S&S Cycle Crankcases for Harley-Davidson 2007–Up Touring Models With Twin Cam 96/103 Engines - Manual (Page 3)

Hardware Identification and Installation
NOTES
• When installing hardware, be careful not to cross-thread fittings or
damage threads. Damage caused by improper installation of hardware
will not be covered under warranty.
• To prevent galling, apply anti-seize compound, pipe sealant, or PTFE tape
to threads of all steel fittings prior to installation in crankcase.
• If PTFE tape is used, loose tape must not enter crankcase or oil passages.
Do not apply tape to first 2-3 threads that screw into hole. If fittings are
removed or replaced be sure no tape shreds remain in holes. Tape shred
could block oil passages causing restriction of oil flow.
CAUTION
Restricted oil flow may result in extensive engine damage not
covered under warranty.
4. Piston Jet Installation
a. Apply a thin film of clean engine oil to new o-ring.
b. Seat o-ring in groove of piston jet mounting flange.
c. With pinhole in the jet pointing upward, install using two T20
TORX screws. Apply Loctite® 243 Blue, then tighten to 20-30 in-lbs.
CAUTION
Piston jets must be installed using the correct o-ring. Leaving out
a piston jet o-ring, installing too small of an o-ring, or pinching
an o-ring at assembly will cause oil to by-pass the jet, resulting in
low oil pressure.
NOTE: Always use a new o-rings when re-installing jets.
5. Transmission Case Drilling
NOTE: If an S&S engine or crankcase is to be installed in a motorcycle, which
has had a catastrophic engine failure, or if for any reason it is suspected
that debris or contaminants have been introduced into the oiling system,
the oil pan must be thoroughly cleaned or replaced. In order to ensure that
all debris is removed from the oil pan, the baffle must be removed. In 2009
and later models, and in current production replacement oil pans for earlier
models, the baffle is welded into the oil pan and is difficult to remove. It is
recommended that oil pans with welded-in baffles be replaced.
Harley-Davidson® replacement oil pan part number for touring bikes is
62489-99A.
CAUTION
Failure to remove debris or contaminants from the oil pan may
result in serious damage to the engine.
These instructions assume that the engine has been installed, and that
the inner primary cover and oil pan have been removed. However,
transmission case drilling can be done before engine is installed. Tool
Kit 530-0006 is recommended for easy and professional drilling and
tapping of vent and return fittings.
If Tool Kit 530-0006 is not available, a 9/16" drill bit and a 3/8-18 NPT
tap must be obtained. Refer to dimensions shown in Figure 1 to
determine the locations of the vent and return fitting holes. Once the
holes are drilled and tapped, the rest of the installation is the same.
a. Clean areas of drilling, gasket surfaces etc
b. Install Drill jig as shown in Picture 1, above left with two 5/16-18
fasteners, snug fasteners enough to hold jig securely, see Picture
2, above right.
c. Lubricate jig bushing hole and 9/16" drill with engine oil, install drill
bushing into either hole in drill jig and drill hole. Repeat for second
hole.
See Pictures 3 & 4, next page .
d. Remove Drill jig and de-burr both holes inside and out. See Picture
5, next page
e. Mask pipe tap so .770" of thread is exposed, this marks the depth
you want to tap the two holes
f. Lubricate pipe tap with thread cutting oil or engine oil.
g. Re-install drill jig. Using a 5/8" 12pt socket, guide the tap into the drill
jig bushing and start the tap a couple of turns in each hole, be sure
to tap far enough so that you will be able to re-start the tap to finish
the holes.
See Picture 6,next page.
h. Remove drill jig. Finish tapping each hole to the 0.770" depth
marked by the masking tape. See Picture 7, next page. De-burr
and clean both holes inside and out with compressed air and a
solvent such as brake cleaner.
3
Picture 1
Figure 1
Picture 2