S&S Cycle Clearancing Harley-Davidson Sportster Model Flywheels for 34-7800 Connecting Rods - Manual (Page 2)

Current S&S ® 34-7800 connecting rods are wider in certain areas than those manufactured previously. This results in interference
between lower portion of female connecting rod and inner rim of stock Harley-Davidson ® flywheels. Material must be removed from
flywheels to obtain proper clearance. Although it remains the engine builder’s responsibility to confirm all clearances as described in
S&S Connecting Rod Instruction 51-1025, connecting rod-to-flywheel clearance should be adequate when using S&S flywheels.
NOTE: Because amount of metal removed from flywheel is minimal, engine balance should not be affected. It is recommended that
flywheel balance be checked, however, if more than a few grams of metal are removed. Refer to Instruction 51-1025 for additional
comments on balancing flywheels for S&S connecting rods.
Failure to follow recommended clearancing procedures may cause damage to rods and/or other engine components.
Removing material from connecting rod will weaken it, possibly causing it to break without warning. This can result in
catastrophic engine failure with subsequent loss of control of motorcycle and severe injury to rider and others.
Clearancing Procedure
1. Place crankpin in drive side flywheel, followed by pre-lubricated bearings, bearing retainers and female connecting rod. Locate
rod in relieved area of flywheel rim insuring that thrust face of rod rests against flywheel. Gently rotate rod forward on crankpin
until it contacts flywheel. Mark flywheel at contact area and rotate rod in opposite direction until flywheel is contacted again.
Mark second contact area.
2. Remove connecting rod and bearing assembly from flywheel.
3. Remove sufficient metal from contact areas of flywheels to provide .060” clearance between flywheel and rods.
NOTE: It is not necessary to remove metal around entire rim of flywheel. Slight bevel where corners contact rod should be sufficient.
Metal particles are potentially harmful. Always wear safety glasses, hearing protection, gloves and other protective clothing
when grinding, filing or otherwise machining metal.
4. Repeat procedure on other flywheel.
5. Carefully remove burrs and smooth relieved areas to eliminate possible stress risers.
6. Proceed with assembly according to Connecting Rod Instruction 51-1025.
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CAUTION
WARNING
WARNING
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