S&S Cycle | Motorcycle Accessories | Service manual | S&S Cycle Motorcycle Accessories Service manual

Instruction 510-0015
S&S Cycle, Inc
Copyright © 2009, 2012
by S&S® Cycle, Inc.
Phone: 608-627-1497 • Fax: 608-627-1488
14025 County Highway G PO Box 215
Viola, Wisconsin 54664
Technical Service Phone: 608-627-TECH (8324)
Technical Service Email: sstech@sscycle.com
Website: www.sscycle.com
All rights reserved.
Printed in the U.S.A.
S&S Power Tune Duals For Touring Models
1995-2008 (PN 550-0003 & 550-0142)
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.
Statements in this instruction sheet preceded by the following words are of
special significance.
Means there is the possibility of injury to yourself or others.
Means there is the possibility of damage to the part or motorcycle.
Other information of particular importance has been placed in italic type.
S&S recommends you take special notice of these items.
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
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.
(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.
ATTENTION INSTALLER (if other than owner):
Please forward this instruction sheet to the purchaser of this product. These instructions also contain valuable information necessary to the end user.
These instructions describe the procedure for properly installing S&S® Power Tune Duals. Review instructions carefully before beginning, as they
contain important information. Please retain for future reference.
All Models:
•• This system may not be compatible with swing arm pivot suspension stabilizers.
•• Right side floorboard must be mounted in the lowest position.
•• On pre- 1999 models the brake pedal may need to be modified to gain additional clearance to the heat shield.
Ground and cornering clearance may be reduced. Clearance will be reduced when bikes are fitted with shorter shocks.
1 – ¼" drive ratchet 1 – 7/16" box wrench
1 – ¼" drive ½" socket
1 – 1/2" box wrench
1 – 3/16" Allen wrench 1 – 9/16" box wrench
1 – ¼" drive 6" extension 1 – 5/16" Allen wrench
Supplies: New muffler clamps and 243 Loctite®.
1 – ¼" nut driver 1 – 15mm box wrench
1 – 3/8" Allen wrench
1- Remove right front floorboard and floorboard brackets.
2- Remove saddlebags.
3- Remove mufflers, save clamps (Harley-Davidson® states clamps are not reusable). See step 19.
4- Disconnect the O2 sensors (2007-up). Remove heat shields and exhaust headers. Save the 5/16-24 hex flange port nuts.
5- Remove and save retaining rings and exhaust flanges from old exhaust headers.
6- Remove the rear exhaust bracket mounted to transmission, this bracket is not needed. Remove transmission end cover to access fasteners
(1999-'06). Replace screws.
7- Remove the left side exhaust/starter bracket. Replace screws.
8- Remove and discard four of the ¼" socket heads closest to the rear of the oil pan (leave center rear screw intact). See the photo.
9- Remove and discard exhaust port gaskets. Install new conical gaskets.
New conical port gaskets (S&S 106-5029) must be used to avoid leaks.
10-Install flanges and retaining rings on new exhaust headers. Oxygen sensors and/or supplied plugs/gaskets may be installed at this time. Use
anti-seize on threads.
11-Install new header system using saved 5/16-24 hex flange nuts. Seat front pipe first then rear. A firm pull rearward on the rear header, while
keeping the front header seated, may be necessary to clear the rear head casting. Be careful not to damage gaskets. Do not fully tighten
nuts yet.
12-Install the supplied Torca/AccuSeal pipe clamp on the expanded end of the crossover pipe weldment with the open end down and the nut
facing out (cannot be installed later).
13-Position the crossover weldment under the oil pan and slide its expanded end onto the end of the front header pipe.
14-Align the slots in the crossover pipe mounting brackets with the oil pan mounting holes. Install the four ¼-20 x 3.50" hex cap screws, ¼" flat
washers and the two crossover spacer weldments. Use 243 Loctite on the threads. Torque the fasteners to 90-108 in-lbs.
15-Torque the port flange nuts evenly. Do not tighten the Torca clamp until the heat shields are in place.
To ensure there are no leaks and the system is properly aligned the front and rear port nuts must be evenly torqued.
16-Clean header pipes and crossover (see step 22).
17-Insert worm gear clamps into slots on the back side of the heat shields. All clamp screws except the upper two on the rear shield should be
positioned so the screw heads can be accessed from the front or bottom of the headers. Tip: Insert clamps halfway into the slots and bend the
ends outward to ease installation over header pipes.
18-Install heat shields. Connect and loosely tighten all worm gear clamps. Position screw heads for easiest access and tighten with a ¼" nut driver
or screwdriver.
19-Install mufflers. Torque left and right muffler and header/crossover supplied Torca/AccuSeal clamp. Make sure header/crossover clamp does
not contact frame. Tip: Use anti-seize on threads of used muffler clamps. If they clamp down securely they don’t need to be replaced, however
they may be stretched and require replacement.
20-Place the provided floorboard spacers between the frame and floorboard brackets and install in the lowest position. Apply Loctite® and use the
3/8" Allen wrench to tighten the bolts. Next, install the floorboard to the brackets with the original fasteners.
21-Reconnect oxygen sensor electrical plugs.
22-Before operating motorcycle, clean pipes and mufflers with soap and water or window cleaner. Any grease or oil will permanently burn onto
pipes. Dry thoroughly.
Carefully read the enclosed Important Notice sheet. Re-jetting and or recalibration may be required.
Check all mounting hardware to be sure it is tight before and after first operation of motorcycle. Periodically, check tightness of all
mounting hardware.
USE AND CARE: Wash your accessories with the same care you use when washing your motorcycle. Use mild soap and water. DO NOT use abrasive
chemicals or cleaners, or high pressure washers.
Cover ends of mufflers when washing motorcycle. Mufflers may internally corrode if saturated with water and allowed to sit.
Header weldment 1
Crossover weldment 1
Torca/AccuSeal Clamp 1
Front heat shield 1
Rear heat shield 1
Left heat shield 1
Heat shield clamps 10
Crossover Spacer Weldment 2
¼-20 x 3.50 oil pan bolts 4
Oil pan washers 4
O2 plugs 2
O2 washers 2
Floorboard spacers 2
Exhaust port gaskets 2
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