Owner manual

ManualsBrandsS&S Cycle ManualsFor motorcyclesEasy Start Camshafts for X-Wedge Engines

S&S

Cycle, Inc.

14025 County Highway G PO Box 215

Viola, Wisconsin 54664

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

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

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

Installation Instructions for S&S Easy Start Camshafts

for X-Wedge® Engines

IMPORTANT NOTICE:

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



WARNING

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

CAUTION

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

NOTE

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

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

WARRANTY:

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

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

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

ADDITIONAL WARRANTY PROVISIONS:

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



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

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

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

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

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

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

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

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

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

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

SAFE INSTALLATION AND OPERATION RULES:

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

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

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

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

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

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

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

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



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

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



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

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

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

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



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

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



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

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

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



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

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

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

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

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

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



DISCLAIMER:

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

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

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

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

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

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

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

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

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



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Instruction 106-3982

12-2-08



 





Summary of content (12 pages)

PAGE 1
2-2-08 S&S Cycle, Inc Copyright © 2008 by S&S® Cycle, Inc. Phone: 608-627-1497 • Fax: 608-627-1488 Instruction 106-3982 ® . 14025 County Highway G PO Box 215 Viola, Wisconsin 54664 All rights reserved. Printed in the U.S.A. Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.
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ROCKER COVERS The rocker covers on an S&S® X-Wedge® engine are just covers. They provide no support to the rocker arms or valve train and may vary in style from OE manufacturers, but their only function is to be a cover. It should also be noted that the stock S&S covers are interchangeable between the front and rear cylinder and the hardware used to secure them is all the same. Removal 1- Remove five 5/16 x 18- 17/8” Allen head fasteners from the rocker covers.
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ROCKERS ARMS/PUSHRODS The rocker arms used in an S&S® X-Wedge® are stamped steel. They are identical across both cylinders, but we recommend that they be reinstalled in their original position once used. Also, all pushrods are the same length, but we recommend that they be installed in their original position during reassembly. Removal 1- Verify that the front cylinder is on the base circle of the cams. Note: Base circle of the cam is when the tappet is at its lowest point of the camshaft lobe.
PAGE 4
BELT REMOVAL 1- Remove the belt cover. Picture 5 NOTE: A broken belt can be a sign of a stuck valve. 2- Rotate the engine until the timing pin locations on all three cams (marked with white circles below) line up with their corresponding holes in the intermediate cam cover. The FTDC mark will align with the notch in the pinion sprocket. Picture 6 34- Remove the pinion bolt and washer using a TP45 tool. Insert the 3/16” diameter dowel pins into the cam sprocket timing holes.
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- Use the special S&S® socket PN 106-0750 or an 11/16” wrench to take the tension off the cam belt tensioner. Once it is fully relieved, you can use a bolt in the lower intermediate cam cover mounting area to hold the wrench or ratchet in place. Picture 8 6- Picture 9 Remove the two idler sprockets at the top of the intermediate cam cover. Note their orientation—the rear has a bevel facing the intermediate cam cover and the front faces away.
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CAUTION Do not substitute a standard Torx® T45 in place of the Torx Plus TP45. 1- Use magnets to hold the tappets up (if still in place). Picture 11 2- Loosen and remove the intermediate cam cover assembly. Place the intermediate cam cover on a flat surface protected by a clean rag. Picture 12 NOTE: A small drain pan will be required as oil from the cam chest area will be present when cover is removed.
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NOTE: Use caution throughout this process to avoid damaging the camshaft lobes, camshaft plate bearings and the gasket surfaces. CAMS- Standard and Easy Start The S&S® X-Wedge® is a three-cam design engine. It features a common intake and two separate exhaust cams. The intake cam is located in the center and has two lobes. The exhaust cams feature one lobe and compression releases. The front exhaust cam has its lobe located closed to the cam plate (outward).
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CAM SHAFT INSTALLATION- Standard and Easy Start 1- Install key into camshaft (S&S® recommends the center cam first—but you can start with any cam). Install the cams and sprockets in the following order: Intake, front exhaust, rear exhaust. Picture 17 NOTE: The X-Wedge® engine uses three different camshafts, one intake and two exhaust. The intake cam has two lobes and is located in the center. The exhaust cams contain the compression release features.
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- The intermediate cam cover can now be installed onto the crankshaft and crankcase—be sure not to damage the pinion shaft seal. NOTES: Before installing the intermediate cam cover, apply a coating of high-temp wheel bearing grease to the inside of the pinion seal. Position all four cam lobes toward the center of the intermediate plate before installing on to the crankcase to aid in clearing the rollers on the tappets.
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BELT INSTALLATION/REPLACEMENT 1- Installation of a new belt is simple, but requires the use of S&S® Cam Alignment pins for each of the three cams. WARNING Do not bend the belt tighter than the size of the sprockets. Do not twist the belt, crimp or crease it. 2345- Make sure the tension is removed from the belt tensioner. Rotate the cams until they are positioned over their alignment holes and then insert the pins. Next, rotate the engine to FTDC and align the timing mark.
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INSTALLATION/ADJUSTMENT 1- Pushrods in the X-Wedge® are all the same size and length. It is still recommended that they be put back in the place they started, rather than mixing them around. Picture 23 2- Start with one cylinder at T.D.C. on the compression stroke—which puts the tappets at the base circle of the cams. Install the pushrods back in the position they started in. Apply assembly lube to both ends of the pushrod.
PAGE 12
3- Install the rocker channel over the studs. There are front and rear channels with “F” and “R” identifying marks. Picture 26 45- Insert the rocker arm fulcrum into the rocker and then pass the assembly over the stud in the head. Apply assembly lube to the fulcrum surface and rocker arm tip. Be sure to install the washer under the retaining nut and then tighten the nut to 30 ft-lbs. for valve travel testing.