S&S Cycle Big Twin Engines with 3-1/2 and 3-5/8 Bore Crankcases and Special Application (SA) 4 Bore Crankcases - Manual (Page 2)

INTRODUCTION
S&S ® big twin and shovelhead engines are available in several
stages of completion. Final assembly depends upon which version
was purchased. Engine Instructions often refer to procedures
described in other S&S instructions or a Harley-Davidson
® Service
Manual. These materials should be cross-referenced as necessary.
Because of the large number of instructions provided with each
engine, it is recommended that they be arranged in sequence
according to Instruction Sheet # printed in top left corner.
In most instances, assembly of S&S big twin and shovelhead
engines is similar. Exceptions will be noted where applicable. All
engines are designed for frames that accept Harley-Davidson
® big
twin engines. Most fit stock Harley-Davidson ® and similar frames
without modification. Some engines are significantly taller than
stock as a result of increased stroke, and may require frame
modifications. While this applies mostly to 96, 98 and 103 cubic
inch shovelhead and 103 in. big twin engines, S&S strongly
recommends trial-fitting every engine before frame is painted or
powder coated.
Because the Special Application crankcase is 1/4 inch wider than
stock, fit of exhaust, rear brake master cylinder, and foot
controls must be closely checked when installing 4 inch bore or
other engines with SA crankcases. Some components may
require modification.
In some instances, brake master cylinder must be spaced out
from frame to clear SA crankcase. UNDER NO
CIRCUMSTANCES SHOULD MASTER CYLINDER OR BRAKE LINE
BE ALLOWED TO CONTACT EXHAUST PIPE IN FINAL
INSTALLATION. Heat transferred to brake fluid may expand
and cause brakes to seize, resulting in possible fire hazard
and loss of control of motorcycle with injury or death to rider
and others.
IMPORTANT NOTES:
●
Lubrication - S&S supplies Torco ® Engine Assembly Lube with
each engine. It should be used as specified in following
instructions. While other brands of assembly lube are
acceptable, other lubricants are not. In no instance should an
aerosol lubricant be substituted for assembly lube.
● Engine tuning - Ignition timing and carburetor jetting are
responsibilities of the customer. General tuning guidelines
appear in these instructions and Carburetor Instruction
Sheet #51-1012.
Incorrect ignition or carburetor tuning can cause extensive
engine damage not covered under warranty.
● Powder coating and polishing - While S&S does manufacture
some powdercoated engines, it does not recommend having
engine parts powdercoated or otherwise modified
elsewhere. Many such procedures leave abrasive residues
which are difficult to remove completely. Also, powder
coating is cured at high temperatures that can change the
strength characteristics of some metals.
Glass bead and polishing residues are abrasive and can be
difficult to remove from recesses and small passages.
Abrasive residues can cause oil contamination and extensive
engine damage. Engine damage caused by powder coating,
polishing, glass bead blasting, or other modification will not
be covered under warranty.
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WARNING
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CAUTION
CAUTION
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