Ultima SHOVELHEAD ENGINES Service manual

Ultima SHOVELHEAD ENGINES Service manual
07-25-12
S&S Cycle, Inc
Copyright © 2009, 2010, 2012
by S&S® Cycle, Inc.
Phone: 608-627-1497 • Fax: 608-627-1488
Instruction 51-1012
®
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14025 Cty Hwy G PO Box 215
Viola, Wisconsin 54664
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 and Jetting Instructions for
S&S Super E and G Series "Shorty" Carburetors
DISCLAIMER:
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 affect 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 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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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.
INTRODUCTION
S&S® Super E and G Shorty carburetors are designed for and Harley-Davidson® big twin and Sportster® models as well as other American v-twin
engines. They are butterfly type carburetors with fully adjustable idle mixture and changeable air bleed and mid range and high speed jets. Both
carburetors also feature an adjustable accelerator pump and variable enrichment/fast idle device for improved throttle response, engine starting
and warm ups.
The Super E has a 17⁄8" (47.6mm) bore and 19⁄16" (39.6mm) venturi. It is identified by an "E" cast into the throttle linkage side of the body below the
letters "S&S SUPER". The Super E is recommended for use on any displacement big twin or Sportster.
NOTE: Because S&S carburetors are significantly larger than OEM units, unmodified, small displacement engines such as 883 and ironhead Sportster
models may experience sluggish low speed response when equipped with S&S carburetors. This can often be minimized with careful tuning.
The Super G has a 21⁄16" (52.3mm) bore and 3⁄4" (44.5mm) venturi. It is identified by a "G" cast into the carb body. See Picture 1. The Super G is
recommended for use on modified engines of 100 cubic inches or more. While both carburetors can be made to work on most engines, the Super G
is not recommended for small, low compression engines. If there is doubt as to which carburetor to use, S&S suggests the Super E.
Picture 1
IMPORTANT NOTE - Recommended for Racing Only.
S&S carburetors are not legal for use in California on motor vehicles operated on public highways or in other states where similar pollution laws
apply. The user shall determine the suitability of the product for his or her use and shall assume all risk and liability in connection therewith.
Kit Contents:
Each complete carb kit includes:
One S&S Super E or Super G gas carburetor
One S&S teardrop air cleaner assembly
One manifold
Mounting hardware
Fuel line, fuel line insulator, clamps and overflow line
Extra main and intermediate jets
VOES tubing and additional hardware (when applicable)
Installation and jetting instructions
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CHROME PLATING THE CARBURETOR
NOTE: S&S does not recommend chrome plating the Super E or G carburetor. Preparation requires polishing with abrasive buffing compounds. These
materials invariably plug air and/or fuel passages and other orifices regardless of precautions taken.
CAUTION
The chrome plating process can alter critical operating tolerances in several areas. Additionally, chrome may obstruct fuel passages,
possibly altering the fuel mixture and causing engine damage. All manufacturer warranties become void if any part of the carburetor is
polished, chrome plated or otherwise altered.
2
THROTTLE REQUIREMENTS
NOTE: S&S Super E and G carburetors require the use of a two cable, pull open - pull closed throttle assembly. All 1980 and earlier stock H-D® models
equipped with a single cable throttle mechanism must be converted to the two cable, pull open-pull closed type. S&S offers these throttle assemblies but
does not include them with any carburetor kit because of the multitude of chassis designs and fitment requirements.
WARNING
Single, braided wire cable throttle mechanisms cannot mechanically close the throttle. If throttle inadvertently sticks in open position,
loss of control of motorcycle and personal injury to operator or others may result.
1980 and Earlier Motorcycles
All stock chassis 1980 and earlier, or any motorcycle equipped with single cable throttle system must be converted to a two cable system. Throttle
assembly kits may be ordered separately. See descriptions below.
1981 to Present Big Twin Models
Stock big twin models from 1981 to 1989 have two cable throttle system designed for stock, butterfly type carburetors. Big twins from 1990 to
present have a two cable throttle system designed for the stock, constant velocity (CV) type carburetor. In spite of the differences in throttle cables
for these year groups, stock throttle cables on all 1981 to present big twin models can be installed on the S&S Super E or G throttle linkage with no
cable modification. S&S Super E and G carb kits for 1936 to 1989 big twins contain a throttle cable guide designed for butterfly type throttle cables,
and kits for 1990 and later big twins contain a taller throttle cable guide designed for CV type throttle cables. See Picture 2. The two throttle cable
guides are interchangeable on the carburetor body, and can be changed very easily to update older carburetors or to accommodate custom throttle
cables which are not stock for a particular year chassis.
Picture 2
1981 to Present Harley-Davidson® Sportster® Models
Stock Sportster models from 1981 to 1987 have two cable throttle system designed for butterfly type carburetors. 1988 to present models have
a two cable throttle system designed for use with the stock constant velocity (CV) type carburetor. A tall guide should be used on 1990-'06
carbureted Harley-Davidson® Sportster® models. See S&S Throttle Cable Application Chart (Chart 1).
S&S® THROTTLE CABLE APPLICATION CHART
Length
Total Housing
Length
Vinyl Housing
Part Number
Open Side
Part Number
Close Side
36"
32"
19-0430
19-0431
For Buell® with 7⁄8" handlebars
36"
32"
19-0432
19-0433
To 1995, 1981-'85 FX and FL; All 1981-'85 XL
(Also pre-1981 w/2-cable throttle housing replaced)
For Buell® with 1" diameter handlebar
36"
32"
19-0436
19-0437
1996-'06 883-1200 XL
39"
35"
19-0434
19-0435
To 1995 Softail® (FXCTC, FXST, FLSTC, FLSTC, FLSTF)
1986-'94 FXR,1993-'95 Dyna®
39"
35"
19-0438
19-0439
1996-'05 Softail (FXSTS, FXSTC, FLSTC, FLSTF)
1996-'05 Dyna
42"
38"
19-0446
19-0447
To 1995 Custom Application
42"
38"
19-0440
19-0441
1996-'05 Custom Application
Fitment
48"
44"
19-0462
19-0463
To 1995 All FLT Models
48"
44"
19-0464
19-0465
1996-'05 All FLT Models
Chart 1
3
1996 to 2002 Buell® Models
1996 and 1997 Buell models require special S&S butterfly style throttle cables, which are compatible with the stock 1996-1997 throttle assembly.
1998-'02 carbureted Buell models require installation of stock 1996-‘97 throttle grip and the special S&S throttle cables for Buell models when
installing Super E or G carburetors.
S&S THROTTLE KITS
S&S throttle kits fit 1" handlebars and can be used on most chassis. (An adapter sleeve is available for use with earlier, 7⁄8" OEM handlebars originally
equipped with internal throttle cable.) Barrel fittings on S&S® cables readily "plug in" to S&S Super E, G, and stock H-D® 1981-'90 butterfly type carb
throttle linkage. Kits include one opening and one closing side cable, left and right grips, and handlebar clamps. Kits with 36", 39", 42", or 48" length
cables are available. Length specified refers to overall cable length. Vinyl covered outer housing is 4" shorter than overall length.
Throttle Kit with 36" Cables
Throttle Kit with 39" Cables
Throttle Kit with 42" Cables
Throttle Kit with 48" Cables
Adapter Sleeve - 7⁄8" to 1" Part 19-0450
Part 19-0448
Part 19-0482
Part 19-0449
Part 19-0235
NOTE: Cables supplied with above kits are interchangeable with 1981-'90 stock H-D butterfly style throttle cables.
S&S Throttle Cables For 1996 and Later Chassis
These throttle cables feature the "plug in" cable fastener to fit 1996 and later throttle grips, and the correct length inner cable for use with S&S
butterfly style carburetors with the shorter cable bracket. These cables must be used in 1996-'02 Sportster installations. These cables may be used
on 1996 and later big twin installations if the S&S carb is equipped with the short cable guide bracket. Cables for Buell models fit threaded 1996-’97
Buell throttle grip.
CARB INSTALLATION
Read instructions thoroughly to familiarize yourself with all procedures before beginning installation. Since this manual covers installation on all
models, it may be helpful to highlight the steps that apply to your application.
NOTE: Installation of S&S® Super E and G carb kits on certain models is easier with gas tanks removed. Some owners may elect to perform installation
without removing gas tanks. This is left to individual discretion. If installer elects to remove tanks or other stock parts, S&S recommends referring to
appropriate Harley-Davidson® service manual for correct removal procedure as necessary.
1- Remove Old Carburetor And Manifold
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WARNING
Gasoline is extremely flammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic
when inhaled. Perform installation in a well ventilated area away from open flames or sparks. Any gasoline leak or spill constitutes a
health and fire hazard.
If motorcycle has been running, wait until engine and exhaust have cooled to avoid getting burned during installation.
Electrical sparks can ignite explosive gasoline fumes. Failure to disconnect battery while working on motorcycle can also result in
inadvertent engagement of starter and personal injury.
A- Shut off fuel petcock and disconnect battery.
B- Remove air cleaner assembly. Drain fuel from existing carburetor. Remove carburetor, manifold, choke cable and any carburetor mounting
hardware.
NOTES:
•• Removing and tightening hard to reach Allen bolts like carb-manifold mounting bolts and manifold flange bolts can be greatly simplified by using
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some special tools. The S&S rocker cover wrenches work very well for this application. See Picture 3 on next page. Allen ball-end drivers are also very
helpful, and are available at most automotive and tool supply houses. See Picture 4 on next page. As an alternative, standard hex wrench can be
shortened for convenience.
Some Buell® motorcycles have a breather fitting with 90° elbow on rear head. Due to proximity of frame, elbow must be removed before fitting can be
taken off engine.
Loosen fitting and rotate to position convenient for cutting elbow. Secure fitting by tightening against cylinder head. Elbow may be inaccessible to
hacksaw. In most instances, a die grinder with cutoff wheel will remove elbow with little difficulty. If die grinder is unavailable, grasp elbow firmly with
pliers and snap off, then remove fitting.
Picture 3
Picture 4
CAUTION
Extreme care must be taken to prevent metal chips from entering engine when elbow is removed. S&S® recommends packing breather
fitting with grease before removing elbow. Metal chips inside engine will cause extensive damage. Installer bears all responsibility for
containment of chips and other debris.
2- Prepare Air Cleaner Backplate
NOTE: Fast idle lever screws must not be over tightened. Loctite® or other thread locking compound may be used sparingly on threads to prevent screws
from vibrating loose.
CAUTION
Over tightening fast idle lever screws may damage backplate.
A- 1936-’84 models
1- Knucklehead & panhead, 1936 to 1965 - Install plugs into holes in air cleaner backplate. See Picture 5
2- Shovelhead, 1966 to 1979 and ironhead (IH) Harley-Davidson® Sportster® models, 1957 to 1979 - Install plug into hole in air cleaner
backplate. See Picture 6.
Picture 5
Picture 6
5
3- Shovel, 1980 to 1984 and Sportster® models 1980 to 1985 - Screw crankcase breather vent elbow fitting into hole in air cleaner backplate
and angle downward as shown in Picture 7.
4- On 1983 and 1984 shovel engines press plug into other hole on left.
5- Assemble fast idle mechanism as shown in Figure A. On current backplates the pivot point for the enrichener does not have a screw
holding it; a boss has been cast onto the backplate to replace this.
Picture 7
Figure A
B- 1984-’92 Evolution® big twin engines
1- Install plug into hole on left in air cleaner backplate as shown in Picture 8.
2- Screw vent hose elbow fitting into remaining hole at right. See Picture 8.
3- Refer to step 5 above about assembling the fast idle mechanism.
C- 1986 to 1990 Sportster models
1- Install plug into hole on right in air cleaner backplate as shown in Picture 9.
2- Screw vent hose nipple fitting into remaining hole at left. See Picture 9. Elbow fitting supplied in kit may also be used in this location if
required.
Picture 8
Figure 9
3- Assemble fast idle mechanism as shown in Figure A. On current backplates the pivot point for the enrichener does not have a screw
holding it; a boss has been cast onto the backplate to replace this.
D- 1993-up big twin & 1991-up Harley-Davidson® Sportster®
1- Install plugs into both holes in air cleaner backplate as shown in Picture 10.
2- Refer to step 3 above about assembling the fast idle mechanism.
E- Buell® motorcycles, 1994 and '02 - Refer to step 3 above about assembling the fast idle mechanism.
Picture 10
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3- Throttle Preparation
NOTE: Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation. Throttle must snap closed when
released. Cable routing must be free of tight bends to minimize friction between cable and housing.
WARNING
If throttle does not work freely, it may inadvertently stick open possibly causing loss of control of motorcycle and personal injury to
operator or others.
A- Install new throttle assembly - Motorcycles not equipped with two cable pull open-pull closed type throttle assembly.
1- Remove existing throttle cables and throttle grip assembly. Note routing of stock cables.
2- Install new throttle assembly and throttle cables. Position grip and cables similar to stock position so cables can be angled back toward
carb for easy adjustment and free operation.
3- Apply light coat of cable lubricant to cables/fittings.
4- Loosen cable freeplay adjustment locknuts and thread adjusting screw so half of threads are exposed. See Picture 11.
B- Prepare existing throttle assembly - 1981-1989 Harley-Davidson® Sportster® and 1981 and later big twin chassis equipped with two cable
pull open-pull closed type throttle assembly.
1- Loosen cable freeplay adjustment locknuts and thread adjusting screw so half of threads are exposed. See Picture 11.
2- Clean grease and dirt off cables, cable housings and cable fittings.
3- Apply light coat of cable lubricant to cables and fittings.
C- Replace throttle cables - Buell® models equipped with constant velocity (CV) type carb.
1- Carefully remove existing cables noting how they are routed.
2- 1998-'02 Buell models – replace throttle assembly with stock 1996-'97 throttle assembly.
3- Install replacement cables using same routing as stock cables.
4- Loosen cable freeplay adjustment locknuts and thread adjusting screw so half of threads are exposed. See Picture 11.
5- Apply light coat of cable lubricant to cables and fittings.
Picture 11
4- Install New Manifold and Mounting Hardware
NOTE: When applicable, all carburetor mounting brackets and hardware supplied in kit must be installed to secure carburetor and air cleaner backplate
assembly or air horn rigidly to engine.
CAUTION
••Improperly mounted carburetor could loosen unexpectedly, resulting in air leak, poor performance and possible damage to engine or
carburetor.
••Incorrect combinations of mounting hardware may cause mounting bolts to bottom out in holes or inadvertently contact other parts
possibly causing damage to engine or carburetor components.
WARNING
Improperly mounted carburetor may break free in event of collision or other vehicle accident creating a fire hazard with potential
personal injury to operator/others.
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A- All models: Clean intake ports on cylinder heads to insure proper manifold to head seal.
NOTE: Cylinder heads for knucklehead engines 1936-'47 and panhead engines 1948-'54 must be converted to o-ring style manifold and seals. Conversion
kits are available from S&S®. See the Flathead Power® vintage section of the S&S Catalog.
B- All models: Install S&S® intake manifold. If applicable, vacuum advance fitting must point upward. For Harley-Davidson® Evolution® and
Twin Cam 88® engines manifold flange and seal assembly order, See Figure B. Note that bevel side of seal goes toward recess in manifold
flange, flat side of seal against head. Do not completely tighten manifold clamps or flange bolts at this time.
Figure B
C- Knucklehead and panhead engines - Remove center crankcase stud nut between tappet blocks. Install bracket, to connect bottom carbmanifold mounting bolt to crankcase stud and reinstall nut.
D- Shovelhead engines 1966 to 1982 - Bolt bracket to front rocker cover using 5⁄16"-18 x 5⁄8" bolt, 5⁄16" flatwasher and 5⁄16" lockwasher provided in
kit. Do not tighten at this time. End of bracket with sharp bend goes toward rocker cover.
E- Shovelhead engines 1983 to 1984 - Remove center crankcase stud nut between tappet blocks. Install bracket to connect lower carbmanifold mounting bolt to crankcase stud and reinstall nut.
F- Sportster® models 1957 to 1982 - Bolt bracket to front tappet guide using 5⁄16"-18 x 11⁄4 " bolt, 5⁄16" flatwasher and 5⁄16" lockwasher provided in
kit. Do not tighten. End of bracket with sharp bend goes toward tappet guide.
NOTE: E & G carb will not fit Sportster® models equipped with OEM style magneto due to interference between magneto and carb fuel inlet fitting. S&S
manufactures no adapters or other components for installing E or G carb on magneto equipped Sportster.
G- Sportster models 1983-'06 and all 1984-'05 big twins- Connect vacuum operated advance ignition switch (VOES) to manifold using 8" piece
of black tubing supplied in kit. Cut tubing to shorter length if necessary.
H- Twin Cam 88®, 1999-'06 engines - Install stock map sensor in S&S manifold. See Picture 12. Secure sensor to manifold with stock clip and
screw. See Picture 13. Install manifold on engine with stock hardware. Connect fuel petcock vacuum hose to manifold fitting and connect
wiring harness to map sensor. See Picture 14.
Picture 12
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Picture 13
Picture 14
5- Install Carb
A- Check idle mixture and idle speed screw settings.
1- Check setting of idle mixture screw on top of carb body. See Picture 15. Turn screw clockwise to close screw, counting number of turns
to fully closed position - setting should be 11⁄2 turns. Reset by turning screw counterclockwise to 11⁄2 turns open. After engine is started,
screw must be reset as explained in "Adjusting Idle Mixture" section of instructions.
Picture 15
NOTE: Turn idle mixture screw in only far enough to contact seat. Do not over tighten.
CAUTION
Over tightening idle mixture screw may cause irreversible damage to carburetor body.
2- Check setting of idle speed adjusting screw. See Picture 16. Turn screw counterclockwise until it no longer contacts throttle linkage
spool. Next, turn screw clockwise until it just contacts spool. Then turn additional 1⁄2 turn clockwise to slightly open throttle plate.
B- Install throttle cables on carburetor.
1- Install the proper throttle cable guide on the carburetor.
2- Install opening side throttle cable barrel fitting and throttle cable in throttle linkage and appropriate side of throttle cable housing
bracket. Opening side cable housing outside diameter is smaller and measures .190".
3- Repeat step 2 for closing side throttle cable. Closing side cable has a spring around inner cable wire. See Picture 17.
4- Apply drop of Loctite® 242 or equivalent to threads of cable bracket screw and reinstall bracket on carburetor.
Picture 16
Picture 17
C- Install carb on manifold
1- Bolt carb and insulator block to intake manifold using two 3⁄8"-16 socket cap screws provided in kit. (O-ring side of block faces manifold.)
Most carb kits for big twins include two 3⁄8"-16 x 11⁄4" socket cap screws. Knuckle/pan and 1983-’84 shovel kits include one 11⁄4" screw and
one 13⁄8" screw. The 13⁄8" screw is longer to compensate for thickness of support bracket for pan/knuckle or for 1983-’84 shovel engines)
and must go in bottom hole. Kits for Harley-Davidson® Evolution® Sportster® models sold after 6-15-01 contain a thicker (3⁄8") insulator
block and two 3⁄8"-16 x 13⁄8" socket cap screws to compensate for the additional thickness of the spacer block. (See important note below
and caution concerning insulator block.)
NOTE: If insulator block is not installed, manifold bolts supplied in kit will be too long and may bottom in holes. Shorter manifold bolts must be used if
insulator block is not installed.
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CAUTION
If insulator block is not installed, lower manifold bolt may damage carburetor bowl causing possible gasoline leak.
WARNING
Gasoline is extremely flammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic when
inhaled. Any gasoline leak or spill constitutes a health and fire hazard.
D- Adjust throttle cables
1- Turn threaded throttle cable adjusters to remove excessive freeplay.
2- Test throttle to insure that it opens and closes freely. Turn handlebars to extreme left and open and close throttle, then turn bars to
extreme right and open and close throttle. If throttle binds, loosen cable adjusters to put more freeplay in cables. Tighten adjusting
screw locknuts after making final adjustments.
NOTE: Throttle must not bind and must snap shut to fully closed position when released.
WARNING
If throttle does not return to fully closed position when released, it may inadvertently stick open, causing possible loss of control of
motorcycle and personal injury to operator or others.
E- Slip fuel overflow hose onto fitting on carb bowl and neatly route behind pushrod tubes. On a big twin model, hose should go toward back
of engine. On a Harley-Davidson® Sportster® model, hose should go toward front of engine. Exit end of overflow hose must extend down
below engine and away from exhaust pipes. See Pictures 18 and 19
Picture 18
Picture 19
WARNING
Overflow hose must not contact hot surface such as exhaust pipe where it could melt and catch fire.
F- Slip hose clamp over end of fuel line. Apply thin coat of oil to carb fuel inlet fitting and slip end of fuel line on fitting. Position fuel line in
such a way as to avoid contact with cylinders and other hot engine parts. Tighten hose clamp. Slip protective fuel line covering over fuel
line and position where contact with engine parts could occur. On models equipped with fuel line support guide, use guide if possible.
Connect other end of fuel line to gas tank petcock using hose clamp provided.
NOTE: Some early Super E and G carbs were equipped with a banjo style swivel fuel inlet. This banjo inlet is no longer available. If this early swivel inlet
requires repair, it must be replaced with either a straight inlet, o-ring, and 90° fuel line or current production 360° swivel inlet with 90° inlet and a straight
fuel line. See carburetor parts list and line drawing on pages 26 and 27.
WARNING
Fuel line must be clamped securely and not contact hot surfaces such as exhaust pipes where it could melt and catch fire.
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6- Install Air Cleaner Backplate
NOTE: Air cleaner backplate screws supplied with kit have thread locking compound on threads. If screw without thread locking compound is used, a
thread locking product such as Loctite® 242 must be applied, and screws properly tightened.
CAUTION
Failure to apply thread locking compound or properly tighten screws may cause screws to loosen and fall into engine, causing engine
damage not covered under warranty.
A- All big twin & Sportster® models 1966 to 1982
1- Mount air cleaner backplate on carb using three 1⁄4"-20 x 9⁄16" screw/washer assemblies. Confirm that enrichment device lever, engages
enrichment device plunger. See Picture 20. Tighten backplate mounting screws to 5-7 ft-lbs (60-84 in-lbs).
2- Bolt carb mounting bracket to air cleaner backplate. Head of 5⁄16"-18 x 1" bolt should rest in hex recess on inside of backplate with
threaded portion extending through backplate, two 1⁄8" shims and bracket. Secure with 5⁄16" flatwasher and locknut provided.
Picture 20
3- Final tighten of all mounting bracket bolts and manifold clamps.
4- 1980-’84 big twin & Harley-Davidson® Sportster® models 1980 to 1985 - Connect crankcase breather hose to air cleaner backplate hose
fitting. See Pictures 21 and 22.
B- Evolution® big twin 1984 to 1992 and Sportster models 1986 to 1990
1- 1992 big twin models with crankcase breather vented from cases to air cleaner backplate - Install thread-sert in each cylinder head air
cleaner mounting bolt hole. This converts stock 1⁄2"-13 thread to 5⁄16"-18 thread. Surface of thread-sert should be just below surface of
cylinder head. See Picture 23.
Picture 21
Picture 22
Picture 23
NOTES:
•• Most 1992 big twins have crankcase breather routed from case to air cleaner backplate. However, some late 1992 engines have breather routed from
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heads to air cleaner backplate through air cleaner mounting bosses. If crankcase breather is routed through heads, 1993 and later carb kit must be
installed. Follow instructions for installation on 1993 engine.
Thread-serts may be supplied with or without thread locking compound on threads. Loctite® 242 or equivalent should be applied to threads of threadserts not supplied with thread locking compound. Thread-serts should be installed in desired position and left in place.
Installing thread-sert in hole activates thread locking compound making it difficult to change position of thread-sert after installation.
CAUTION
Cylinder head vent passages in "head breather" type engine must not be plugged as oil leakage and engine damage may result. Same
applies to crankcase vent in "case breather" type engine.
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2- Mount the air cleaner backplate on carb using three 1⁄4"-20 x 9⁄16" screw/washer assemblies. Confirm that enrichment device lever,
engages enrichment device plunger. See Picture 20. Tighten backplate mounting screws to 5-7 ft-lbs (60-84 in-lbs).
3- Fill gap between backplate mounting ears and cylinder heads with shims provided in S&S shim kit.
4- Bolt backplate to cylinder heads with 5⁄16"-18 x 11⁄4" bolts, flat washers and lock washers. See Picture 24.
Picture 24
5- Final tighten all mounting bracket bolts and manifold clamps.
6- Connect crankcase breather hose to air cleaner backplate hose fitting. See Pictures 21 and 22, page 11.
C- Evolution® big twin engines 1993-’99 (kits sold after 2/1/01), Sportster® models 1991-’06 (kits sold after 6-15-01), and all Twin Cam 88®
engines 1999-up.
1- Install breather fittings in heads. See Picture 25. Apply red Loctite® to threads and torque to 15-20 ft-lb. See Picture 26 for component
placement.
1999-Up BT
1991-'12 XL & 1993-'99 BT
Picture 25
Picture 26
2- Install breather hose between breather fittings with long hose runner toward rear cylinder breather fitting. Position hose in such a way
that it is not kinked and does not interfere with travel of the enrichment lever. Trim ends of vent hose as required. Secure hose to fittings
with spring clamps.
3- Install backplate and gasket. Connect the short "T" of the breather hose to the steel nipple fitting on the back of backplate. See Picture
27, below left. Secure hose to backplate fitting with hose clamp. Confirm that fast idle lever has properly engaged enrichment plunger.
Tighten screws holding backplate to carburetor to 5-7 ft-lbs (60-84 in-lbs).
4- Determine which of the provided shims correctly fills the gaps between backplate and breather fittings. See Picture 28, below right.
Picture 27
12
Picture 28
5- Fill gap between backplate mounting ears and cylinder heads with correct shims. Install screws to attach backplate to breather fitting.
Torque to 8-12 ft-lb with no Loctite. See Picture 29.
D- Buell® models 1994-’02
1- Place washer on breather screw.
2- Roll 5⁄8" O.D. o-ring into large diameter o-ring groove closest to head of breather screw.
3- Roll 1⁄2" O.D. o-ring into small diameter o-ring groove of breather screw. Apply thin film of light grease to o-rings.
4- Repeat for other breather screw
5- Loosely install bracket on front head using spacers and breather banjo bolt assembly. See Picture 30. Install banjo bolt assembly in rear
head, but do not tighten.
Picture 29
Picture 30
NOTE: At least one thick spacer will be required between breather banjo fittings and heads. Breather fitting o-rings are easily damaged. It is suggested
that they be lubricated with light grease before installation. If possible, replacement o-rings should be obtained beforehand if banjo assemblies are
removed in future.
6- Position of backplate support bracket must be determined before backplate can be permanently installed. Temporarily install backplate.
Rotate bracket to align hole in bracket with hole in backplate. Mark position of bracket with pencil mark on cylinder head to act as guide
for final installation. Remove backplate.
7- Place ends of rubber T-hose over breather fittings for trial fit. See Picture 31. Temporarily install backplate using correct number of
spacers. Hose must be routed so as to be free of kinks and not interfere with operation of fast idle lever.
8- Remove backplate, shorten hose ends as needed for correct fit, reinstall hose and secure with tie-wraps. Tighten banjo bolt breather
screws.
Picture 31
9- Install backplate for final assembly. Confirm that fast idle lever has properly engaged enrichment plunger and secure backplate to
support with 1⁄4" bolt, flat washer, and locknut provided. Tighten three backplate screws to 5-7 ft-lbs (60-84 lbs).
NOTE: Backplate screws supplied with kit have pre-applied thread locking compound on threads. If screw without thread locking compound is used, a
thread locking compound such as Loctite® 242 must be applied to threads, and screws properly tightened. If screws are removed in future, Loctite® 242 or
equivalent must be applied before reinstallation.
CAUTION
Failure to apply thread locking compound or properly tighten screws may cause screws to loosen and fall into engine, resulting in engine
damage not covered under warranty.
13
10- For street use, insert 11⁄4" steel tubing provided into short "tee" of T-hose and place 3⁄8" O.D. x 2.80" hose over other end of tubing. Hose
must rest in notch in backplate, with bevel down. Secure with Tie-wraps when correctly positioned. See Picture 32.
Picture 32
NOTE: An additional, 36" length of hose is provided for "Race Only" applications. It should be attached to T-hose in place of 2.80" hose, and routed to
overflow or "catch can" as required by event organizer. Breather hose should be routed in upward direction as much as possible. Because crankcase oil-air
mist exits from hose, hose and catch can must be mounted securely and well away from hot or moving parts as well as tires and brakes.
WARNING
Oil on tire or brakes can result in loss of control of motorcycle, resulting in possible serious injury or death to operator and others.
7- Final assembly and checks.
A- Check carb to manifold mounting bolts.
B- Check carb to air cleaner backplate mounting screws.
C- Check each of following that is applicable:
• Carb mounting bracket to head bolts
• Mounting bracket to air cleaner bakplate.
• Mounting bracket to center case stud.
• Mounting bracket to tappet guide bolt.
• Mounting bracket to head breather vent fitting.
• Air cleaner backplate to head mounting bolts.
D- Check fuel line connections and routing. Avoid hot surfaces.
E- Check vacuum operated ignition advance connections if applicable.
F- Check crankcase to backplate vent hose connections if applicable.
G- Check fuel overflow hose routing. Avoid hot surfaces.
H- Test throttle to be sure it opens and closes freely. Turn handlebars to extreme left and open and close throttle, then turn bars to extreme
right and check throttle. When released, throttle should snap closed in all positions.
I- Reassemble components that were removed or disassembled for carb installation. Consult authorized Harley-Davidson® service manual for
installation procedure for stock parts not covered in S&S® carb instructions.
J- Check fuel needle and seat assembly. Fill gas tank with just enough fuel to test system. Lean motorcycle over towards carburetor side, turn
on fuel petcock and wait 20 seconds. If gas runs out end of carb or out overflow hose, turn off petcock and check needle and seat. See
"General Information."
K- Check fuel inlet fitting and fuel line connections for leaks. Hose clamps must be tight.
NOTE: Fuel needle and seat assembly must completely shut off fuel supply to carburetor bowl. Fuel inlet fittings and fuel line connections must not leak.
CAUTION
Gasoline leaking past inlet needle may flood engine causing contamination of oil supply and damage to engine.
WARNING
Any gasoline leak represents a health and fire hazard.
14
L- Install air cleaner element and air cleaner cover using three 3⁄4"-20 x 1" mounting screws provided. Insure that element goes around outside
edge of locating tang at 9 o'clock position on backplate. Correctly installed element will remain in place on backplate without support.
Filter element supplied with carb kits for Buell® models is foam type. Beveled vent hose in kits for Buell bikes must rest in notch in backplate
and go between air cleaner element and chromed outer cover. Hose bevel should angle down toward element. See Picture 33.
Picture 33
M- Fill gas tank.
INSTALLATION NOTES:
In designing the S&S® Super E and G carbs S&S has made every effort to keep overall assembled length as short as possible. Due to the short installed
length of the carb assembly, the air cleaner cover may contact the gas tank of four-speed shovelhead chassis. In such instances an optional chromed,
notched cover that will provide additional clearance can be ordered. See Picture 34, below right. If a new, undamaged Super E/G cover is shipped to
S&S prepaid, it will be exchanged for the difference in cover prices. See your authorized S&S dealer for this service.
An optional 1" spacer block can be installed between carb and manifold as an alternative, or existing air cleaner cover modified to provide 1⁄8" minimum
clearance.
Bowl vent screw should be removed for any all-out racing application which includes use of air horn or air cleaner without filter element. Exposed passage
in carb body maintains equal pressure between float bowl and atmosphere. See Picture 35, below left.
On any application where air horn is used instead of air cleaner, S&S carb mounting bracket must be used to securely fasten carb to engine. See line
drawing on page 28.
••
••
••
••
Picture 35
Picture 34
CAUTION
Improperly mounted carburetor may loosen from engine resulting in gas or air leaks, poor performance and possible damage to
carburetor or other components.
WARNING
Any gasoline leak represents a potential health and fire hazard.
15
•• G carb using air cleaner assembly without filter element flows approx. 7 CFM (10" test pressure) less than carb with 4" air horn. E carb w/air cleaner
assembly, no filter, flows same as with 4" air horn. S&S recommends using air filter element for all street applications.
•• S&S has found that trimming approximately 3⁄4" off rim of S&S air cleaner cover has resulted in as much as 3 HP increase on Dynojet® 150 chassis
dynamometer. However, this increases exposure of filter element to weather and contamination, so filter should be inspected regularly and washed or
replaced as needed.
CARB OPERATION
1. Starting Procedure of Carb Operation
S&S Super E & G carburetors do not have a conventional choke. Instead, a mixture enrichment/fast idle device is used for starting and engine
warm-ups. The enrichment device utilizes separate air and fuel pickup passageways and is engaged by pulling fast idle leve upward. See
Picture 36, below left. Super E & G carburetors also feature a fully adjustable accelerator pump which is actuated by quick throttle movements
at partial throttle openings and can be used as an additional starting aid.
ENRICHMENT DEVICE NOTES:
Enrichment/fast idle pickup tube located directly below fast idle plunger, is pressed into carburetor body and must not be removed. See Picture 37,
••
Picture 37
Picture 36
CAUTION
Removal of enrichment/fast idle pickup tube from carburetor body may cause irreversible damage to carburetor.
•• Plunger nut, plunger spring, and plunger, may be removed for cleaning purposes.
•• If air cleaner backplate is removed, be sure fast idle lever and enrichment plunger are engaged properly when backplate is reinstalled. See Picture 20.
•• S&S® enrichment system operates on manifold vacuum. If throttle is opened while starting engine, vacuum will be reduced and enrichment system will
not function normally.
A- Cold Starts
1- Open fuel petcock.
NOTE: When motorcycle is not running, fuel petcock/shutoff valve should be turned off to prevent possible leakage should needle and seat not seal
properly.
CAUTION
Gasoline leaking past inlet needle may flood engine causing oil contamination and engine damage.
WARNING
Gasoline leaking past inlet needle may flood engine and surrounding area creating a potential health and fire hazard.
2- Prime engine with one or more squirts from accelerator pump. Ambient temperatures below 60° may require increased priming, up to
6-7 squirts depending upon exact temperature and carb jet size.
3- Pull fast idle level, to fully raised position.
4- Turn on ignition.
NOTE: Some engines, especially those equipped with magnetos, will start easier if given two prime kicks BEFORE ignition is turned on. For reliable starting,
magneto should be equipped with kill button to disable ignition for prime kicks.
16
5- With throttle closed, kick engine through or engage electric starter.
6- If engine fails to start immediately, crack throttle enough to barely open butterfly and continue to kick or engage starter until engine
fires.
7- After engine starts, position lever to maintain rpm at approximately 1000-1200 rpm with throttle closed. Lever may gradually be pushed
down to closed position as engine warms. Engine should be warmed sufficiently to idle with fast idle lever off in 1 to 4 minutes or after
a few miles of riding.
NOTE: Operating engine with fast idle lever up for excessive time will result in fouled spark plugs. Push lever completely down as soon as engine will run
smoothly without enrichener.
B- Hot Starts
1- Open fuel petcock.
2- Turn on ignition.
3- With throttle closed, kick engine through or engage electric starter.
4- If engine fails to start immediately, open throttle slightly and continue to kick or engage starter until engine fires.
C- Troubleshooting Tips - engine will not start:
1- Fuel supply exhausted.
2- Weak or no spark - discharged battery, worn points, faulty condenser, ignition module, coil, spark plug wires, or magneto.
3- Plug gap too wide - S&S uses .025" to .030" plug gap on engines with points type ignition and stock coil. Electronic ignitions and high
output coils can run wider plug gaps.
4- Improper ignition timing - Worn or poorly maintained mechanical advance units sometime stick in advanced position causing hard
starting, kick-back and erratic idle.
5- Tight tappet adjustment - If solid tappets are adjusted too tightly, valves may not seat properly, and the loss of compression may
prevent the engine from starting.
6- Improper idle mixture and/or engine idle rpm setting. If idle mixture is set incorrectly, throttle plate must be opened farther with the
idle speed screw in order to maintain idle speed. This reduces manifold vacuum and makes the enrichment circuit less effective. See
"Adjusting Carburetor - Idle Circuit."
7- Enrichment device feed hole (See Picture 38) in bowl plugged. Clear with compressed air.
Picture 38
CAUTION
Do not use wire or drill to clear hole. If size of hole is changed, starting system will be altered and carburetor bowl irreversibly damaged.
WARNING
Compressed air and particles dislodged by compressed air are potentially harmful to eyes and body. Wear protective goggles when using
compressed air and always direct air stream away from yourself and others nearby.
8- Improper diagnosis of rich or lean mixture condition. If engine backfires in carb, mixture is usually lean and engine must be reprimed. If
there is no response after three kicks or if engine pops in exhaust pipes, mixture is probably too rich. Leave switch on and slowly open
throttle 1⁄4 turn with each successive kick until engine fires.
17
9- If engine was running properly before installation of carburetor, no other changes were made and carb settings were confirmed as
instructed previously, hard starting is likely caused by incorrect intermediate jet or starting routine. Remain calm and patient while
attempting to start motorcycle, and experiment with different starting procedures (throttle and enrichener position, number of squirts
from accelerator pump, etc.), especially with kickstart motorcycle. Carb tuning and ignition tuning and maintenance are critical for kick
start motorcycles.
If severe flooding is suspected, turn ignition off, slowly roll throttle to wide open position, and kick 6-8 times to clear engine. Then close
throttle to approximately 1⁄8 turn, turn ignition on and kick until engine starts.
If insufficient fuel is suspected, remove air cleaner cover and confirm accelerator pump operation, with motor off, by snapping throttle
open from closed position. Fuel should exit accelerator pump nozzle directly behind main discharge tube in carburetor bore.
If not, increase accelerator pump setting by turning adjustment screw out, in counterclockwise direction. Replace air cleaner cover and
attempt to start motorcycle according to procedure previously described.
If more than 2-3 squirts from accelerator pump are required to start motorcycle with temperature 60° or above, larger intermediate
jet may be required. This may also be caused by incorrect idle mixture adjustment or a manifold leak. Refer to following sections for
additional information on tuning.
2- Adjusting Carburetor
A- Adjusting Idle Circuit - Idle mixture screw regulates air/fuel mixture at idle speeds and has been angled forward for greater accessibility.
See Picture 39, below left. Throttle stop/engine rpm adjustment screw is located on boss on rear side of carburetor body. See Picture 40,
below right. During assembly S&S® adjusts both screws to settings that should work for first start-up after installation.
Picture 39
Picture 40
1- Start engine and run until slightly warm (approximately 1 to 2 minutes).
2- Turn RPM adjustment screw to obtain idle of approximately 1000 RPM.
3- Turn idle mixture screw clockwise, slowly leaning mixture until engine starts to die. Next, turn screw counterclockwise, slowly richening
mixture, until engine RPM fall off. Mixture adjustment is correct when screw is positioned about halfway between these points, or
approximately 1⁄4 to 1⁄2 turn out from lean side of adjustment range.
NOTE: Turning screw out (counterclockwise) makes idle mixture richer. Turning screw in (clockwise) makes mixture leaner. Normally, correctly adjusted
screw will be between 11⁄4 and 3⁄4 turns out from bottom if intermediate jet size is correct. Note that mixture screw must be adjusted according to Step 3
above. Do not leave screw at initial 11⁄2 turn setting without fine tuning.
4- After initial idle mixture adjustment, reset engine idle to approximately 1000 RPM. Lower idle speed can cause hard starting, poor
throttle response, erratic idle and unnecessary engine wear.
5- After engine has reached normal operating temperature, repeat Steps 3 and 4.
IDLE CIRCUIT NOTES:
If idle adjustments are made before engine is fully warmed, idle mixture will be rich when engine reaches operating temperature. This is especially true
for engines with aluminum cylinders such as Harley-Davidson® Evolution® and Twin Cam 88®. If ambient temperature is below 60 degrees, engine may
require 10-15 minutes of normal riding to reach operating temperature.
Whenever intermediate jet change is made, idle mixture screw must be readjusted.
If the idle mixture screw is more than 13⁄4 turns out after idle mixture is correctly adjusted, it is a fairly good indication that the intermediate jet may be
too small and should be changed to the next larger size. If the idle mixture screw ends up less than 11⁄4 turn out, the intermediate jet may need to be
changed to the next smaller size. Be aware that idle mixture screw adjustment can be effected by other factors, but can quite often indicate rich or lean
intermediate jetting.
If idle mixture screw is turned completely in, engine should not run at idle. If engine continues to run at idle with idle mixture screw seated, recheck initial
setting of idle speed screw, and make sure enrichment plunger is seated.
••
••
••
••
18
B- Troubleshooting Tips - engine will not idle:
1- Improper idle mixture or rpm setting.
2- Intake manifold air leak.
3- Malfunctioning automatic advance mechanism or other ignition problem.
4- Foreign material in air or gas passageway in carb causing gas flow restriction to idle or intermediate circuit. Picture 41 shows
intermediate air bleed metering hole. Picture 41 shows intermediate jet metering hole. Clear holes with compressed air.
Picture 41
CAUTION
Do not use wire or drill to clear hole. If size of hole is altered, starting system will be altered and carburetor bowl irreversibly damaged.
WARNING
Compressed air and particles dislodged by compressed air are potentially harmful to eyes and body. Wear protective goggles when using
compressed air and always direct air stream away from yourself and others nearby.
5- Enrichment/fast idle plunger not seated causing excessively rich mixture. Be sure enrichment lever is fully disengaged (in down
position) allowing plunger to bottom and seal passageway. Remove air cleaner backplate. Lift and release plunger several times, letting
it "snap" closed to fully seat against carb body. When backplate is reinstalled on carb, be sure lever is engaged in plunger properly and
that plunger is not lifted as mounting screws are tightened. See Picture 20, page 11.
6- 1⁄4" insulator block between carb and manifold omitted. Heat transfer from manifold to carb may cause temporary rich condition at idle
and low rpm when engine restarted after being shut off for 10 to 20 minutes. Install insulator block to minimize heat transfer.
C- Adjusting Intermediate System - (See Jetting Chart Page 23) Intermediate range is used most often under normal riding conditions. It
controls fuel delivery from just off idle to approximately 2500-3000 rpm or 55 to 60 mph depending on gearing. Close attention must be
paid when selecting intermediate jet to achieve optimum performance and best gas mileage. Intermediate jet (See Picture 42), is reached
by removing float bowl assembly. Size of metering hole in intermediate jet is stamped in thousandths of an inch on end or side of jet. Size
of intermediate jet installed in new carburetor from S&S® is indicated on tag attached to carb or on printed label on carburetor packing box.
Keep this information handy for future reference, especially when contacting S&S Technical Services Dept. for assistance. It is a good idea
to record any jetting changes for future reference.
Picture 42
19
Intermediate Jetting Procedure:
1- Ride motorcycle several miles to bring engine up to normal operating temperature.
2- Check idle mixture adjustment to be sure setting is correct with fully hot engine.
3- Check throttling characteristics by slowly rolling throttle on from a steady speed. This should be done at rpm levels of approximately
2000, 2500, and 3000 rpm. (Depending upon gearing, vehicle speeds will usually be between 30 and 60 MPH). "Popping" or "spitting"
(backfiring) in air cleaner indicates lean condition requiring that intermediate jet be changed to next larger size (size is stamped on end
or side of jet).
4- Change jet accordingly, adjust mixture screw and repeat road test. Smallest intermediate jet that eliminates this condition should
provide best gas mileage.
INTERMEDIATE SYSTEM NOTES:
•• It is helpful to shut off accelerator pump while fine tuning intermediate circuit as fuel supplied by pump can mask jetting symptoms. Consult "Accelerator
Pump" section of instructions.
•• Whenever intermediate jet is changed, idle mixture screw must be readjusted.
•• Elevation changes: A simple readjustment of idle mixture screw will often compensate for changes in elevation of several thousand feet. S&S test riders
••
••
have ridden through changes upwards of 7000 feet without changing jets. In other cases, and depending upon accuracy of initial jetting, a change in
intermediate and/or main jet may be required.
Higher elevation makes engine run richer, meaning that smaller jets may be required to correct overly rich condition. Lower elevation, nearer sea level,
makes engine leaner so larger jets may be required. While rich condition can cause fouled spark plugs and poor performance, lean condition can result in
engine damage. If smaller jets are installed for higher elevation, remember to install larger jets for operation at lower elevation.
Intermediate jet provides majority of fuel under average operating conditions. While it is tempting to change main jet because it is more accessible, in
most cases intermediate jet should be changed to properly address elevation/altitude-related problem.
D- Adjusting High Speed Circuit or Main Jet - High speed circuit begins around 2500-3000 rpm or 55-60 mph under steady speed conditions,
and operates to maximum attainable speed. High speed circuit will be pulled in at much lower rpm if throttle is cracked open. Main jet
size is best determined by testing at drag strip or dynamometer because maximum miles per hour, rpm and horsepower are most reliable
indicators of correct jetting. Main jet (See Picture 43), is reached by removing bowl plug. (See Jetting Chart Page 23).
Picture 43
High Speed (Main) Jetting Procedure:
1- Drag strip/dynamometer procedure
a- Sufficiently warm engine to begin testing.
b- Make run noting engine rpm and final speed or horsepower.
c- Richen main jet by increasing jet size .004" and make second run. Again, note rpm and final speed or horsepower.
d- Continue procedure until mph/horsepower falls off.
e- Decrease or lean main jet size by .002" to gain best rpm and mph. When making runs on drag strip, strive for consistent miles per
hour, not lowest ET.
2- Street Procedure - S&S uses "rpm" method to determine main jet size. Under racing conditions this level is where horsepower peaks
and begins to taper off and is where gear shifts occur. Main jet that makes engine accelerate strongest or rpm through gears quickest
is correct.
NOTE: Placing engine under load by accelerating uphill may make result of jet change more pronounced and easier to interpret.
a- Warm engine to operating temperature.
b- Accelerate rapidly through gears noting how quickly and smoothly engine reaches rpm level where pull of engine begins to fade
and gear shift occurs.
c- If engine backfires in carburetor and sputters or "breaks up"and/or dies during acceleration, increase or richen main jet size .004"
larger and road test again. Note engine smoothness and how easily engine reaches rpm where gear shift occurs.
20
d- If engine runs flat and sluggish or "blubbers" or will not take throttle, decrease or lean main jet size .004" smaller and road test
again. Note engine smoothness and how easily engine reaches rpm where gear shift occurs.
e- Continue changing main jets until jet which makes engine accelerate or rpm through gears quickest and smoothest is identified.
S&S's® experience is that jetting about .006" smaller (leaner) than correct will make engine break up and quit. Jetting about .006"
larger (richer) will make engine blubber and miss.
NOTES:
Correct carb jetting is essential for optimum performance on street, strip and dynamometer. Other common causes of poor performance in modified
engine are inappropriate exhaust and incorrect ignition timing.
S&S special main jet tool is extremely handy for changing main jets. Try it, you'll like it!
••
••
E- Troubleshooting Tips for Intermediate and High Speeds Engine will not run at steady speed or rpm or quits for no apparent reason:
1- Restriction in fuel supply system - Gas tank vent plugged, needle and seat not working properly (See "General Information"), gas
petcock too small, or defective vacuum petcock. Stock petcock is generally adequate, but may require running on reserve to provide
sufficient fuel for big inch engines. If fuel delivery to carb is questionable, S&S recommends Pingel brand high flow petcock.
2- Faulty ignition/electrical system - Fouled plugs, worn points or condenser, defective coil or solid state module, improper ignition
timing, loose wire, faulty circuit breaker or ignition switch. Many ignition/electrical problems occur repeatedly at same rpm because of
vibration specific to that rpm.
3- Incorrect intermediate and/or high speed jetting. See "Adjusting Carb - Intermediate System" and "High Speed Circuit or Main Jet."
4- Foreign material in air or gas passageway in carb causing flow restriction. Picture 41 (page 19) shows intermediate air bleed metering
hole. Picture 44 shows main discharge air bleed metering jet. Use compressed air to clear holes.
Picture 44
CAUTION
Do not use wire or drill to clear hole in carb bowl. If size of hole is altered, starting system will be altered and carburetor bowl irreversibly
damaged.
WARNING
Compressed air and particles dislodged by compressed air are potentially harmful to eyes and body. Wear protective goggles when using
compressed air and always direct air stream away from yourself and others nearby.
NOTE: Small amounts of engine oil deposited on air cleaner element by crankcase or cylinder head vent is normal and should not cause problem.
21
6- No air cleaner used or air cleaner used is brand other than S&S. Some air cleaners restrict air flow so that carb cannot draw air as freely
as needed. Also, some air cleaners may obstruct bowl vent hole on inlet end of carb and change bowl air pressure. See Picture 45.
Picture 45
NOTE: Bowl vent hole passage leads to cavity above fuel in bowl. Passage equalizes bowl pressure and atmospheric pressure. If high or low bowl pressure
relative to atmospheric pressure develops, engine may run erratically.
7- Insulator block between carb and manifold not used. Heat transfer from manifold to carb may cause temporary rich condition at idle
and low rpm when engine is restarted after being shut off for 10 to 20 minutes. Install insulator block to reduce heat transfer.
8- Air cleaner without element or air horn used without removing bowl vent screw located in downward facing boss on throttle cable side
of carburetor body. See Picture 35, page 15.
9- Valve train defect - Leaking or sticky valves, weak or broken springs, pushrod flex, improper clearances for high lift cam, or defective
camshaft with improper valve timing.
10-Inappropriate exhaust system.
NOTE: S&S® has found that long, large diameter exhaust pipes, either baffled or unbaffled, may present insurmountable tuning problems when combined
with S&S carburetor. If engine equipped with such pipes does not respond to normal tuning procedure, contact exhaust manufacturer for his tuning
suggestions or call S&S for exhaust recommendation.
11-Too much gear- Horsepower insufficient to pull gearing.
12- Incorrect float setting - Setting float too high will cause engine to run rich at idle and at low speeds, and may prevent jet change from
correcting over rich mixture. Float setting too low will cause poor off idle response and may cause mixture to "lean out" at high speed
or when motorcycle leaned over in curve due to insufficient fuel reserve in bowl. See General Information on Page 25 for float jetting
instructions and specifications.
13-Fuel standoff - Occasionally, fuel may be seen misting out carburetor when air cleaner is removed. Because carburetor is simply a
conduit through which air and fuel enter engine, it does not cause fuel standoff. Usual cause is cam timing.
14-Overflow hose missing from the carb bowl can cause engine to miss and break up at high speeds. This problem will more than likely not
occur on the dyno because the motorcycle is not moving through the air.
Adjustable Air Bleed for Super E and G Carburetors
The main air bleed passage in S&S Super "E" and "G" carburetors produced for the 2004 model year and later is fitted with a replaceable .040"
jet in place of the .040" drilled main air bleed passage. The replaceable jet allows changing the size of the main air bleed. Carburetors with this
modification can be identified by a serial number that begins with the letter E or higher. See Picture 46.
.040" drilled main air bleed. All E & G with
serial number starting with D or lower.
.040" replaceable man air bleed. All E & G
with serial number starting with E or higher.
Picture 46
22
NOTES:
The standard .040" diameter air bleed is the optimum size for most engine combinations, and should not be changed under most circumstances,
regardless of intermediate and main jet selections.
Changing the main air bleed size should be done only after determining a mid range driveability problem cannot be corrected by changing the
intermediate and main jets.
For tuning the main air bleed, S&S® recommends an initial increase from the standard .040" jet to an .048" jet as a starting point. Available jets and part
numbers are listed in the S&S catalog.
It is never necessary to reduce the size of the main air bleed below .040".
Shifting the start of main jet operation to a point higher up the rpm scale can lessen the effects of mid rpm driveability problems caused by mismatched
cam and exhaust systems, but will not allow the engine to perform as well as it would with a well designed exhaust system.
••
••
••
••
••
INTERMEDIATE AND HIGH SPEED NOTES:
Carburetor jetting and spark plug color - While spark plug color may be used to help determine carburetor jetting, S&S recommends that our instructions
be used as primary jetting guide and that plug color indications be used as secondary aid. Different brands of gasoline, gasoline additives, engine heat,
type of plugs, and spark plug heat range can effect plug color making plug reading difficult for average tuner. Also, new plugs usually require road test of
10 miles or more to properly develop color. This means that quarter mile tests may not be long enough to be a good indication of carb jetting. It is best to
use recommended spark plug type and to consult spark plug manufacturer with questions.
If bike is used exclusively on drag strip where engine temperatures vary, slightly richer jets may be necessary to obtain best performance. Larger jets and
richer mixtures will enable one to run colder engine which is sometimes desirable. This is best determined by experimentation.
Cams and exhaust systems can make some engines difficult to carburate. S&S has found that certain cams and exhaust systems cause poor performance
at a specific rpm, and attempts to correct problem with carb tuning usually degrade carburation at other rpm ranges. A combination of cam overlap,
reversion, and back pressure, or even lack of back pressure, can cause mixture dilution at certain rpm. This will result in loss of power, engine roughness,
or misfiring.
Drag pipes - For knucklehead, panhead, shovelhead, and ironhead Harley-Davidson® Sportster® models, 13⁄4" O.D. drag pipes with straight cutoff end
28" to 30" long will work well with almost any camshaft or other performance modification. 2" O.D. drag pipes are not recommended for any application
except very large competition engines.
The use of drag pipes is not recommended for Evolution motors in street application.
Mufflered exhaust systems - A good, economical street exhaust system consists of stock header pipes with cross-over tube and low restriction mufflers
such as S&S® slip-on mufflers. This system typically produces 10 horsepower more than drag pipes in midrange, where vast majority of normal riding
occurs. Contact S&S for current exhaust recommendations.
For any all-out racing application which includes use of air cleaner without element or use of air horn, bowl vent screw (See Picture 36, page 13), should
be removed to insure atmospheric air pressure exists in bowl. If high or low bowl pressure relative to atmospheric pressure develops, engine may run
erratically.
Modifying S&S® carburetor - While it is not S&S' intent to discourage purchase of other manufacturers' products, they should be approached with the
understanding that some alter the S&S carburetor's design and function. In such cases, manufacturer of installed item must be contacted for tuning
guidelines, not S&S.
••
••
••
••
••
••
••
••
F- Adjusting Accelerator Pump - Function of accelerator pump is to improve throttle response when rapidly opening throttle at low rpm and
to aid cold starts. Pump travel screw regulates volume of fuel delivered by accelerator pump. See Picture 47. During assembly, S&S sets
screw for maximum volume to aid during initial start-up after installation. Turning screw inward or in clockwise decreases delivered pump
volume. Turning screw outward or counterclockwise increases delivered volume.
Picture 47
1- Warm engine to operating temperature.
2- Turn pump travel adjusting screw inward or clockwise until screw contacts pump actuator arm. This limits actuator arm travel and shuts
off pump.
23
CAUTION
Closing adjusting screw with excessive force may cause irreversible damage to screw threads in carburetor body.
3- Perform intermediate and high speed jetting tests to determine proper jetting.
4- With engine warm and at idle, blip throttle and note throttle response.
5- Turn pump travel screw outward or counter clockwise about 1⁄4 turn at a time and recheck throttle response until engine no longer
hesitates. This is usually about two turns out.
6- Road test motorcycle noting throttle response at idle and at levels in 500 rpm increments from idle to 3000-3500 rpm.
7- Set pump travel screw at point where best throttle response is noted with minimum pump travel. Minimum pump travel is recommended
to conserve fuel, prevent spark plug fouling, and curtail black smoke from pipes when “blipping” throttle. Black smoke from pipes is
usually an indication of a rich condition or excessive accelerator pump travel.
NOTE: Final accelerator pump adjustment should be confirmed by riding motorcycle and noting throttle response with motorcycle underway. Because of
displacement, compression ratio, cam timing, exhaust design and other, related factors, many engines will stumble or bog if throttle is abruptly cranked
fully open with engine at idle. If correct carburetor (E or G) is installed and engine properly tuned and equipped with appropriate exhaust and cam,
stumble should disappear under normal riding conditions.
GENERAL INFORMATION NOTES:
•• Carburetor body has six drilled passages that are permanently sealed with drive plugs.
CAUTION
Removal of these plugs may cause irreversible damage to carburetor.
•• To insure proper seal so needle completely shuts off fuel supply entering bowl, float hinge, needle lift and needle must work freely and not bind. Float must
••
not contact bowl gasket. If problem is suspected, remove bowl and check float movement. If obvious misalignment, binding or sticking occurs, remove,
straighten and reinstall to obtain free movement. Reset float level and double check for free movement. To check, remove bowl (not accelerator pump
cap) and raise float until needle is in closed position and spring in top of needle is compressed. Top of float opposite the needle and seat assembly should
be 1⁄8" to 3⁄16" below bowl gasket surface. Float must not contact bowl gasket. See cut away bowl in Picture 48.
When motorcycle is not running, fuel shutoff valve should always be turned off to prevent possible leakage should needle and seat not seal completely.
Picture 48
CAUTION
Gasoline leaking past inlet needle may flood engine causing contamination of oil supply and damage to engine.
WARNING
Any gasoline leak constitutes a fire and health hazard.
24
•• Throttle plate and throttle shaft should be checked annually for signs of wear. Replace if necessary. If carb body throttle shaft bushings are worn, carb
must be returned to S&S® for repair. If throttle plate removed, be sure to reinstall correctly. See Figure C. Beveled edges of plate must fit flat against carb
throat.
Figure C
•• If accelerator pump cap is removed, lift cap slowly so small spring checkballs and o-rings are not lost.
•• For racing, S&S offers two air horn conversion kits which include appropriate mounting hardware and a substitute enrichment device. One includes a 21⁄2"
air horn and the other includes a 4" air horn.
•• If fuel delivery from stock petcock appears insufficient, S&S recommends that a high flow performance petcock be installed.
IMPORTANT NOTES:
We at S&S feel we have designed and manufactured a superior product and will stand behind it. If you have questions or problems, first refer to this
instruction manual. Answers to nearly all questions can be found herein. If your problem cannot be resolved, call 608-627-8324 for technical assistance.
Do not, however, call until you have become thoroughly familiar with this manual.
S&S also has a complete carburetor repair and rebuild service that provides quality work at a fair price. If you are not properly equipped to service an S&S
carburetor and do not have a qualified repair shop nearby, we recommend that you contact us for a Return Authorization (RA) number and send the
carburetor to us. Be sure to include a note with your name and address, RA number, and a detailed description of any problems or repairs needed. Thanks
for using S&S products!
••
••
S&S® SUPER E & G JETTING
Displacement
Stockers
88ci
96ci
100ci
107ci
113ci
Idle Mixture Screw
1 to 11⁄2
Turns
1 to 11⁄2
Turns
1 to 11⁄2
Turns
1 to 11⁄2
Turns
1 to 11⁄2
Turns
1 to 11⁄2
Turns
Intermediate Jet
0.028
0.0295
0.031
0.031
0.031
0.031
Main Jet
0.066
0.072
0.076
0.076
0.076
0.078
25
SUPER E & G CARBURETOR BODY AND RELATED PARTS
1. Carb body assembly
17⁄8" Super E . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2381
21⁄16" Super G. . . . . . . . . . . . . . . . . . . . . . . . . . 11-2391
2. Throttle shaft
17⁄8" Super E – Includes two plate screws. . . . . 11-2383
21⁄16" Super G – Includes two plate screws. . . . . 11-2483
3. Throttle plate screw - (two required)
each. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0055-S
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0064
4 Throttle plate
17⁄8" Super E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2055
21⁄16" Super G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2355
5 Throttle return spring (each) . . . . . . . . . . . . . . . 11-2382
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3502
6 Throttle spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2385
7 Throttle shaft lock washer (two required). . . . 50-7031
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7073
8 Throttle shaft nut (two required) (each) . . . . . . . 11-2350
5 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2363
9 Throttle shaft nylon washer (each). . . . . . . . . . .50-7050
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7072
10 Pump actuator lever. . . . . . . . . . . . . . . . . . . . . . . 11-2376
11 Actuator spring (each) . . . . . . . . . . . . . . . . . . . . 11-2375-S
5 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3501
12 Pump actuator arm. . . . . . . . . . . . . . . . . . . . . . . . 11-2377
13 Idle mixture screw (each) . . . . . . . . . . . . . . . . . . . 11-2354
5 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2378
w/O-ring Groove (each). . . . . . . . . . . . . . . . . 110-0003
Idle Mixture Screw Kit for 4 hole carbs
(contains 110-0003 & 500-0036) . . . . . . . . . . . . . . 110-0068
14 Idle mixture screw spring (each). . . . . . . . . . . . . 11-2052
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2060
15 Idle speed screw (each) . . . . . . . . . . . . . . . . . . . . . 50-0038
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0150
16 Pump adjustment screw (each). . . . . . . . . . . . . . 50-0039
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0146
17 Idle speed/pump adjuster spring (each) . . . . . 11-2048
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2053
18 Plunger nut (each). . . . . . . . . . . . . . . . . . . . . . . . . . 11-2344
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2372
19 Plunger spring (each). . . . . . . . . . . . . . . . . . . . . . . 11-2340
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2359
20 Fast idle plunger . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2343
21 Cable guide assembly
Use with butterfly style cables. . . . . . . . . . . . 11-2339
Use with constant velocity style cables. . . . . . . 11-2338
2004 - 06 XL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2337
22 Cable clamp/float pin screw (each) . . . . . . . . . . 50-0041
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0062
23 O-ring
17⁄8" Super E (each) . . . . . . . . . . . . . . . . . . . . . . . . 50-8016
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8094
21⁄16" Super G (each) . . . . . . . . . . . . . . . . . . . . . . . . 50-8015
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8093
24 Bellows seal (each) . . . . . . . . . . . . . . . . . . . . . . . . . 11-2266
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2279
25 Bowl vent plug (each). . . . . . . . . . . . . . . . . . . . . . . 50-0105
26
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0151
26 Main discharge tube. . . . . . . . . . . . . . . . . . . . . . . 11-2085
27 Main jet –State size – See jet section
28 Intermediate Jets – State size – See jet section in
catalog
Series #94 fits all Super 17⁄8", 21/16", 21⁄4" gas carburetors.
Sizes available: .025", .0265", .028", .0295", .031", .032",
.033", .036", .040".
29 Bowl gasket (each) . . . . . . . . . . . . . . . . . . . . . . . . . 11-2386
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2387
30 Float. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2187
31 Float pin (each). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2369
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2370
32 Bowl screw
10-24 x 3⁄4" - Three required. (each). . . . . . . . . 50-0034
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0063
10-24 x 23⁄8" - One required (each). . . . . . . . . . . 50-0040
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0061
33 Carb bowl (only). . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2388
Carb bowl complete assembly . . . . . . . . . . . 11-2388P
34 Bowl plug (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2090
5 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2092
35 Seat o-ring* – (required with part #11-2465 & #11-2466
only when replaces 360°style fuel inlet.) (each) . . 50-8009
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8095
36 Needle
17⁄8" Super E & 21⁄16" Super G . . . . . . . . . . . . . . 11-2195
Racing only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2197
37 Seat
17⁄8" E & 21⁄16" G (Replaces part #11-2347)
Uses part #11-2195 needle.. . . . . . . . . . . . . . . . 11-2465
Racing only (Replaces part #11-2348)
Uses part #11-2197 needle.. . . . . . . . . . . . . . . . 11-2466
Racing only -threaded fuel inlet (6AN .157" ID for Super E
or G)
Uses part #11-2195 needle.. . . . . . . . . . . . . . . . 11-2395
Racing only -threaded fuel inlet – (6AN .235" ID for Super E
or G)
Uses part #11-2197 needle.. . . . . . . . . . . . . . . . 11-2396
Permeation Compliant fuel inlet seat Super E or G.
Uses part #11-2195 needle.. . . . . . . . . . . . . . . 106-2011
38 Ejector nozzle o-ring (each) . . . . . . . . . . . . . . . . . 50-8011
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8096
39 Pump pushrod (each). . . . . . . . . . . . . . . . . . . . . . . 11-2373
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2393
40 Ball check - (two required) (each). . . . . . . . . . . .50-8090
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8125
41 Ball check spring (each). . . . . . . . . . . . . . . . . . . . . 11-2374
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2392
42 Pump cap o-ring - (two required) (each). . . . . 50-8012
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8100
43 Pump cap assembly . . . . . . . . . . . . . . . . . . . . . . . 11-2389
44 Overflow hose per 24" (each). . . . . . . . . . . . . . 19-0262-S
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-0263
45 Pump cap screw 8-32 - (two required) (each).50-0042
10 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0098
46 Diaphram spring (each). . . . . . . . . . . . . . . . . . . . . 11-2275
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2278
47 Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2282
48 Gasket, backplate (each) . . . . . . . . . . . . . . . . . . . 106-1724
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-2328
49 Enrichment device (Use with air horn only). . . . . . 11-2084
50 Fuel line With 90° bend* 19"
Use with part #11-2465 or #11-2466
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-0475A
Straight Permeation Compliant, 311" x .563" x 17.5"
Use with part #106-2011 , 90° seat. . . . . . . . 190-0001
51 Fuel line insulator – 12"
19-0172
52. Spacer,Kit,Carb,1-7/8" x 1". . . . . . . . . . . . . . . 16-0057*
Spacer,Kit,Carb,2-1/16" x 1". . . . . . . . . . . . . . . 16-0357*
Spacer,Kit,Carb,2-1/4" x 1". . . . . . . . . . . . . . . 16-0157*
*Use with 1" Spacer Block. . . . . . . . . . . . . . . 16-0058
53. Insulator Block,Manifold,Super E,w/O-ring,
17/8" x 1/4". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-0491
17/8" x 3/8". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-0497
Insulator Block,Manifold,
Super G,w/O-ring,2-1/16" x 1/4". . . . . . . . . . . . . . 16-0492
Insulator Block,Manifold,
Super G,w/O-ring,2-1/16" x 3/8". . . . . . . . . . . . . 16-0498
Insulator Block,Manifold
Super D,w/O-ring,2-1/4" x 1/4" . . . . . . . . . . . . . 16-0499
54. Screw,
1" x 3⁄8"-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0161
11⁄4" x 3⁄8"-16 . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0162
13⁄8" x 3⁄8"-16 . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0163
2" x 3⁄8"-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0164
21⁄4" x 3⁄8"-16. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0165
21⁄2" x 3⁄8"-16. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0166
11⁄4" x 1⁄4"-20. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0008
11⁄2" x 1⁄4"-20. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0079
21⁄4" x 1⁄4"-20 . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0078
55. Tube,Fast Idle Pick-Up,Super E/G,.
125" x 2.350",Brass . . . . . . . . . . . . . . . . . . . . . . 0381F
56. Tube,Ejector Nozzle,Super E/G,Flared,Brass.106-6124
57. O-ring, 3mm x 5mm x 1mm, Fluorosilicone
each. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-0036
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-0148
58.Cap, VOES Fitting, 3/16" x 5/16" x 1/2",
Rubber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8372
*Early Super E & G Carburetors equipped with a 360° banjo style
fuel inlet that require service must be converted to the current
production style fuel inlet. To update production Super E and G
carburetors equipped with an early 360° style inlet select the
appropriate fuel inlet seat and fuel line from this line drawing
…Continued: Super E & G Carburetor Body and Related Parts
22
18
13
2
6
16
19
20
17
53
21
3
5
57
15
54
23
17
58
14
4
49
24
1
52
9
10
25
48
26
11
28
12
27
55
9
8
29
22
36
38
31
30
56
41
42
47
40
46
43
37
45
51
32
35
32
50
34
44
27
REPLACEMENT PARTS FOR S&S SUPER E & G AIR CLEANERS FOR 1936-UP BIG TWINS
1 Air cleaner cover – All
(Except shovelhead w/5 gallon tanks & cylinders + .075".)
Chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0378
Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0384
Slasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0004
Shovelhead w/5 gallon tanks & cylinders +.075" 17-0372
2 Element, pleated carbon . . . . . . . . . . . . . . . . . . . . 17-0375
Element, pleated cotton . . . . . . . . . . . . . . . . . 106-4722
3Backplate
BT 1936-'84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0330
BT 1984-'92, S&S 41/8" bore
Manufactured prior to 1-1-03 . . . . . . . . . . . . . . . 17-0380
BT 1993-'99, BT 1999-up . . . . . . . . . . . . . . . . . . . 17-0336
41/8" Bore – Manufactured after 1-1-03 . . . . . . 17-0387
4 Cover Screw
Nickel (each). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0072
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-0094
Black (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0310-S
3 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0310
TÜV Style (Chrome) (each) . . . . . . . . . . . . . . . 50-0347-S 10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0347
5 Backplate screw, with threadlock . . . . . . . . . 106-2105
6 Fast idle friction washer . . . . . . . . . . . . . . . . . . 50-7035
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7058
7 Fast idle steel washer . . . . . . . . . . . . . . . . . . . . 50-7037
9 Fast idle lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0329
10 Fast idle brass washer . . . . . . . . . . . . . . . . . . . . 50-7007
b BT 1993-'06
5⁄8" x .025" . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7113
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7010
11 Fast idle lever screw (one required for current
backplate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0041
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7110
5⁄8" x .050" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7114
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0062
12 Shim kit
BT 1984-'92 . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0314
(Includes two each 5⁄16" x .018", 5⁄16" x .030",
5⁄16" x .048", 5⁄16" x .105", and four each 5⁄16" x .125".)
BT 1993-'99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0464
(Includes two each 1⁄2" x .018", 1⁄2" x .030",
1⁄2" x .048", 1⁄2" x .105", and four each 1⁄2" x .125".)
13Shims,
a BT 1984-'92, S&S 41/8" Bore
5⁄16" x .018" . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7038
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7107
5⁄16" x .030" . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7039
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7070
5⁄16" x .048" . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7040
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7112
14 Backplate mounting bolt – BT 1936-'84
5⁄16"-18 x 1" . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0108
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0155
15 Elbow fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8110
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1005
16 Breather screw
Standard length . . . . . . . . . . . . . . . . . . . . . . . . . 17-0338
1" Longer (Use with 1" spacer block.) . . . . . . 17-0343
17 Breather screw o-ring – 5⁄8" O.D . . . . . . . . . . . . . . 50-8032
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8130
18 Breather screw o-ring – 1⁄2" O.D . . . . . . . . . . . . . . 50-8006
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7068
5⁄16" x .105" . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7041
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 Breather fitting . . . . . . . . . . . . . . . . . . . . . . . . . .
2 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 Crankcase breather hose
a. BT 1978-'92 . . . . . . . . . . . . . . . . . . . . . . . . . .
b. BT 1993-'99 . . . . . . . . . . . . . . . . . . . . . . . . . .
22 Vent hose connector . . . . . . . . . . . . . . . . . . . . .
23. Backplate plug 1⁄8"-27 . . . . . . . . . . . . . . . . . . . .
50-7066
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7061
8 Fast idle nylon washer . . . . . . . . . . . . . . . . . . . . 50-7036
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
6
11
10
23
17-0399
12
5
22
9
24
28
29
28
14
1
27
26
6
27
7
8
11
10
8
15
23
25
27
28
29
23
5
1936-'84 Big Twin
22
17-0400, 17-0440 Notched
3
2
4
28
17-0113
17-0339
50-8111
50-8331
1984-’92 Big Twin
21a
13a
2
17-0350
17-0355
15
7 8
3
1
50-8077
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1015
24 Locknut – 5⁄16"-18
(Use with support bracket - see #26.) . . . . . . 50-5021
50-7060
9
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 Breather screw washer . . . . . . . . . . . . . . . . . . . 50-7119
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7062
5⁄16" x .125"
(Use on BT 1936-'84 when insulator block
is installed.) . . . . . . . . . . . . . . . . . . . . . . . . . 50-7042
50-7111
5⁄8" x .075" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7115
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
21a
…Continued: Replacement Parts for S&S® Super E and G Air Cleaners
36
1999–'06 Harley-Davidson Twin Cam 88
®
®
34
13c
20
17-0403
8
9
1993–’99 Big Twin
6
17-0404
21b
10
11
7 8
23
35
2
23
5
3
13a
37
1
4
6
3
8
9
10
11
7 8
23
25
27
25 Flatwasher – 5⁄16" x 1⁄16" . . . . . . . . . . . . . . . . . .
26 Support bracket
XL 1957-'85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BT 1966-'82 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BT 1983-'84 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BT 1948-'65 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 Mounting bracket bolt – Big Twin
1966-'84 – 5⁄16"-18 x 5⁄8" . . . . . . . . . . . . . . . . .
23
50-7034
5
17-0393
17-0392
16-0471
16-0096
1984–'05 Big Twin
2
50-0106
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0220
1984-'92, S&S 41/8" Bore – 5⁄16"-18 x 11⁄4" . . . 50-0110
28 Lockwasher – 5⁄16" . . . . . . . . . . . . . . . . . . . . . . . 50-7032
29 Flatwasher – 5⁄16" x 1⁄8" . . . . . . . . . . . . . . . . . . . 50-7032
30 Wire tie (NS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8003
31 Hose clamp (NS) . . . . . . . . . . . . . . . . . . . . . . . . . 50-8002
32 Air cleaner assembly
Includes:
Chrome cover, backplate, filter element,
and hardware kit.)
BT 1936-'84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0400
BT 1966-'84 with five gallon tanks
and cylinders .075" longer than stock . . . . . . 17-0440
BT 1984-'92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0399
BT 1993-'99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0404
BT 1999-'06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0403
33 Mounting hardware package (NS)
Includes all parts needed to install following style air
cleaners:
BT 1936-'84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0441
BT 1984-'92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0458
BT 1993-'99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0439
BT 1999-'06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0437
41/8 Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0460
34 Screw vent fitting
a. BT 1993-'99 . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0347
b. BT 1999-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0345
35 Screw, air cleaner to head . . . . . . . . . . . . . . . . . 17-0346
4
41/8" Bore
17-0416
1
36. Washer, silicone coated steel
BT 1993-'99 & BT 1999-up, .520" . . . . . . . . . . 50-7055
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7057
BT 1999-up, .380" . . . . . . . . . . . . . . . . . . . . . . . 50-7054
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37. Shim, .850" x .325" x .400"
S&S 41/8" Bore . . . . . . . . . . . . . . . . . . . . . . . . . . .
38. Spring clamps (NS) . . . . . . . . . . . . . . . . . . . . . .
39 Thread insert 1⁄2"-13 to 5⁄16" -18 (NS)
(Used on 1992 big twins.) . . . . . . . . . . . . . . . . .
40 Breather conversion kit BT (NS) . . . . . . . . . . . .
50-7059
50-7027
50-8001
50-8151
17-0486
Convert early S&S air cleaners for 1993-'99 BT with o-ring
breather fittings to new style breather hardware.
NOTE:
The line drawing is used for
illustration purposes only. Not all of
the parts shown are included and
used in every carb installation. Parts
followed by an N/A are no longer
available. Those followed by an (NS)
means parts are not shown.
29
REPLACEMENT PARTS FOR S&S® SUPER E AND G AIR CLEANERS FOR 1986-UP HARLEY-DAVIDSON® SPORTSTER® MODELS
1. Air cleaner cover
13. Shims,
a. XL 1986-’90
5⁄16" x .018" (each) . . . . . . . . . . . . . . . . . . . . . 50-7038
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7107
Chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0378
Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0384
Slasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0004
2. Element, pleated . . . . . . . . . . . . . . . . . . 106-4722
Element, pleated carbon . . . . . . . . . . . . . 17-0375
16. Breather screw
Standard length . . . . . . . . . . . . . . . . . . . . . . 17-0338
1" Longer (Use with 1" spacer block.) . . . . . . . . . . 17-0343
17. Breather screw o-ring – 5⁄8" O.D. (each) . . . 50-8032
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8130
5⁄16" x .030" (each) . . . . . . . . . . . . . . . . . . . . . 50-7039
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7070
5⁄16" x .048" (each) . . . . . . . . . . . . . . . . . . . . . . . . 50-7040
3. Backplate
XL 1957-'85 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0330
XL 1991-'03 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0336
XL 1986-’90 Manufactured prior to 1-1-03 . . . . 17-0380
XL 2004-’06 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0361
4. Cover screw
Chrome (each) . . . . . . . . . . . . . . . . . . . . . . . . . 50-0072
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0094
Black (each) . . . . . . . . . . . . . . . . . . . . . . . . . 50-0310-S
5. Backplate screw, Zinc Plated (each) . . 106-2084
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-2105
6. Fast idle friction washer (each) . . . . . . . . 50-7037
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7061
8. Fast idle nylon washer (each) . . . . . . . . . 50-7036
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7060
9. Fast idle lever . . . . . . . . . . . . . . . . . . . . . . 17-0329
10. Fast idle brass washer (each) . . . . . . . . . . 50-7007
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7010
11. Fast idle lever screw (one required) . . 50-0041
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0062
12. Shim kit
XL 1986-’90 . . . . . . . . . . . . . . . . . . . . . . . . 17-0314
(Includes two each 5⁄16" x .018", 5⁄16" x .030",
5⁄16" x .048", 5⁄16" x .105", and four each 5⁄16" x .125")
XL 1991-up . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0464
(Includes two each 1⁄2" x .018", 1⁄2" x .030",
1⁄2" x .048", 1⁄2" x .105", and four each 1⁄2" x .125")
each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8006
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8077
19. Breather screw washer . . . . . . . . . . . . . . 50-7119
20. Breather fitting (each) . . . . . . . . . . . . . . . . 17-0350
2 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-0355
21. Crankcase breather hose
a. XL 1978-’90 . . . . . . . . . . . . . . . . . . . . . . 17-0113
b. XL 1991-’06 . . . . . . . . . . . . . . . . . . . . . . 17-0339
22. Vent hose connector . . . . . . . . . . . . . . . 50-8111
23. Backplate plug 1⁄8"-27 (each) . . . . . . . . . . 50-8331
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1015
24. Locknut – 5⁄16"-18
(Use with support bracket - see #26) . . . . . . . . . . 50-5021
25. Flatwasher – 5⁄16" x 1⁄16" . . . . . . . . . . . . . . . 50-7034
26. Support bracket
XL 1957-’85 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0393
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7028
5⁄16" x .105" (each) . . . . . . . . . . . . . . . . . . . . . 50-7041
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7062
5⁄16" x .125" (Use on BT 1936-'84 and XL 1957-'85
when insulator block is installed.) (each) . . . . . . . . . . 50-7042
18. Breather screw o-ring – 1⁄2" O.D. (H-D® #11110)
2 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7042P
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7066
b. XL 1991-up
5⁄8" x .025" (each) . . . . . . . . . . . . . . . . . . . . . 50-7113
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7110
5⁄8" x .050" (each) . . . . . . . . . . . . . . . . . . . . . 50-7114
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7111
5⁄8" x .075" (each) . . . . . . . . . . . . . . . . . . . . . 50-7115
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7112
.515" x 1" x .125"(each) . . . . . . . . . . . . . . . . . . . 50-7090
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-7101
14. Backplate mounting bolt – XL 1957-'85
5⁄16"-18 x 1" (each) . . . . . . . . . . . . . . . . . . . . . 50-0108
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0155
15. Elbow fitting (each) . . . . . . . . . . . . . . . . . . 50-8110
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-1005
XL 2004-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0305
27. Mounting bracket bolt – XL 1957-’90 and
2004-’06
5⁄16"-18 x 11⁄4" . . . . . . . . . . . . . . . . . . . . . . . . 50-0110
28. Lockwasher – 5⁄8" . . . . . . . . . . . . . . . . . . . 50-7032
29. Flatwasher – 5⁄16" x 1⁄8" . . . . . . . . . . . . . . . 50-7033
30. Wire tie (N/S) . . . . . . . . . . . . . . . . . . . . . . . 50-8003
31. Hose clamp (N/S) . . . . . . . . . . . . . . . . . . . 50-8002
12
9
6
7
8
11
10
8
15
23
25
27
23
5
22
3
2
4
30
1
1986-’90 Sportster® Models
17-0399
21a
Continued...Replacement Parts for S&S® Super E and G Air Cleaners For 1986-Up Harley-Davidson® Sportster® Models
32. Air cleaner assembly (Includes: Chrome cover,
backplate,
filter element, and hardware kit)
XL 1957-’85 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0400
XL 1986-’90 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0399
XL 1991-'03 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0404
33. Mounting hardware package (N/S)
Includes all parts needed to install following style air cleaners:
XL 1957-'85 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0441
XL 1986-’90 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0458
XL 1991-'03 . . . . . . . . . . . . . . . . . . . . . . . . . 17-0439
34. Screw vent fitting
a. 1991-'12 XL . . . . . . . . . . . . . . . . . . . . . . . 17-0347
35. Screw, air cleaner to head . . . . . . . . . . . 17-0346
36.Washer, silicone coated steel
XL 1991-'06, .520" (each) . . . . . . . . . . . . . . 50-7055
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7057
37. Spring clamps (N/S) . . . . . . . . . . . . . . . . 50-8001
38. Breather conversion kit (N/S)
Convert early S&S air cleaners for 1991-’03 XL with o-ring breather
fittings to new style breather hardware. XL kits
include special insulator block, and manifold screws.
XL 17⁄8" carbs . . . . . . . . . . . . . . . . . . . . . . . . 17-0487
36
34
13b
20
8
9
21b
10
11
7 8
6
23
35
2
23
5
3
1991-'03 Sportster® Models
17-0404
1
4
(N/S) = Not Shown
34
36
20
36
9
6
8
7
21b
10
11
35
8
23
26
29
24
13a
5
3
27
2
4
1
2004-'06 Sportster® Models
17-0428
NOTE:
The line drawing is used for illustration purposes only. Not all of the parts shown are
included and used in every carb installation. Parts followed by an N/A are no longer
available. Those followed by an (NS) means parts are not shown.
31
REPLACEMENT PARTS FOR S&S® AIR CLEANERS FOR BUELL® MOTORCYCLES
1. Air cleaner cover
Chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0078
Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0075
2. Air cleaner element . . . . . . . . . . . . . . . . 17-0079
3. Air cleaner backing plate
Super E & G carburetors . . . . . . . . . . . . . 17-0000
Stock carburetors . . . . . . . . . . . . . . . . . . . 17-0003
4. Cover screw
Chrome (each) . . . . . . . . . . . . . . . . . . . . . . . . 50-0072
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0094
Black (each) . . . . . . . . . . . . . . . . . . . . . . . . . 50-0310-S
5. Air cleaner backplate screw
For S&S Super E&G
Zinc Plated (each) . . . . . . . . . . . . . . . . . . . . 106-2084
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-2105
For CV (each) . . . . . . . . . . . . . . . . . . . . . . . . . 50-0076
6. Cap screw, breather, &
air cleaner mount . . . . . . . . . . . . . . . . . . 17-0338
7. Shim, .620" I.D. x .800" O.D. x .185"
each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7120
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-2956
8. O-ring 1⁄2" O.D. x 5⁄8" I.D. x 1⁄16" CS (each) 50-8032
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8130
11
6
9
7 8
Buell® Motorcycles
with S&S E&G Carb
17-0402
10
14 16
14
12 13
17
15
21
23
22
19 20
5
24
18
4
2
3
19
25
1
9. O-ring 3⁄8" O.D. x 1⁄2" I.D. x 1⁄16" CS (H-D® #11110)
each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8006
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8077
10. Breather fitting (each) . . . . . . . . . . . . . . . 17-0350
2 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0355
11. Shim kit air cleaner backplate
(includes 4 each of .018", .030", .048") . . . . . 17-0464
Replacement Shims
1⁄2" x 1" x .018 (each) . . . . . . . . . . . . . . . . . 50-7085
1⁄2" x 1" x .030 (each) . . . . . . . . . . . . . . . . . 50-7086
1⁄2" x 1" x .048 (each) . . . . . . . . . . . . . . . . . 50-7087
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7098
1⁄2" x 1" x .105 (each) . . . . . . . . . . . . . . . . . 50-7089
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7097
1⁄2" x 1" x .125 (each) . . . . . . . . . . . . . . . . . 50-7090
5 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7101
12. Washer, friction, spring (each) . . . . . . . 50-7035
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7058
13. Washer, flat .323" x 5⁄8" x 1⁄32" (each) . . . 50-7037
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7061
14. Washer, flat, nylon .323" x 5⁄8" x .020"
each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7036
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7060
15. Lever, fast idle, . . . . . . . . . . . . . . . . . . . 17-0327
16. Washer, flat w/step, brass (each) . . . . . 50-7007
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7010
17. Screw, PH slotted 10-24 x 1⁄4" (each) . . 50-0041
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0062
18. Screw, HH, cap, 1⁄4"-28 x 7⁄8" . . . . . . . . 50-0074
19. Washer, flat, 1⁄4" x 5⁄8" x 1⁄16" (each) . . . . . 50-7020
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7076
20. Locknut - 1⁄4" -28 (H-D® #7683)(each) . . . . 50-5010
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5015
21. Hose, breather vent . . . . . . . . . . . . . . . 17-0365
22. Fitting, hose, Buell air cleaner . . . . . 50-8121
23. Hose, breather . . . . . . . . . . . . . . . . . . . . 17-0339
24. Bracket, carb support, air cleaner . . 17-0309
25.Tubing, rubber - 3⁄8" x 5⁄8" x 3' . . . . . .
32
19-0169A
NOTE:
All reference to H-D® 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 H-D® part number shown.
REPLACEMENT MANIFOLD PARTS
1-3-
4-
5-
6-
7-
8-
9-
10-
11-
12-
13-
14-
Intake manifold
See S&S® Catalog for part numbers.
Manifold bolts
3⁄8"-16 x 1" ........................................................................................................50-0161
10 pack.................................................................................................................50-0186
3⁄8"-16 x 11⁄4"......................................................................................................50-0162
10 pack................................................................................................................................................... 50-0177
(Use in bottom hole with 16-0096 or 16-0471 bracket or in top
and bottom holes with 16-0491 or 16-0492 inslator block.)
3⁄8"-16 x 13⁄8"......................................................................................................50-0163
5 pack..................................................................................................................................................... 50-0178
(Use in bottom hole with 16-0096 or 16-0471 bracket and 16-0491 or
16-0492 insulator block.)
3⁄8"-16 x 2".........................................................................................................50-0164
5 pack..................................................................................................................................................... 50-0185
3⁄8"-16 x 21⁄4"......................................................................................................50-0165
5 pack..................................................................................................................................................... 50-0180
3⁄8"-16 x 21⁄2"......................................................................................................50-0166
Manifold o-ring - 1955-'78 Harley-Davidson® BT & Sportster®.........................50-8046
10 pack................................................................................................................................................... 50-8132
Manifold rubberband - 1979-'85 BT & Sportster...............................................16-0238
10 pack................................................................................................................................................... 16-0245
Manifold o-ring - 1984-up BT & 1986-up Sportster
S&S Manifold.....................................................................................................16-0235
10 pack................................................................................................................................................... 16-0243
Manifold clamps
O-ring pre 1979.................................................................................................16-0230
Band 1979 to ’85...............................................................................................16-0231
Manifold Flanges 1984-’06 BT & 1986-’06 Sportster
Front mounting flange......................................................................................16-0232
5 pack..................................................................................................................................................... 16-0600
Rear mounting flange.......................................................................................16-0233
5 pack..................................................................................................................................................... 16-0601
Carb mounting bracket - 1948-’65 BT ...............................................................16-0096
Carb mounting bracket assembly......................................................................16-0471
(Includes 1 each 2-piece bracket 50-0108, 50-7034, 50-5021)
Support bracket bolt – 5⁄16"-18 x 1"...................................................................50-0108
10 pack................................................................................................................................................... 50-0155
Flat washer – 5⁄16" x 1⁄16".....................................................................................50-7034
Lock nut – 5⁄16"-18.............................................................................................50-5021
15-
16-
17-
18-
1" Aluminum spacer blocks
For 17⁄8" Super E ................................................................................................16-0057
(Includes 1 each 1" spacer block & 50-8013 o-ring)
For 21⁄16" Super G...............................................................................................16-0357
(Includes 1 each 1" spacer block & 50-8015 o-ring)
Insulator blocks
17⁄8" Super E – All big twins...............................................................................16-0491
(Includes 1 each insulator block & 50-8016 o-ring)
21⁄16" Super G – All big twins.............................................................................16-0492
(Includes 1 each insulator block & 50-8015 o-ring)
17⁄8" E – for Sportster (Manufactured after 6-15-01)........................................16-0497
(Includes 1 each insulator block & 50-8016 o-ring)
21⁄16" – for Sportster (Manufactured after 6-15-01) .........................................16-0498
(Includes 1 each insulator block & 50-8015 o-ring)
Manifold orings
For 17⁄8" E carb body & insulator block..............................................................50-8016
10 pack.................................................................................................................................................. 50-8094
For 17⁄8" spacer block..................................................................................... 50-8034-S
2 pack..................................................................................................................50-8034
For 21⁄16" G carb body, insulator block, & spacer block.......................................50-8015
10 pack.................................................................................................................................................. 50-8093
VOES tubing - 9" piece......................................................................................19-0395
5 pack..................................................................................................................19-0398
4
2
5
6
8
17
15
4
17
4
16
14
3
12
13
1
4
10
9
11
7
18
33
NOTES:
34
NOTES:
35
36
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