather screw assemblies Do not tighten at this time 8 Align breather fitting outlets to permit installation of T hose 9 Install rubber T hose 17 0339 over cylinder head breather fittings with hose tee toward rear of engine Hose must not be kinked or otherwise obstructed and should be trimmed to length as needed to align tee with backplate cut out Once proper fit is obtained secure T hose to breather fittings with black tie wraps or clamps provided See Picture 4 Item C 12 Place wire tie
6. eneenees Part 17 0105 1999 up Twin Cam with stock carburetor or single runner fuel injection EE Part 17 0101 11993 up Big Twin ssi 1991 up Sportster 1999 up Twin Cam 1994 up Buell S amp S Air Cleaner Assemblies for Stock Carburetors Parts and Mounting Hardware Air cleaner Cover sssnesssssenssennserenenesenns Part 17 0078 17 Vent hose 19901upNL eee Part 17 0365 SEI eege Part 17 0079 18 90 Elbow ging Part 50 8110 Backplate 19 Hose fitting ccecccececesesssseeseseseseseseeeeeee Part 50 8121 1966 89 Big Twin 1966 87 Sportsters Part 17 0180 20 Flatwasher 2 Part 50 7021 1993 Up Big TWin sssssessssensnnnsenesnnensrrnn Part 17 0001 21 Backplate plug black plastic Part 50 8312 1991 Up Sportster eeeeeeeeeeeeees Part 17 0002 22 Plug press in clear last Part 50 8313 1994 uUp Buell ccccccceeecseeeeeeeeeeees Part 17 0003 23 Support bracket locknut 28 sm Part 50 5010 Soren ELE Xi wn Pan aso o074 Ai lsaner support rack Backolaie eee 1984 91 V BT amp 1986 90 V XL Part 17 0312 ey GE DEE 25 Support bracket screw 18 x 1 Part 50 0110 b SLTD FH w lockwasher 20 x 1 Part 50 0076 26 LOCKWASNE a Part 50 7032 Shim kit 27 Support bracket AC head V stock Part 17 0311 a BT 1966 1989 amp XL 1966 1987 28 Air cleaner support bracket 1966 82 BT Part 17 0092 includes 2 ea lt x 018 s x 030 Ye x 048 29 S
7. him head vent 620 I D x 800 O D x 185 cee ean ebe Part 50 7120 Ee _ Breather screw o ring OD Part 50 8032 TWIG QIN EE Part 17 0345 _ Breather screw o ring OD Part 50 8006 23 Washer silicone EE Part 50 7055 _ Vent fitting 44 Washer silicone BT 1993 up amp XL 199 up Part 17 0337 Eege Part 50 7055 _ Crankcase breather vent hose ALWIL AG AN eae tae vate a tliat Ss Part 50 7054 a BT 1984 1992 amp XL 1986 1990 Part 17 0113 45 Shims each Fuel Injected only b BT 1993 up amp XL 1991 Up ee Part 17 0339 1620 XaC60 XO EE Part 50 7113 Air cleaner support bracket 1957 85 XL Part 17 0093 1620 X 3860 Ee ened Part 50 7114 Vent hose connecter nipple saassa00sn Part 50 8111 1620 ER E EE Part 50 7115
8. n 7 Tighten all mounting hardware 8 Install crankcase vent hose to fitting installed in step 2 WARNING Vent hose must not contact hot or moving surfaces that could damage it and expose brakes or tires to crankcase oil air mist Oil on these components could result in loss of control of motorcycle with death or severe injury to operator and others 9 Install filter element and air cleaner cover Secure with three air cleaner cover screws 50 0072 to complete installation 10 Start motorcycle inspect for leaks and test ride Engine should run smoothly after proper warm up Surging or misfire may indicate lean carburetion If necessary consult professional mechanic regarding possible need to install larger carburetor jetting Picture 1 Crankcase vent hose 1984 92 V2 INSTALLATION KIT 17 0108 1984 1989 Big Twins and 1986 1987 Sportsters Crankcase vented only See line drawing on page 6 1 Remove existing air cleaner assembly and related hardware if applicable Refer to authorized Harley Davidson Service Manual as needed 2 Prepare air cleaner backplate A 1984 1989 Big Twins Press plug 50 8312 into hole B in backplate Apply Teflon tape or thread lubricant to threads and screw crankcase breather vent elbow fitting 50 8110 into hole A See Figure A B 1986 and 1987 Sportsters Press plug 50 8312 into hole A in backplate Apply Teflon tape or thread lubricant to threads and
9. nkcase pressure must be vented into air cleaner assembly not directly into atmosphere Pressure relief passages in crankcase and or cylinder heads must not be plugged as gasket failure and oil leakage may result Figure A NOTES Air cleaner assembly must be firmly supported S amp S includes support brackets only with kits for OEM carb or single runner fuel injection Brackets for other applications are listed in the S amp S catalog and may be purchased separately Parts from different year group installed on motorcycle by previous owners may require different Support bracket Adjustable bracket 16 0471 attaches to center case bolt and lower carb manifold bolt It is recommended for 1983 84 Shovels and works on most other models as well Kits may contain wire ties or metal clamps for securing vent hoses depending on application A 36 length of hose is provided for race applications This hose may be used to route crankcase fumes oil mist to a catch can or similar device as required and approved by race organizer INSTALLATION KIT 17 0199 1966 1984 Shovels and 1957 1985 Sportsters See line drawing on page 6 1 Remove existing air cleaner assembly and related hardware if applicable Refer to authorized Harley Davidson Service Manual as needed 2 Prepare air cleaner backplate A 1966 1979 Shovels and 1957 1979 lronhead Sportsters Press plugs 50 8313 into holes D in backplate See Fig
10. or metal clamp over tee of T hose insert steel tube 50 8121 part way into tee and tighten clamp Then slide short length of beveled hose 1 7 0365 over steel tube with beveled end out and facing down and tighten clamp See Picture 1 13 Apply a few drops of Loctite 242 blue or equivalent to threads install nuts and lockwashers 14 Tighten all mounting hardware 15 Install filter element and air cleaner cover Secure with three air cleaner cover screws 50 0072 to complete installation WARNING Vent hose must not contact hot or moving surfaces that could damage it and expose brakes or tires to crankcase oil air mist Oil on these components could result in loss of control of motorcycle with death or severe injury to operator and others 16 Start motorcycle inspect for leaks and test ride Engine should run smoothly after proper warm up Surging or misfire may indicate lean carburetion If necessary consult professional mechanic regarding possible need to install correct carburetor jetting 1966 1984 Shovel Big Twin and 1957 85 Sportster with Stock carburetor cceseceeeceneceneceneseneeenes Part 17 0199 1984 89 Big Twin 1986 87 Sportster with stock carburetor Part 17 0108 33 1993 up Big Twin and 1991 up Sportster with stock carburetor c ccccceeseeeeeneeeeeneeeeeeeeeeaes Part 17 0100 1994 up Buell with stock carburetor cccccseseeseseeeeseeeeneeeeeeeeeneee
11. s and 1986 1987 Sportsters Kit 17 0110 fits 1991 up Sportsters and1993 up Big Twins Kit 17 0101 fits 1999 up Twin Cam models with carburetor or single runner fuel injected models Kits are not available for 1989 1992 Big Twins 1988 1990 XL s or any dual runner fuel injected models WARNINGS Gasoline is highly flammable explosive under certain conditions and the fumes toxic when inhaled Be sure gasoline petcock is OFF before beginning installation provide adequate ventilation and disconnect battery ground cable to avoid sparks and accidental engagement of electric starter Improperly mounted carburetor may become detached from motorcycle resulting in immediate health and fire hazard CAUTIONS If improperly tightened or loosened by vibration bolts screws etc located inside air cleaner assembly may fall into engine causing extensive damage not covered under warranty S amp S recommends applying Loctite 242 or equivalent thread locking compound to threads of all bolts screws and nuts located inside air cleaner assembly Mounting bracket bolt of incorrect length may cause parts damage not covered under warranty It is the owner s responsibility to determine if the installation of this air cleaner assembly is in accordance with applicable legal and emissions requirements Crankcase and cylinder head vents must be open and free of restriction To meet C A R B and similar standards if applicable cra
12. stall correct carburetor jetting INSTALLATION KIT 17 0100 17 0101 1993 up Big Twins 1991 up Sportsters and 1999 up Carbureted and Single Runner Fuel Injected Twin Cams See line drawing on page 7 1 Remove existing air cleaner assembly and related hardware including cylinder head breather fittings if applicable Refer to authorized Harley Davidson Service Manual as needed 2 Assemble both head breather bolt assemblies as pictured in line drawing 3 Screw breather assemblies into breather vent holes in the heads Do not tighten completely at this time 4 Install rubber T hose 17 0339 over cylinder head breather fittings with hose tee toward rear of engine Hose must not be kinked or otherwise obstructed and should be trimmed to length as needed Once proper fit is obtained secure T hose to breather fittings with black tie wraps or metal clamps provided See Picture 2 5 Tighten the head breather vent bolts NOTE Use Loctite 262 Red on breather fitting to head threads 6 Picture 2 Vent hose breather fittings and air cleaner mounts installed Insert 4 28 bolt through backing plate from filter side On Big Twins only position the 200 thick spacer between the backplate and support bracket Next install the bracket flat washer and the Nyloc nut Repeat with the other mounting bracket See Picture 3 Item C Align the backplate on carburetor Do not tighten completely at this time NOTE
13. upport bracket Panhead 00nn0000nn Part 16 0096 Se X 105 amp 4 ea Xo X Im Part 17 0314 30 Support bracket 1983 84 Shovels Part 16 0471 b BT 1993 up XL 1991 up Buell 1994 up CH ER LOCK TILL et Osco ee ete ie Mee Part 50 5021 includes 2 ea x 018 x 030 x 048 32 Flat washer 6 X Vie eee eeeeeeeeeeeeeeee een eeeees Part 50 7034 x 105 and 4 ea x 125 Part 17 0464 33 Support bracket screw 18 X 1 Part 50 0108 Shim 34 Rubber tubing sieft Part 19 0169 BT 1966 1989 amp XL 1966 1987 35 Wire tie Not SHOWN eeeeeeeeeeeees Part 50 8003 ly Fie E EE Part 50 7038 36 Hardware kit Not shown e ce 06 eegene Part 50 7039 Air cleaner mounting 1994 up Buell Part 17 0050 Co Vie ER Part 50 7040 Air cleaner mounting E G 1994 up Buell Part 17 0051 a ie a nl ee ee Part 50 7041 Air cleaner mounting NV Part 17 0244 Cis OGIO EE Part 50 7042 Air cleaner mounting 1993 up BT Part 17 0052 BT 1993 up XL 1991 up Buell 1994 up 37 Washer flat 4 x 4 jd Part 50 7053 Eege Part 50 7085 38 Carb support bracket Oe EL ME Part 50 7086 V2 w CV carb 1994 up Buell Part 17 0309 A X ee ee Part 50 7087 39 Screw air cleaner backplate support Part 17 0346 i Si X ge NEE Part 50 7089 40 Shim nu 4 x 200 Part 17 7024 i coi ann ee dos ees 41 Carb support bracket cccccccccceeeeeees Part 17 0308 _ S
14. ure A B 1980 84 Shovels and 1980 1985 lronhead Sportsters Apply Teflon tape or thread lubricant to threads of crankcase breather vent elbow fitting 50 8110 and install in hole A in backplate See Figure A 3 Attach mounting bracket to engine Do not tighten bracket completely at this time A 1966 1982 Shovels normally utilize bracket 17 0092 which attaches to bottom of front rocker box and air cleaner backplate B lronhead Sportsters normally utilize bracket 17 0093 which attaches to front intake lifter guide bolt and air cleaner back plate NOTE Backplate screws supplied with this kit have thread locking compond on threads If screw without thread locking compound is used a thread locking compound such as Loctite 242 must be applied and screws properly tightened 5 Align hole in other end of bracket with hole in backplate Bracket may require slight bend or shims for correct fit If gap exists between backplate and mounting bracket install shims or washers not supplied to fill gap Secure bracket to backplate with 28 bolt flatwashers and Nyloc locknut Tighten to 10 12 ft lbs If bracket attaches to manifold bolt confirm that adequate thread engagement exists between bolt and carburetor body If longer bolt is required insure that bolt is not long enough to bottom out against carburetor 6 Apply a few drops of Loctite 242 blue or equivalent to threads install nuts and lockwashers and tighte
Download Pdf Manuals
Related Search