S&S Cycle Super E and G Series Shorty Carburetors - Manual (Page 4)

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1996 to 2002 Buell® Models
1996 and 1997 Buell models require special S&S butterfly style throttle cables, which are compatible with the stock 1996-1997 throttle assembly.
1998-'02 carbureted Buell models require installation of stock 1996-‘97 throttle grip and the special S&S throttle cables for Buell models when
installing Super E or G carburetors.
S&S THROTTLE KITS
S&S throttle kits fit 1" handlebars and can be used on most chassis. (An adapter sleeve is available for use with earlier, 7⁄8" OEM handlebars originally
equipped with internal throttle cable.) Barrel fittings on S&S® cables readily "plug in" to S&S Super E, G, and stock H-D® 1981-'90 butterfly type carb
throttle linkage. Kits include one opening and one closing side cable, left and right grips, and handlebar clamps. Kits with 36", 39", 42", or 48" length
cables are available. Length specified refers to overall cable length. Vinyl covered outer housing is 4" shorter than overall length.
Throttle Kit with 36" Cables Part 19-0450
Throttle Kit with 39" Cables Part 19-0448
Throttle Kit with 42" Cables Part 19-0482
Throttle Kit with 48" Cables Part 19-0449
Adapter Sleeve - 7⁄8" to 1" Part 19-0235
NOTE: Cables supplied with above kits are interchangeable with 1981-'90 stock H-D butterfly style throttle cables.
S&S Throttle Cables For 1996 and Later Chassis
These throttle cables feature the "plug in" cable fastener to fit 1996 and later throttle grips, and the correct length inner cable for use with S&S
butterfly style carburetors with the shorter cable bracket. These cables must be used in 1996-'02 Sportster installations. These cables may be used
on 1996 and later big twin installations if the S&S carb is equipped with the short cable guide bracket. Cables for Buell models fit threaded 1996-’97
Buell throttle grip.
CARB INSTALLATION
Read instructions thoroughly to familiarize yourself with all procedures before beginning installation. Since this manual covers installation on all
models, it may be helpful to highlight the steps that apply to your application.
NOTE: Installation of S&S® Super E and G carb kits on certain models is easier with gas tanks removed. Some owners may elect to perform installation
without removing gas tanks. This is left to individual discretion. If installer elects to remove tanks or other stock parts, S&S recommends referring to
appropriate Harley-Davidson® service manual for correct removal procedure as necessary.
1- Remove Old Carburetor And Manifold
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Gasoline is extremely flammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic
when inhaled. Perform installation in a well ventilated area away from open flames or sparks. Any gasoline leak or spill constitutes a
health and fire hazard.
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If motorcycle has been running, wait until engine and exhaust have cooled to avoid getting burned during installation.
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Electrical sparks can ignite explosive gasoline fumes. Failure to disconnect battery while working on motorcycle can also result in
inadvertent engagement of starter and personal injury.
A- Shut off fuel petcock and disconnect battery.
B- Remove air cleaner assembly. Drain fuel from existing carburetor. Remove carburetor, manifold, choke cable and any carburetor mounting
hardware.
NOTES:
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Removing and tightening hard to reach Allen bolts like carb-manifold mounting bolts and manifold flange bolts can be greatly simplified by using
some special tools. The S&S rocker cover wrenches work very well for this application. See Picture 3 on next page. Allen ball-end drivers are also very
helpful, and are available at most automotive and tool supply houses. See Picture 4 on next page. As an alternative, standard hex wrench can be
shortened for convenience.
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Some Buell® motorcycles have a breather fitting with 90° elbow on rear head. Due to proximity of frame, elbow must be removed before fitting can be
taken off engine.
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Loosen fitting and rotate to position convenient for cutting elbow. Secure fitting by tightening against cylinder head. Elbow may be inaccessible to
hacksaw. In most instances, a die grinder with cutoff wheel will remove elbow with little difficulty. If die grinder is unavailable, grasp elbow firmly with
pliers and snap off, then remove fitting.
WARNING