S&S Cycle Sidewinder 3 5⁄8 Big Bore Cylinders for Harley-Davidson Sportster Models—1986–2003 - Manual (Page 2)

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INTRODUCTION
Installation of an S&S® Harley-Davidson® Sportster® model 35⁄8" bore stroker Sidewinder® Kit is easy and can be performed by any Harley-Davidson®
repair shop equipped to do complete engine overhauls.
NOTES:
• To make installation of S&S Sidewinder series 35⁄8" bore kits easier, S&S has designed several Special Tools worth considering. They are:
Part 53-0002—Connecting Rod Checking Pin—helps check piston alignment in cylinder bore.
Part 53-0020—Degree Wheel Kit—used to check and set ignition timing and to check cam timing. This kit can also be used to check crankcase
breather gear timing in big twin engines.
Part 53-0006, 53-0007, and 53-0008—Crankcase Boring Fixture and Crankcase Boring Spacers—adapts most boring bars so crankcases can be
bored to fit larger diameter spigots on big bore cylinders. Enables qualified operator to bore cases in about an hour after initial setup. Can also be
used to bore pre-1984 style big twin heads when installing big bore cylinders.
• S&S pinion shafts for Evolution® Sportster® models are the 1987 style splined shaft because this design is stronger than the later style stock straight
shaft and key. As a result, the engine builder must use a 1986–1987 style pinion gear, S&S PN 33-4152 through 33-4156 (H-D® #24055-86 through
#24061-86) and oil pump drive gear, S&S PN 33-4228 (H-D® #26318-75). Stock Torrington® pinion main bearing in 1986 crankcases must be replaced
with 1987 race and later steel caged roller bearing. See Steps 6 and 10.
• Due to increased cylinder length, S&S Sidewinder kits of 96" and larger displacement require that stock cylinder studs be replaced with big twin
cylinder studs.
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 parts or that they are equivalent to the corresponding Harley-Davidson® part number shown.
Read instructions thoroughly before starting work. When they are completely understood proceed with installation. It is strongly recommended
that the engine builder also obtain a copy of a Harley-Davidson® service manual of the same year as the engine being built.
INSTALLATION STEPS:
1. Clearance Frame*
2. Crankcase Alignment
3. Cylinder Mounting Studs (96” and larger engines only)
4. Bore Crankcases
5. Modify Crankcases for Oil Returning from Heads
6. Convert Pinion Main Bearing To 1987 and Later (1986 crankcases only)
7. Connecting Rod Preparation (79” engines only)
8. Lower End Assembly
9. Crankcase and Piston Skirt Clearancing
10. Connecting Rod Alignment*
11. Cylinder Head Preparation
12. Piston to Head and Piston to Valve Clearancing
13. Final Assembly and Engine Installation
14. Engine Break-In Procedure
15. Performance Notes
*NOTE: S&S recommends that engine builder consider performing some steps during initial engine removal and disassembly. Checking clearance
between stock engine and frame will allow an accurate estimate of amount and location of clearancing required after kit is installed. While
entire flywheel and rod assembly may be replaced, it is sometimes helpful to check original parts combination and note problems that can be
corrected more easily before engine is reassembled.