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 8)

Having to force gear cover indicates alignment problem.
Problem must be identified and corrected before operating
engine. Operating engine with forced gear cover could result
in broken pinion shaft or other engine damage.
11. Rotate flywheels to check for binding. If present, cause of
bind must be determined and corrected. If assembly rotates
freely, pour approximately four ounces of oil into gear
compartment after allowing crankcase sealant to cure per
manufacturer’s instructions.
INSTALL LIFTERS AND LIFTER GUIDES
(All Unassembled)
NOTE - S&S ® installs HL
2
T (Hydraulic Lifter Limited Travel) Kit in
lifters in assembled big twin engines. HL
2
T Kit is included with
unassembled big twin engines, but not installed. S&S
recommends using kit. If desired, install kit according to
Installation Instructions for S&S Hydraulic Lifter Limited Travel Kit
#5038 before proceeding.
Install big twin lifters and guides as follows:
1. Remove oil pressure sending unit behind rear lifter
guide opening.
2. Identify gaskets for front and rear lifter guides and apply
thin film of Hylomar ® or preferred sealant to both sides of
each. Gaskets are not interchangeable.
3. Coat lifter guide bores with assembly lube and insert lifters.
Work lifters back and forth in guides, assuring that they
move freely and without binding. Apply assembly lube to
lifter rollers and remove any excess.
4. Thoroughly clean and dry gasket surfaces of lifter guides and
crankcase. Place rear gasket on crankcase, assuring that oil
hole in gasket aligns with passage in case.
5. Taking care not to dislodge or contaminate gasket, lower
rear guide assembly into place. Fingers can be inserted
through front lifter guide opening to support lifters.
All reference to Harley-Davidson ® part numbers is for
identification purposes only. We in no way are implying that
any of S&S
® Cycle’s products are original equipment or that they
are equivalent to the corresponding Harley-Davidson ® part
number shown.
6. Insert Harley-Davidson ® alignment tool H-D ® #33443 or
similar tool from other source in lifter guide screw hole by oil
passage. See Picture 19. Install and tighten guide screws in
three remaining holes. Remove tool, install fourth screw, and
tighten all to 10-12 ft-lbs.
7. Repeat procedure for front lifter-guide assembly.
Assembly lube will usually hold lifters in guide during
installation. If resistance encountered, check to see if lifter
has become dislodged.
8. Apply thread sealant to threads of oil pressure switch
and install.
Install shovelhead lifters and guides according to
manufacturer’s instructions.
CRANKCASE VENT (Big Twin Engines)
Before further assembly, it must be decided whether engine is to
vent crankcase pressure out crankcase, cylinder heads, or both.
S&S big twin engines are compatible with both, and S&S
recommends dual venting whenever possible, especially with
four inch bore engines. If different gear cover is installed by
customer, for crankcase vent or dual venting it must be of Harley-
Davidson
® ‘92-older and used with correct gasket. ‘93-up lower
rocker covers and correct gaskets must be used for cylinder head
venting and dual vent arrangement. See Pictures 20 & 21.
Center sections with umbrella valves must also be used.
8
Picture 18 Picture 19
CAUTION
Picture 20
1993-Later 1992-Earlier