Manual

ManualsBrandsS&S Cycle ManualsFor motorcyclesSuper Stock and Special Application Crankcases for 1936-99 Big Twin Engines

S&S

Cycle, Inc.

14025 Cty Hwy 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: S&S® Super Stock® and Special Application

Crankcases for 1936-'99 Big Twin Engines

IMPORTANT NOTICE:

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



WARNING

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

CAUTION

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

NOTE

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

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

WARRANTY:

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

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

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

ADDITIONAL WARRANTY PROVISIONS:

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



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

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

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

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

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

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

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

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

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

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

SAFE INSTALLATION AND OPERATION RULES:

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

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

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

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

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

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

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

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



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

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



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

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

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

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



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

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



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

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

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



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

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

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

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

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

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



DISCLAIMER:

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

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

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

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

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

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

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

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

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

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Instruction 106-5058

3-9-09



 





Summary of content (20 pages)

PAGE 1
3-9-09 S&S Cycle, Inc Copyright © 2009 by S&S® Cycle, Inc. Phone: 608-627-1497 • Fax: 608-627-1488 Instruction 106-5058 ® . All rights reserved. Printed in the U.S.A. 14025 Cty Hwy G PO Box 215 Viola, Wisconsin 54664 Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.
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Introduction Installation of S&S® Super Stock® crankcases for big twin engines is easy and can be performed by any v-twin repair shop equipped to do complete engine overhauls. No special tools other than those used in normal engine building operations are required. S&S Special Application big twin crankcases can be ordered for heavy duty street or race applications.
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The customer must also verify that the serial numbers on the crankcase and attached information tag correspond with those on the certificate of origin and packing carton. Note that all 4” bore engines require Special Application crankcases, which may be identified by the letters “SA” cast into the left crankcase below the serial numbers and into the right crankcase immediately ahead of the front lifter guide opening.
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NOTE: This step is not necessary in S&S® crankcases manufactured with large wiring recess. CAUTION Do not increase depth of recess. Remove minimum amount of material that will allow alternator stator to mount on crankcase without crimping wiring harness. Removing excess material may weaken crankcase.
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CAUTION Restricted oil flow may result in extensive engine damage not covered under warranty. A- Gear cavity vent passage Location: Hole A. See Pictures 3, 4, 5 & 6. Hardware: 50-8115 hose fitting or 31-2018 oil line fitting. See Line Drawings on last page, items 35 and 39. Function: Vents gear cavity. Equalizes pressure in gear case and oil tank. Is also connected to primary chain case in 1965 - 1984 models with dry clutch and engine-supplied primary chain oiling.
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B- Crankcase oil screen assembly Location: Hole B. See Pictures 4, 5 & 6. Hardware: 31-2010 crankcase oil screen, 31-2011 spring, 50-8008 o-ring, and 31-6021 cover screw. See Line Drawings, items 15, 16, 17, 18. Function: Prevents oil-borne contaminants from reaching tappets and cylinder heads in 1948 and later engines. Installation: All engines 1948 and later. 1- Slip spring over screen and insert in hole B with open end facing down See Picture 8.
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D- Primary housing oil scavenge passage Location: Hole D. See Pictures 5 & 6. 1965 - early 1984 engines with dry clutch and engine supplied primary chain oiling. Hardware: 31-2019 primary oil return fitting and 50-8331 socket head pipe plug. See Line Drawing, items 32 & 34. Function: Hole D leads to vacuum side of crankcase breather gear. Hole D is normally used to scavenge oil from primary chain case in 1965 - early 1984 models with dry clutch and engine-supplied primary oiling.
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Installation: 1980 and later models with crankcase breather vented to carburetor air cleaner. 1- Install 50-8113 45° 1⁄4“ pipe x 3⁄8“ hose fitting (See Line Drawing, item 33) in hole E. 2- Connect 3⁄8“ hose to 50-8113 fitting and route in stock-like manner to breather fitting on rear of air cleaner backplate. Installation: 1993 and later style engines with crankcase pressure vented through cylinder heads. Install 50-8330 1⁄4 -18 pipe plug in hole E.
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Installation: 1- Thread plug in hole until it bottoms out against case surface. 2- Tighten plug after ignition timing has been static timed and before starting engine. H- Assorted screws, washers, etc. See Line Drawing, items 44, 45, 48.
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5- Cylinder studs Unless otherwise requested, S&S® installs appropriate cylinder studs in all S&S crankcases prior to shipment. A- Crankcases made for knucklehead, panhead, or shovelhead cylinders - Cylinder studs are installed to 1.330” for use with S&S Sidewinder® big bore cylinders as well as stock cylinders. If cylinder base plate is used to increase cylinder height, stud must protrude through gaskets, plate and flange of cylinder far enough to allow full thread engagement of base nut.
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NOTE: Older S&S® Sidewinder® big bore cylinders may not fit over late style cylinder studs correctly, preventing cylinder from seating on crankcase. See Figure 3. Interference may seem minor, but forcing cylinders down over collar may cause distortion of cylinder bore and accelerated wear. Stud holes in S&S cylinders produced after 4-95 have been enlarged to provide adequate clearance. Stud collar may prevent cylinder from contacting crankcase.
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6- Circuit Breaker Drive Gear and Idler Gear Shafts S&S® ships generator style crankcase kits with circuit breaker drive gear and idler gear shafts pressed and bolted in place. Installation is performed at S&S using a special fixture to insure proper alignment with gearcover. Care must be taken to avoid hitting these shafts during handling and assembly. Prior to installation of flywheel assembly in crankcases, it is recommended that gear cover to be used be slipped over shafts and dowel pins to check fit.
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Selecting color where columns intersect provides proper fit for normal service. If looser fit is desired, select bearing color directly to right of color indicated from selection process. If color indicated from selection process is located in right color column, go to next row directly below and select color in left color column. 2- Fitment method B - Use Chart 2 below. a- Refer to information tag on crankcases to determine final honed size of inside diameter of pinion shaft main bearing race.
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F- Breather gear timing - Breather gear window in crankcase is machined to maximum specifications and should require no further machining. In addition, breather passage between flywheel cavity and breather gear bore is cast in a special “ported” shape designed to optimize flow of crankcase vapors and oil mist. G- Oil pump 1- Oil pump compatibility a- 1936 to 1947 (knucklehead) engines - Original stock cast iron, early stock alloy 1968 to 1969, or S&S 31-6250 oil pump may be used.
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I- Gearcover NOTES S&S® crankcases accept S&S and stock gearcovers. Mounting holes are 1⁄4-20 thread. Tighten to 8-10 ft-lbs. in all applications. Mounting screws are not furnished, but are available separately. Some aftermarket gearcovers have incorrect machining that may cause poor alignment of oil passages, pinion shaft, cam and dowel locations.
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3- Installation a- Thoroughly clean all parts. b- Prior to flywheel installation, slip gearcover over alignment dowel pins in crankcase. Cover must not be forced. If resistance is encountered, determine cause and correct. Remove cover. c- After flywheels and cases have been assembled but before pinion gear and cam are installed, reinstall gear cover to check fit over pinion shaft. Remove cover. d- Install pinion gear and camshaft, and repeat step 3.
PAGE 17
9- Frame S&S® crankcase installation in frame/chassis is essentially the same as stock, although additional clearancing and shimming may occasionally be required. Main areas of concern are between cases and frame motor mounts and, in 1965 to 1969 engines, between cases and primary chain cover.
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S&S® Super Stock® Big Twin Crankcases 1- Crankcase assembly, half............................................ N/A 2- Race, right main bearing, All S&S BT Standard (H-D#24599-58B). ...................................31-4004 +.002” O.S. (H-D#24600-58B)................................31-4006 +.005” O.S. (H-D#24601-58B)................................31-4007 +.025” O.S.........................................................31-4028 Clearanced for .
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S&S® Super Stock® Alternator Crankcase Assembly 19 20 30 54 52 55 56 13 28 10 Bolt Position Diagram 57 31 8 53 2 25 17 18 17 27 9 5 12 36 8 24 22 6 1 14 16 15 7 21 3 4 50 20 1 2 26 5 6 11 32 3 20 34 34 48 7 35 4 33 24 23 49 48 19 28 20 30 31 27 10 36 18 17 8 20 9 22 51 13 14 16 15 2221 24 20 45 46 44 44 1 2 29 1 40 41 43 26 42 35 34 39 47 32 34 47 33 3 20 11 24 24 23 5 6 7 4 23 S&S® Super Stock® Generator Crankcase Assembly 19
PAGE 20
S&S® Special Application Big Twin Crankcases For #'s 1-19, use replacement parts on page 18. 20- Crankcase Hardware Special Application Crankcases (For Engines With 4” Cylinder Bore or Greater) 4” and 41/8” Bore Cases Manufactured Before 6-1-08 33- Plug, SH pipe, 1⁄4”-18, 1965-’69 S&S BT (H-D#45830-48)........................................................50-8330 34- Fitting, hose - 1⁄8”-27 pipe male (H-D#63533-41)........................................................50-8115 35- Dowel pin, .