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

Page 6

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Some solvents, degreasers, gasoline and other chemicals are
harmful to skin, eyes and other body parts. Many items are
flammable and present a fire hazard. Read manufacturer’s
instruction label for proper use. Use in well ventilated area
and wear protective clothing when using them to avoid
personal injury.

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Compressed air and particles dislodged by compressed air
are harmful to eyes and body. Wear protective goggles
when using compressed air and always direct air stream
away from body parts such as hands and eyes and other
people near you.

Perform following steps when assembling flywheels:

Thoroughly clean all parts to be used. This includes
mainshafts, main bearings, connecting rods, rod
bearings, crankpin nut retainers and screws if they
are to be used, keys and flywheels including tapers
and keyways.

Burrs, dirt, filings, etc. left on flywheel assembly parts may
circulate in oil damaging other parts possibly causing
engine failure.

Check both mainshafts between centers for taper
surface to bearing surface concentricity.

Make sure

centers on shafts are clean beforehand. If tapers and
bearing surfaces are concentric with each other and
with center, then truing will be easier. See Picture 7.

NOTE - S&S

prefers to see .0003” or less of runout between taper

and bearing surface with an absolute maximum of .0005”. S&S
shafts are .0003” or less.

Inspect keyways and oil holes for burrs in flywheels and
remove if necessary.

With key in shaft, insert into respective tapered hole in
flywheel and check to see that key does not bottom in
groove. If key bottoms out, file flat side of key, not
rounded side, until shaft with key in place fits in
flywheel without bottoming out. Check crankpin and
crankpin key also.

Reclean mainshaft tapers, crankpin and flywheel tapers
with lacquer thinner.

Assemble mainshafts in respective flywheels. Coat taper
and threads of each shaft with green Loctite

RC 609 or

Omni Fit 1730 during assembly. Install crankpin in
camside flywheel using Loctite

also. Tighten all nuts to

at least factory torque specs minimum. When S&S shafts
are used, follow instructions included with them.

NOTE - S&S recommends to tighten nuts very tight. We use a

⁄

”drive breaker bar and a five foot piece of pipe when

assembling flywheels.

After right side flywheel, pinion shaft and crankpin are
assembled, blow air through pinion shaft oil feed hole to check
for blockage.

Partially or completely blocked oil feed passageways may
cause irreversible damage to bearings and other engine
components.

Measure width of female rod on crankpin end. See
Picture 8. Measurement should be 1.481” to 1.483”.

Assemble left and right flywheels and moderately
snug nuts. Do not worry about them being true.
Measure distance between connecting rod thrust
pads. See Picture 9.

NOTE - S&S recommended rod side play is .015” to .035”.

Rod Side Play = (Distance from Pad to Pad) - (Female Rod Width)

Incorrect connecting rod side play may cause excessive rod
side thrusting and potential damage to rods, flywheels and
other engine components.

If difference is less than .020”, female rod must be ground on
sides as final tightening will pull wheels closer together. Rod side
play diminishes about .015” when crankpin nut is final tightened.
Take equal amounts off each side if amount to be removed is
more than .010”. If there is no rod side play try different
crankpin. If rod side play is more than .035”, try different
crankpin. We have run side play of as much as .045” without
serious consequences. If side play is excessive and different
crankpins do not correct problem, contact us.

NOTE - If material is removed from sides of female rod, overall
width of bearing cages must be reduced so bearings and cages
are free to float with rods without contacting flywheel thrust
pads. Bearing cage side clearance of .008 to .020 less than rod
width is recommended.

Connecting rod bearing and cage assemblies that are wider
than female rod may become damaged upon contact with
flywheel thrust pads. Damaged rod bearing assemblies
and/or foreign material from damaged components
circulating in oil could cause further destruction and possible
failure of other engine parts.

WARNING

CAUTION

Picture 7

CAUTION