- S&S Cycle

Instruction 51-1065
4-27-09
S&S Cycle, Inc
Copyright © 2009
14025 Cty Hwy G
Viola, Wisconsin 54664
by S&S Cycle, Inc.
®
.
Phone: 608-627-1497 • Fax: 608-627-1488
Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: [email protected]
Website: www.sscycle.com
All rights reserved.
Printed in the U.S.A.
Installation Instructions for
S&S PN 90-4925 Mechanical Compression Release
DISCLAIMER:
IMPORTANT NOTICE:
S&S parts are designed for high performance, closed course, 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.
Statements in this instruction sheet preceded by the following words are of
special significance.
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 breathed. 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 judgment when performing installation and operating
motorcycle. Good judgment begins with a clear head. Don’t let
alcohol, drugs or fatigue impair your judgment. 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
breathed. Run motorcycle in a well ventilated area where fumes can
dissipate.
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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.
Mechanical Compression Release Kit
NOTES
S&S® compression releases are intended to be installed only in cylinder heads machined specifically for S&S compression releases. Stock or other
aftermarket cylinder heads may not have enough material in required areas to allow machining for S&S compression releases
S&S mechanical compression releases can be used with OEM or aftermarket rocker boxes. Since the height of the installed compression release assembly
will be slightly below the lower rocker cover mounting surface, the mechanical compression releases do not require the use of rocker boxes with a center
chimney for clearance.
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A. Installing Compression Releases
1. Remove fuel tank, rocker covers and bases, pushrods, and rocker arms. Consult appropriate manuals as needed.
2. Remove the supplied 14mm hex plug from the top of the cylinder head. Inspect the machined hole to make sure that it is clean and free of
debris. See Picture 1.
Picture 1
3. Apply a small amount of anti-seize type thread lubricant to the threads of the compression release valve assembly. Compression release
assemblies are identical and can be installed in either cylinder head.
4. Make sure that the supplied compression washer is held in its groove in the valve body. The washer must remain in this position when the
compression release is held in a vertical position. If it does not stay in position, a very small amount of white lithium grease between the
washer and the valve body will hold the washer in place during installation. See Picture 2.
5. Thread the compression release valve assembly into the pre-machined mounting hole. Hand tighten as far as possible. Make sure the
compression washer remains in position until the compression release contacts the head. See Picture 3.
6. Slide the S&S special socket PN 53-0045 over the valve assembly. See Picture 4. Make sure the compression washer is seated properly
before final tightening is done. Torque the compression release to 35-40 ft-lbs.
Picture 2
Picture 3
2
Picture 4
7. Apply a small amount of Loctite® 272 (red) to the threads of the detent assembly body.
8. Push the detent assembly over the plunger and thread into valve assembly until hand tight. See Picture 5. Make sure that no Loctite is
allowed to contact the plunger. Torque the detent assembly into the valve assembly to 28-30 ft-lb. Using a pliers, carefully pull the valve
plungers up to close the valves. The valves must be closed to properly adjust the cables. Plunger protrusion above detent assembly will be
approximately .200” if the valve is closed, and .100” when valve is open. See Picture 6.
Picture 6
Picture 5
B. Install Cam and Cable Assemblies
1. Remove the 10-24 set screws from the cam assemblies and place a small drop of Loctite® 242 (blue) on the threads.
2. Reinstall set screws in the cam assemblies.
3. Place cam assemblies over the plungers of the detent assemblies. Index the cam assemblies and cables so the cables lay toward the intake
manifold, but are not contacting the cylinder heads. See Picture 7.
4. When cam assemblies are positioned correctly, tighten set screws to prevent them from moving. See Picture 8.
5. Install activator assembly in stock choke bracket. See Picture 9. If bracket has a mounting hole instead of a mounting notch, it will be
necessary to remove the pull knob, lock washer, and jam nuts in order to install activator assembly.
NOTE – Because of the variety of chassis and bracket designs, the mounting of the activator assembly may be somewhat different from that shown in
Picture 9. It may be necessary to fabricate a different bracket or to modify the existing bracket.
Picture 7
Picture 8
Picture 9
6. With the activator assembly in position in the mounting bracket, install the 3⁄8” lockwasher and jam nut if removed, and tighten jam nut
firmly. Install knob and 1⁄4” jam nut if they have been removed. If billet knob is used, rotate to desired position and turn jam nut against knob
to lock it in place.
NOTES
Do not apply any type of thread locker to the 3⁄8” or 1⁄4” jam nuts or to the knob. Doing this will make disassembly extremely difficult and may cause
damage if parts must be disassembled.
S&S offers an optional polished billet aluminum knob which is installed in the same manner as the black plastic knob. See Picture 10. (Polished billet
pull knob is available for a custom look.
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Picture 10
3
C. Adjust Cables
NOTE - Adjustment of the actuating cables is critical for proper operation of S&S® manual compression releases. Failure to adjust cables correctly may
result in damage to the compression release and the engine.
1. Make sure that both compression release valves are closed. Lightly push the cam against the plunger. If the compression release valve is
open, the cam will be in a vertical position when it contacts the plunger. If the cam is not in a vertical position when the cam is in contact
with the plunger, the valve is closed. See Pictures 11 and 12. If one or both valves is open, it will be necessary to remove cam assemblies
and close valves by pulling the plungers up with pliers.
Picture 12
Picture 11
2. Adjust the free play in the cables.
a. Make sure that the compression release valves are both in the closed position, and the cable is in the normal position.
b. Turn the adjusters out of the activator housing just enough to remove free play in the cable. Do not make the cable tight. There
should be no pressure on the plunger.
c. Screw the cable adjusters one half turn into the activator housing to give the cables a small amount of free play. A small amount
of movement should be felt if the activator cam is pushed by hand. This clearance is required so that there is no pressure on the
plungers except when the activator knob is pulled. It is very important to insure that the valves are allowed to close freely at all times.
3. After cables have been adjusted, tighten cable adjuster jam nuts against activator housing to lock adjusters in place.
4. Re-install rocker covers, pushrods, and rocker arms according to standard assembly procedures. Consult appropriate manuals as needed.
If adjustable pushrods are used, they should be readjusted. Reinstall gas tank and any other components removed during installation of
compression releases.
D. Operation
When the activator knob is pulled, the compression release valves are opened and are held open by the detent assembly. The knob is released
and returns to its normal position. When the engine turns over, the compression release valves allow some of the cylinder pressure to bleed off
into the exhaust port. The reduced cylinder pressure makes it easier for the starter to turn the engine. When the engine starts, the increased
cylinder pressure from combustion automatically closes the compression release valves. All cylinder pressure is then contained in the
combustion chamber and the engine runs normally with full compression.
Replacement Parts For Manual Compression Release
1. Compression release assembly.......................................90-4920
2. Valve assembly, compression release, manual...............90-4921
3. Washer, compression, 14mm ........................................50-7094
4. Cable assembly, compression release manual................90-4919
5. Activator assembly, compression release, manual.......90-4932Z
6. Knob, 1" x 1⁄4 -20, black plastic................................... 50-8700-S
1" x 1⁄4 -20, polished billet aluminum............................50-8701
7. S&S two piece comp. release socket kit (Not Shown).....53-0045
8. S&S compression release hole plug (Not Shown)...........90-4916
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