User guide

ManualsBrandsS&S Cycle ManualsFor motorcycles49-State EPA Certified Engines

S&S

Cycle, Inc.

235 Causeway Blvd.

La Crosse, Wisconsin 54603



Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

IMPORTANT NOTICE:





WARNING



CAUTION



NOTE





WARRANTY:

            

















     

            

    













ADDITIONAL WARRANTY PROVISIONS:











           

       





 





SAFE INSTALLATION AND OPERATION RULES:







 





           

         



 





         

      







 

  



        

           

         



 

         





           

           



DISCLAIMER:





   

  











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Emission-Related Installation Instructions for

S&S® 49-State EPA Certied Engines

Instruction 106-2027

12-26-07



 .





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Summary of content (8 pages)

PAGE 1
Instruction 106-2027 12-26-07 S&S Cycle, Inc Copyright © 2007 235 Causeway Blvd. La Crosse, Wisconsin 54603 by S&S® Cycle, Inc. ® . Phone: 608-627-1497 • Fax: 608-627-1488 Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.com All rights reserved. Printed in the U.S.A.
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Installation Overview This S&S® 49-State EPA Certified Engine is approved for use in assembled highway motorcycles and conforms to USEPA regulations applicable to the model year in which it was produced. A small volume manufacturer, kit manufacturer or assembler using this engine does not have to apply for a separate emission certificate with the EPA. A vehicle built according to the requirements given is considered a certified vehicle by the EPA.
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The exposed surface area of the gaskets is considered to be the surface area of the gasket that is exposed to fuel or fuel vapor. To determine the exposed surface area of a circular gasket the following equation would be used: Exposed Surface Area= a x 3.14 x d where: a = thickness of the gasket d = ID of circular opening To determine the exposed surface area on an o-ring seal the following equation would be used: Exposed Surface Area= 0.25 x 3.
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II- Connect the VOES hose from the switch to the nipple in the manifold. Trim the hose to be as short as possible without stretching or kinking it. III. Make electrical connections according to following chart and wiring diagram.
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C- Clamp off the open end of the oil feed line and fill the oil tank with oil of the appropriate type and grade recommended in the S&S® 49-State EPA Certified Engine Owner’s Manual. D- Unclamp the feed line to allow the line to fill with oil; then quickly attach it to the fitting on the oil pump. The oil pump was primed at the factory so no further priming should be necessary. It is necessary to confirm that oil is circulating properly prior to operating the motorcycle.
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Optional S&S Two Cable Throttle Kits Kits fit 1” (25.4mm) O.D. handlebars and can be used on most chassis. An adapter sleeve is available for use with handlebars having 7/8” (22.2mm) ends. Fittings on provided cables readily “plug in” to S&S® Super E, G, or stock H-D 1981 and later butterfly type carburetors. Kits include one opening side cable, one closing side cable, left and right handlebar grips, and handlebar clamps.
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G- Position the main harness with the compression release lead wires so they are not pulled tightly against anything. Once the best position is found, zip-tie the connectors and that end of the harness securely to the frame to prevent movement. H- Working from the end that you secured earlier, work out a routing position for the remaining portion of the wire harness, making sure the wires will not be crushed, cut, scuffed, or otherwise damaged by operation of the motorcycle.
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10- Troubleshooting Tips A- Engine will not start: I- Fuel tank may be empty or petcock may be in closed position. II- Weak or no-spark condition may be caused by a discharged battery, damaged ignition module, or damaged coil. Verify the condition of components. III- Spark plug gap may be too wide. B- Engine will not run at steady speed or rpm: I- There may be a restriction in fuel supply system (gas tank vent plugged, needle and seat not working properly, etc.) II- Faulty ignition system.