S&S Cycle 49-State EPA Certified Engines - Manual (Page 7)

G- Position the main harness with the compression release lead wires so they are not pulled tightly against anything. Once the best position
is found, zip-tie the connectors and that end of the harness securely to the frame to prevent movement.
H- Working from the end that you secured earlier, work out a routing position for the remaining portion of the wire harness, making sure the
wires will not be crushed, cut, scuffed, or otherwise damaged by operation of the motorcycle. The black wire will need to be routed to a
ground, and the green wire to power supplied during cranking only.
I- Find a suitable place to splice the supplied fuse holder into the green wire of the harness as close to the power source as possible.
J- Once the position of the fuse holder has been determined, cut the protective sleeve at that point, being careful not to damage the wires
inside.
K- Cut the green wire of the harness where it meets the fuse holder lead wire and slide one of the supplied pieces of shrink-wrap on it.
L- Strip the green wire and a wire from the fuse holder and connect them with the supplied butt connector. After making sure the wires are
securely connected, seal them in place with heat shrink. Use the same procedure to connect the other side of the fuse holder.
M- Install a small piece of protective sleeve over the remaining fuse holder wire that runs up to the connection point.
7- Install Fuel Tank
A- Install fuel tank making sure it does not come in contact with engine or sensors.
8- Fuel Line
A- Slip hose clamp over end of fuel line with 90° bend. Lubricate the fuel inlet fitting on the carburetor by applying a thin coating of oil. Slip
end of fuel line with 90° bend over fitting.
B- Position fuel line to avoid contact with hot cylinders or other engine parts. Tighten hose clamp. Slip protective fuel line covering over fuel
line and position to prevent direct contact between fuel line and cylinders or other engine parts.
C. Connect fuel line to gas tank petcock using hose clamp provided.
WARNING
CAUTION
WARNING
Gasoline is extremely flammable and explosive under certain conditions. Do not smoke or expose gasoline to sparks or open flame.
Gasoline fumes are toxic when inhaled. Perform installation in a well ventilated area away from open flames or sparks. Unwarranted
sparks and inadvertent engagement of starter while working on electrical components can cause serious injury or death.
Engines vented through heads must not have breather bosses plugged, as oil leakage and damage may occur.
Fuel line must be clamped securely and not contact any hot surfaces where it could melt or catch fire, causing serious injury or death.
9- Final assembly and checks.
A- Connect vacuum petcock hose (if equipped).
B- Check fuel line routing and connections.
C- Test throttle to ensure it opens and closes freely. Turn handlebars to extreme left and open and close throttle, and then turn bars to extreme
right and repeat. Throttle must snap closed in all positions.
D- Reassemble any remaining components.
E- Install emission control label on motorcycle frame.
F- Verify all emission related instructions and requirements have been met.
G- Fill gas tank.
H- Check carburetor fuel inlet fitting and fuel line connections for leaks.
NOTE: Fuel needle and seat assembly must completely shut off fuel supply entering bowl. Fuel inlet fitting and fuel line connections must not leak.
CAUTION
Gasoline leaking past inlet needle may flood engine causing fire hazard or damage to components.
WARNING
Gasoline leaks at inlet o-rings, fuel line connections, or inlet needle may flood engine and overflow into surrounding area creating fire
hazard.
I- See S&S® 49-State EPA Certified Engine Owner’s Manual for engine starting instructions.
CAUTION
Failure to break-in engine according to correct procedure may result in serious damage to engine that is not repairable under warranty.