S&S Cycle Big Bore Kits 97 & 106 for 1999–06 & 2007–Up Big Twins - Manual (Page 2)

2
INSTALLATION AND REASSEMBLY
A- Setting Ring End Gaps
NOTES
•
Important! The gap of the second ring should be larger than the top ring;
this will help keep the top ring seated for improved performance. •
Each ring should be fitted to the particular cylinder in which they will be
installed. •
Oil rails can be installed without adjusting the end gap. The minimum
gap should be 0.010" •
Never alter the end gap of the oil expander ring. •
Always install the ends of the expander facing up as shown in Picture 3,
top of next page.
1- Thoroughly wash cylinders with hot soapy water, then wash with
brake cleaner and wipe with a clean white towel. Repeat until
towel does not show evidence of debris and apply a light coat
of oil immediately.
2- Check the ring end gap by placing the ring into the cylinder. Use
a piston or caliper to ensure that the ring is placed squarely in
the bore.
3- Measure the ring end gap with a feeler gauge.
4- See table for proper end gap measurement. If adjustment to the
gap must be made, use a proper ring end gap filing tool.
5- Always file from the ring face towards the inside diameter to
avoid damaging the face coating.
6- Remove material from only one end of the ring.
GENERAL INFORMATION
•
Thoroughly read and understand all the instructions before
starting installation. •
S&S 106" big bore kits contain 3.927" bore pistons with 1.090" deck
height. These kits are intended for stock stroke (4.375") 2007–up
big twin engines. •
S&S 97" big bore kits contain 3.927" bore pistons with 1.270" deck
height. These kits are intended for stock stroke (4.000") 1999–’06
big twin engines. •
Pistons are the same for the front and rear cylinders and can be
used with either cylinder. •
The 3.927" piston is marked with an arrow that should point to the
front of the engine when installed. •
The pistons are machined during manufacturing, to provide the
correct running clearance when cylinders are bored to nominal
size of 3.927". In other words the clearance it built into the
piston diameter. If you wish to confirm piston diameter be sure
to measure the piston only at the micrometer windows on the
front and rear skirts of the piston. Measuring the piston in areas
with non-stick coating applied will result in incorrect readings.
Cylinder measurements must be taken with the cylinder in torque
plates with bolts tightened at correct torque value to simulate
conditions in an assembled engine. •
In all cases it is the engine builder’s responsibility to confirm
proper clearances when assembling an engine. This is especially
critical with performance components such as larger valve, high
performance heads and high lift camshafts. •
In addition to clearances mentioned, 0.060" valve to piston
clearance must be confirmed.
CAUTION
Failure to follow instructions and perform required clearancing,
installation and/or break-in procedures may result in damage
to pistons and or other engine components not covered under
warranty. The proper break-in procedure is in Section 4 of these
instructions.
DISASSEMBLY
Refer to the Harley-Davidson® manual for your specific motorcycle for
the correct disassembly procedure.
The engine should be disassembled to the short block i.e. induction
system, exhaust system, cylinder heads, cylinders, and pistons should
be removed.
KIT CONTENTS
(2) 3.927" pistons (front and rear pistons are the
same)
(2) 0.927" piston pins
(4) Piston pin clips
(2) Ring packs which include the top, second,
oil rail, and expander rings
(2) Cylinders
(2) MLS (Multi Layer Steel) head gaskets
(2) Cylinder base O-rings
(2) Cylinder base dowel O-rings
(2) Exhaust gaskets
SPECIAL TOOL REQUIREMENTS
• Harley-Davidson® service manual for the
specific model you are working on
• Piston C-clip installer
• Piston ring compressor
• Piston ring expander
• Piston ring end gap filing tool
• Digital or dial calipers
• Feeler gauge
INSTRUCTION CONTENTS
General Information
Disassembly
Installation and Reassembly
A- Setting Ring End-Gap
B- Piston Ring Installation
C- Piston Installation
D- Cylinder Installation
E- Cylinder Head Installation
F- Final Assembly
E- Break-in Procedure
Picture 1
Picture 2
Suggested ring end gaps
Ring
Ring Gap Tolerance (inches)
Min Max
Top 0.016 0.022
2nd 0.016 0.026
Oil ring rails 0.010 0.050