S&S Cycle TÜV Long Block Assembly User Manual

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S&S TÜV Long Block Instruction Guidelines

S&S Long Blocks include instruction sheets for individual
components. Most instructions apply to all S&S Long Blocks. In
the following instances, however, components or procedures
supplied with and described for TÜV Long Blocks are different
from those for other S&S Long Blocks.
A.

Some S&S Long Blocks may be configured to allow
crankcase pressure to exit via the crankcase and/or cylinder
head vents. TÜV Long blocks must utilize cylinder head
venting only.

The special carbon air cleaner element supplied with TÜV
Long Blocks was designed for superior flow and efficiency.
The element reduces intake noise emissions, as well as
prevents fuel vapors from entering the atmosphere while
the engine is shut off, and thererfore, must be used. Filter
service requirements are described in th TÜV Engine
Owner’s Manual.

The camshaft supplied in TÜV Long Blocks is of proprietary
S&S design and reduces exhaust emissions. Substitution
of a cam with different specifications is not permitted under
TÜV standards.

The carburetor supplied with TÜV Long Blocks is not to be
adjusted. For service requirements, contact S&S Cycle
Technical Services, 608-627-1497. The tuning instructions
described in S&S Carburetor Instruction Sheet No. 400 do
not apply to carburetors supplied with TÜV Long Blocks.
Refer to the S&S TÜV Long Block Owner's Manual for proper
setting of idle speed.

The OEM Harley-Davidson ignition system is to be replaced
with one of the following aftermarket ignition systems:
Compu-Fire Elite 1, Dualfire (Complete Kit P/N: 10880,
Module P/N: 21832-5); Crane Hi-4, Dualfire (Module P/N
8-1100); or Dyna "S" Single-fire (Complete Kit P/N: DSK6-2,
Module P/N: DS6-2). Ignition system should be adjusted
as per manufacturer's instructions. VOES switch is not to
be used.

The OEM Harley-Davidson exhaust system must be used.

On all models, rear wheel drive pulley must be replaced
with a 61-tooth pulley. Stock Harley-Davidson 32-tooth
transmission pulley must be used for a 1:1.90625 ratio.

TÜV Long blocks are equipped with special intake restrictor
devices for the purpose of emissions compliance. To
maintain compliance with TÜV regulations, these devices
must not be removed.

This S&S replacement engine has been manufactured, assembled,
and calibrated by S&S Cycle, Inc. Before proceeding further, verify
that this engine has the exact set of options required for your
motorcycle. Installing an S&S replacement engine into a Harley-
Davidson motorcycle requires specialized knowledge, skills, and tools.
For this reason installation should be left to a professional mechanic.

WARNING - Improper installation of engine or related
components could result in injury or death to the operator and/
or passenger and damage to the motorcycle.

Installation
1.

Remove the original engine according to the applicable Harley-
Davidson (H-D) Service Manual.

Install the S&S engine into the motorcycle chassis according to
the H-D Service Manual, but do not install the fuel tank until last.

Install the ignition module, ignition coil, and wiring according to
the H-D Service Manual and applicable Ignition Installation
Instructions.

Install Oil Lines
A.

First flush the oil tank and lines and install a new oil filter.

Clamp off one end of the oil feed line and connect the
opposite end to the oil tank.

Fill the oil tank with oil of the type and grade recommended
in the S&S TÜV Engine Owner’s Manual.

Unclamp the feed line to allow the line to fill with oil, then
quickly attach it to the correct fitting (marked “S”) on the oil
pump. The oil pump was primed at the factory so no further
priming should be necessary. It is imperative, however, to
confirm that oil is circulating properly prior to operating the
motorcycle.

CAUTION - Lack of oil circulation through the engine will cause
damage to the internal engine components.

Remove both spark plugs.

Remove the oil return line from the oil tank and place the end in
a container.

Using the starter, turn the engine several rotations. Oil should
come out the return line. If not, repeat the procedure as needed.

Reconnect the return line to the oil tank and install the spark
plugs.

Throttle Requirements
S&S Super E & G carburetors are designed exclusively for Harley-
Davidson Big Twin and Sportster engines. The carburetors included
with TÜV Long Blocks are butterfly type carbs with a preset idle mixture
screw and preset midrange and high speed jets. The carbs also
features an accelerator pump and a variable fast idle device for
improved throttle response, engine starting and warm ups. The Super
E has a 1

⁄

" (47.6mm) bore at the butterfly and a 1

⁄

" (39.6mm) venturi.

The Super G has a 2

⁄

" (52.3mm) bore at the butterfly and a 1

⁄

(44.5mm) venturi.

NOTE - S&S Super E & G carburetors require the use of a two
cable, pull open - pull closed throttle assembly. All 1980 and earlier
stock H-D models equipped with a single cable throttle mechanism
must be converted to the two cable, pull open - pull closed type.
S&S offers these throttle assemblies but does not include them
because of the multitude of chassis designs and installation
requirements.

WARNING - Single, braided wire cable throttle mechanisms cannot
mechanically close throttle. If throttle inadvertently sticks in open
position, loss of control of motorcycle and personal injury to you or
others may result.

All stock chassis 1980 and earlier and any other motorcycle equipped
with single cable throttle system must be converted to a two cable
system. Kits with 36" (91cm), 39" (99cm), 42" (107cm), 48" (122cm),
or 52" (132cm) length cables are available. Throttle assembly kits
may be ordered separately. See descriptions below.

Stock models from 1981 to 1989 have a two cable throttle system
designed for a butterfly type carburetor. Existing cable fittings on
these models can simply be “plugged in” to the S&S Super E or G
throttle linkage.

Throttle cables on 1990 and later models or any motorcycle fitted
with a constant velocity (CV) carb will not work with S&S Super E or
G carbs. The braided wire inner cables of throttle cables designed
for constant velocity carbs are about 1-1/2" (38mm) longer than those
designed for butterfly carbs, resulting in excessive free play. Throttle
cables on these models must be changed to throttle cables designed
for butterfly carbs. Throttle cables on 1981 to 1989 models will directly