Instruction 51-1023

4-24-06

Copyright © 2005, 2006 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

Because every industry has a leader

Installation Instructions: S&S

®

Valve Spring Kits for

1984-2004 Big Twin & 1986-2003 Four- C a m

#90-2077 and #90-2078

D I S C L A I M E R :

S&S parts are designed for high perf o rmance, 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 w a rr a n t y. In addition such installation and use may violate cert a i n 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 there w i t h .

The words Harley ® , Harley-Davidson ® , H-D ® , Sport s t e r ® , Evolution ® , and all H-D part numbers and model designations are used in re f e rence only.

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

SAFE INSTA L L ATION AND OPERATION RULES:

B e f o re installing your new S&S part it is your responsibility to read and follow the installation and maintenance procedures in these i n s t ructions and follow the basic rules below for your personal safety.

● Gasoline is extremely flammable and explosive under cert a i n conditions and toxic when inhaled. Do not smoke. Perf o rm 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 perf o rming any installation steps.

● B e f o re perf o rming 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 pro c e d u res are completely understood before perf o rming 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 m o t o rcycle with a S&S part on it.

● Consult an appropriate service manual for your motorcycle for corre c t disassembly and reassembly pro c e d u res for any parts that need to be removed to facilitate installation.

● Use good judgment when perf o rming installation and operating m o t o rcycle. Good judgement begins with a clear head. Don't let alcohol, drugs or fatigue impair your judgement. Start installation when you are fre s h .

● Be sure all federal, state and local laws are obeyed with the i n s t a l l a t i o n .

● For optimum perf o rmance and safety and to minimize potential damage to carb or other components, use all mounting hard w a re that is provided and follow all installation instru c t i o n s .

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

I M P O RTANT NOTICE:

Statements in this instruction sheet preceded by the following word s a re of special significance.

WA R N I N G

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

C A U T I O N

Means there is the possibility of damage to the part or motorc y c l e .

N O T E

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

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

WA R R A N T Y:

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 re p a i red or replaced at S&S’s option if the parts are re t u rned to us by the purchaser within the 12 month warranty period or within 10 days there a f t e r.

In the event warranty service is re q u i red, 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 re t u rn authorization number must be obtained from S&S.

The parts must be packaged properly so as to not cause further damage and be re t u rned prepaid to S&S with a copy of the original invoice of p u rchase 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, re p a i r, 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 org a n i z a t i o n .

(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, impro p e r 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 warr a n t i e s , the failure to deliver, delay in delivery, delivery in non-conform i n g 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 ® a n d 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.

2

S & S ® valve spring and collar kits #90-2077 and 90-2078 accommodate valve lifts up to .640” using standard length, 5 ⁄

1 6

” diameter valves, and are compatible with stock style valve guides and valve guide seals. These spring kits are included with S&S Super Stock

E v o l u t i o n ®

® cylinder heads for Harley-Davidson ® and Twin Cam 88 ® engines.

N O T E S

● Spring kit components are not interchangeable with those f rom other S&S valve spring kits.

● Titanium top collars supplied with kit #90-2078 do not re q u i re steel wear plate used with previous S&S titanium collars.

3. Using following pro c e d u re, determine installed spring height and clearance between top collar and valve guide.

A. Lubricate valve stem and install valve in guide.

B. Install bottom collar, valve seal, top collar, and valve keepers. Pull top collar tightly against keepers to seat keepers in collar.

C. While holding valve firmly against seat in closed position, measure installed spring height (distance between lower valve spring seating surface and outside step of top collar). See Figure A, Dimension A. Record m e a s u re m e n t .

D. M e a s u re distance between top collar keepers and top of valve guide or seal (if applicable). See Figure A,

Dimension B. Distance must be at least .060” gre a t e r than valve lift of cam to be used. If dimension B is not

.060” greater than valve lift, valve guide must be s h o rtened to obtain re q u i red clearance.

CAUTION

Mixing of valves, springs or collars between early and late

S&S high-lift kit can cause extensive engine damage not covered under warranty.

Installation of 90-2077 or 90-2078 spring kits does not usually re q u i re modification for S&S or most stock heads. Exceptions are

B u e l l ® T h u n d e r s t o rm heads and certain Sport s t e r ® models and big twin heads with diff e rent machining in valve spring pockets.

In such cases, removing a small amount of material

( a p p roximately .030”) from O.D. of S&S bottom collar should allow collar to rest flat in spring pocket for correct installation.

It may be necessary to machine the valve spring pocket deeper to achieve the correct installed height when installing springs in

Twin Cam 88 ® cylinder heads.

90-2077 and 90-2078 spring pressures are as follows at 1.800” installed height: Closed valve - 171 lbf; .560” lift - 389 lbf; .630

lift - 416 lbf.

Spring Installation Procedure

1. Remove heads from engine and disassemble. If cylinder heads/valves are to be reconditioned, proceed at this time a c c o rding to standard pro c e d u re. Refer to Harley-Davidson ® s e rvice manual as necessary.

2. Place lower spring collar in valve spring pocket in head. Place outer spring on collar. Collar must sit flat on cylinder head and spring coils must not contact sides of spring pocket in head. If necessary, machine lower collar and/or spring pocket to obtain minimum clearance of .030”. Do not modify spring in any way.

Dimension A:

Installed spring height must be adjusted to 1.800" ± .020"

Dimension B:

Must be .060" greater than valve lift for camshaft to be used.

Figure A

E .

Repeat Steps A-D for remaining valves and re c o rd all m e a s u rements. Be sure to keep track of all parts during assembly to assure they are installed in same location and with same valves clearances were measured with

4. Adjust installed spring height for all valves to 1.800” ± .020”.

If spring height is too high, place shims under lower collar to achieve correct spring height. Shims are available from S&S ® and local sources such as automotive parts houses. If spring height is too low, grind valve or valve seat, or machine bottom of valve spring pocket to achieve correct spring height. Special valve spring pocket cutting tools are available from various tool manufacture r s .

N O T E S

● Installed spring height is same height as outer valve spring when valve and spring are installed and in closed position.

C o rrect installed spring height for S&S #90-2077 and #90-2078 is 1.800” ± .020”.

● For race and similar applications, experienced engine builders may elect to shim valve spring assembly to installed height less than 1.800” if cam with less than .640” valve lift is used. In such cases, installed height should be not less than

1.170” + valve lift ± .020". For example, with .500 lift cam, installed height could be shimmed to 1.170” + .500”, or

1.670” ± .020”. In such cases, spring pre s s u re and valve train wear will increase significantly. Engine builder assumes all responsibility for installing springs at height other than

1.800” ± .020”.

CAUTION

● Installing springs at height less than re c o m m e n d e d dimension will cause rapid spring fatigue resulting in possible engine damage. Engine should be frequently disassembled for spring tension measurement.

● Installing springs at height above re c o m m e n d e d dimension will decrease spring tension resulting in possible valve float and engine damage.

● Failure to establish required clearances may cause valve seal failure and other, more extensive engine damage not covered under warranty.

WARNING

Valve spring assembly is under considerable tension when c o m p ressed and is potentially dangerous. Wear eye protection and take due caution when checking for coil bind and during installation. After assembly, carefully strike tip of valve stem with plastic hammer to insure that keepers are seated. Direct spring assembly away from face and body during this procedure.

5. O b s e rving previous warning, check for coil bind as follows:

A. Place outer spring in vise or spring checking device and c a refully compress to 1.800” - valve lift - .060”. Using

.630 lift cam, for example, compress spring to 1.800” -

.640” - .060”, or 1.100”.

B. M e a s u re clearance between adjacent coils. Minimum is

.060”. If clearance between spring coils is insufficient, a d i ff e rent spring pack or cam with less lift must be used.

C. Repeat pro c e d u re for middle and inner spring for each spring assembly.

6. Install valves and valve springs in heads. Install all S&S outer springs with O.D. chamfer toward top collar. Be sure valve guide seals are in place. Install middle and inner springs followed by top collar and keepers.

NOTE - Installed height should be the same for each spring a s s e m b l y.

7. C o n f i rm that rocker arm does not contact top collar. This is most likely to occur when valve is fully closed. Clearance should be at least .040”.

8. C o n f i rm rocker arm to rocker cover clearance.

A. Install pushrods and rocker assemblies. Adjust pushro d s per manufacture r’s instru c t i o n s .

B. Place thin deposit of clay or putty on inside of top ro c k e r cover directly above pushrod and valve spring are a s .

C. Install top cover and rotate flywheels two complete revolutions (720°).

NOTE - Do not force engine if resistance is encountered. Instead remove top cover and determine cause.

D. Remove top cover and examine clay for indentation caused by rocker arm. Thickness of clay beneath indentation should be at least .060”. Carefully re m o v e metal from cover or rocker arm to obtain corre c t c l e a r a n c e .

NOTE - Remove minimum amount of metal needed for corre c t clearance. Care must be taken not to break through rocker covers or alter rocker arm heat treatment by overheating while grinding. Oil is supplied to top end through pushrods and ro c k e r a rms, so it is also important not to disturb oil passages.

3

Because every industry has a leader