Instruction 510-0226 S&S Cycle, Inc · S&S ® Cycle, Inc 14025 Cty Hwy G PO Box 215 Viola, Wisconsin 54664 Phone: 608-627-1497 • Fax: 608-627-1488 Technical Service Phone: 608-627-TECH

S&S® Cycle, Inc.

14025 Cty Hwy G PO Box 215Viola, Wisconsin 54664

Phone: 608-627-1497 • Fax: 608-627-1488Technical Service Phone: 608-627-TECH (8324)Technical Service Email: [email protected]

Website: www.sscycle.com

Installation Instructions: S&S Stealth Air Cleaner Covers

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 part or motorcycle.

NOTE

Other information of particular importance has been placed in italic type.

S&S recommends you take special notice of these items.

WARRANTY:All S&S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve (12) months from the date of purchase. Merchandise that fails to conform to these conditions will be repaired or replaced at S&S’s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter. In the event warranty service is required, the original purchaser must call or write S&S immediately with the problem. Some problems can be rectified by a telephone call and need no further course of action. A part that is suspect of being defective must not be replaced by a Dealer without prior authorization from S&S. If it is deemed necessary for S&S to make an evaluation to determine whether the part was defective, a return authorization number must be obtained from S&S. The parts must be packaged properly so as to not cause further damage and be returned prepaid to S&S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem, how the part was used and the circumstances at the time of failure. If after an evaluation has been made by S&S and the part was found to be defective, repair, replacement or refund will be granted.

ADDITIONAL WARRANTY PROVISIONS: (1) S&S shall have no obligation in the event an S&S part is modified by any other person or organization.(2) S&S shall have no obligation if an S&S part becomes defective in whole or in part as a result of improper installation, improper maintenance, improper use, abnormal operation, or any other misuse or mistreatment of the S&S part.(3) S&S shall not be liable for any consequential or incidental damages resulting from the failure of an S&S part, the breach of any warranties, the failure to deliver, delay in delivery, delivery in non-conforming condition, or for any other breach of contract or duty between S&S and a customer. (4) S&S parts are designed exclusively for use in Harley-Davidson® and other American v-twin motorcycles. S&S shall have no warranty or liability obligation if an S&S part is used in any other application.

SAFE INSTALLATION AND OPERATION RULES:

Before installing your new S&S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety. • Gasoline is extremely flammable and explosive under certain conditions

and toxic when breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks. • If motorcycle has been running, wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps. • Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components. • Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps. Contact S&S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S&S part on it. • Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation. • Use good judgment when performing installation and operating motorcycle. Good judgment begins with a clear head. Don’t let alcohol, drugs or fatigue impair your judgment. Start installation when you are fresh. • Be sure all federal, state and local laws are obeyed with the installation. • For optimum performance and safety and to minimize potential damage to carb or other components, use all mounting hardware that is provided and follow all installation instructions. • Motorcycle exhaust fumes are toxic and poisonous and must not be breathed. Run motorcycle in a well ventilated area where fumes can dissipate.

DISCLAIMER:S&S parts are designed for high performance, closed course, racing applications and are intended for the very experienced rider only. The installation of S&S parts may void or adversely affect your factory warranty. In addition such installation and use may violate certain federal, state, and local laws, rules and ordinances as well as other laws when used on motor vehicles used on public highways, especially in states where pollution laws may apply. Always check federal, state, and local laws before modifying your motorcycle. It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use, and the user shall assume all legal, personal injury risk and liability and all other obligations, duties, and risks associated therewith.

The words Harley®, Harley-Davidson®, H-D®, Sportster®, Evolution®, and all H-D part numbers and model designations are used in reference only. S&S Cycle is not associated with Harley-Davidson, Inc.

Instruction 510-0226 09-03-13

Copyright ©2013 by S&S® Cycle, Inc.

All rights reserved. Printed in the U.S.A.

2

Kit Contents:• Air Cleaner Cover

•WARNING

The safety of the motorcycle rider is dependent of proper installation of this product. If you are not certain of your capabilities or do not have the correct tools for this installation, please consult a shop to have it done. Improper installation of this product could result in injury or death to the rider.

InstallationInstalling S&S® Air Cleaner Covers With Single Center Mounting Bolt1. Attach an S&S air cleaner cover to the stealth air cleaner kit by

installing the 5/16" button head screw with 243 blue Loctite® applied to the threads and torque to 10 ft.-lbs. as illustrated in Picture 1.

2. If your cover comes with a small cap and o-ring, as illustrated in Picture 2, apply a small amount of grease to the o-ring and install around the center cap groove as illustrated in Picture 3.

3. Push the cap into the air cleaner cover until you feel the cap snap into place.

Installing the S&S Muscle Air Cleaner Cover for E&G Carburetors using S&S Stealth Air Cleaner Kit

1. This step should only be done if you are installing the S&S Muscle cover on an S&S E or G carburetor. Remove the lanyards from the supplied gasket by squeezing the rivets on the small end with a pair of pliers as illustrated in Picture 4. This gasket will not be needed for the installation on the E&G carburetors.

2. Remove the two flanged head screws from the filter top plate and the 5/16" button head screw as illustrated in Picture 5.

3. Install the two threaded pin studs in place of where the flanged head screws were removed. A small amount of 243 blue Loctite® should be applied to the threads of the pin stud. Picture 6 illustrates the pin studs.

4. Tighten the pin studs down and make sure the holes are horizontal. Picture 7 illustrates the pin studs installed and the holes in a horizontal position with the lynch pins installed.

5. If the lynch pins are not sitting straight on the pin studs take this time adjust them to the desired location.

6. Remove the lynch pins from the pin studs.7. Attach the lanyards to the carburetor using the carburetor bowl

screws pointed out in Picture 8.8. Remove one screw at a time and tighten down making sure the

eyelets and cables are pointed outward and not interfering with the backplate or the carburetor.

NOTE: Picture 9 illustrates the carburetor without the backplate and filter assembly but you should be able to install the lanyards with the backplate and filter assembly on the carburetor and attached to the motorcycle.

9. Install the Muscle cover over the pin studs followed by a flat washer, a spring washer, a flat washer and the lynch pin. Picture 10 illustrates the Muscle cover assembled on the motorcycle.

10. Picture 11 illustrates a diagram of the Muscle cover and parts assembly.

Picture 1

Picture 4

Picture 3

Picture 2

3

Picture 9

Lanyards Installed

Picture 8

Carburetor Bowl Screws

Picture 6

Picture 7

Picture 5

5/16" Button Head Screw

Flanged Head Screws

Picture 10

Picture 11

Lynch Pin

Flat Washer

Spring Washer Cover

Filter

Backplate

4

Installing the S&S® Muscle Air Cleaner Cover for Stock CV Carburetors, Stock Delphi EFI and Stock Throttle by Wire Throttle bodies using the S&S Stealth Air Cleaner Kit

1. Remove the air cleaner assembly from the motorcycle you are working on.

2. Locate the gasket that has the lanyards attached. Picture 12 illustrates the lanyard gasket.

3. Slide the lanyard gasket over the screws as illustrated in Picture 13.4. Pass the breather bolts through the backplate mounting holes

using the same number of rubber coated washers that were used prior to disassembly.

5. Apply a drop of 243 blue Loctite® to the threads of each screw and breather bolt. Picture 14 illustrates all five fasteners that require 243 blue Loctite.

6. Fit the backplate to the carburetor or throttle body and the cylinder heads. Start the threads of all the screws and tighten evenly until the backplate is snug.

7. Now that the backplate is positioned, finish torque the ¼" X 20 fasteners to 72 in.-lbs. as illustrated in Picture 15.

8. Thread the breather bolts in and finish torque breather bolts to 10-12 ft.-lbs.

9. Remove the 5/16" button head screw from the plastic top filter plate if it has not been already. Picture 14 illustrates the button head screw. Hold the filter on the backplate and put the filter top plate on top of the filter making sure that the word “Down” is facing down and sitting flat on the filter and locked into the groove as illustrated in Picture 16.

10. Install the two threaded pin studs in place of where the flanged head screws were removed at disassembly. A small amount of 243 blue Loctite® should be applied to the threads of the pin stud. Picture 17 illustrates the pin studs.

11. Tighten the pin studs down and make sure the holes are horizontal. Picture 18 illustrates the pin studs installed and the holes in a horizontal position with the lynch pins installed.

12. If the lynch pins are not sitting straight on the pin studs take this time adjust them to the desired location.

13. Remove the lynch pins from the pin studs.14. Install the Muscle cover over the pin studs followed by a flat

washer, a spring washer, a flat washer and the lynch pin. Picture 19 illustrates the Muscle cover assembled on the motorcycle.

15. Picture 20 illustrates a diagram of the Muscle cover and parts assembly.

Picture 12

Picture 13

Picture 14

Apply 243 Loctite®

Picture 15

5

Cover

Picture 18

Lynch Pin

Flat Washer

Spring Washer

Filter

Backplate

Picture 19

Picture 17

Picture 18

Picture 16

DOWN

5/16" Button Head Cover Screw

6

S&S® Air Cleaner Covers

1. Round Covers w/center mounting boltsa. Bobber Dished

Black Jack .........................................................................................170-0123 Chrome ..............................................................................................170-0119

b. Bobber Domed Black Jack ..........................................................................................170-0124 Chrome ..............................................................................................170-0120

c. Torker Cover .................................................................................. 170-0206

d. Tri-Spoke Cover ...........................................................................170-0210

e. Air 1 Cover .......................................................................................170-0214

2. Muscle Black Jack ..........................................................................................170-0136 Chrome ..............................................................................................170-0172

3. Airstream Black Jack ..........................................................................................170-0122 Chrome ..............................................................................................170-0118

1

9

34

4

5

6

67

2

8

4. Screw, SHCB, 5/16-18 x .500", Polished, Stainless Steel .......500-0051

5. Pin, Lynch, .125" x .84", Usable Length (Each) 2 required ........500-0083

6. Washer, Fender, .344" x .750" x .050", Chrome Plated, Steel (Each) 4 required ........................................ 500-0094

7. Spring, Wave, .012" Wire, .312" x .060" x .240", Stainless Steel (Each) 2 required ......................................................500-0093

8. Screw, Hex, Hood Pin, Electro Polish, ¼-20 UNC X 1.60", Stainless Steel (Each) 2 required ........................................... 500-0113

9. Gasket, Backplate, Throttle Body, Stock CV/EFI, Throttle-by-Wire, Lanyard Style, 1991-Up xl/bt ..................170-0137

7

3

S&S® Cycle, Inc.

14025 Cty Hwy G Viola, Wisconsin 54664

Phone: 608-627-1497 • Fax: 608-627-1488Technical Service Phone: 608-627-TECH (8324)Technical Service Email: [email protected]

Website: www.sscycle.com

Installation Instructions: S&S 4” Slip-On Mufflers For 1995-2016 Harley-Davidson® Touring Models

IMPORTANT NOTICE:


WARNING


CAUTION


NOTE



WARRANTY:

All S&S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve (12) months from the date of purchase. Merchandise that fails to conform to these conditions will be repaired or replaced at S&S’s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter.

In the event warranty service is required, the original purchaser must call or write S&S immediately with the problem. Some problems can be rectified by a telephone call and need no further course of action.

A part that is suspect of being defective must not be replaced by a Dealer without prior authorization from S&S. If it is deemed necessary for S&S to make an evaluation to determine whether the part was defective, a return authorization number must be obtained from S&S. The parts must be packaged properly so as to not cause further damage and be returned prepaid to S&S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem, how the part was used and the circumstances at the time of failure. If after an evaluation has been made by S&S and the part was found to be defective, repair, replacement or refund will be granted.

ADDITIONAL WARRANTY PROVISIONS:

(1) S&S shall have no obligation in the event an S&S part is modified by any other person or organization.

(2) S&S shall have no obligation if an S&S part becomes defective in whole or in part as a result of improper installation, improper maintenance, improper use, abnormal operation, or any other misuse or mistreatment of the S&S part.

(3) S&S shall not be liable for any consequential or incidental damages resulting from the failure of an S&S part, the breach of any warranties, the failure to deliver, delay in delivery, delivery in non-conforming condition, or for any other breach of contract or duty between S&S and a customer.


Before installing your new S&S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety.

• Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks.

• If motorcycle has been running, wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps.

• Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components.

• Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps. Contact S&S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S&S part on it.

• Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation.

• Use good judgment when performing installation and operating motorcycle. Good judgment begins with a clear head. Don’t let alcohol, drugs or fatigue impair your judgment. Start installation when you are fresh.

• Be sure all federal, state and local laws are obeyed with the installation. • For optimum performance and safety and to minimize potential

damage to carb or other components, use all mounting hardware that is provided and follow all installation instructions.

• Motorcycle exhaust fumes are toxic and poisonous and must not be breathed. Run motorcycle in a well ventilated area where fumes can dissipate.

DISCLAIMER: NOT LEGAL FOR SALE OR USE IN CALIFORNIA ON ANY POLLUTION CONTROLLED MOTOR VEHICLES.

*Qualified Manufacturer Declared Emissions Replacement Part on models not originally equipped with mufflers containing catalyst. Applicable models shown below.

California Models:FL Touring Fuel Injected 1995-2003, 2007, and 2009-2016CVO FL Touring 2000-2003, 2009-2016

49 State Models:FL Touring Carbureted 1995-2005FL Touring Fuel Injected 1995-2005, 2007-2016CVO FL Touring 2000-2005, 2009-2016

Instruction 510-046102-13-2017

Version 1Copyright © 2017

by S&S® Cycle, Inc.


2

Installation Steps

1. Tools Required:

• ½” and 9/16” Combination Wrench

• 3/8” Drive Ratchet with 4” Extension

• ½” Standard Socket

• 9/16” Deep Well Socket

2. Removal of Stock Mufflers:

Remove the saddlebags and set aside

a. Loosen the muffler clamps on the front of each muffler.

b. Remove and discard the 5/16” screws that secure the mufflers to the saddle bag supports. New fasteners are included in the hardware kit.

c. Remove the stock mufflers. The application of penetrating oil on the muffler/head pipe joint and a slight rocking motion will allow for easier muffler removal. Remove and discard the stock muffler clamps.

3. S&S Muffler Installation:

a. Identify the right and left mufflers. Only the right side muffler has a clearance dimple for the axle nut. When the muffler is installed, the clearance dimple always goes to the inside, toward the axle.

b. Apply Anti-seize to the threads of the new muffler clamps, included in the hardware pack, and install the clamps onto the mufflers. The nut of the clamp should be on the inside of the muffler and facing down.

c. Slide each muffler onto the correct header pipe. If there are burrs on the pipe, removing them with a file or emery cloth will make muffler installation easier.

d. Attach rear muffler hanger tabs to mufflers with 5/16” screws and

washers from the hardware kit, and tighten to 18 ft-lb.

e. Make sure the mufflers are aligned vertically and that the ends are even. Tighten the muffler clamps to 40-44 ft-lb.

f. Thoroughly clean the mufflers and exhaust system before starting the motorcycle. Any oil residue or finger prints on the chrome will cause permanent stains once the system heats up.

g. Re-install the saddle bags.

h. After the first test ride and after the bike has cooled down, re-check torque of the muffler clamps.

HELPFUL HINTS TO MAINTAIN FINISH OF EXHAUST PIPES AND MUFFLERS

• Air filters must be serviced at regular intervals.

• Intake air leaks can cause engine to run lean and overheat, and thus discolor pipes.

• Make sure there are no exhaust leaks at the junction of the cylinder head and the exhaust pipe.

• Use fans to ensure that the exhaust system is not over heated when the motorcycle is operated on a dyno.

• Avoid long periods of idling.

• Follow closely your owner’s manual instructions regarding use of the starting enrichener on carbureted bikes. If left on longer than recommended, discoloration may be accelerated.

• Avoid the use of pressure washers, harsh chemicals or abrasive cleaners. If water gets into muffler during washing, remove moisture to prevent corrosion. Start engine to warm up exhaust system.

Replacement parts for S&S 4” Mufflers - 1995-2016 Touring Models

1. 4” Muffler assembly w/o end cap Left, Chrome ......................................................................................................... 551-0055 Right, Chrome.......................................................................................................551-0056 Left, Black ............................................................................................................... 551-0057 Right, Black ............................................................................................................551-0058

2. 4” Muffler assembly Slash Down Left, Chrome ......................................................................................................... 551-0059 Right, Chrome.......................................................................................................551-0060 Left, Black ............................................................................................................... 551-0061 Right, Black ............................................................................................................551-0062

3. End Cap (Left and Right)................................................................................... 551-0188

4. Main baffle assembly (Left and Right) ........................................................ 551-0053

5. dB killer baffle (Left and Right) ......................................................................551-0063

6. Button head cap screw, Stainless, 1/4”-20x3/8” ...................................... 500-0441

7. Socket head cap screw, Stainless, 10-32x3/4” ......................................... 500-0569

8. Button head cap screw, Stainless, 10-32x3/8” .........................................500-0570

9. Hardware kit, muffler clamps and screws (N/S) ....................................... 551-0027

1

2

37

5

5

8

46

6

S&S® Cycle, Inc.


Phone: 608-627-1497 • Fax: 608-627-1488Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: [email protected]: www.sscycle.com

Installation Instructions: S&S Standard and Easy Start Chain Drive Camshafts for 2006 Harley-Davidson® Dyna® models and

all 2007-up Big TwinsIMPORTANT NOTICE:


WARNING


CAUTION


NOTE



WARRANTY:All S&S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve (12) months from the date of purchase. Merchandise that fails to conform to these conditions will be repaired or replaced at S&S’s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter. In the event warranty service is required, the original purchaser must call or write S&S immediately with the problem. Some problems can be rectified by a telephone call and need no further course of action. A part that is suspect of being defective must not be replaced by a Dealer without prior authorization from S&S. If it is deemed necessary for S&S to make an evaluation to determine whether the part was defective, a return authorization number must be obtained from S&S. The parts must be packaged properly so as to not cause further damage and be returned prepaid to S&S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem, how the part was used and the circumstances at the time of failure. If after an evaluation has been made by S&S and the part was found to be defective, repair, replacement or refund will be granted.

ADDITIONAL WARRANTY PROVISIONS: (1) S&S shall have no obligation in the event an S&S part is modified by any other person or organization.(2) S&S shall have no obligation if an S&S part becomes defective in whole or in part as a result of improper installation, improper maintenance, improper use, abnormal operation, or any other misuse or mistreatment of the S&S part.(3) S&S shall not be liable for any consequential or incidental damages resulting from the failure of an S&S part, the breach of any warranties, the failure to deliver, delay in delivery, delivery in non-conforming condition, or for any other breach of contract or duty between S&S and a customer. (4) S&S parts are designed exclusively for use in Harley-Davidson® and other American v-twin motorcycles. S&S shall have no warranty or liability obligation if an S&S part is used in any other application.


Before installing your new S&S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety. • Gasoline is extremely flammable and explosive under certain conditions

and toxic when breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks.

• If motorcycle has been running, wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps.

• Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components.

• Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps. Contact S&S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S&S part on it.

• Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation.

• Use good judgment when performing installation and operating motorcycle. Good judgment begins with a clear head. Don’t let alcohol, drugs or fatigue impair your judgment. Start installation when you are fresh.

• Be sure all federal, state and local laws are obeyed with the installation. • For optimum performance and safety and to minimize potential

damage to carb or other components, use all mounting hardware that is provided and follow all installation instructions.

• Motorcycle exhaust fumes are toxic and poisonous and must not be breathed. Run motorcycle in a well ventilated area where fumes can dissipate.

DISCLAIMER:S&S parts are designed for high performance, closed course, racing applications and are intended for the very experienced rider only. The installation of S&S parts may void or adversely affect your factory warranty. In addition such installation and use may violate certain federal, state, and local laws, rules and ordinances as well as other laws when used on motor vehicles used on public highways, especially in states where pollution laws may apply. Always check federal, state, and local laws before modifying your motorcycle. It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use, and the user shall assume all legal, personal injury risk and liability and all other obligations, duties, and risks associated therewith.

The words Harley®, Harley-Davidson®, H-D®, Sportster®, Evolution®, and all H-D part numbers and model designations are used in reference only. S&S Cycle is not associated with Harley-Davidson, Inc.

Instruction 106-591202-21-14

Copyright © 2009–2014

by S&S® Cycle, Inc.


2

Introduction and Specifications

The S&S® chain drive cams outlined in this instruction sheet are intended for 2007-up big twin and 2006-up Harley-Davidson® Dyna® models.

NOTES:• 2005-up stock valve springs will handle camshafts with lift up to 0.585". If a camshaft with higher lift is installed, high performance valve springs

capable of handling a greater lift must be used. • A cam with over 0.585” of lift will cause interference between the valve spring top collar and the valve seal with stock valve springs. • Piston to valve clearance will need to be confirmed when using a cam with over 0.585" of lift. Clearance should be at least 0.060" intake and .080"

exhaust.• Valve to valve clearance will need to be confirmed when using a cam over 0.585" lift. Clearance should be a minimum of 0.060". • Installation of S&S chain drive cams requires special tools. See Picture 1 for the required tools. Attempting the cam change operation without these

tools will be difficult. Damage can result which will not be covered under warranty. • Possible failure may result if thread locking compound is not applied to the cam drive sprocket flange bolts. Always prepare threads according to the

instructions on the container.• All reference to Harley-Davidson part numbers is for identification purposes only. We in no way are implying that any of S&S Cycle’s products are

original equipment parts or that they are equivalent to the corresponding Harley-Davidson part numbers.

Contents Of Chain Drive Camshaft Kit 106-5929:

• Chain drive cams front and rear

• Inner cam bearings

• Retaining ring

• Cam cover gasket

• Oil pump scavenge o-ring

• 5ml tube of Loctite® 262

• 5ml tube of Loctite 243

Instruction Contents:

Introduction and Specifications

Securing Motorcycle

Disassembly

Reassembly

• Crankcase Preparation

• Cam Installation

• Rear Cam Endplay Adjustment

• Final Assembly

• Pushrod Installation & Adjustment

Cam Name LobeTiming

Duration Lift Centerline TDC Valve Lift

05-UP Models Works with stock valve springs

Works with stock pushrodsOpen Close

510CInt 20° 38° 238°

0.510" 99° 0.187"

X XExh 52° 20° 252° 106° 0.179"

551C (E)Int 17° 19° 216°

0.550" 91° 0.178"

X XExh 41° 17° 238° 102° 0.170"

557Int 6° 27° 212°

0.557" 100° 0.113"

X XExh 39° 12° 231° 103° 0.146"

570C (E)Int 20° 40° 240°

0.570" 100° 0.187"

X XExh 55° 20° 255° 107.5° 0.179"

583C (E)Int 5° 18° 203°

0.583" 96.5° 0.113"

X XExh 58° 24° 262° 107° 0.206"

585C (E)Int 20° 45° 245°

0.585" 102.5° 0.186"

X XExh 60° 20° 260° 110° 0.179"

625C (E)Int 20° 55° 255°

0.625" 107.5° 0.189"

Exh 60° 20° 260° 110° 0.184"

635Int 19.5° 43.5° 243°

0.635" 102° 0.186"

Exh 58.5° 37.5° 276° 100.5° 0.284"

640C (E)Int 25° 60° 265°

0.640" 107.5° 0.228"

Exh 65° 25° 270° 110° 0.214"

HP103Int 20° 49° 249°

0.575" 102.7° 0.199"

X XExh 45° 26° 251° 101.5° 0.206"

MR103Int 13° 33° 226°

0.585" 100° 0.097"

X XExh 50° 22° 252° 104° 0.191"

Complete Chain Drive Camshaft Kit

3

Overview of Easy Start camshafts (if equipped):

S&S® has developed Easy Start Cams to assist starting with a centrifugally operated compression release. The operation is simple: at cranking speeds a spring loaded decompression lever holds the exhaust valve open slightly. Once the engine fires and exceeds 750 RPM, centrifugal force takes over and sends the lever to a retracted position, allowing the engine to run normally.

Important Notes Regarding Easy Start Camshafts:

• Stock EFI engines require a minimum of 80 PSI cranking compression, checked with the throttle open, for the ECU to fire the spark plugs.

• S&S easy start cams were designed to work with specific compression ratio and displacement combinations. If an Easy Start cam set is used in an application other than what it was designed

for occasionally an engine may not build the required compression to start the bike.

• Cranking compression numbers are no longer a valid health check of the engine. We recommend performing a leak down test.

• If the lifters have been disassembled or bled down for any purpose, the starter may have difficulty with the initial start. Although the decompression lobe lifts the lifter body, the lifter is not pumped up and it will not lift the exhaust valve. You may need to remove the spark plugs and crank the engine to get oil pressure to the lifters.

• Easy Start cams require no special service. If they are ever removed for any reason however, inspect the mechanism for wear and verify that the lever operates smoothly.

• When the engine is turned off, you may hear a slight click as the decompression lever resets. This is normal and does no harm.

• If engine speed drops below 900 RPM, you may hear clicking as the decompression lever starts engaging. Idle speed should be adjusted higher. The engine idle should be set at 1000-1100 RPM.

Securing the motorcycle

Motorcycle must be adequately secured during the cam change operation! Use of tie down straps on both sides of the motorcycle is recommended.

1. Place motorcycle on a suitable repair stand so that the motorcycle is stable and secure with the rear tire elevated.

2. Disconnect the negative terminal of the battery to eliminate potential sparks and inadvertent engagement of the starter while working on the motorcycle.

3. Place motorcycle in top gear. Remove spark plugs. These steps are necessary so that the rear tire can be used to rotate the engine to correctly align the cam timing marks during installation, and align the oil pump during reassembly.

Disassembly

Cutting the pushrods with a saw may result in metal chips entering the engine and causing extensive damage which will not be covered under warranty.

Cutting pushrods without relieving valve spring force on the pushrods may result in injury.

Easy Start Chain Drive Cams

Picture 1

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Crankshaft/Camshaft Sprocket Locking Tool, H-D® Part Number: 47941

Camshaft Needle Bearing Remover/Installer, H-D Part Number: 42325

• All reference to Harley-Davidson part numbers is for identification purposes only. We in no way are implying that any of S&S Cycle’s products are original equipment parts or that they are equivalent to the corresponding Harley-Davidson part numbers.

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CAUTION

CAUTION

CAUTION

Cam Intended Displacement Intended Compression Ratio

551 88–106 9.0–10.0

557 96-103 9.6-10.0

570 88–106 9.0–10.0

583 88–106 9.0–10.0

585 88–106 9.2–10.5

625 95+ 10.0–10.75

635 106-124 10.2-10.8

640 95+ 10.5–11.5

675 120+ 11+

HP103 103 9.6-10.0

MR103 103 9.6-10.0

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1. Remove pushrods.

a. Remove pushrod cover clips with a small screwdriver and compress pushrod covers to expose pushrods. Lift rear tire of motorcycle with a suitable jack. Rotate the engine until one of the cylinders is on “top dead center compression stroke” (TDCC). TDCC can be found by rolling the rear tire forward while watching or feeling the pushrods move through their travel. When BOTH pushrods are at the lowest point of their travel and the piston for that cylinder is at TDC, the engine is at TDCC. Rotate the pushrods to ensure there is no load on them. If the pushrods will not rotate freely by hand, either the engine is not on TDCC, or the lifters need to bleed down. It may be necessary to let the lifters bleed down for a few minutes before the pushrods will rotate freely.

b. If stock non-adjustable pushrods will not be re-used, they may be removed by cutting them. When cutting pushrods, S&S recommends a bolt cutter be used as it is the cleanest method. Be sure to only cut the pushrods that are not loaded and rotate freely by hand.

c. If stock one piece pushrods are to be re-used, they must be removed using the factory procedure. Remove the gas tank and rocker box covers. Remove the rocker arm support by first removing the two smaller bolts which hold the breather cover in place. Next break loose the four bolts holding the rocker arm support plate in place with an alternating pattern. Remove the four rocker arm support plate bolts, and then the rocker arm support assembly. The pushrods may now be removed by sliding them up into the head slightly and then pulling the bottom of the pushrod towards you. Mark the original pushrod location as it is removed to ensure it is replaced in its original position. The intake pushrod is shorter than the exhaust pushrod. Interchanging the intake and exhaust pushrods upon reassembly, will cause the intake valve to stay open on the compression stroke and the engine will not run.

d. Rotate the engine so the other cylinder is on TDC compression and repeat the above procedure.

2. Remove cam cover and gasket. Secure lifters with a magnetic tappet tool or a tool made from a large binder clip spring. See Picture 2, below.

3. Rotate rear wheel to align timing marks on the primary cam chain.

4. Remove the primary chain tensioner by removing the two retaining bolts and install sprocket locking tool.

5. Remove the crank sprocket bolt and flat washer.

6. Remove rear cam sprocket bolt and flat washer.

7. Remove sprocket locking tool.

8. Gently pry off crank sprocket and rear cam sprocket.

Cam Support Plate and Cam Removal

1. Gradually loosen and remove the four oil pump bolts/washers according to the sequence shown in Picture 3, below.

2. Gradually loosen and remove the six support plate bolts/washers according to the sequence shown below.

3. Remove spacer from rear cam, this spacer is thicker than the front spacer.

4. Remove cam plate and cams from engine.

5. Remove retaining ring and spacer from front cam. This spacer is 0.100" thick.

6. Remove the secondary cam chain tensioner.

7. Remove the cams and cam chain. Mark the direction of the cam chain so that it is installed in the original direction of rotation with the new cams.

Reassembly

Crankcase Preparation

1. When using 551G, 570G, 583G, 585G, 625G, or 640G camshafts clearance between the pinion bearing boss and the rear cam lobe must be checked. See Pictures 4 & 5, top of next page. Remove just enough material to provide .030" of clearance between the top of the cam lobe and the pinion bearing boss when the camshafts are rotated in the inner needle bearing. Also check clearances between the cam lobe and the tappet guide bosses. To avoid contamination of the engine with chips, we recommend that all holes in the gear case be taped off with duct tape and that the gear case be thoroughly cleaned with parts cleaner or solvent after clearancing is performed.

2. Replace inner cam needle bearings. Be sure to use a full complement needle bearing such as those supplied with the chain drive installation kit. These bearings offer a higher load carrying capacity associated with high lift camshafts. Refer to the H-D® service manual for proper installation procedure.

NOTE: Before reinstalling cam support plate, replace oil pump scavenge o-ring (supplied in kit) even if the original appears to be in good condition. The stock o-ring can become brittle and provide a poor seal if reused. This can cause poor oil scavenging, oil carry-over and loss of power.

Picture 3

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Picture 2

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Cam Installation

1. Place the cam support plate on a flat surface with the outside of the support plate facing down. Place supports under the cam support plate so that the cams can be easily installed.

2. Install the secondary cam chain around the front and rear cam sprockets. Ensure that the timing marks are still aligned. Also, the timing chain should be installed in its original direction of rotation. See Picture 6, below.

3. Lubricate the cam bearing cavities on the cam support plate with engine assembly lube, or suitable clean engine oil.

4. Install the cams into the cam support plate. Be careful not to damage the cam support plate while installing the cams.

5. Install the secondary cam chain tensioner. Apply Locite® 243 and torque bolts to 100-120 in-lbs.

6. Turn the cam support plate over. Take care so that the cams do not slide out of the support plate. Install the 0.100" spacer over the end of the front cam. Install the new retaining ring.

7. Double check to make sure the oil pump has not pulled out of the crankcase.

8. Lubricate the cam needle bearings and decompression lever, if equipped, with assembly lube and install the cam support plate assembly.

9. Apply a small amount of Loctite 243 to the six bolts that hold on the cam support plate and torque in the sequence shown in Picture 3, page 4. Torque to 100-120 in-lbs.

10. Apply a small amount of Loctite 243 to the four bolts that hold the oil pump to the cam support plate. While rotating the engine, alternatively tighten bolts 1 and 2 until the bolts are snug. Tighten bolts 3 and 4 until they are snug. Finally, torque the four bolts in the sequence shown in to 90-120 in-lbs. This procedure ensures that the oil pump is properly centered.

Rear Cam Endplay Adjustment

1. Install the spacer over the end of the rear cam. Install the primary cam sprocket to the rear cam and hand tighten bolt.

2. Install the crank sprocket to the crankshaft and hand tighten bolt.

3. Align the timing marks and install the sprocket locking tool and torque each bolt to 15 ft-lbs.

4. Push crank sprocket towards the drive side of the motorcycle to eliminate end play. Push the rear cam inwards to eliminate end play.

5. Lay a straight edge across the face of the crank sprocket and the primary cam sprocket. If the gap between the straight edge and the sprocket faces is smaller than 0.010", no adjustment of the spacer behind the rear cam sprocket is necessary. Select the proper spacer for the rear cam so that this gap is no greater than 0.010". Spacers are available from Harley-Davidson® in the following sizes and part numbers: .100" thick H-D® Part Number 25729-06 .110" thick H-D Part Number 25731-06 .120" thick H-D Part Number 25734-06 .130" thick H-D Part Number 25736-06

6. Remove sprockets so that the outer drive chain can be installed for the final assembly.

Final Assembly

1. Place primary chain over the rear cam sprocket. Install the crank sprocket into the primary chain so that the timing marks on both sprockets are aligned as shown in Picture 7.

2. Install the primary timing chain assembly onto the crankshaft and rear cam.

NOTE: Align the crankshaft and rear cam so that the primary timing chain assembly fits so that the timing marks are aligned.

Picture 6

Timing Marks

Picture 4 Picture 5

Picture 7

6

3. Thoroughly clean the flange bolts and apply a small amount of Loctite® 262, 271, or 272 to the threads. Apply a drop of clean 20W-50 engine oil under the bolt flanges.

4. Install the sprocket locking tool and tighten the crankshaft gear bolt to 25 ft.-lbs. torque. Torque the camshaft gear bolt to 34 ft.-lbs.

5. Install primary cam chain tensioner, tighten fasteners to 100-120 in-lbs.

6. Inspect the blind tapped holes for the cam cover in the crankcase for cleanliness. Remove any foreign debris.

7. Install cam cover with new gasket. Torque the 10 bolts to 125-155 in-lbs in the sequence shown below in Picture 8.

8. Remove the clips holding the tappets in place.

Adjustable Pushrod Installation And Adjustment

1. Rotate engine so one piston is at TDC compression, by rotating the rear tire while feeling the tappets. When both tappets are at the bottom of their lift, and the piston is at TDC, the cylinder is at TDC compression. If equipped with compression releases, you must use extra care when installing pushrods. Because the decompression lobe is near TDC, it is possible to adjust the pushrod while the tappet is on the lobe if it is not exactly at TDC. This will cause incorrect exhaust pushrod adjustment. To verify correct position, you can rotate the engine in the forward direction and feel for the exhaust tappet to slightly lift ( about .030") and set back down on base circle. This is the proper point to install the pushrods.

2. Insert the adjustable pushrods into the collapsed pushrod tubes. Make sure the proper o-rings are installed in the tappet covers, and on the cylinder head end of the pushrod covers.

3. If the pushrod kit contains different length pushrods, the longer pushrods go in the exhaust locations and the shorter pushrods are for the intakes.

4. Insert the top of the pushrod into the hole in the head, then drop the bottom into the tappet cover.

5. While holding the top of the pushrod into the cup of the rocker arm, extend the bottom end into the tappet until the pushrod is just making contact with the cup of the tappet. From this point, extend the pushrod 24 flats (4 full turns). Move the jam nut on the threaded portion of the pushrod to lock the end in place and tighten.

NOTE: S&S® adjustable pushrods have 32 threads per inch, and 24 flats will place the pushrod in the optimal position of the stock style tappet. If pushrods other than S&S adjustable or quickee's are used, refer to the manufacturer's instruction sheets to find the number of flats needed.

6. Allow the tappet to bleed down until you are able to rotate the pushrod freely by hand, before adjusting the next pushrod.

7. Repeat steps 5 and 6 for the other pushrod on the same cylinder.

8. Ensure both pushrods rotate freely, then repeat steps 1 through 6 for the other cylinder.

9. Install pushrod clips.

10. Shift transmission into neutral.

11. Lower motorcycle onto lift and remove jack.

12. Install spark plugs and plug wires.

13. Reconnect Negative battery cable.

If the engine is rotated before the tappets have bled down and the pushrods can be rotated by hand, valve to valve or valve to piston contact may occur. Serious engine damage could result.

Stock Non-Adjustable Pushrod Installation

NOTE: Using stock pushrods is only possible if the camshafts installed have the same base circle as stock, and no more than .585" lift. S&S® labels these cams as "Bolt-In" for easy reference. Currently S&S 510, 551 and 583 cams are bolt-in.

1. Rotate engine so one piston is at TDC compression, by rotating the rear tire while feeling the tappets. When both tappets are at the bottom of their lift, and the cylinder is at TDC, the cylinder is at TDC compression. If equipped with compression releases, you must use extra care when adjusting pushrods. Because the decompression lobe is near TDC, it is possible to adjust the pushrod while the tappet is on the lobe if it is not exactly at TDC. This will cause incorrect exhaust pushrod adjustment. To verify correct position, you can rotate the engine in the forward direction and feel for the exhaust tappet to slightly lift (about .030") and set back down on base circle. This is the proper point to adjust the pushrods.

2. Insert the pushrods into the collapsed pushrod tubes. Make sure the proper o-rings are installed in the tappet covers, and on the cylinder head end of the pushrod covers.

3. Verify the correct locations for the pushrods that were removed. The longer pushrods go in the exhaust locations and the shorter pushrods are for the intakes.

4. Insert the top of the pushrod into the hole in the head, then drop the bottom into the tappet cover.

5. Apply assembly lube or suitable clean engine oil to the pushrod tips where they will contact the rocker arms.

6. Insert the rocker arm support assembly into the rocker box.

7. Ensure that the pushrod tips are fully engaged in the rocker arms.

Picture 8

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CAUTION

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8. Apply Loctite® 243, then evenly snug the four 5/16” bolts which hold the rocker arms in place just finger tight at this time.

9. Start the two breather cover bolts at this time, but do not tighten them.

10. Begin tightening the rocker arm bolts. Following the sequence of lowest bolt on spark plug side, highest bolt on intake side, lowest bolt on intake side, then highest bolt on spark plug side. Tighten each bolt ¼ turn at a time following this sequence until they have reached a torque of 18-22 ft-lbs.

11. Tighten the two breather cover bolts to 90-120 in-lbs.

12. Allow lifters to bleed down, then check to ensure both pushrods rotate freely by hand.

13. Install pushrod cover keepers.

14. Install new rocker box gasket, and rocker box top cover.

15. Apply blue threadlocker to the six rocker cover bolts and tighten in a star pattern to 15-18 ft-lbs.

16. Repeat for the other cylinder, following steps 1 through 15.

17. Install the gas tank.

18. Shift transmission into neutral.

19. Lower motorcycle onto lift and remove jack.

20. Install spark plugs and plug wires.

21. Reconnect negative battery cable.

NOTE: The tappets may be noisy upon initial start-up after installing cams and adjusting pushrods. This is normal after the tappets have all been bled down, and will go away shortly as long as the proper oil pressure is available to the tappets.

S&S® Cycle, Inc.




S&S® Cycle, Inc.




S&S® Cycle, Inc.




S&S® Cycle, Inc.




Instruction Supplement: CARBfor instruction sheets 510-0054 & 510-0055




Supplement 510-0256 01-20-14

Copyright ©2014by S&S® Cycle, Inc.All rights reserved.

Printed in the U.S.A.

Supplement 510-0256 01-20-14



Supplement 510-0256 01-20-14



Supplement 510-0256 01-20-14



CARB label here

CARB label here

CARB label here

CARB label here

• On 2001 and later fuel injected bikes apply the included label containing the EO number to the frame down tube above or below the factory label. Do not cover up any portion of the factory label.

• The Stealth Air Cleaner is exempt under CARB EO # D-355-11 for fuel injected motorcycles.

• Use of the Stealth Air Cleaner on carbureted motorcycles is limited to closed course competition use only.










Documents

Instruction 510-0226 S&S Cycle, Inc · S&S ® Cycle, Inc 14025 Cty Hwy G PO Box 215 Viola, Wisconsin 54664 Phone: 608-627-1497 • Fax: 608-627-1488 Technical Service Phone: 608-627-TECH