Instruction 51-1032

4-19-06

Copyright © 1997, 2002, 2005 by S&S Cycle, Inc.

All rights reserved.

Printed in the U.S.A.

®

S&S Cycle, Inc.

235 Causeway Blvd.

La Crosse, Wisconsin 54603

Phone: 608-627-1497 • Fax: 608-627-1488

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

Technical Service Email: [email protected]

Website: www.sscycle.com

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Installation Instructions:

S&S

®

Big Twin Crankcase Gearcover Kits

DISCLAIMER:

S&S parts are designed for high performance, off road, racing applications and are intended for the very experienced rider only. The installation of S&S parts may void or adversely effect your factory warranty. In addition such installation and use may violate certain federal, state, and local laws, rules and ordinances as well as other laws when used on motor vehicles used on public highways, especially in states where pollution laws may apply. Always check federal, state, and local laws before modifying your motorcycle. It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use, and the user shall assume all legal, personal injury risk and liability and all other obligations, duties, and risks associated therewith.

The words Harley ® , Harley-Davidson ® , H-D ® , Sportster ® , Evolution ® , and all H-D part numbers and model designations are used in reference only.

S&S Cycle is not associated with Harley-Davidson, Inc.

SAFE INSTALLATION AND OPERATION RULES:

Before installing your new S&S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety.

● Gasoline is extremely flammable and explosive under certain conditions and toxic when inhaled. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks.

● If motorcycle has been running, wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps.

● Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components.

● Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps.

Contact S&S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S&S part on it.

● Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation.

● Use good judgement when performing installation and operating motorcycle. Good judgement begins with a clear head. Don't let alcohol, drugs or fatigue impair your judgement. Start installation when you are fresh.

● Be sure all federal, state and local laws are obeyed with the installation.

● For optimum performance and safety and to minimize potential damage to carb or other components, use all mounting hardware that is provided and follow all installation instructions.

● Motorcycle exhaust fumes are toxic and poisonous and must not be inhaled. Run motorcycle in a well ventilated area where fumes can dissipate.

IMPORTANT NOTICE:

Statements in this instruction sheet preceded by the following words are of special significance.

WARNING

Means there is the possibility of injury to yourself or others.

CAUTION

Means there is the possibility of damage to the part or motorcycle.

NOTE

Other information of particular importance has been placed in italic type.

S&S recommends you take special notice of these items.

WARRANTY:

All S&S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve (12) months from the date of purchase. Merchandise that fails to conform to these conditions will be repaired or replaced at S&S’s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter.

In the event warranty service is required, the original purchaser must call or write S&S immediately with the problem. Some problems can be rectified by a telephone call and need no further course of action.

A part that is suspect of being defective must not be replaced by a

Dealer without prior authorization from S&S. If it is deemed necessary for S&S to make an evaluation to determine whether the part was defective, a return authorization number must be obtained from S&S.

The parts must be packaged properly so as to not cause further damage and be returned prepaid to S&S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem, how the part was used and the circumstances at the time of failure. If after an evaluation has been made by S&S and the part was found to be defective, repair, replacement or refund will be granted.

ADDITIONAL WARRANTY PROVISIONS:

(1) S&S shall have no obligation in the event an S&S part is modified by any other person or organization.

(2) S&S shall have no obligation if an S&S part becomes defective in whole or in part as a result of improper installation, improper maintenance, improper use, abnormal operation, or any other misuse or mistreatment of the S&S part.

(3) S&S shall not be liable for any consequential or incidental damages resulting from the failure of an S&S part, the breach of any warranties, the failure to deliver, delay in delivery, delivery in non-conforming condition, or for any other breach of contract or duty between S&S and a customer.

(4) S&S parts are designed exclusively for use in Harley-Davidson ® and other American v-twin motorcycles. S&S shall have no warranty or liability obligation if an S&S part is used in any other application.

Year

Group

1970-1972

1973-1992

1993-Up

Flange Style

Points/Electronic

31-0210

31-0211

31-0212

Billet

Points/Electronic

31-0242

31-0209

31-0243

Flangeless Tall

Points/Electronic

31-0202

31-0203

31-0204

Flangeless Tall

Electronic Only

31-0206

31-0207

31-0208

2

S&S ® crankcase gearcover kits are available in four styles, and each style is available for three year groups. (See chart above.)

Because of differences in oiling and scavenging systems, kits for different year groups are not interchangeable. Correct kit must be used to insure proper oil circulation. All S&S gearcase covers may, however, be used with either end-oiling or side-oiling pinion shafts without modification.

KIT CONTENTS

● Gearcase cover and gasket

● Chrome outer cover and gasket

● Inner and outer timing covers and gasket

● Mounting hardware

NOTES

● Camshaft endplay must be checked whenever a different gearcase cover is installed. A new rear lifter guide gasket and, in some instances, camshaft thrust washer may be required to complete this installation.

● The procedure for installing an S&S gear cover is essentially the same as stock. If in doubt, consult a professional mechanic or refer to the appropriate Harley-Davidson ®

Service Manual.

● It is recommended that S&S bushings and gaskets be used for rebuilds, although in most instances stock components may be substituted if necessary.

● S&S gearcovers are supplied ready to use, with both bushings machined to stock specifications. No further machining is required.

INSTALLATION

1. Thoroughly clean engine and surrounding area. Some motorcycles require that front exhaust pipe and/or right footboard be removed prior to installation. Harley-

Davidson ® Evolution ® engines generally require removal of rocker covers and rocker arms.

2. Remove all four pushrod cover clips and rotate engine until rear pushrods are at their lowest point. Remove rear pushrods, oil pressure sending unit, rear lifter guide, and lifters.

3. Rotate engine to bring front pushrods to their lowest point.

Loosen adjusters to eliminate pressure on camshaft. If nonadjustable stock pushrods are used, they should be removed as directed in Harley-Davidson ® Service Manual.

4.

Remove ignition cover and ignition components located inside gearcover. Take care that camshaft and/or breather gear and thrust washer do not come out with gearcover. If this occurs, they must be reinstalled according to standard

Harley-Davidson ® procedure. Insure that marks on breather valve, camshaft, and pinion gear align correctly.

5.

Clean gearcover gasket surface on crankcase. All traces of gasket material and oil must be removed.

6.

Clean new cover with warm, soapy water and rinse in clean water. Paying particular attention to oil passages, dry thoroughly with compressed air.

7.

Check camshaft endplay as follows:

A. Temporarily install cam, gear cover, and new gasket.

Torque cover mounting bolts to 10-12 ft. lbs.

NOTE: Gearcover should slide over dowel pins, pinion shaft, and cam with little or no resistance. If gear cover does not slide on easily, cause of resistance must be determined and corrected.

Under no circumstance should cover be forced into place.

CAUTION

Forcing gear cover on may subject pinion shaft to unwarranted flexing and side loading which can cause shaft to fatigue and break during operation.

B. A dial indicator or feeler gauge should be used to establish endplay according to standard procedure.

Recommended end play is .003” to .015”. A thinner or thicker camshaft thrustwasher may be installed to correct endplay.

NOTE: S&S has thrustwashers available in .005” increments from

.050” to .070”. See S&S catalog for parts numbers.

8. Coat both bushings with fresh motor oil and permanently install gear cover. A small amount of gasket sealer may be used if desired. Torque cover bolts to 10-12 ft. lbs.

9.

Install front pushrods and pushrod tube assemblies. Adjust pushrods according to manufacturer’s instructions. Reinstall pushrod cover clips.

10. Clean rear lifter guide and crankcase gasket surfaces. Install rear lifter guide, gasket, and lifters.

NOTE: Coating lifter guide bores with assembly lube or other thick oil will help hold lifters in place as guide assembly is installed.

11. Rotate engine to place rear lifters at their lowest point.

Install and adjust rear pushrods and pushrod tube assemblies according to manufacturer’s instructions.

12. Coat threads with thread sealer and install oil pressure sending unit.

13. Using provided ignition cover standoff screws 31-0224, install and time ignition system according to manufacturer’s instructions. Route ignition sensor wire through channel in lower part of cover and secure with retainer 31-2029.

NOTE: Sensor wire must not contact exhaust or hot surface.

14. Attach chrome outer cover and gasket to gearcase cover body.

A. Flange and billet types - Attach outer cover and gasket using 8 each 10-24 screws and washers (billet cover only). Ignition wire must rest in channel of gearcover so as not to chafe against edge of outer cover.

B.

Flangeless type

1. Install 31-0236 cover clips using 50-0004 panhead screws, line drawing parts #8 & #9.

2. Install 31-0215 ignition cover, line drawing part

#3. Rotate cover to engage tabs on cover with cover clips.

15. Install timing cover, gasket, and backing plate on outer cover with 8-32 x 1 ⁄

2

” screws.

16. Reinstall any parts removed prior to installation: exhaust, footboards, etc.

17. Start engine and check for leaks.

1.

Gearcover assembly . . . . . . . . . . . N/A

2.

Gasket, gearcover

1936-'69 bt (H-D ® #25225-36C)

(10 Pack)

. . . . . . . . . . . . . . . . . . 31-2060

1970-'99 bt

(H-D ® 25225-70B, 93)

(10 Pack) . . . . . . . . . . . . . . . . . . 31-2059

3.

Outer cover, gearcover - 1970-'99 bt

Flanged type - steel, chrome 31-0217

Flanged type - steel, black . . 31-0262

Flanged type - billet . . . . . . . 31-0241

Flangeless type - chrome . . . 31-0238

Flangeless type - black . . . . . 31-0263

4.

Gasket, outer cover - 1970-'99 bt

Flanged type

(5 Pack)

. . . . . . . 31-0256

Flangeless type (5 Pack) . . . . . 31-0261

5.

Ignition cover, inner - 1970-'99 bt

Flanged type . . . . . . . . . . . . . 31-0215

Flangeless type . . . . . . . . . . . 31-0235

6.

Gasket, ignition cover - 1970-'99 bt

(H-D ® 32591-80) (10 Pack) . . . . . . . 31-0260

7.

Ignition cover, outer - 1970-'99 bt

(H-D ® #32524-83) . . . . . . . . . . . . . 31-0227

8.

Screw, SH - 8-32 x 1 ⁄

2

"

(Replaces H-D ® rivets.)

Stainless Steel

(10 Pack)

. . . . . . 50-0236

Chrome (10 Pack) . . . . . . . . . . . 50-0332

9.

Screw, SH

10-24 x 1 ⁄

4

" for steel cover

(10 Pack) . . . . . . . . . . . . . . . . . . 50-0128

10-24 x 3 ⁄

8

" - chrome for billet cover

(10 Pack) . . . . . . . . . . . . . . . . . . 50-0136

10. Washer, flat .192" x 5 ⁄

16

" x .035"

(Use with 50-0023.) (10 Pack) . 50-7011

11. Screw, SH - Use in all positions

1 ⁄

4

"-20 x 7 ⁄

8

"

(H-D ® #884) (10 Pack) . . . . . . . . . . 50-0197

1970-'99 BT - 1 ⁄

4

"-20 x 1 1 ⁄

4

" (H-D ® #3482A)

Zinc (10 Pack) . . . . . . . . . . . . . . 50-0153

Chrome (10 Pack) . . . . . . . . . . . 50-0330

4 3

6 5

17

14

7

12. Washer, flat

1 ⁄

4

" x .474" x .050" (10 Pack) . . 50-7076

1 ⁄

4

" Flat washer, chrome, billet covers

(12 Pack) . . . . . . . . . . . . . . . . . . 50-7013

13. Wire harness clip

(H-D ® #38711-93) . . . . . . . . . . . . . 31-2029

14. Cam bushing, gearcover

1936-'69 bt

(H-D ® #25581-36)

. . 31-4025

1970-'99 bt (H-D ® #25581-70) . . 31-4019

15. Pinion shaft bushing, gearcover

1936-'53 bt (H-D ® #25582-36) . . 31-4029

1954-'72 bt . . . . . . . . . . . . . . . 31-4020

1973-'99 bt (H-D ® #25582-93) . . 31-4031

16. Gearcover oil seal 1970-'99 bt

(H-D ® #88162-51) . . . . . . . . . . . . . 31-4022

17. Screw, timing mechanism

(H-D ® #32606-82) (10 Pack) . . . . . . 31-0264

18. Screw, standard panhead 8-32 x 3 ⁄

8

"

(10 Pack) . . . . . . . . . . . . . . . . . . 50-0058

19. Clip, outer cover (5 Pack) . . . . 31-7007

15

16

2

1

13

12

11

10 9

All reference to Harley-Davidson ® part numbers is for identification purposes only. We in no way are implying that any of S&S ® Cycle’s products are original equipment parts or that they are equivalent to the corresponding Harley-Davidson ® part number shown.

1

8

19 18

4

3

5 6

3

Because every industry has a leader