S&S Cycle Crankcases for Harley-Davidson 2007–Up Touring Models With Twin Cam 96/103 Engines - Manual (Page 2)

Please read these instructions thoroughly before starting work. Proceed
with the installation only after they are completely understood. These
instructions should be supplemented by the appropriate OEM service
manual for your motorcycle. Follow all safety information.
Introduction
S&S® crankcase assemblies for Harley-Davidson® 2007-up
noncounterbalanced big twin engine applications. Installation can
be performed by any repair shop equipped to do complete Harley-
Davidson® engine overhauls.
Stock bore cases are perfect for stock replacement applications, 4.125"
bore cases are a natural for use with the S&S® Hot Set Up kit® for Twin
Cam 96™ & 103™, and 4.375" bore cases make it possible to build really
large displacement custom engines.
S&S crankcases for 2007-up big twins are available for stock bore
engines as well as engines with 4.125" and 4.375" bore cylinders.
Inspect these crankcases to make sure they are machined for the
correct cylinders.
NOTE: S&S crankcases are sold in matched sets only. Individual case halves
are not available.
ADDITIONAL OIL LINE INSTALLATION KIT REQUIRED
• FL - PN 310-0435
Additional features:
• Greater overall strength than stock crankcases, especially in the
front motor mount, an important consideration in high performance
applications.
• All oil passages between the crankcase and gear cover are o-ring
sealed.
• Compatible with stock components. Use stock oil pump, cam support
plate, gear cover, etc.
• 1999-2002 Timken® style sprocket shaft bearing. (Included)
• Uses 2003-up pinion shaft bearing
• Special order crankcases offer your choice of cylinder spigot bore,
cylinder stud pattern.
Polishing, Painting, Plating, or Powder Coating S&S cases
S&S Cycle cautions against modifying these crankcases due to the
possibility of damaging or weakening them. Modifying S&S crankcases
in any fashion voids all manufacturer warranties. Should the customer
elect to modify the crankcases regardless, it is imperative that they
and the information tag attached to them be inspected beforehand
to confirm that the correct model, style, bore size, etc. have been
provided. The customer must confirm that crankcases and related
parts are correct before assembling them or having them modified in
any manner, and assumes all liability for modifications.
The customer must also verify that the serial numbers on the crankcase
and attached information tag correspond with those on the certificate
of origin and packing carton.
Under no circumstance will S&S be held responsible for expenses
related to the modification of any S&S part in the event warranty
service is required. Modified parts will not be accepted for credit or
exchange. This will apply regardless of cause or fault: customer, retailer,
manufacturer, or other.
For further information, contact S&S Technical Services at 608-627-
8324, FAX 608-627-1488 or e-mail [email protected]
NOTE: Modification includes but is not limited to appearance changes such
as painting, Powder coating, plating, and polishing. Proper preparation
for these procedures as well as the processes themselves may require the
use of polishing compounds, chemicals or procedures that are potentially
harmful to crankcases.
CAUTION
Passages and internal cavities may become obstructed by
residues from materials used to polish, paint, plate or powder
coat surfaces. Additionally, surface finishing processes can
damage critical machined surfaces. Any of the above may cause
premature wear, damage or failure of other engine components
as well as the crankcases themselves.
Powder coating - Subjecting heat-treated alloys such as those used
in S&S® crankcases to excessive heat can drastically alter their strength
and their critical properties. The degree of change depends upon the
temperatures reached and the duration of exposure. When powder
coating or otherwise processing alloy parts, S&S exposes them to a
maximum temperature of 370°F for no longer than 20 minutes. Under
no circumstances should parts be heated past 400°F!
Preparation and Installation
1. Inspection
a. Inspect crankcases to confirm that they are correct style and
machined for correct bore size. Refer to tag wired to crankcases.
b. Verify that serial numbers on crankcases match numbers on
packing carton and certificate of origin. Contact S&S immediately if
numbers do not match.
NOTE: Valid certificate of origin is required for any transfer or sale of
aftermarket crankcases or complete engines built with aftermarket
crankcases. Certificate of origin is required to title and license any
motorcycle which is to be driven on public streets and highways.
2. Crankcase Test Fit
If possible, bare crankcase should be positioned in motorcycle frame
before assembly to check clearances.
a. Position case in frame, check for clearance at frame, and alignment
to transmission. It is a good idea to replace rubber engine and
transmission mounts at this time. Old mounts deform over time
and may and induce unwanted stresses on the engine case.
NOTE: Crankcases damaged by improper installation are not covered
under warranty.
3. Pre-Assembly Cleaning
a. Clean crankcases in hot soapy water or solvent to remove any
dirt or contamination which may have been introduced during
shipping, handling, or set-up. Dry components and check passages
with compressed air.
WARNING
Compressed air and particles dislodged by compressed air
are potentially harmful. Wear protective goggles when using
compressed air and always direct air stream away from yourself
and others nearby.
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