Caution – S&S Cycle Bore Stroker Kit 3 3/16 for Harley-Davidson Sportster Models User Manual

Page 2

Installation of an S&S

Stroker Kit is easy and can be performed

by any average Harley-Davidson

repair shop equipped to do

complete engine overhauls. No special tools other than those
used in normal overhaul operations are required.

Read instructions thoroughly before starting work. When they
are completely understood proceed with installation.

Installation Steps:

Crankcase Alignment and Cylinder Mounting Studs (All)

Lower Oil Return Holes (All)

Crankcase and Piston Skirt Clearancing (All)

Connecting Rod Preparation (All)

Lower End Assembly (All)

Connecting Rod Alignment (All)*

Breather Timing (All)

Piston to Valve Clearancing (All)

Final Top End Assembly and Engine Installation (All)

10. Timing, Carburetion, Exhaust, Gearing and Break-in (All)

*NOTE - S&S recommends that engine builder consider
performing some steps during initial engine disassembly.
Breather timing check requires that most components be
assembled, and performing check upon disassembly may save
reassembly and cleaning time. While some or all related parts
concerned in connecting rod alignment check may be replaced, it
is helpful to check original parts combination and note
discrepancies which may alter installation of new parts.

Crankcase Alignment and Cylinder Mounting Studs (All)

NOTE - Some crankcase base gasket surfaces on which cylinders
are positioned do not align properly. This usually occurs when
crankcase halves used are from different crankcase assemblies
and were not paired and machined together at Harley-
Davidson

. It is recommended to check for crankcase

misalignment even if crankcase halves are correctly matched to
prevent potential oil leaks and other mechanical problems.

Mismatched gasket surfaces due to improperly aligned
crankcase halves may cause unwarranted stress on cylinder
base flanges which could result in cylinder flange failure.

Clean cases thoroughly and assemble both cases
without flywheels and tighten all case bolts as in
final assembly.

Place straight edge across base gasket surface. See
Picture 1.

If any misalignment exists, remove cylinder base studs
and place masking tape over cam and mainshaft
bearings to keep chips out.

Place cases squarely in mill and take minimum cut
necessary to clean up.

If stock cylinder studs are to be used, reinstall to
original height. If studs are provided in kit, install to
height that equals: thickness of cylinder base flange,
plus base gasket, plus cylinder base plate, plus washers,
plus base nut. Use Loctite

Stud and Bearing Mount to

secure studs.

Lower Oil Return Holes

Harley-Davidson

Sportster

model cylinder oil return holes must

be lowered in those stroker conversions where oil ring crosses
stock oil return hole. This is necessary to prevent oil from
returning above oil ring which will cause engine to smoke.
Several lowering methods have been used successfully but rather
than give them all, we decided to provide the one that requires
the fewest special tools and materials.

Picture 1

⁄

" Diameter hole

⁄

" Diameter hole

Line A

Line B

⁄

Figure 1

CAUTION