S&S Cycle Three Piece Flywheel Assemblies for S&S V-Series Engines for 1984-99 Harley-Davidson Big Twins User Manual

Page 2

Special Tool Requirements

• Harley Davidson service manual or S&S service manual for your

specific engine

• Timken® bearing installing tool
• 2" “C” or “V” micrometer with .0001" accuracy
• Digital or dial calipers
• Dial indicator
• Torque wrench

General Information

• Thoroughly read and understand these instructions. In addition

to this instruction sheet you may wish to purchase S&S 4 1/8" bore
V-Series Service Manual #510-0104.

• Please inspect your flywheels and confirm that they are the correct

style and stroke for your engine. See the chart below.

• If you don’t have the required tools for installing these flywheels

either acquire them or refer installation to a professional mechanic.

• It is the engine builders responsibility to confirm proper clearances

when assembling an engine

SPECIAL NOTE - Camside case of S&S 4 1/8" bore crankcase sets with
serial numbers lower than NE00203X must be machined to provide
adequate clearance for current production flywheel assemblies. See
Page 4 for more information.
NOTE: If you do not have machining capabilities, crankcases may be
sent to the S&S Service and Speed Center® and we can machine them for
you. Contact your S&S dealer. Dealers, please contact your S&S Customer
Service Representative at 608-627-1497 for a return authorization number.

Flywheel Installation

1. Remove flywheels assembly from packaging material. Handle with

care to avoid dropping assembly. Avoid any sharp blows to the
mainshafts which could potentially shift the flywheels out of true.

2. Using a clean lint free cloth, thoroughly clean flywheel assembly to

remove rust preventative oil. Rust preventative oil is not suitable for
use as engine oil and must be removed prior to installation. Be sure
that assembly remains free of foreign material or contamination
before and during installation.

NOTE: Do not immerse or wash assembly in solvent. Connecting
rod bearings are coated with assembly grease, which may become
contaminated by dirt and grit unless absolutely new, clean solvent is used.

3. Refer to the Harley Davidson service manual for the specific model

of motorcycle you are working on for the correct engine removal
procedure.

4. Remove engine from the frame of the motorcycle and completely

disassemble.

5. Inspect crankcases carefully. If pinion bearing race is damaged or

oversized, it must be replaced according to procedure outlined in
the S&S 4 1/8" bore V-Series Service Manual #510-0104.

6. Clean all lower end parts for final assembly. Ensure that all

passages, including piston oilers, are open and free from debris or
contamination.

7. Wash the cases in warm soapy water, rinse and blow dry. Wipe

them one last time with a clean, dry cloth.

8. Thoroughly clean crankcase mating surfaces with solvent and

a scrubbing pad to remove any residual sealant from the sealing
surfaces.

NOTE: Cleaning parts prior to and during assembly and keeping parts
clean after final assembly are imperative to minimize contaminants that
may circulate in oil and shorten engine life. Many parts can be cleaned
with soap and water first. Then, reclean all internal parts and gasket
mating surfaces using high quality solvent that does not leave any harmful
residues.

9. Measure the pinion shaft bearing surface outside diameter and

pinion race inside diameter to an accuracy of .0001". Use the
following table to select the correct pinion bearing. See Picture 1.

10. Check Timken® sprocket shaft bearing end play.

Picture 1

Stroke Codes

Code

Stroke

3.600"

3 7/8"

4 1/8"

4 3/16"

4 ¼"

4 3/8"

4 ½”

4 5/8"

4 ¾"

4 13/16"

Engine Style

Code

Engine Style

SGX3

4 1/8” Bore
V-Series

Flywheel Diameter

Code

Diameter

8 ¼"