Sportster PG 2005

Add to my manuals
52 Pages

advertisement

Sportster PG 2005 | Manualzz

Table Of Contents

S&S Sportster & Buell Style Engines Pages 1-3

Using cutting edge technology to provide a better power plant for V 2 style Sportsters & Buell style motorcycles.

Slip-On Performance Mufflers Pages 4-5

S&S performance mufflers make a great high-performance exhaust system with a low price tag.

Hot Set Up Kits Pages 6-8

Proven combinations fo components that offer the best performance value.

Sidewinder

& Stroker Kits Pages 9-11

S&S Sidewinders ™ have always been a good way to increase displacement of an existing engine. Stock bore strokers are still the most economical and cost effective way to make more power because the existing stock cylinders are used.

Carburetor Kits Pages 12-16

The most popular performance carbs for Harleys in the world.

Also, get our new air cleaner covers and air filter elements for your Super E & G Carb.

Jets Page 17

Carburetor replacement jets and a handy tool for changing main jets.

Cleaner Kits & Air Filter Elements Pages 18-20

Get our new air cleaner covers and air filter elements for your

Super E & G Carb. Also find new air cleaner cover designs.

Crankcases Pages 21-22

S&S Super Stock ™ Sportster and Buell style crankcases are an excellent choice for stock replacement for 1991 and later engines, and other high performance engine upgrades.

Tappet Guides & Tappets Pages 23-24

Tappet Guides for 1986-up V 2 Sportster style engines and

Hydraulic Tappets for 1986-'90 style Sportsters.

Camshaft Kits

Meeting the needs of high performance engines.

Page 25

Valve Spring Kits Page 26

S&S valve spring kits are designed to simplify high-lift cam installation.

Adjustable Pushrod Kits Pages 27-28

Pushrods for V 2 Sportsters and Ironhead Sportsters.

Super Stock

Cylinder Head Kits Pages 29-33

One of the most important things that needs to be done to get more horsepower out of any engine is to get more air into it.

S&S can help.

Rocker Covers Pages 34-35

S&S manufactures two types of rocker covers for V 2 engines, billet and die-cast.

style

Rocker Arms and Rocker Shafts Pages 36-37

S&S forged roller rocker arms or new forged standard rocker arms.

Speedometer Calibrator Page 38

The S&S Speedometer Calibrator allows the rider to correct Harley-Davidson ® electronic speedometers easily.

S&S Warranty Information

S&S Website and Show Schedule

We've just updated our website.

Suggested Retail Price List

Pages 39-42

Page 53

Pages 44-47

S&S 10-Second & 11-Second Club

Are you fast enough to join?

Page 48

Overview

America's Engine Builder

Ask American V-Twin enthusiasts to name one manufacturer of high performance engines, and nine times out of ten they'll say S&S! And you gotta' wonder about the one guy who didn't. S&S is the largest manufacturer of engines for the

V-Twin high performance aftermarket.

S&S engines power more custom V-Twins than anyone else's, and they have always been popular as a high performance upgrade in stock motorcycles. What could be simpler? Take your old engine out, and put a new S&S engine in. It's just that simple, and you have a sleeper hog that will run the wheels off the competition. The reason that S&S engines are so popular can be summed up in two words: "Proven Performance".

These industry awards pretty much tell the story. S&S engines have been receiving awards from industry magazines for years. Some that we are most proud of are the "Engine Of The Year" awards from both Hot Bike and V-Twin magazines for the S&S 124 and Tribute 145 engines.

visit us at www.sscycle.com

When you stop and think about it, the trophies that company founder George Smith won at the race track in the late 1940's early 1950's were awards that really tell you what S&S is all about . . . Proven Performance.

Performance and Reliability

Everybody knows that S&S engines make a lot of power. What you may not be aware of is that because of our innovative designs and premium materials, they last a lot longer than you might think was possible for a high performance engine. Let's face it, the stroker engines of the late 1960's and early 1970's were pretty crude by today's standards, and they gave high performance motors a bad reputation as far as engine life is concerned.

But keep in mind that the high performance industry has come a long way in the last 35 years or so, and S&S has been a leader in the quest not only for more power, but also for greater dependability and improved engine life. So if you could double your horsepower and still get near stock engine life, wouldn't that be a fair trade off? Judging from the number of large displacement S&S engines on the street, the answer seems to be "Yes!".

1

Engines

2

S&S 91" & 100" SPORTSTER & BUELL STYLE ENGINE

S&S complete Engines for Sportsters and Buells are available in 91" and 100" displacements. The 91" engines have 3 5 ⁄

8

" stroke with a 4" bore. Cylinder length is stock so the engine fits in all frames with little or no modification. Compression ratio of the 91" engine is

9.5:1. The 100" engine has 4" stroke with a 4" bore.

Cylinder length is .260" taller than stock. The 100" engine will generally fit in stock Sportster frames with no modification, but due to the increased cylinder length, requires the S&S billet motor mount to fit in the Buell chassis. Exhaust modifications may also be required to gain frame clearance when installing a 100" engine in a

Buell frame. Compression ratio of the 100" engine is

10.3:1. Crankcases have 1986-'90 (four-speed) style cam geometry, 1991-up (five-speed) style driveside, and are available only in natural aluminum finish. Primary components, charging system, ignition system, oil pump, and transmission components are not included.

Complete Sportster and Buell

Engines Include:

Special Application XL or Buell style crankcases.

Complete S&S flywheel assembly.

S&S Super Stock ™ cylinder heads.

S&S cylinders and pistons.

S&S 555 camshaft set and required gearcase components.

Adjustable pushrods and pushrod cover assemblies.

S&S billet tappet guides with hydraulic tappets.

Super G carburetor kit.

S&S gear billet XL style cover kit.

S&S billet aluminum rocker covers and roller rocker arms.

Options Include:

Natural aluminum or black powdercoat finished cylinders and heads.

Unfinished, polished, or chrome plated billet rocker covers.

Assembled by S&S technicians or unassembled.

NOTES:

The S&S billet motor mounts are required for installaton of the 100" Buell style engines due to the increased engine height. Although the 91" engine can be installed with a stock Buell motor mount, we recomend the S&S billet mounts to be used for the increased strength.

The S&S Sportster and Buell style engines do not include drive train components or charging system. Engine builder must supply 1991 and later style (5-speed) transmission, clutch, primary components, and charging system.

Stock or aftermarket 1986 and later Sportster style oil pumps may be used. 1986-'87 bolt-on oil filter mount is also required.

S&S Complete Engines for Sportsters

Engine, complete, 100" Sportster

31-9299

Engine, complete, 91" Sportster ..................................31-9302

S&S Complete Engines for Buells

Engine, complete, 100" Buell*.....................................31-9301

Engine, complete, 91" Buell.........................................31-9300

* Requires S&S billet motor mount.

Frame to exhaust clearancing may be required.

email us at [email protected]

Motor Mounts

S&S Billet Motor Mounts for Buells

S&S billet front motor mounts for 1996 -'02 V-Twin

Buell motorcycles are machined from 6061-T6 billet aluminum and offer a considerable increase in strength over stock. They are available in three versions. The first version is intended to be a heavy duty replacement motor mount for Buells with stock height engines. The second version is designed to allow the S&S 100" engine to be installed in a stock Buell chassis. A special order front motor mount is also available. The special order front motor mount allows builders to install custom engines which are between .200" shorter and

.430" taller than stock. Keep in mind that when installing some non-stock height engines in a stock Buell chassis, exhaust and frame clearance may be a problem.

A slotted steel top motor mount is also required for taller than stock engines.

S&S Front Motor Mounts

for 1996 -'02 V-Twin Buells

For Stock Height Engines.................................................93-4059

For S&S 100" Engines......................................................93-4060

Special Order ...................................................................93-4061

Slotted Steel Top Motor Mount........................................93-4062

visit us at www.sscycle.com

3

Mufflers

S&S Slip-On

Performance Mufflers

One of the most popular and cost effective performance upgrades you can make to a

Harley-Davidson ® motorcycle is to replace the stock exhaust with a set of low restriction, high performance mufflers. The stock exhaust pipes and S&S performance mufflers make a great high performance exhaust system with a low price tag.

New for 2005!

S&S High Performance Exhaust for 2004-Up Sportsters

S&S introduces a new high performance exhaust for 2004 and later Sportsters. These mufflers slip on to the stock header pipes, and are similar in design and performance to the S&S

Mufflers for 1987-2003 Sportsters. However they are designed to be a direct replacement for stock 2004-up XL style mufflers and connect to the crossover pipe built into the stock muffler support bracket.

4

50

40

80

DYNORUN 014

DYNORUN 001

◆ Max Power = 66.5

◆ Max Power = 59.4

◆ Max Torque = 68.8

◆ Max Torque = 63.2

70

60

30

2.0

2.5

3.0

3.5

RPM (x1000)

4.0

4.5

5.0

5.5

This dyno chart compares the performance of a 1200 XL with stock exhaust and S&S Super E carburetor with the same bike after installing the S&S Slip-On Performance Mufflers. Seven more horsepower and over five more ft/lb of torque. That is a very cost effective increase in performance.

Dyno results from Dyno Jet 150 chassis dynamometer at S&S

Cycle’s Research and Development facility.

40

30

60

50

80

70

1987-'03 Sportster Style -- Chrome 55-6008

2004-up Sportster Style -- Chrome 55-6031

S&S Slip-On Muffler Kits

1987-'03 Sportster Style, Chrome ...........................55-6008

2004-up Sportster Style, Chrome ............................55-6031

NOTES:

It may be necessary to rejet the carburetor or recalibrate the fuel injection system for best performance when a change is made in the exhaust system.

Dyno results are from tests performed on a DynoJet 150 dynamometer at the S&S Research and Development facility in Viola, Wisconsin.

S&S performance mufflers are designed for closed course competition motorcycles only and do not conform to U.S. EPA noise emission standards. Use on motorcycles subject to EPA noise regulations constitutes tampering and is a violation of federal law unless it can be shown that use does not cause the motorcycle to exceed applicable federal standards.

email us at [email protected]

Hot Set Up Kits

Air Cleaner and Exhaust Hot Set Up Kits

Okay, so maybe your budget isn't ready for a new big inch S&S engine yet. But better performance is still within your reach.

Consider the NEW S&S Muffler and Air Cleaner

Hot Set Up Kits. For under $500 you can gain more than 10 horsepower. Dollar for dollar, that's about as good as it gets. The big motors will be there when you're ready, but in the mean time why not pick some low hanging fruit and get more power right now?

S&S Exhaust and Air Cleaner

Hot Set Up Kits...

are the perfect way to balance the performance budget. Kits include a set of S&S performance mufflers and a high flow S&S air cleaner that will fit on either a stock carburetor. A jet kit is also included for maximum power gains and improved drivability.

1987-Up Sportsters

Air Cleaner and Exhaust

Hot Set Up Kits

1987-'03 Sportsters .................................55-6500

2004-up Sportsters .................................55-6501

55-6500

2004 Sportster

visit us at www.sscycle.com

2004-Up Sportsters 55-6501

This dyno comparison show the gains in horsepower and torque that can be had with these simple "bolt on" kits.

Tests were conducted on a DynoJet 250 chassis dynamometer at the

S&S Research and Development facility in Viola, Wisconsin.

5

Hot Set Up Kits

74 XLSS Hot Set Up Kit

Includes S&S Super Stock

Cylinder Heads

For Evolution Sportsters.

This Hot Set Up puts some "sport" in your

Sportster. Turns any 883cc, 1100cc, or 1200cc

Sportster into a potent 74 inch street bike. The combination of S&S Super Stock ™ heads and an aggressive cam profile produce a power curve that is ideal for the light weight of the Sportster. All components are carefully selected for performance and dependability. Flywheel rebalancing is not required in stock 833cc and 1200cc engines.

Dyno results from Dyno Jet 150 Chassis dynamometer at

S&S Cycle’s Research and Development facility in Viola, WI.

The 74XLSS Hot Set Up

yields 74 cubic inches, and is available in compression ratios of

9.2:1 and 10.5:1. Kit includes a Super Stock ™ cylinder head kit with valves and springs installed, manifold with o-rings and flanges, required hardware, top end gaskets, .500 lift cams, adjustable chrome moly pushrods, an HL

2

T kit, a Super E carb kit, and installation instructions.

S&S pistons must be ordered separately.

S&S 74" HOT SET UP KITS

FOR EVOLUTION SPORTSTER ENGINES

Model Year

1980-'90

1991-up

Kit Number

Black

90-0326

90-0327

Kit Number

Natural

90-0324

90-0325

NOTE:

Pistons are available for 883 and 1200 cc engines that do not require rebalancing of the stock flywheels. Flywheels for the 1100cc engines should be rebalanced.

6

This kit requires special S&S pistons.

Order the correct piston oversize from these charts.

92-2016 SERIES PISTONS

74" XL S&S Heads 10.5:1 Compression

No rebalancing for 1200cc.

Oversize Part Number

Standard 92-2016

+.005

+.010

92-20165

92-2017

+.020

+.030

92-2018

92-2019

Cylinder & Piston Kit - Natural 91-3014

Cylinder & Piston Kit - Black 91-3908

92-2056 SERIES PISTONS

883 to 1200XL V 2 S&S Heads 10.5:1 Compression

No rebalancing for 883cc.

Oversize Part Number

Standard 92-2056

+.005

+.010

+.020

+.030

92-20545

92-2057

92-2058

92-2059

Cylinder & Piston Kit - Natural 91-3012

Cylinder & Piston Kit - Black 91-3906

92-2036 Series Piston

email us at [email protected]

Hot Set Up Kits

89 XL HOT SET UP KIT

Sidewinder

/Stroker Kit 89"

For Evolution Sportsters with Stock H-D Cylinder Heads.

The 89XL Hot Set Up is based on the

S&S 89" XL Sidewinder ™ which is the largest practical motor that will fit into the stock Sportster chassis with only minor modifications. This kit is for the serious street performance and competition rider. Our Hot Set Up 89 has gained a hard-earned reputation as the "Giant Killer".

Stock crankcases must be bored to accept the 3 5 ⁄

8

" big bore cylinders. Sportsters 1991-up require conversion to the 1986-'90 style pushrod cover assemblies.

Pushrod adapters are included.

89" XL Hot Set UP

...........................................................32-3089

89 XL Hot Set Up...

yields 89 cubic inches with a compression ratio that is determined by the extent of modification to stock cylinder heads. Hot Set Up includes an 89"

Sidewinder ™ kit with 4 5 ⁄

16

" stroker flywheels assembled with mainshafts and connecting rods, S&S 3 5 ⁄

8

" bore

Sidewinder ™ cylinders and pistons complete, a valve spring kit, an HL

2

T kit, head bolts, pushrod cover keepers, front and center engine mounts, a Super E carb kit, and installation instructions.

Renee...

Renee started riding dirt/mini bikes when she as 10 years old. Growing up on a dairy and quarter horse farm, she snuck her first mini bike home in the back of a friend’s boat, kept it hidden in the woods and stole chainsaw gas from her dad. However, her secret only lasted a month or two. After selling her horses

(four legged kind), she purchased a new 883 XL in

1987 and that bike now has 55,000 miles on it. Also in her stable is a 1989 heitage softail with an S&S carb. Renee has been at S&S Cycle for 6 years and works in the Sales Department selling horsepower.

visit us at www.sscycle.com

7

Hot Set Up Kits

8

89 XLSS HOT SET UP KIT

Sidewinder

/Stroker Kit 89"

For Evolution Sportsters

Includes S&S Super Stock

Cylinder Heads.

Adding S&S Super Stock ™ heads to the popular 89XL kit takes performance to the next level. This is the biggest Hot Set Up kit we offer for Sportsters. Not for the faint of heart! Stock crankcases must be bored to accept the 3 5 ⁄

8

" big bore cylinders. Sportsters

1991-up require conversion to the

1986-'90 style pushrod cover assemblies using adapters provided. Some frames may require minor clearancing.

89 XLSS

Hot Set Up Kits

9.5:1 Compression Ratio ............ 90-0389

10.2:1 Compression Ratio............90-0352

This dyno chart shows the performance gains of an 89"

XLSS Hot Set Up over a stock 1200cc Sportster.

Dyno results from Dyno Jet 150 Chassis dynamometer at S&S Cycle’s Research and Development facility in

Viola, Wisconsin.

The 89 XLSS Hot Set Up...

yields 89 cubic inches at 9.5:1 or 10.2:1 compression and includes 4

5

16

" stroker flywheels assembled with mainshafts and connecting rods, 3

5

8

" bore Sidewinder ™ cylinders and pistons complete, a Super Stock ™ cylinder head kit with valves and springs installed, manifold with o-rings and flanges, required hardware, top end gaskets, .500" or .550" lift cams, adjustable chrome moly pushrods, an HL

2

T kit, head bolts, pushrod cover keepers, pushrod tube adapters (1991-up kit only), front and center engine mounts, a Super E carb kit, and installation instructions. Select kit with desired compression ratio, and specify model year and carburetor preferred.

email us at [email protected]

Sidewinder

& Stroker Kits

S&S Sidewinder

Big Bore and Stock Bore Stroker Kits

S&S stock bore stroker kits and

Sidewinder ™ 3

5

8

" big bore kits are designed to increase the displacement of an existing stock engine. More cubic inches means more power but in addition to horsepower gains, reliability, ease of installation, and compatibility with stock components are also important considerations to our customers. With an S&S kit, you can build a performance street engine with confidence. Our years of experience add up to proven performance.

Shown here is the 89" V2 Sportster Kit. Typical Sidewinder ™ stroker kits include everything necessary for a complete installation.

91-3204

For all OHV Big Twins and Sportsters.

The easiest, most cost effective way to increase the performance of your Harley.

Increased displacement for better performance.

Maximum running life through innovative design features and premium materials.

Flexibility for a variety of performance needs.

Minimal installation problems.

Kit Selections

There is kit available to match nearly any riding style—for touring, riding double, sidecar or trailer operation, and drag strip.

Ironhead Sportster 72" or 74"

Sportster V 2 s from 74" to 103"

Buells 74" to 79"

Selection

Considerations:

Lower compression kits will tolerate lower quality gasoline and generally last longer than higher compression kits.

Cast pistons generally allow tighter running clearances for extended life and quieter operation.

Forged pistons are noted for strength and durability in high performance applications.

Engine Size - Smaller displacements retain stock-like engine life while providing significant additional horsepower. Larger, higher compression kits provide greater horsepower gains with some reduction of engine life.

Stock Compatibility

Oil feed and oil return systems to and from heads match the stock systems.

All kits are made to work with stock components and come complete so it is not necessary to buy other aftermarket parts.

An almost deceptive stock-like appearance!

Ease of Installation:

All kits can be installed by any

H-D repair shop doing engine rebuilding who has access to a boring bar, no sophisticated machine shop facilities are required.

Most kits come complete with all parts necessary to make the conversion.

visit us at www.sscycle.com

9

Stroker Kits

10

Continued...

S&S Sidewinder Big Bore and Stock Bore Stroker Kits

S&S Sidewinder

Big Bore and Stock Bore Stroker Kits

General Information

The S&S stock bore stroker kits described and pictured in this section are available for Ironhead

Sportster engines. S&S big bore Sidewinder ™ kits are available for Evolution Sportster engines. All kits include complete installation instructions which detail the model-specific modifications sometimes required. Additional information pertaining to basic engine assembly procedures and recommended running clearances is available in the appropriate

Harley-Davidson Factory Service Manual.

Making It All Work...

Sidewinder ™ and stroker kits create large displacement engines which can be difficult to start. This should be kept in mind when considering one of these kits. Using an appropriate cam with longer duration, and later intake closing time to reduce cranking compression will make starting easier. Not only will the appropriate cam make starting easier, but it is necessary in order for the engine to achieve its full potential. We urge you to consider purchasing an S&S Hot Set Up Kit that includes the recommended camshaft. (See pages 8 through 10 of this

Catalog or see page 25 for help with camshaft selection.)

74" Kit for 1972-'85 Sportsters includes a set of stroker flywheels, a pair of stroker pistons complete with rings, wristpins, buttons , and installation instructions.

NOTES :

Rod length varies for Evolution Sportster kits. 79" engines require stock length 6.926" rods. 89" require special 7.113" rods. 96" and larger Evolution Sportster engines require 7.440" rods.

A number of options make it easy...

to build big bore and stroker engines to achieve your specific goals.

Do your own flywheel assembly and balancing or allow S&S to do it for you.

These kits are available with or without sprocket and pinion shafts and are shipped unassembled or completely assembled and ready to install into the cases.

However, Evolution Sportster engines must use S&S mainshafts since stock mainshafts are not reusable.

IRONHEAD SPORTSTER STOCK BORE STROKER

KITS

Displacement Stroke Bore

72"

74"

4 1 ⁄

2

" 3 3 ⁄

16

"

4 5 ⁄

8

" 3 3 ⁄

16

"

Compression Piston

Ratio Type

8:1

9:1

Piston

Series

Piston

Page #

Application

Forged 92-3700 P. 4-50 Short Trips, street & strip

Forged 92-3700 P. 4-50 Short Trips, street & strip

Engine Life

Fair

Fair

Order stroker pistons separately. Refer to page listed in chart for correct oversize.

Kit Part

Number

32-3772

32-3774

EXTRA COST OPTIONS

Pinion Sprocket

Shaft Shaft

Connecting

Rod

Assembly

Flywheels

Assembled

email us at [email protected]

Sidewinder

Kits

S&S V

2

Sportster & Buell Big Bore Sidewinder

Kits

S&S offers several Sidewinder ™ Kits for Evolution Sportsters. The 79" Kit is a top end kit with stock length cylinders and can be used with stock XL flywheels. Rebalancing is neccessary. The 89" Kit is the biggest kit that will fit in a stock frame, and inlcudes a set of 4 5 ⁄

16

" stroke S&S flywheels. The 103" Kit requires extensive frame modificatons due to the increased engine height and includes a set of S&S 5" stroke XL flywheels.

V

2

SPORTSTER & BUELL BIG BORE SIDEWINDER

KIT SUMMARY CHART

Displacement Stroke Bore

Compression

Ratio

3

13

16

" 3

5

8

" 9.2:1 or 11.0:1

Compression

Ratio

Piston

Type

F

Cylinder

Length

Stock

Engine Life Model Year

79" **

89"

103"

4 5 ⁄

16

" 3

5" 3

5

5

8

" 9.5:1 or 10.2:1

8

" 10.5:1 or 11.8:1

F

F

+.437"

(5.087")

+1.100"

(5.750")

Stock-like

Very good

Poor

1986 to present

1986 to 1990

1991 to present

*

1986 to 1990

1991 to present

NOTES:

C - Pistons supplied are cast type.

F - Pistons supplied are forged type.

– Denotes kit supplied in Hot Set Up.

‡ Compression ratio depends on cylinder head type used. If stock heads are used extensive cylinder head modifications must be performed, making compression ratios completely dependent on final combustion chamber volume.

*

* 1991 and later engines using adjustable pushrods require conversion to 1986-'90 style pushrod tube assemblies. S&S kits for 1991 and later engines include a special pushrod tube adapter. Pushrod tube assemblies are not included and must be purchased separately.

Kit Part

Number

91-3002

91-3204

91-3206

91-3504

91-3506

** This kit has stock height cylinders and will fit Buell motorcycles.

PARTS INCLUDED IN V

2

SPORTSTER & BUELL BIG BORE SIDEWINDER

KITS

EXTRA COST

OPTION

79"

89"

103"

NOTES:

3

4

13

5

16

"

16

"

5"

91-3002

91-3204

91-3206

91-3504

91-3506

C - Pistons supplied are cast type.

F

F

F

F

F

F - Pistons supplied are forged type.

– Denotes kit supplied in Hot Set Up.

An economical way to get more out of your 883 Sportster!

Use these pistons to convert an

883cc engine to 1200cc. Bore the stock 883cc cylinders out to 3 1 ⁄

2

" bore or use 1200cc cylinders. A template is included for modifying stock 883cc cylinder heads to adjust compression and increase flow. It is recommended that flywheels be rebalanced during the next complete overhaul.

92-2446 SERIES PISTONS

Oversize

Standard 92-2446

+.005

+.010

+.020

+.030

Part Number

92-24465

92-2447

92-2448

92-2449

visit us at www.sscycle.com

11

Carburetors

Half a million and still going strong. . .

The S&S Super E & G Carbs...

were a ground breaking development when they were first introduced in October of 1990. Since then they have become the best selling performance carburetor in the V-Twin aftermarket, and have remained so to this day – in mid 2004, S&S produced the 500,000th Super Shorty carb. The combination of good looks, easy tuning, exceptional performance, and not least of all the technical support of a manufacturer with as many years of experience as S&S, made the S&S Super Shorty carbs the ones to get. Today the Super E and G carbs are still top selling carburetors, and are standard equipment on all S&S engines (another best selling product).

So how do you improve on that?

A fairly simple design change has given the Super Shorty carbs an even higher degree of tunability, which improves compatibility with some of the more radical cams and exhaust systems. For the vast majority of our customers, this new design will not change the way they dial in our carbs, but for our customers who use extreme cams and exhaust systems, designed for maximum performance, the change will make life a lot easier.

The new replaceable main system air bleed, accepts readily available

S&S main jets which allows a wide range of adjustment. Installing a larger air bleed jet causes the main jet to "come in" at a higher rpm, and can help eliminate the transient midrange rich condition when tuning engines with radical cams and exhaust systems.

12

How does it work?

The design change involves the main fuel circuit air bleed. In the past, S&S Shorty carburetors have had a fixed air bleed for the main circuit that was sized for the best all around performance.

However, starting October 1,

2003, all Super E and G carbs have a replaceable jet in place of the fixed main circuit air bleed.

This allows for fine tuning of the main circuit. The main circuit air bleed determines the rpm at which the main fuel circuit begins to feed fuel. A smaller air bleed will cause the main circuit to

"come in" at a lower rpm. A larger air bleed causes the main jet to come in at a higher rpm.

The air bleed installed at the factory is the same size as we have always used because it works best in the majority of applications. However, the ability to change the size of the air bleed can be very useful when tuning engines with high performance exhaust systems, which often, exhibit some harmonic reversion problems. Harmonic reversion usually inhibits exhaust flow at a specific rpm. In extreme cases, aggravated by very aggressive cam timing, the reversion pulses can actually push air back out of the intake valve. This pulse of air picks up fuel as it goes out past the main discharge tube of the carburetor, and is then drawn back through the carburetor where it picks up additional fuel.

This causes a transient rich condition at that specific rpm.

Since this usually occurs at the same rpm at which the main circuit comes in, the rich condition can often be reduced, and midrange performance improved, by making the main jet come in at a slightly higher rpm.

This can be done by installing a larger main circuit air bleed jet.

email us at [email protected]

Carburetors

Do I Need a Super E or Super G Carburetor?

As a general rule we recommend a Super E carb for street engines up to about 100 cubic inches in displacement.

The Super E's smaller 1 7 ⁄

8

" (47.6mm) bore size creates higher air velocity, which results in better low and midrange response and power. The Super G is recommended for street engines of no less than 90 cubic inch displacement. However, in spite of the fact that the Super G's larger 2

1

16

" (52.3mm) bore size allows more air to pass, and generally provides more peak horsepower, slower air velocity at lower rpm causes poor throttle response and weaker midrange torque in engines under 100 cubic inches. For the vast majority of street engines in the 90-100 cubic inch displacement range we strongly recommend the Super E because of the improved low and midrange response. However, if maximum peak horsepower is the most important consideration, a Super G carb would be appropriate.

Tune for those Drag Pipes!

This dyno chart shows two runs on a 124" SSW+ engine with a Super G carb and 2" drag pipes. The two runs are very similar except in the 2500 to 3500 rpm range. One run shows approximately 10 ft/lb more torque in this range than the other. The curve with increased torque was the result of replacing the standard .040" main circuit air bleed with a larger bleed. Note that the maximum torque and horsepower was not changed significantly. However, the additional 10 ft/lb of midrange torque will make this motorcycle feel much more responsive and powerful on the street since this is the rpm range most used in street applications.

Dyno results from Dyno Jet

150 Chassis dynamometer at S&S Cycle's Research and Development facility in

Viola, Wisconsin.

visit us at www.sscycle.com

NOTES:

Throttle cable guides–S&S Super E and G carburetors require the use of a two cable, pull open-pull closed throttle assembly.

Throttle cables for Sportsters–Any 1980 or earlier stock H-D

Sportster chassis including models equipped with a single cable throttle mechanism requires conversion to a two cable, pull open-pull closed type. S&S offers high quality two cable throttle assemblies for this purpose. The long throttle cable guide for use with CV style throttle cables on Big Twins can not be used on Sportster chassis due to clearance problems.

As a result, Sportster models 1988-up fitted with a constant velocity (CV) carb require conversion to 1981-1987 "butterfly" style throttle cables. (See Throttle Assemblies section of this catalog for more information.)

1998 and later carbureted Buells require the use of 1996

Buell throttle assembly and S&S throttle cables when installing a Super E or G carburetor.

Super E and G carbs cannot be used on Ironhead Sportster engines equipped with vertical magnetos due to clearance problems.

Recommended for Racing Only – This carburetor is not legal for use in California on motor vehicles operated on public highways or in other states where similar pollution laws may 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.

Polishing and Chrome Plating the Carburetor – S&S does not recommend polishing and chrome plating the Super E or G carburetor. Proper preparation to achieve a good finish requires polishing using buffing compounds. The polishing and plating processes and the materials used invariably plug air and/or fuel passageways and feed holes and alter operating tolerances in critical areas regardless of the precautions taken.

13

Carburetors

What makes the S&S

Super E & G so popular?

The popularity of the S&S Super

E & G "Shorty" carburetors is largely because of results. Ease of installation, easy tuning, excellent performance, and the technical support of a company with over 45 years of experience in the high performance V-Twin industry are all factors in the popularity of the Super "Shorty" carbs. It can be best summed up by the S&S company motto:

"Proven Performance".

Them Changes!

Ann (pictured at right) has been with S&S for eleven years, and currently works as a Current Product

Engineering Test Technician. Formerly the supervisor of the cylinder head finishing department, Ann "ports a mean head", and her 1993 Sportster is not one to be trifled with. The engine has gone through a series of changes: from 883 to 1200 to 89" with S&S ported heads. Ann loves to go fast, but she also enjoys going on trips.

14

Easy Installation

Installation is easy because carbs are sold in complete kits that contain everything needed to install the carb on the specified model motorcycle. All kits include a comprehensive, step by step installation instruction booklet and tuning guide that takes the "rocket science" out of installation and tuning.

Throttle Cable Compatibility

For the sake of safety, all S&S carbs are designed to use a two cable pull open/pull closed throttle system. Super

"Shorty" carbs for Sportsters are compatible with stock

1981-'87 throttle cables. Due to inadequate frame clearance the taller throttle bracket can not be used on Sportsters.

Therefore, late model Sportsters and Buells require the installation of earlier butterfly style throttle cables.

S&S "Shorty" Carbs...Easy Tuning

The S&S "Shorty" carbs are easy to tune due to the simplicity of the functional design. The Super E & G's are butterfly style carbs and have only two fuel circuits, not counting the starting system or accelerator pump. In addition, idle mixture, idle speed, and accelerator pump adjustments are easily accessible when the carburetor is installed on a motorcycle.

The low speed circuit which handles engine speeds from idle up to about 2500 rpm, is controlled by a changeable intermediate jet which meters fuel to the intermediate system as well as the idle mixture control needle. The intermediate jet is selected to provide the best performance and fuel economy in the lower rpm range, and the idle mixture screw allows for precise adjustment of the air/fuel mixture at idle. The adjustable accelerator pump eliminates off idle hesitation and can be adjusted to provide the correct amount of fuel for a wide variety of engine displacements and styles. The accelerator pump is also very useful as a starting aid.

The main, or high speed system features a replaceable main jet, and in carbs manufactured after 10-1-03, a replaceable main circuit air bleed. The main jet meters fuel for high rpm and full throttle conditions, while the air bleed can be used to control the rpm at which the main system comes into play. Adjustment of the air bleed is normally not needed with standard engine configurations, but can be very useful when tuning engines with radical cams and exhaust systems.

email us at [email protected]

Carburetors

Continued...

S&S Super E & G Carburetors

These S&S Super E & G carburetor kits contain everything you need for a complete installation.

Performance by Design

The S&S "Shorty" carbs do not use a traditional choke plate for starting enrichment. Instead a separate adjustable enrichment circuit is used for cold starts. The enrichment circuit is activated by pulling the enrichment lever on the air cleaner to the up position. Once the engine starts, the lever can be moved downward to function as an adjustable fast idle to keep a cold engine running until the bike is underway or the engine is warm enough to idle normally.

By using an enrichment circuit instead of the usual choke mechanism, the bore of the carburetor is not restricted by hardware that is only used on cold starts. That means that the carb can supply more air to the engine at full throttle, and that equates to more power.

Another reason the "Shorty" carbs are capable of making more power is the design of the air cleaner. This design takes into account two of the most significant factors that can improve air flow into a carburetor. The most important factor is a filter element that does not restrict the flow of air, and almost as important is the elimination of turbulence at the inlet of the carburetor.

The filter area of the "Shorty" carbs is maximized by an ingenious backplate design that wraps slightly around the carb to allow room for a wider filter element than a straight back plate would allow. The pleated S&S filter element looks like paper, but is actually a special resin impregnated cellulose fiber media that provides excellent filtration as well as superior flow. That makes for improved performance and better engine protection.

Application

SUPER E & G CARBURETOR COMPLETE KITS

SELECTION CHART

Year & Type of Engine

Super E Carb Kit

Standard

Super G Carb Kit

Standard

Sportster

1957-'78 XL‡

1979-'85 XL

1986-'90 XL

1991-up XL

Buell

1994-up

‡ Does not fit engines equipped with vertical magneto.

11-0404

11-0406

11-0408

11-0409

11-0448

11-0424

11-0426

11-0428

11-0429

11-0449

visit us at www.sscycle.com

Reducing turbulence is almost as important as finding a filter media that allows air to pass with a minimum of restriction. The shape of the S&S air cleaner backplate provides a radiused inlet similar to an air horn or velocity stack. This provides a smooth path for air to follow while traveling into the carburetor inlet. This results in less turbulence which allows more air to flow into the carb. The flow of air is also enhanced by a directional cone inside the air cleaner cover which also directs the air smoothly into the inlet of the carburetor.

Since the radiused inlet and directional cone are contained within the filter element, air flowing into the carb is not effected by turbulent air flowing past the carburetor when the motorcycle is traveling at high speeds. So the air cleaner cover and the filter element also play an important role in eliminating turbulence and increasing flow.

While installing an S&S Super E or G carburetor on a stock engine will result in more power, the addition of a performance cam and exhaust system will result in even more power gains. Take a look at the S&S

Hot Set Up kits on pages 8-10 of this catalog for more information.

The Super E & G "Shorty" carburetors are designed for

American V-Twin applications and are protected by US

Patent #5,128,071 which covers thirteen specific design elements.

15

Carburetors

S&S Super B Carburetors

Since its introduction in 1975 the 1

7

8

" S&S

Super B carb has been a favorite of Harley high-performance enthusiasts the world over.

It has under gone a few changes over the years, but it is still true to the original idea. A simple, no frills, high-performance carb that works well on the street and the drag strip.

Applications:

The S&S Super B gas carburetor has a 1

7

8

" throat and is recommended for use on any displacement H-D Big Twin or Sportster engine with any degree of performance modifications. This includes stock engines and as well as performance engines.

Super B carb kits are not available for 1991-later

Sportsters, 1992-later Big Twin, or Twin Cam 88 engines.

16

NOTES:

Two Cable Throttle Required – S&S Super B carburetors require the use of a two cable, pull openpull closed throttle assembly. Any chassis including

1980 and earlier stock H-D models equipped with a single cable throttle mechanism requires pull open-pull closed type. S&S offers a high quality two cable throttle assembly for this purpose. (See your local S&S

Dealer for more informaion.) Stock models from 1981 to present have a two cable throttle which can easily be modified to work with the Super B carburetor.

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 may 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.

Polishing and Chrome Plating the Carburetor – S&S does not recommend polishing and chrome plating any S&S carburetor. Proper preparation to achieve a good finish requires polishing using buffing compounds. The polishing and plating processes and the materials used invariably plug air and/or fuel passageways and feed holes and alter operating tolerances in critical areas regardless of the precautions taken.

S&S Super B complete gas carburetor kits...

include an S&S Super B gas carburetor, an S&S

Teardrop air cleaner kit, manifold, mounting hardware, fuel line and clamps, two extra main jets, and installation and jetting instructions.

SUPER B CARBURETOR KITS

Application

Sportster

No

Manifold

Year & Type of Engine

1957-'78 XL

1979-'82 XL

1983-'85 XL

1986-'90 XL V 2

Carb only

Carb kit w/o manifold

Carb

Kit

11-0104

11-0105

11-0120

11-0115

11-0111

11-0100

NOTE:

Many 1979-'80 engines may be equipped with either o-ring or band style heads. Check before ordering.

email us at [email protected]

Jets

S&S Carburetor Replacement Jets

For those who need to rejet their carburetor because of engine modifications, exhaust modifications, or changes in altitude, we have extra jet kits available which are designed to cover most jetting situations. Compare your jets with those in the pictures to determine the proper jet series. The description given tells what carburetors it fits and the sizes available. Also listed are the various groups of sizes offered and their respective part numbers.

Riders & Tuners

It is often difficult to know exactly what jetting combination is best for a particular engine without actually trying it. That is why S&S offers jet packs with a range of jets that gives the tuner the flexibility to try different jetting combinations to achieve the best performance.

For even more jetting options S&S offers high range, low range, and master jet packs for the professional tuner.

Intermediate Jets

Series #94

Intermediate Jets

Series #94 fits all Super 1 7 ⁄

8

", 2 1 ⁄

16

", 2 1 ⁄

4

" gas carburetors–sizes available:

.025", .0265", .028", .0295", .031", .032",

.033", .036", .040".

Sold in packages of 3 jets.

11-7270

1 each .025", .0265", .028".............11-7100

1 each .0265", .028", .0295"...........11-7101

1 each .028", .0295", .031".............11-7102

1 each .0295", .031", .032".............11-7103

1 each .031", .032", .033"...............11-7104

1 each .032",.033", .036" ................11-7105

1 each .033", .036", .040"...............11-7106

Low Range Jet Pack

For jetting most stock and moderate performance engines. – Includes 1 each intermediate jets (.025", .0265", .028",

.0295") and 1 each main jets (.062",

.064", .066", .068", .070", .072", .074").

..................................................11-7270

High Range Jet Pack

For jetting some stock and all performance engines. – Includes 1 each intermediate jets (.0295", .031", .032",

.033") and 1 each main jets (.072", .074",

.076", .078", .080", .082", .084").

..................................................11-7271

visit us at www.sscycle.com

Master Jet Pack

For jetting all Super B, E, and G equipped engines. – Includes 1 each intermediate jets

(.025", .0265", .028", .0295", .031", .032",

.033") and 1 each main jets (.062", .064",

.066", .068", .070", .072", .074", .076", .078",

.080", .082", .084").

........................................................11-7272

Main Jets

Series #72 fits all Super 1 7 ⁄

8

", 2 1 ⁄

16

", 2 1 ⁄

4

" gas carburetors – sizes available: .040" to .108"

(in increments of .002").

Sold in packages of 3 to 6 jets.

1 each .062", .064", .066", .068", .070", .072"

....................................................11-7200

1 each .066", .068", .070", .072", .074", .076"

....................................................11-7201

1 each .072", .074", .076", .078", .080", .082"

....................................................11-7202

1 each .078", .080", .082", .084", .086", .088"

....................................................11-7203

1 each .090", .092", .094", .096", .098"

....................................................11-7204

1 each .100", .102", .104", .106", .108"

....................................................11-7205

Main Jet Tool

For changing series #72 main jets

.......................................53-0452

17

Air Cleaner Kits

The S&S Teardrop Air Cleaner

The S&S Teardrop Air Cleaner is one of the most recognizable shapes in the industry. This is testimony to its distinctive good looks and outstanding performance features – features like the uniquely designed backplate with air horn style radiused entryway and the dimpled cover with air directional cone on the inside. Both features help maximize air flow by giving intake air an efficient, easy path to follow into the carburetor. And the beauty of it all is that the S&S Teardrop air cleaner is also available to fit stock Tillostson, Bendix and

Keihin butterfly, CV carbs, or any carb with the same air cleaner mounting bolt pattern.

When ordering...

To ensure that the correct air cleaner kit is shipped to you please specify the type and year of the engine, carburetor to be used, and part numbers of the air cleaner kit and mounting hardware (when applicable).

S&S Air Cleaner Kit for 1991-up carbureted Evolution Sportsters.

17-0117

Model Year

1991-up Sportster

1988-'90 Sportster

1986-'87 Sportster

1966-'85 Sportster

1994 & Up Buell

*Must be used with 3 ⁄

8

" thick insulator block 16-0497 or 16-0498.

AIR CLEANER SELECTION CHART

Stock CV and EFI

S&S L,

H-D Tillostson

Bendix, Keihin

17-0117

17-0105

17-0108

17-0199

Super B

17-0107

17-0107

17-0099

Super E & G

17-0404*

17-0399

17-0399

17-0400

17-0402

Super D

17-0198

17-0198

17-0198

18 email us at [email protected]

Air Cleaner Covers

S&S "Patriot" Flag

Air Cleaner Cover

There are only a handful of companies that have been around long enough to claim to have helped shape the industry and lifestyle that is so popular around the world today. One, of course makes motorcycles in Milwaukee.

Another is S&S Cycle, Inc.

Founded in 1958, S&S has been building high performance engines and engine components for the heavyweight cruiser market without interruption for over forty-five years.

Quality, performance, and dependability are the values that

S&S is famous for and the legendary S&S teardrop air cleaner cover is a symbol to all that its owner feels the same way we do, second best is not good enough.

To celebrate the rich heritage of S&S and its place in the

American motorcycle industry, we are offering for a limited time only this "Patriot" version of the famous teardrop air cleaner cover. An American flag on an American carburetor on an American motorcyle.

Patriot Air Cleaner Cover 17-0385

S&S "Desperado"

Air Cleaner Cover

A second design, the "Desperado", is also now available. The Desperado had its beginnings in much more down-to-earth circumstances. While developing the new Super Sidewinder ™ of engines we found that their increased

Plus series performance called for a better breathing intake tract and of course the air cleaner cover is the first part in that tract. During dyno testing, a 1-2 horsepower gain was realized and, as with the

Patriot air cleaner cover, it does not require any jetting changes to a properly jetted carburetor.

Good looks and better performance.

Desperado Air Cleaner Cover 17-0004

Patriot and Desperado air cleaner covers are available for S&S Super E & Super G "Shorty" carburetors only.

visit us at www.sscycle.com

19

Air Filters

20

S&S High Flow Air Filter and Adapter Kit

With larger and larger street engines becoming more common, S&S has developed a high flow air filter kit for Super E and G carburetors. The new

S&S high flow filter is 1" taller than our standard filter and features a low restriction, pre-oiled filter element. The low restriction element, combined with the larger surface area provided by the 1" filter taller, adds up to an airflow increase of 37% percent over our standard filter - the ultimate free breathing set-up for your engine! The filter and filter adapters extend the teardrop housing out 1".

The resulting band of exposed filter peeking out from under the teardrop imparts a high performance street racer look. Kit installs in minutes, no permanent modifications required.

* Not for use with S&S Super B or Super D carburetors, or Super E & G Kits for Buells.

High-flow filter with high performance looks

Extended filter kit provides maximum airflow for air hungry engines. This free breathing set-up looks like it just came from the track. Easy to install, kit is one inch taller than our standard teardrop filter, and features premium filter media. Includes filter and three plated steel air cleaner extensions.

High Flow Filter Kit Contains:

(1) High flow filter for S&S Super E or G Teardrop air cleaner. (One inch taller than the standard S&S filter.)

(3) 1" Tall plated steel filter adapters.

Air Filter & Adapter Kit

For S&S Super E and G Carburetors

.....................................................................................17-0045

Replacement Filter

.....................................................................................17-0055

email us at [email protected]

Crankcases

S&S Evolution Sportster and Buell Style Crankcases

We’ve made some changes to our Sportster and Buell style crankcases. By making a couple of small machining changes we’ve made one crankcase that fits both 1986-'03 Sportsters and 1994-'03 Buell chassis.

It should be noted that although these cases will fit the

1986-'90 four speed style Evolution Sportster chassis, they require a 1991-'03 style five speed transmission, clutch, alternator, and flywheel assembly. For this reason they are not stock replacement crankcases for

1986-'90 four speed engines.

31-1008

Although S&S can supply crankcases with 1986-'90 (four speed) or

1991-'03 (five speed) cam chest geometry, S&S recommends using the 1986-'90 cam chest, tappets, and cover. This style of tappet, which is the same one used in Evolution Big Twin engines, has a larger roller and, has proven to be more reliable in high performance applications. In addition, four speed style cam covers are more readily available to complete scratch built engines.

Crankcases machined for five speed cam geometry require 1991-2003 style cams and 1991-'96 gearcover. Unlike stock five speed crankcases, S&S cases with 1991-'03 style cam chests feature special removable billet aluminum tappet guides which allow the use of 1986-'90 style pushrod covers. These tappet guides, provide a replaceable wear area for tappet travel, and two piece pushrod covers allow access to adjustable pushrods normally used in high performance applications. Pushrods can not be accessed with the stock five speed style one piece pushrod tubes.

All S&S Sportster/Buell style crankcases can be used with any stock

1986-up Sportster oil pump and require a 1986-'90 style oil filter assembly. In addition to the complete compliment of hardware and fittings that are provided with all S&S crankcases, Sportster/Buell style cases also include an S&S heavy duty transmission access door.

The S&S transmission door provides a seal between the primary case and the transmission, allowing the use of different lubricants in each section. A simple modification allows the primary case and transmission to share the same oil. The transmission door is complete with required bearings and bushings installed. Right side transmission case bearings are also installed and ready for assembly.

S&S Sportster/Buell style crankcases for 5-speed (1991-2003) cam geometry include billet tappet guides designed to accept

5-speed tappets. Case with four-speed cam geometry do not include tappet guides since stock can be used.

S&S SUPER STOCK

SPORTSTER/BUELL STYLE

CRANKCASE SELECTION CHART

Cam Geometry

1991-2003

1986-1990

Stock Bore

31-1008*

31-1013

3

5

8

" Bore

31-1009*

31-1014

NOTES: All S&S XL crankcases use 5-speed transmission and primary components.

These cases will not accept 4-speed transmissions or flywheel assemblies.

* Requires use of S&S cam cover gasket. (S&S 31-2052) 1991 & later cases require 1991-'97 gear covers. Includes lifter blocks.

S&S Super Stock

Sportster/Buell style cases...

are available for stock bore and 3

5

8

" bore engines. For bore sizes larger than 3 5 ⁄

8

" and for deck heights taller than stock, S&S

Special Application (SA) Sportster/Buell style crankcases are available. By special order, S&S SA crankcases can be machined for Deck heights as much as 1" taller than stock, and for cylinders with spigots up to

4.635" in diameter.

See your S&S Dealer for more information on S&S Special Application Sportster/Buell style crankcases.

visit us at www.sscycle.com

21

22

Gearcovers

S&S Sportster Billet Gearcovers

Bushing Syle

31-0302

S&S billet Sportster gearcovers are intended for S&S

Sportster style crankcases only. These gearcovers are not recommended for engines with stock 1986-'90 crankcases as they have no provision for the four-speed style crankcase breather. Kits come with hardware and special S&S gearcover gasket.

31-0303

S&S Billet Gearcovers

Bushing Style

1986-'90 ......................................................31-0303

1991-'99 ......................................................31-0302

Replacement Gasket

(5 Pack)

........................31-2099

Replacement Seal

(5 Pack)

............................31-4114

email us at [email protected]

Tappet Guides

Tappet Guides and O-Rings for V

2

Sportster Style Engines

S&S Evolution Sportster style tappet guides are machined from billet aluminum. Assemblies and kits designated as "stock style" fit stock style Sportster style crankcases including S&S Super Stock ™ cases.

Assemblies and kits designated as "SA" are designed for S&S Special Application crankcases with 1 ⁄

2

" cam chest offset. Special S&S 1991-up tappet guides are designed exclusively for S&S Super Stock ™ and Special

Application Sportster style crankcases with 1991-up cams. These cases are machined for removable tappet guides similar to 1986-'90 engines. However, these special tappet guides are designed to be used with the

1991-'99 stock style Sportster tappets.

S&S 1986 -'90 V

2

SPORTSTER

TAPPET GUIDE SELECTION CHART

Set

Front Intake

Front Exhaust

Rear Intake

Rear Exhaust

1986-'90 1986-'90

Stock Style S&S Special Application

33-5375

33-5372

33-5365

33-5362

33-5371

33-5374

33-5373

33-5361

33-5364

33-5363

SPECIAL S&S 1991-UP V

2

SPORTSTER-STYLE

TAPPET GUIDE SELECTION CHART

Set

Front Exhaust/Intake

Rear Exhuast/Intake

1991-Up

S&S Super Stock

Guides

33-5389

33-5385

33-5387

1991-Up

S&S Special Application

Guides

33-5369

33-5381

33-5383

Sportster tappet guide assembly set. 33-5375

Tappet Guide O-ring Kit

1986-'90 Sportster and

1991-up S&S Sportster Style

............................................................................50-8153

Upper O-ring - 1" ID x 13 ⁄

16

" OD x 3 ⁄

32

" CS Viton

(HD#11167A)

(10 Pack)

..............................................50-8079

Lower O-ring - 1" ID x 1 1 ⁄

8

" OD x 1 ⁄

16

" CS Viton

(HD#11168A)

(10 Pack)

..............................................50-8087

Oil Passage O-ring -

3

8

" ID x

1

2

" OD x

1

16

" CS 70 Buna

(HD#11110)

(10 Pack)

................................................50-8077

visit us at www.sscycle.com

23

Tappets

S&S Hydraulic Tappets for Evolution Sportster Style Enignes

S&S Hydraulic Tappets fit all Big Twin V 2 style engines and

1986-'90 Sportster engines. These tappets feature numerous significant design improvements.

Larger inner bearing race reduces stresses to increase axle, bearing, and roller life. The S&S inner bearing race is .123" larger in diameter than the "raceless" roller axles currently used by some manufacturers.

Improved inner race-roller design allows use of more, and larger bearings to increase load-carrying surface area, further reducing stress and wear in the critical roller areach

Redesigned plunger assembly better withstands forces associated with heavyduty valve springs and cams typically used in high-performance applications.

Revised metering device precisely controls oil delivery to top end, insuring rapid lifter pump-up and reducing possibility of oil starvation to bottom end.

Each lifter body and plunger assembly is hand-fit and then pressure-tested to insure correct operation.

S&S Hydraulic Tappet Assembly

Without HL

2

T Kit

(Set of four)

.......................................33-5352

With HL

2

T Kit

(Set of four)

............................................33-5353

NOTE:

Because of close tolerances, tappet in set 33-5353 may require slightly longer bleed-down time than conventional tappets. At temperatures of 65°F and above, however, bleed-down should take 20 minutes or less using 20W50 engine oil.

Robin..

This 2004 Sportster owned by Robin Smith, wife of S&S company President Brett Smith, is equipped with the new S&S Air Cleaner and Muffler Hot Set Up kit.

24 email us at [email protected]

Cams

CAMS FOR V

2

SPORTSTERS

1986-Up Evolution Sportster Style

S&S 500 Cam

For modified 1200s & up to 89 Sportsters with no more than 9.5:1 compression -

"Bolts-in" and works with stock or ported heads - valve spring spacing not required other normal clearancing checks recommended. See "Camshaft Specification

Chart" for overall cam timing information.

S&S 555 Cam

For 79" and larger

Sportsters with compression ratios from 9.5 to 11.5:1 -

Works better with ported heads - broad torque range from 3500 to 6500 rpm - valve spring spacing and other normal clearancing checks must be done. See "Camshaft Specification

Chart" for overall cam timing information.

S&S 500 Camshaft for 1986-up Evolution Sportsters.

33-5081

NOTE:

2000-up Sportsters and Buells with stock flywheel assemblies require a 1991-'99 style pinion gear if S&S cams are to be installed. Engines with S&S flywheels require 1986-'87 style pinion gear available from Harley-Davidson or S&S.

Name

S&S

500

Application

1986-UP EVOLUTION SPORTSTER CAM SPECIFICATION CHART

Model

Year

Camshaft

Part

Number

Valve Timing 1

Open/Close

Valve Duration

Intake Exhaust Intake Exhaust

Valve

Lift

Intake

Lift @ TDC 2

Exhaust

74" to 89" with 9:1 to 10.5:1 CR.

89" to 100" with less than 9.5:1 CR.

Good torque, easy installation.

1986-'90

33-5081

1991-Up

33-5082

34°/50° 56°/28° 264° 264° .500" .241" .212"

Spring Tappet 3

Spacing Type

Required Required

Yes

Solid or

Hydraulic

S&S

74" to 100" with 9.5 to 11:1 CR.

555

Better mid range and top end.

1986-'90

33-5083

33°/53° 53°/33° 266° 266° .555" .240" .240" Yes

Solid or

Hydraulic

1991-Up

33-5084

1 Timing designation is function of zero lash @ .053" off base circle

2 TDC lifts are measured at the valve and are for reference only. Overlap valve lifts must be checked on assembled motor. Minimum valve to valve clearance of .040" is recommended.

3 Cams specified for solid tappets may be used with modern high performance hydraulic tappets with V 2 style hydraulic mechanism. Stock hydraulic tappets are not recommended.

4 1980-81 engines require conversion to late style valve guides.

visit us at www.sscycle.com

25

Valve Spring Kits

High-Performance Valve Spring Kits

S&S valve spring kits are designed to simplify high-lift cam installation and reduce the risk of valve float. They eliminate most of the complicated procedures and specialized tools required to prepare cylinder heads for high lift cams. While confirming critical clearances remains the responsibility of the engine builder, most Evo street cams will require no additional modification of the cylinder head when S&S valve spring kits are used. In some instances, S&S valve spring kits serve as excellent replacements in stock rebuild applications. All kits include detailed instructions.

Valve Spring Kits for1986-up Sportsters

.640" Lift Triple Valve Spring Kit –

Fits S&S Super Stock ™ , H-D, and other V 2 or Twin Cam-type heads that require stock O.D. outer spring. Includes 4 top collars, 4 bottom collars, 4 each outer, middle, and inner springs, 8 shims (4 each .015", 4 each .030"), and 8 keepers.

Use with shoulderless-style valve guides. Special keepers included fit valves with stock 5 ⁄

16

" stems and S&S collars only. Patented steel top collars are drilled for lightness and to increase cooling of valve springs. Spring seat pressure is

170 lbs. at stock 1.800" installed height. Open pressure is 390 lbs. at .560" lift,

415 lbs. at .630" lift.

.640" Lift Triple Valve Spring Kit for V

2 Sportsters

Kit w/steel top collars................................90-2077

Kit w/titanium top collars ..........................90-2078

90-2078

NOTES :

High-lift cams may require the engine builder to obtain additional clearance between the piston and valves, the intake and exhaust valves and the upper spring collar and rocker cover. Clearance should also be checked between the rocker arm and valve spring collar as well as between the rocker arm and rocker cover. It is imperative that the engine builder confirm these clearances and check for spring coil bind, even when using parts specifically designed for high-performance. Most valve train failures can be traced to over-revving or failure to confirm correct clearances during assembly.

When ordering valve springs, please specify engine year.

26 email us at [email protected]

Pushrods

S&S Quickee Pushrods for Evolution Sportster Style Engines

S&S developed a pushrod with a new type of adjuster for use with S&S Shovelhead style tappet guides. This is such a cool idea that we've also made it available for

Evolution and Twin Cam engines. The threaded adjuster screws into the pushrod until the threads disengage and the adjuster simply slides into the pushrod making installation or removal a snap. Once the pushrod is installed and adjusted, the locknut prevents the adjuster from moving. The ball ends of the pushrods are drilled so that oil can flow through the pushrod. This is the stock oiling system for Evo's and Twin Cams, but this allows Shovelhead engines to be set up with 1984 and later style top end oiling, via the pushrods, provided S&S Shovel style tappet guides and roller rocker arms are also used.

S&S

Exclusive

Quickee Pushrods

US P a t e n t

Pending

NOTE:

S&S Quickee pushrods are designed for use with Evolution and Twin Cam style hydraulic tappets. They are not compatible with stock or aftermarket Shovelhead hydraulic tappets or most solid style tappets.

Application

1991-up V 2 XL

1991-up V 2 XL

1986-90 V 2 XL

1986-90 V 2 XL

Special Order

S&S EASY INSTALL PUSHRODS

Displacement

883cc – 89"

103"

883cc – 89"

103"

Specify

Part Number

93-5131

93-5133

93-5130

93-5132

93-5135

Evolution Pushrod Cover Adapter fits 1991-'03 Sportster

S&S Evolution Sportster pushrod cover adapters are designed to convert 1991-'03

Sportster crankcases to accept 1986-'90 style pushrod cover assemblies to allow access to adjustable pushrods. Four are required for each engine.

Adapter

(Set of four)

......................33-5355

visit us at www.sscycle.com

27

Pushrods

S&S Pushrod Kits

Pushrod flex costs horsepower by preventing the valves from following the cam profile. This problem is most common in high-performance applications with heavier-than-stock valve springs.

S&S pushrods are designed to remain rigid and provide positive valve action at all engine speeds, which makes them ideal for stock and high-performance applications. They are available in stock and special lengths. Most S&S pushrods are made of

7

16

" O.D. chrome moly steel tubing with pressed-in heat-treated ends. This provides maximum strength and durability regardless of the application.

All pushrods are listed by length in terms of their relationship to stock. Pushrod length varies directly with effective cylinder lenght.

Adjustable Pushrod Conversion Kits –

Include four adjustable V2 style steel pushrods. These pushrods can be used in place of the stock, non-adjustable pushrods in stock as well as high-performance applications. Compatible with hydraulic and solid lifters.

1986-' 90 V

2

SPORTSTERS

PUSHROD SELECTION CHART

Displacement Part No.

Cylinder Length

883cc, 1200cc, 79"

89"

103"

Special Order

93-5033 4.650" (Stock)

93-5022 5.087" (+.437")

93-5025 5.750" (+1.100")

93-5036 Specify

1991 & '03 V

2

SPORTSTERS

PUSHROD SELECTION CHART

Displacement Part No.

Cylinder Length

883cc, 1200cc, 79"

89"

103"

Special Order

93-5022 4.650" (Stock)

93-5089 5.087" (+.437")

93-5088 5.750" (+1.100")

93-5036 Specify

28

93-5030

93-5030

S&S Pushrod Kits for Ironhead Sportsters

1957–'85 Ironhead Sportsters

900cc and 1000cc -

7

16

" Steel

1957-'85 Sportster – Includes four nonadjustable pushrods. S&S pushrods are a direct replacement for stock.

(HD#17904-57)

1957-'85 IRONHEAD SPORTSTERS

PUSHROD SELECTION CHART

Part No.

93-5037

93-5038

Cylinder Length

5.330" (Stock)

Special Order

email us at [email protected]

Cylinder Heads

S&S Super Stock

Cylinder Heads

Over the last ten years, S&S Cycle has become the leading aftermarket manufacturer of high performance cylinder heads for Harley-Davidson ® and other American V-Twin motorcycles. Old timers will remember that when the S&S Evolution style heads became available, they were the final piece that allowed S&S to offer a relatively complete engine assembly. Time marches on, and today we see S&S engines powering the majority of the custom V-Twins being built today. That's because of reliability and power. S&S quality make our engines reliable, but it's our cylinder heads that make the power. It's pretty fundamental, more air in, more power out!

Performance By Design

S&S cylinder heads are the result of years of design and research work. Using the latest in computer aided design techniques, all S&S parts, are designed and "built" first as

3-D models on the computer. Using our laser rapid prototyping capability, dimensionally correct parts can be produced in plastic from the 3-D model. This allows S&S engineers to solve the majority of dimensional problems before we are committed to tooling and hard parts. By using these cutting edge design methods, we fast-forward the development of our cylinder heads and are way ahead of the game when it comes time for real world testing.

We already know how a cylinder head will flow and what the chamber volume will be before we make the real parts in metal.

visit us at www.sscycle.com

29

Cylinder Heads

Proven Performance – S&S Testing

The S&S company motto is "Proven Performance", and it is not just something we say. It's what we do. S&S cylinder heads have been subjected to a comprehensive testing program to insure that the performance will be there every time you twist the throttle. We've proved it! Flow testing, dyno testing, many thousands of simulated miles on our engine durability stand, and of course many more thousands of miles of real world road miles and countless passes at the race track have proven that S&S cylinder heads do perform.

30

Applications

S&S cylinder heads for Shovels, Evolution Big Twins, Evolution

Sportsters, and Twin Cams are recognized as the "best" in terms of performance and value. They are designed to be easy to install, and to be compatible with stock components whenever possible. Stock-like outer dimensions eliminate most clearance issues often associated with high performance cylinder heads.

However, all S&S heads for Evolution and Twin Cam style engines have larger than stock intake ports for increased air flow. This requires that a special S&S intake manifold be used that matches the diameter of the S&S intake port. Depending on the type, S&S cylinder heads are available in natural aluminum, black wrinkle powdercoat and polished finish.

S&S also has specialized cylinder heads for all-out racing engines which can be found starting on Page 11-46 in the

Racing section of this catalog.

State Of The Art Manufacturing

S&S cylinder heads are machined from heat treated aluminum castings, using "state of the art" NC machining centers for the best possible dimensional precision at the lowest possible cost.

This high degree of capability assures that the quality our customers demand and have come to expect from S&S is consistent in every part we make. The efficiency that we gain from automated machining helps to lower our costs, and that means that our customers can purchase S&S quality components at competitive prices.

email us at [email protected]

Cylinder Heads

Evolution Style Cylinder Heads

For Sporsters

The first cylinder heads S&S introduced in

1994 were for Evolution 3

1

2

" and 3

5

8

" bore

Big Twins and Sportsters. Then in 1998,

S&S introduced the heads for 4" bore Big

Twin and Sportster style engines. Both of these types of cylinder heads are available on complete S&S engines and individually for replacement and custom applications.

Features:

2.000" intake valves and 1.605" exhaust valves.

Special "cast to shape" intake ports with a special directional fin for improved air flow.

Precision CNC machined from heat treated aircraft quality aluminum castings.

Complete assembled heads contain premium valves and S&S .640" lift valve springs.

Available as "bare" sets, fully machined, but without valves or springs.

Available in natural aluminum, black powdercoat, and polished (specific models only) finish.

Super Stock ™ cylinder head kit shown in optional black finish.

Specify finish when ordering. 90-1802

S&S Cylinder Heads

For 3

1

2

" & 3

5

8

" Bore Engines

S&S heads for stock and 3 5 ⁄

8

" bore engines were originally designed for engines using stock crankcases and in some cases, stock cylinders.

Although these heads are machined with the stock

Evolution cylinder stud pattern, and may be used on stock crankcases, special pistons are required with a "pop up" dome shape that matches the contour of the S&S combustion chamber.

visit us at www.sscycle.com

Why Special Pistons?

Even though special pistons add to the expense and effort required to install these heads, there are several good reasons why we designed these cylinder heads to use special pistons. A larger, more open combustion chamber presents less resistance to air flow around the valves. However, in smaller displacement engines like 1200cc Sportsters, 80" Big

Twins, or even a 96" S&S engine, a larger chamber will produce a very low compression ratio with a stock style flat topped piston. We wanted the improved flow of a larger chamber, but we also wanted compression ratios slightly higher than stock. The solution, of course, was to use a larger chamber, for the flow, with a domed piston, to increase compression. We then went a step further and designed a specially shaped combustion chamber and a piston dome, shaped to match the contours of the chamber.

Due to the increased "squish" area of this design, the interaction between the cylinder head and piston dome at

TDC, sets up a controlled turbulence in the combustions chamber. That turbulence improves flame travel for a more efficient burn and reduced detonation. Pistons are available to achieve various compression ratios.

31

32

Cylinder Heads

Ordering Notes

Your S&S dealer can help you put the correct package together for your engine. Following these simple steps will make it easy, and ensure that you have everything you need.

1.

Select the cylinder head kit that is correct for your application. (See chart below.)

2.

Select a cylinder head gasket installation kit for the bore size of your engine.

3.

Select a manifold for the cylinder length of your engine and carburetor you intend to use.

See your S&S dealer for more information.

4.

Select a set of pistons for your bore size, engine displacement, and desired compression ratio.

Your S&S dealer can help you select the correct piston for your application.

Step 1

Cylinder Head Kits

Select a cylinder head kit for your engine style.

Assembled Heads for 3

1

2

" and 3

5

8

" Bore Evolution Style Engines

Bolt Pattern/Bore

V 2 XL 1986-'90

V 2 XL 1991-'03

Buell 1994-'02

Set

90-1302

90-1310

90-1305

Natural

Front

90-1302F

90-1310F

90-1305F

Rear

90-1302R

90-1310R

90-1305R

Set

90-1802

90-1810

90-1805

Black

Front

90-1802F

90-1810F

90-1805F

Rear

90-1802R

90-1810R

90-1805R

email us at [email protected]

Cylinder Heads

Step 2

Gasket Kits For S&S

Evolution Style Cylinder Heads

S&S has convenient cylinder head installation gasket kits that contain high quality S&S head and base gaskets as well as gaskets for the exhaust pipes.

Whether your engine is stock 3 1 ⁄

2

" bore or if it has a 3 5 ⁄

8

" big bore kit the correct gaskets are available. See your S&S dealer for full details.

Gasket Kits

For S&S V

2

Sportster Style Cylinder Heads

Engine and Bore Size

3 1 ⁄

2

" Bore V 2 Sportster/Buell

3 5 ⁄

8

" Bore V 2 Sportster/Buell

Part Number

90-1907

90-1908

Step 3

Manifolds for

S&S V

2

Sportster Style

Cylinder Heads

Select the correct S&S manifold for your engine. Your S&S dealer can help you select a manifold that is the correct length for your engine and the correct size for the carburetor you intend to use. S&S offers manifolds for S&S Super E, Super G and Super D carburetors, as well as the more popular CV carbs.

Step 4

Pistons for S&S 3

1

2

" & 3

5

8

" Bore

S&S V

2

Sportster Style

Cylinder Heads

Select the correct piston for our application. Your S&S dealer can help you select the correct piston for your engine, whether it is a stock 883 or 1200 or if the displacement has been increased with a 3 5 ⁄

8

" big bore kit.

Note:

S&S Super Stock ™ Evolution style cylinder heads must be used with S&S Super Stock ™ pistons. Use with stock flat topped pistons will result in very low compression and poor performance.

visit us at www.sscycle.com

33

Rocker Covers

S&S Rocker Covers for 1986-'03 V

2

Style Sportsters and 1994-'02 Buells

S&S manufactures two types of rocker covers for V 2 style engines, billet and die-cast. Billet covers are manufactured from aluminum billet using computer – controlled machining centers. Cast covers are also made of aluminum but using the more economical die casting process. All S&S rocker covers include formed Viton ® gaskets and o-rings for leak-free operation; our proven two-piece design makes for a simple installation.

Which is better – billet or die-cast? Both work equally well for most applications. The billet covers will allow the use of larger diameter valve springs and valves with extra long stems without additional clearancing.

However, in the vast majority of street applications using S&S Super Stock ™ or H-D cylinder heads, either style rocker covers can be used according to the builder's preference and budget.

S&S die cast rocker covers offer an attractive alternative to billet covers at a much lower price.

NOTE:

In spite of the similarities between different S&S rocker covers, not all parts are interchangeable.

See Replacement Rocker Cover Parts for correct part numbers.

Special Design Features:

S&S rocker covers fit all engines that accept stock H-D V 2 Sportster rocker covers - regardless of year and whether the engine vents through the crankcase or cylinder heads. OEM-style "umbrella" fittings are included with billet rocker boxes for 1991 and up Sportsters engines with cylinder head venting. Cast rocker boxes use an exclusive one way valve which is built into the rocker cover gasket to control oil carry over in "head breathing" engines.

S&S cast rocker covers and billet rocker covers for V 2 style engines include all parts required for installation.

S&S rocker covers are available in three finishes: show-quality chrome, polished, or raw machined. Raw machined is ideal for powdercoating and other custom appearance treatments.

Installation on stock and most comparably sized engines can be performed without removing the engine from the frame. Extremely tall engines such as the 4 3 ⁄

4

" stroke, 98" and 5" stroke, 103" may require removal from the frame for rocker cover installation.

NOTE:

Minor clearancing of the front motor mount is required to install S&S rocker covers on Buell motorcycles.

34 email us at [email protected]

Rocker Covers

Continued...

S&S Rocker Covers for 1986-'03 V 2 Style Sportsters, and Buells

S&S V

2

Rocker Covers and Related Parts

Billet Rocker Covers for 1986-'03 V

2

Sportsters and 1994-'02 Buells

Chrome ............................................................90-4050

Polished...........................................................90-4080

Raw, Machined ................................................90-4055

Gasket Kit ........................................................90-4049

Die-Cast Rocker Covers for 1986-'03 V

2

Sportsters and 1994-'02 Buells

Chrome ............................................................90-4095

Polished...........................................................90-4090

Raw, Cast.........................................................90-4083

Gasket Kit ........................................................90-4091

S&S billet rocker covers are the ulitmate in quality. Strength and beauty are combined in our finest Evolution style rocker covers.

NOTE:

In most instances, only minor clearancing is required to use S&S rocker covers with valve springs larger than 1.660" O.D. Kits include front and rear cover assemblies with base and top cover, rocker shaft supports, gaskets and o-rings, and instructions.

NOTE:

The performance-oriented design of the billet rocker boxes permits valve lifts up to .710" with stock H-D or S&S Super Stock ™ heads, and up to .810" with S&S Special Application heads using stock

H-D or S&S roller rocker arms. Cast rocker boxes may require some minor clearancing, and it is recommended that they be ordered either polished or raw machined, so that clearancing may be done without disturbing chrome plated surfaces.

S&S billet rocker covers accept valve springs up to 1.660" O.D.

without modification. Cast rocker boxes may require minor clearancing. Cylinder heads must be set up correctly for high-lift cams, and it remains the builder’s responsibility to confirm all clearances.

53-0040

S&S Rocker Wrench Set

The S&S rocker wrench set 53-0040 speeds installation and is recommended for professional use. Installation can also be accomplished with shortened allen wrenches.

visit us at www.sscycle.com

35

Rocker Arms

S&S Forged Rocker Arms and Rocker Shafts for 1986-'03 V

2

Sportsters

Our forged steel roller rocker arms were designed for superior strength and to eliminate the failure-prone stress areas found in some other rockers. S&S roller rockers are forged from 4140 steel, heat-treated, and then shot-peened for additional strength and protection from fatigue. Our rockers also utilize 3 ⁄

4

" long bronze bushings, compared to the more common

1

2

" long bushings or needle bearings, and feature a modified lubrication system with unrestricted roller oiling.

The end result is what we believe to be the finest rocker arm available anywhere, for any price.

90-4065

Roller Rocker Arm Set

Includes: 2 each front and rear rocker arms. ...................90-4065

Individual:

Front exhaust or rear intake..............................................90-4065F

Rear exhaust or front intake .............................................90-4065R

Rebuild Kits for S&S Rocker Arms

Current S&S forged rocker arms ......................................90-4104

Bushings

Current S&S forged rocker arms, .750" long....................90-4014

Rocker Arm Shafts

Each

(HD#17611-83)

..............................................................90-4006

Set - Includes 4 each 90-4006 .........................................90-4036

New! S&S Chrome Head Bolt Covers!

36

Dress up your engine with these magnetic chrome head bolt covers. Easy installation, no tools, no messy adhesives. A powerful magnet holds cover in place, yet allows easy removal. Chrome plated steel looks great on any engine, but is a must for polished engines. For S&S head bolts only.

Sold in a set of 4.

S&S

Exclusive

Head Bolt Covers

US P a t e n t

Pending

Chrome Head Bolt Cover set

.......................................................................50-0333

email us at [email protected]

Rocker Arms

Introducing... S&S Standard Forged Rocker Arms!

If are looking for something better than stock Evolution or Twin

Cam style rocker arms, but you're application does not warrant the expense of roller rockers, this is it! S&S now offers an economical solution for stock rebuilds, and mild performance upgrades. S&S standard rocker arms are forged from 4140 steel for greater strength than stock or cast steel rocker arms.

In addition they feature the same .750" long rocker shaft bushings as our S&S roller rockers do. The longer bushing provides 50% more load bearing area than the .500" long bushings used in stock and other aftermarket rocker arms. The valve contact tips are induction hardened for extended durability. Thousands of hours of engine testing have proved them to be superior to any non-roller rocker arm on the market. Fits Evolution Sportster style engines. Recommended for cams of .585" lift or less.

S&S Standard Rocker Arms for V

2

Sportster Style Engines

Set - Includes 2 each front and rear rocker arms ....................90-4119

Individual:

Front exhaust or rear intake ...............................................90-4119F

Rear exhaust or front intake ...............................................90-4119R

90-4119

NOTES:

3 ⁄

4

" long bushings provide 50% more bushing support area than

1

2

" long bushings. They eliminate the risk of engine damage associated with failed needle bearings.

Adjustable pushrods must be used with

S&S roller rocker arms to obtain proper valve clearance.

New rocker arm shafts are recommended for maximum performance and rocker life.

Rocker Arm Shafts

S&S rocker arm shafts can be used for stock replacement as well as with S&S roller rockers or standard rocker arms.

Each

(HD#17611-83)

......................................................90-4006

Set - Includes 4 each 90-4006 .................................90-4036

visit us at www.sscycle.com

37

38

Speedometer Calibrator

S&S Speedometer Calibrator

The electronic speedometer calibrator corrects the reading of stock H-D electronic speedometers when using oversized rear tires, or when other drive train modifications have been done that effect final drive ratio.

The accuracy of electronic speedometers provided on late

Harley-Davidsons can be greatly affected by the installation oversized tires, non-stock wheel or transmission sprockets, and by the replacement of certain transmission gears. These modifications are often made for appearance, to improve acceleration, decrease engine

RPM at highway speeds, or to reduce mechanical noise.

S&S Electronic

Speedometer Calibrator

................................................................................................55-1007

NOTES:

Calculating the difference between actual and indicated speeds/mileage requires only that the rider compare odometer readings to a known distance. Highway mile markers are usually accurate enough to use for calibration, although the test should be repeated between several different markers for confirmation. The S&S Speedometer Calibrator can then be adjusted to increase or decrease the speed and mileage indicated by the speedometer. In most cases it is possible to achieve accuracy within .5%.

The S&S speedometer calibrator will not work with Rev Tech transmissions.

The S&S

Speedometer Calibrator...

allows the rider to correct H-D electronic speedometers easily and without special tools or expensive test equipment. Installation is simply a matter of unplugging the connection between the transmission sensor and speedometer and plugging the two connectors into the S&S Calibrator.

The Calibrator can then be used to correct the difference between actual and indicated speeds and mileage.

Features:

Fits all Harley-Davidson Big Twins and

Sportsters equipped with O.E.M. electronic speedometer.

Allows precise adjustments in 1% increments between -29% and +69%.

Compact size (2.25" x 1.50" x 1.10") permits a neat, simple installation.

Sensitive components are sealed in epoxy for protection from vibration and weather.

email us at [email protected]

Warranty

Limited Warranty Standard Parts

Who Is Covered

By This Warranty?

This warranty covers only the original Consumer Purchaser of these parts and is not transferable.

What Does This Warranty Cover?

S&S Cycle, Incorporated (the "Company") warrants these parts to be free from defects in material and workmanship. If the parts become defective during the warranty coverage period, the

Company will, at its option, repair or replace any, or all, defective parts. Repair or replacement of defective parts is the sole and exclusive remedy.

How Long Is The

Warranty Coverage?

The warranty coverage remains in force for a period of twelve (12) months from the date that the original Consumer Purchaser buys the parts. However, warranty coverage will automatically terminate if the original Purchaser sells or otherwise transfers all or any portion of the purchased parts.

What Is Not Covered by This Warranty?

The Company shall not pay or be responsible for the cost of shipping the defective parts to the Company for service under this warranty, nor will the Company pay for the cost of labor to remove and/or replace the defective parts.

Moreover, the Company shall have no obligation under this warranty in the event that the parts become defective in whole or in part as a result of improper assembly, installation, break-in, maintenance, or use, or any other misuse or mistreatment of the parts, including, without limitation, operation of the parts with fuels, oils or lubricants not conforming to specifications published by the Company or continued operation of the parts after a defect or malfunction occurs or is identified or suspected.

The Company shall have no obligation under this warranty for defects in parts with a powdercoat finish, when that option is selected, if the defects are caused by, but not limited to, negligence of parties other than the Company; an accident; ordinary wear and tear; assembly or disassembly; power washing; natural occurrences like stone chips; bead blasting; improper maintenance including the use of any harsh cleaning agent, chemical or solvent; and salt or other substances used on streets and highways for maintenance and safety.

The Company provides touch-up paint with powdercoated parts. It is the customer's responsibility to repair minor finish damage to prevent or inhibit further deterioration.

It is the responsibility of the original Consumer Purchaser to cease operation as soon as a defect or malfunction is identified or suspected. The failure to cease operation once a defect or malfunction exists can cause substantial damage to the Company's parts that could otherwise be avoided.

In addition, the Company shall have no obligation under this warranty for parts defects caused by alteration including, but not limited to, polishing; powdercoating; painting; removing or reconfiguring any components; modification, repair, or unauthorized service.

The Company shall have no obligation under this warranty if the parts are used in racing or similar competitive activities. The

Company shall have no obligation under this warranty when a competition application, including but not limited to a turbocharger, supercharger or nitrous oxide, is used with the

Engine. Further, the Company shall have no obligation under this warranty for any parts that are included in a Competition Package

Option offered by the Company since the Package is for use in racing and similar competitive activities.

THE COMPANY SHALL NOT BE LIABLE FOR AND DISCLAIMS ALL

CONSEQUENTIAL, INCIDENTAL, PUNITIVE OR SPECIAL DAMAGES

ARISING OUT OF THE USE OF, OR INABILITY TO USE, THESE PARTS.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply to you.

visit us at www.sscycle.com

39

Warranty

Limited Warranty Complete Factory-Assembled Engines

Who Is Covered By This Warranty?

This warranty covers only the original Consumer Purchaser of the

Complete Factory-Assembled Super Stock Engine (the "Engine") and is not transferable.

What Does This Warranty Cover?

S&S Cycle, Incorporated (the "Company") warrants this Engine to be free from defects in material and workmanship. If the Engine or any part thereof becomes defective during the warranty coverage period, the Company will, at its option, repair or replace the Engine or any, or all, defective parts. Repair or replacement of defective parts is the sole and exclusive remedy.

How Long Is

The Warranty Coverage?

The warranty coverage remains in force for a period of twelve (12) months from the date that the original Consumer Purchaser buys the

Engine. Engines specifically designed for and sold with the S&S

Intelligent Spark Technology ignition system are covered by a special twenty four (24) month warranty. However, warranty coverage will automatically terminate if the original Consumer Purchaser sells or otherwise transfers all or any portion of the Engine.

What Is Not Covered by This Warranty?

The Company shall not pay or be responsible for the cost of shipping the defective Engine or part to the Company for service under this warranty, nor will the Company pay for the cost of labor to remove and/or replace the defective Engine or part.

Moreover, the Company shall have no obligation under this warranty in the event that the Engine becomes defective in whole or in part as a result of improper installation, break-in, maintenance, or use, or any other misuse or mistreatment of the Engine, including, without limitation, operation of the Engine with fuels, oils or lubricants not conforming to specifications published by the Company for use in or with the Engine or continued operation of the Engine after a defect or malfunction occurs or is identified or suspected.

The Company shall have no obligation under this warranty for defects in the Engine's black powdercoat finish, when that option is selected, if the defects are caused by, but not limited to, negligence of parties other than Company; an accident; ordinary wear and tear; assembly or disassembly; power washing; natural occurrences like stone chips; bead blasting; improper maintenance including the use of any harsh cleaning agent, chemical or solvent; and salt or other substances used on streets and highways for maintenance and safety. This warranty does not cover consumables, that is, those parts consumed in the normal operation of the Engine.

The Company provides touch-up paint with each powdercoated

Engine. It is the customer's responsibility to repair minor finish damage to prevent or inhibit further deterioration.

40

It is the responsibility of the original Consumer Purchaser to cease operation as soon as a defect or malfunction is identified or suspected. The failure to cease operation once a defect or malfunction exists can cause substantial damage to the Engine that could otherwise be avoided.

In addition, the Company shall have no obligation under this warranty for defects in the Engine caused by alteration including, but not limited to, polishing; powdercoating; painting; removing or reconfiguring any components; modification, repair, or unauthorized service of the Engine.

The Company shall have no obligation under this warranty if the

Engine is used in racing or similar competitive activities. The

Company shall have no obligation under this warranty when a competition application, including but not limited to a turbocharger, supercharger or nitrous oxide, is used with the Engine. Further, the

Company shall have no obligation under this warranty for any

Engine that includes a Competition Package Option since the

Package is for use in racing and similar competitive activities.

THE COMPANY SHALL NOT BE LIABLE FOR AND DISCLAIMS ALL

CONSEQUENTIAL, INCIDENTAL, PUNITIVE OR SPECIAL DAMAGES

ARISING OUT OF THE USE OF, OR INABILITY TO USE, THE ENGINE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply to you.

What Must The Original Consumer

Purchaser Do To Qualify For

Warranty Coverage?

Within thirty (30) days after the date of purchase of the Engine, the original Consumer Purchaser must return a completed Owner's

Registration Card along with a copy of the invoice evidencing such purchase to the Company at the following address:

S&S Cycle, Incorporated

Attention: Technical Services

14025 County Highway G P.O. Box 215

Viola, WI 54664-0215

Phone: 608-627-8324 • Fax: 608-627-0773

Email: [email protected]

Direct Phone: 608-627-TECH (8324)

THIS WARRANTY IS VOIDABLE AT THE COMPANY’S OPTION IF

THE ORIGINAL CONSUMER PURCHASER DOES NOT RETURN TO

THE COMPANY THE OWNER REGISTRATION CARD AND A COPY OF

THE INVOICE WITHIN THIRTY (30) DAYS FROM THE DATE OF

PURCHASE OF THE ENGINE.

email us at [email protected]

Warranty

Limited Warranty Unassembled Engines

Who Is Covered By This Warranty?

This warranty covers only the original Consumer Purchaser of the

Unassembled Engine, the Factory-Assembled Basic Engine or the

Factory-Assembled Basic Engine With Options (the "Engine") and is not transferable.

What Does This Warranty Cover?

S&S Cycle, Incorporated (the "Company") warrants this Engine to be free from defects in material and workmanship. If the Engine or any part thereof becomes defective during the warranty coverage period, the Company will, at its option, repair or replace the Engine or any, or all, defective parts. Repair or replacement of defective parts is the sole and exclusive remedy.

How Long Is

The Warranty Coverage?

The warranty coverage remains in force for a period of twelve (12) months from the date that the original Consumer Purchaser buys the Engine. However, warranty coverage will automatically terminate if the original Consumer Purchaser sells or otherwise transfers all or any portion of the Engine.

What Is Not Covered by This Warranty?

The Company shall not pay or be responsible for the cost of shipping the defective Engine or part to the Company for service under this warranty, nor will the Company pay for the cost of labor to remove and/or replace the defective Engine or part.

Moreover, the Company shall have no obligation under this warranty in the event that the Engine becomes defective in whole or in part as a result of improper assembly, installation, break-in, maintenance, or use, or any other misuse or mistreatment of the Engine, including, without limitation, operation of the Engine with fuels, oils or lubricants not conforming to specifications published by the

Company for use in or with the Engine or continued operation of the

Engine after a defect or malfunction occurs or is identified or suspected.

The Company shall have no obligation under this warranty for defects in the Engine's black powdercoat finish, when that option is selected, if the defects are caused by, but not limited to, negligence of parties other than Company; an accident; ordinary wear and tear; assembly or disassembly; power washing; natural occurrences like stone chips; bead blasting; improper maintenance including the use of any harsh cleaning agent, chemical or solvent; and salt or other substances used on streets and highways for maintenance and safety. This warranty does not cover consumables, that is, those parts consumed in the normal operation of the Engine.

visit us at www.sscycle.com

The Company provides touch-up paint with each powdercoated

Engine. It is the Consumer Purchaser's responsibility to repair minor finish damage to prevent or inhibit further deterioration.

It is the responsibility of the original Consumer Purchaser to cease operation as soon as a defect or malfunction is identified or suspected. The failure to cease operation once a defect or malfunction exists can cause substantial damage to the Engine that could otherwise be avoided.

In addition, the Company shall have no obligation under this warranty for defects in the Engine caused by alteration including, but not limited to, polishing; powdercoating; painting; removing or reconfiguring any components; modification, repair, or unauthorized service of the Engine.

The Company shall have no obligation under this Warranty if the

Engine is used in racing or similar competitive activities. The

Company shall have no obligation under this warranty when a competition application, including but not limited to a turbocharger, supercharger or nitrous oxide, is used with the Engine. Further, the

Company shall have no obligation under this warranty for any

Engine that includes a Competition Package Option since the

Package is for use in racing and similar competitive activities.

THE COMPANY SHALL NOT BE LIABLE FOR AND DISCLAIMS ALL

CONSEQUENTIAL, INCIDENTAL, PUNITIVE OR SPECIAL DAMAGES

ARISING OUT OF THE USE OF, OR INABILITY TO USE, THE ENGINE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply to you.

What Must The Original Consumer

Purchaser Do To Qualify For

Warranty Coverage?

Within thirty (30) days after the date of purchase of the Engine, the original Consumer Purchaser must return a completed Owner's

Registration Card along with a copy of the invoice evidencing such purchase to the Company at the following address:

S&S Cycle, Incorporated

Attention: Technical Services

14025 County Highway G P.O. Box 215

Viola, WI 54664-0215

Phone: 608-627-8324 • Fax: 608-627-0773

Email: [email protected]

Direct Phone: 608-627-TECH (8324)

THIS WARRANTY IS VOIDABLE AT THE COMPANY’S OPTION IF

THE ORIGINAL CONSUMER PURCHASER DOES NOT RETURN TO

THE COMPANY THE OWNER REGISTRATION CARD AND A COPY

OF THE INVOICE WITHIN THIRTY (30) DAYS FROM THE DATE OF

PURCHASE OF THE ENGINE.

41

Warranty

Limited Warranty Return Authorization

What Are The Procedures To Obtain

Service Under This Warranty?

To obtain service under this warranty, the original Consumer

Purchaser should immediately contact the dealer where the Engine was purchased. The dealer will then contact the Company for a determination as to whether the defect in the Engine or part is covered by this warranty.

THE DEALER OR SERVICE PROVIDER MUST RECEIVE

AUTHORIZATION FROM THE COMPANY BEFORE PROVIDING

SERVICE UNDER THIS WARRANTY.

In the event that the Company determines the Engine or part must be returned to the Company for evaluation or service, the

Company will provide the dealer with a Return Authorization

Number to put on the shipping container for identification.

The original Consumer Purchaser or dealer must clean and properly package the Engine or part so as not to cause further damage and return the Engine or part, shipping costs prepaid, to the Company.

The Return Authorization Number must be clearly visible on the outside of the shipping container. If the Engine or part must be cleaned prior to warranty inspection the cost of cleaning will be charged to the original Consumer Purchaser or dealer.

The original Consumer Purchaser or dealer must also send to the

Company a detailed explanation of the relevant facts concerning the nature of the problem, the specific use of the Engine, and the circumstances giving rise to the defect or problem.

If it is not practicable to contact the dealer for warranty service, the original Consumer Purchaser may contact the Company at the following address, telephone number, fax number or e-mail address:

S&S Cycle, Incorporated

Attention: Technical Services

14025 County Highway G P.O. Box 215

Viola, WI 54664-0215

Phone: 608-627-8324 • Fax: 608-627-0773

Email: [email protected]

Direct Phone: 608-627-TECH (8324)

Are There Other Warranties?

THE WARRANTIES STATED IN THIS WARRANTY REPLACE ALL

OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING

WITHOUT LIMITATION, THOSE OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE, AND ANY OTHER

OBIGATIONS OR LIABILITIES ON THE PART OF THE COMPANY

WHETHER IN CONTRACT, WARRANTY, NEGLIGENCE OR

OTHERWISE, TO THE EXTENT NOT PROHIBITED BY LAW.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

How Do State Laws

Relate To This Warranty?

This warranty gives you specific legal rights. You may also have other rights that vary from state to state.

42 email us at [email protected]

Be On The Lookout For S&S

We've just updated our website!

If you haven't visited our website recently, you're in for a pleasant surprise. Direct your web browser to www.sscycle.com and get ready for an all new S&S web experience. The difference will be apparent immediately with an all new look, but the further you dig the more you'll find. There are little differences like the improved dealer locator. You can search for a dealer in your area or find an S&S VFI tuning center, and we will even provide you with a map showing you how to get there.

But wait there's more!

The new searchable product catalog makes finding what you want quick and easy. Up to the minute online race results, an events calendar, events photos and videos, customer bike photos, tech tips, and forums are just some of the features that you'll find. But that's not all!

New to the S&S Website is an E-commerce area for apparel items. Check out our new apparel line! But now, if something catches your eye, you can order it online. Keep in mind that while we sell apparel items direct to consumers, engine parts are still available exclusively through S&S

Dealers. Anybody can make a T-shirt work, but installing and using high performance equipment successfully requires the qualified, personal involvement and support of our dealer network.

Speaking of dealers, they have their own area on our website were they can check stock, place orders, and track orders on line 24/7 365 days a year.

S&S Tours...

are available Wednesday through Friday 11:00 A.M. - 3:00 P.M. Schedule a tour by calling 608-627-2080 Ext. 1363 or email [email protected].

Takin' It To The Streets!

During 2004, the S&S semi truck display made its way to all the major rallies around the continental United States.

On display, were the fabulous 124 VFI Shoot out bikes.

Built around the S&S 124 VFI SSW+ engine, these are some of the most beautiful custom bikes you could hope to see, but the best part about them is that they were built to ride! A successful road trip and heads-up drag racing showed that they could indeed be ridden and ridden fast. A celebratory, five bike, simultaneous burn out on the dance floor of the Broken Spoke Saloon in Sturgis wrapped up the

124 VFI Challenge, and a good time was had by all!

Keep and eye on the coming issues of Hot Bike Magazine for details of a totally new event for the 2005 riding season.

Event Schedule –

Watch for the S&S Semi Display at the following events:

Daytona Bike Week

March 5- 12, 2005

Daytona International Speedway

Myrtle Beach Rally

May 14-21, 2005

Broadway at the Beach, Myrtle Beach SC

Sturgis Motorcycle Rally

August 6-13. 2005

1535 Lazelle Street Sturgis, SD

Laughlin River Run

April 20-23, 2004

Riverside Hotel & Casino, Laughlin NV

visit us at www.sscycle.com

Laconia Bike Rally

June 11-18 2005

Meredith Harley-Davidson, Meredith NH

43

Suggested Retail Pricing

Suggested Retail Pricing in the Continental United States

Part No.

Description Suggested Retail Price

11-0100 Carb kit w/o manifold, Super B .......................................................................................................................................... $374.95

11-0104 Carb kit, Super B - 1957-'78 XL......................................................................................................................................... $384.95

11-0105 Carb kit, Super B - 1979-'82 XL......................................................................................................................................... $398.60

11-0111 Carb assembly, Super B ..................................................................................................................................................... $289.10

11-0115 Carb kit, Super B - 1986-'90 XL......................................................................................................................................... $420.05

11-0120 Carb kit, Super B - 1983-'85 XL......................................................................................................................................... $401.65

11-0404 Carb kit, Super E - 1957-'78 XL ......................................................................................................................................... $416.65

11-0406 Carb kit, Super E - 1979-'85 XL ......................................................................................................................................... $427.75

11-0408 Carb kit, Super E - 1986-'90 XL ......................................................................................................................................... $446.20

11-0409 Carb kit, Super E - 1991-2003 XL ...................................................................................................................................... $454.70

11-0424 Carb kit, Super G - 1957-'78 XL......................................................................................................................................... $427.75

11-0426 Carb kit, Super G - 1979-'85 XL......................................................................................................................................... $438.85

11-0428 Carb kit, Super G - 1986-'90 XL......................................................................................................................................... $457.75

11-0429 Carb kit, Super G - 1991-2003 XL...................................................................................................................................... $466.15

11-0448 Carb kit, Super E - 1994-2002 Buell................................................................................................................................... $517.50

11-0449 Carb kit, Super G - 1994-2002 Buell .................................................................................................................................. $524.65

11-7100 Jet, intermediate - 3 pack - all Super gas (series 94) .......................................................................................................... $19.90

11-7101 Intermediate jet - 1 each: .0265, .028, .0295 - all Super gas ............................................................................................... $19.90

11-7102 Intermediate jet - 1 each: .028, .0295, .031 - all Super gas ................................................................................................. $19.90

11-7103 Intermediate jet - 1 each: .0295, .031, .032 - all Super gas ................................................................................................. $19.90

11-7104 Intermediate jet - 1 each: .031, .032, .033 - all Super gas ................................................................................................... $19.90

11-7105 Intermediate jet - 1 each: .032, .033, .036 - all Super gas ................................................................................................... $19.90

11-7106 Intermediate jet - 1 each: .033, .036, .040 - all Super gas ................................................................................................... $19.90

11-7200 Main jet - 1 each: .062, .064, .066, .068, .070, .072............................................................................................................ $11.40

11-7201 Main jet - 1 each: .066, .068, .070, .072, .074, .076............................................................................................................ $11.40

11-7202 Main jet - 1 each: .072, .074, .076, .078, .080, .082............................................................................................................ $11.40

11-7203 Main jet - 1 each: .078, .080, .082, .084, .086, .088............................................................................................................ $11.40

11-7204 Main jet - 1 each: .090,.092, .094, .096, .098 ........................................................................................................................ $9.50

11-7205 Main jet - 1 each: .100, .102, .104, .106, .108 ....................................................................................................................... $9.50

11-7270 Jet kit, low range - engines up to 93"/96"............................................................................................................................. $39.80

11-7271 Jet kit, high range - engines 93"/96" & up............................................................................................................................ $39.80

11-7272 Jet kit, master - all engines .................................................................................................................................................. $68.65

17-0004 Cover, air cleaner, Super E & G, slotted, SSW+ .................................................................................................................. $82.35

17-0045 Air cleaner kit, tall, element and spacers.............................................................................................................................. $41.15

17-0055 Element, air cleaner, tall ....................................................................................................................................................... $15.40

17-0099 Air cleaner assembly - 1955-'84 BT, 1957-'85 XL w/GBL, GAL, Super B........................................................................... $101.95

17-0105 Air cleaner assembly - 1994-2002 Buell w/stock CV carb.................................................................................................. $158.25

17-0107 Air cleaner assembly - 1984-up V

17-0108 Air cleaner assembly - 1984-up V

2

2 w/Super A, B ............................................................................................................... $130.35 w/stock butterfly type carb.......................................................................................... $129.15

17-0117 Air cleaner assembly - 1993-up BT (V 2 &TC), 1991-2003 XL- w/stock CV carb ................................................................ $188.45

17-0198 Air cleaner assembly - Super D.......................................................................................................................................... $113.35

17-0199 Air cleaner assembly - 1966-'84 BT, 1966-'85 XL w/L series, stock butterfly type carb.................................................... $103.45

17-0385 Cover, air cleaner - Super E & G, U.S. Flag .......................................................................................................................... $97.80

17-0399 Air cleaner assembly, Super E, G - 1984-'92 BT, 1986-'90 XL (after 3-'94) ...................................................................... $131.45

17-0400 Air cleaner assembly, Super E, G - 1936-'84 BT, 1957-'85 XL........................................................................................... $113.15

17-0402 Air cleaner assembly, Super E, G - 1994-2002 Buell.......................................................................................................... $166.25

17-0404 Air cleaner assembly, Super E, G - 1993-'99 V 2 BT (after 2-'01)........................................................................................ $148.95

31-0302 Gearcover kit, crankcase, bushing style - 1986-'90 XL ...................................................................................................... $393.10

31-0303 Gearcover kit, crankcase, bushing style - 1991-'99 XL ...................................................................................................... $393.10

44 email us at [email protected]

Suggested Retail Pricing

Suggested Retail Pricing in the Continental United States

Part No.

Description Suggested Retail Price

31-1008 Crankcase assembly - stock bore - 1991-2003 cam geometry - XL/Buell ...................................................................... $2,212.25

31-1009 Crankcase assembly - 3

5

8

" bore - 1991-2003 cam geometry - XL/Buell ........................................................................ $2,212.25

31-1013 Crankcase assembly - stock bore - 1986-'90 cam geometry - XL/Buell ......................................................................... $2,212.25

31-1014 Crankcase assembly - 3 5 ⁄

8

" bore - 1986-'90 cam geometry - XL/Buell ........................................................................... $2,212.25

31-2099 Gasket, gearcover - 1986-up XL - 5 pack............................................................................................................................. $14.95

31-4114 Seal, gearcover cam oil - 1971-up XL - 5 pack .................................................................................................................... $39.95

31-9299 Engine, Complete - 100" S&S Sportster Style .............................................(Price varies with options selected)......Call for pricing

31-9300 Engine, Complete - 91" S&S Buell Style ......................................................(Price varies with options selected)......Call for pricing

31-9301 Engine, Complete - 100" S&S Buell Style ....................................................(Price varies with options selected)......Call for pricing

31-9302 Engine, Complete - 91" S&S Sportster Style ...............................................(Price varies with options selected)......Call for pricing

32-3089 Hot Setup, 89" - 4

5

16

" F (92-1900) - 1986-2003 XL ......................................................................................................... $2,194.95

32-3772 Stroker kit, 72" - 4 1 ⁄

2

", 8:1CR F (92-3700) - 1972-'85 XL.................................................................................................... $368.00

32-3774 Stroker kit, 74" - 4 5 ⁄

8

", 9:1CR F (92-3700) - 1972-'85 XL.................................................................................................... $368.00

33-5081 Cam set, 500 (Andrews V6) - 1986-'90 XL ........................................................................................................................ $280.75

33-5082 Cam set, 500 (Andrews V6) - 1991-2003 XL ..................................................................................................................... $280.75

33-5083 Cam set, 555 (Andrews V9) - 1986-'90 XL ........................................................................................................................ $280.75

33-5084 Cam set, 555 (Andrews V9) - 1991-2003 XL ..................................................................................................................... $280.75

33-5352 Tappet set, hydraulic - 1984-'99 BT, 1986-'90 XL.............................................................................................................. $199.95

33-5353 Tappet set, hydraulic, w/ HL

2

T - 1984-'99 BT, 1986-'90 XL............................................................................................... $214.95

33-5355 Adapter, pushrod cover - 1991-2003 XL (set of 4) .............................................................................................................. $24.95

33-5361 Tappet guide assembly, - FE - 1986-'90 cams - S&S XL ..................................................................................................... $55.10

33-5362 Tappet guide assembly, - FI - 1986-'90 cams - S&S XL ...................................................................................................... $55.10

33-5363 Tappet guide assembly, - RE - 1986-'90 cams - S&S XL..................................................................................................... $55.10

33-5364 Tappet guide assembly, - RI - 1986-'90 cams - S&S XL...................................................................................................... $55.10

33-5365 Tappet guide set - 1986-'90 cams - S&S XL...................................................................................................................... $220.20

33-5369 Tappet guide set - 1991-2003 cams - S&S XL................................................................................................................... $220.20

33-5371 Tappet guide assembly, - FE - 1986-'90 XL (HD#18616-86)................................................................................................ $55.10

33-5372 Tappet guide assembly, - FI - 1986-'90 XL (HD#18617-86)................................................................................................. $55.10

33-5373 Tappet guide assembly, - RE - 1986-'90 XL (HD#18618-86) ............................................................................................... $55.10

33-5374 Tappet guide assembly, - RI - 1986-'90 XL (HD#18619-86)................................................................................................ $55.10

33-5375 Tappet guide set - 1986-'90 XL .......................................................................................................................................... $220.20

33-5381 Tappet guide assembly, - FE/FI - 1991-2003 cams - S&S XL .............................................................................................. $55.10

33-5383 Tappet guide assembly, - RE/RI - 1991-2003 cams - S&S XL ............................................................................................. $55.10

33-5385 Tappet guide assembly, - FE/FI - 1991-2003 XL................................................................................................................... $55.70

33-5387 Tappet guide assembly, - RE/RI - 1991-2003 XL ................................................................................................................. $55.10

33-5389 Tappet guide set - 1991-2003 XL ....................................................................................................................................... $220.20

50-0333 Cover set, S&S head bolt, chrome ...................................................................................................................................... $49.95

50-8077 O-ring -

3

8

" ID x

1

2

" OD x

1

16

" CS 70 Buna (cylinder vent fitting,upper tappet block. 1986-'90 XL) - 10 pack ......................... $5.40

50-8079 O-ring - 1" ID x 1

3

16

" OD x

3

32

" CS Viton (HD#11167A) (upper tappet block. 1986-'90 XL) - 10 pack................................... $14.95

50-8087 O-ring - 1" ID x 1 1 ⁄

8

" OD x 1 ⁄

16

" CS Viton (HD#11168A) (lower tappet block. 1986-'90 XL) - 10 pack ...................................... $9.40

50-8153 Kit, o-ring, S&S XL tappet blocks ........................................................................................................................................ $11.90

53-0040 Set, rocker cover allen wrench ............................................................................................................................................. $77.20

53-0452 Wrench, main jet (72 main jet)............................................................................................................................................. $10.85

55-1007 Calibration unit, electronic speedometer - all models w/electronic speedo........................................................................ $123.55

55-6008 Kit, muffler, slip-on - 1987-'03 XL ..................................................................................................................................... $249.95

55-6031 Kit, muffler, slip-on - 2004-up XL ...................................................................................................................................... $299.95

55-6500 Hot set-up kit, air cleaner & exhaust - 1987-'03 XL........................................................................................................... $484.95

55-6501 Hot set-up kit, air cleaner & exhaust - 2004-up XL............................................................................................................ $529.95

90-0324 Top end kit, 79" SS - .630" lift", 11.1CR F (92-1100) - 1994-'98 Buell............................................................................ $1,799.95

visit us at www.sscycle.com

45

Suggested Retail Pricing

Suggested Retail Pricing in the Continental United States

Part No.

Description Suggested Retail Price

90-0325 Hot Set Up kit, 74" SS - 3 13 ⁄

16

" - 1991-2003 1200 XL ....................................................................................................... $1,924.95

90-0326 Hot Set Up kit, black, 74" SS - 3 13 ⁄

16

" - 1986-90 1200 XL................................................................................................. $1,869.95

90-0327 Hot Set Up kit, black, 74" SS - 3

13

16

" - 1991-2003 1200 XL............................................................................................. $1,994.95

90-0352 Hot Set Up kit, 89" SS - 4 5 ⁄

16

", 10.3:1CR F (92-1120) - 1991-2003 XL ........................................................................... $3,444.95

90-0389 Hot Set Up kit, 89" SS - 4 5 ⁄

16

", 9.5:1CR F (92-1060) - 1986-2003 XL .............................................................................. $3,444.95

90-1302 Head kit, cylinder - stock pattern SS, .630" lift - 1986-'90 XL ........................................................................................ $1,003.00

90-1302F Head assembly, front cylinder - stock pattern SS, .630" lift - 1986-'90 XL ........................................................................ $601.80

90-1302R Head assembly, rear cylinder - stock pattern SS, .630" lift - 1986-'90 XL ......................................................................... $601.80

90-1305 Head kit, cylinder - stock pattern SS, .630" lift - 1994-2002 Buell XL................................................................................ $997.20

90-1305F Head assembly, front cylinder - stock pattern SS, .630" lift - 1994-2002 Buell XL ............................................................ $598.30

90-1305R Head assembly, rear cylinder - stock pattern SS, .630" lift - 1994-2002 Buell XL ............................................................. $598.30

90-1310 Head kit, cylinder - stock pattern SS, .630" lift - 1991-2003 XL ..................................................................................... $1,003.00

90-1310F Head assembly, front cylinder - stock pattern SS, .630" lift - 1991-2003 XL ..................................................................... $601.80

90-1310R Head assembly, rear cylinder - stock pattern SS, .630" lift - 1991-2003 XL & Buell.......................................................... $601.80

90-1802 Head kit, cylinder, Black - stock pattern SS, .630" lift - 1986-'90 XL .............................................................................. $1,073.00

90-1802 Head kit, cylinder, Black - stock pattern SS, .630" lift - 1986-'90 XL .............................................................................. $1,073.00

90-1802F Head assembly, front cylinder, Black - stock pattern SS, .630" lift - 1986-'90 XL.............................................................. $643.80

90-1802R Head assembly, rear cylinder, Black - stock pattern SS, .630" lift - 1986-'90 XL ............................................................... $643.80

90-1805 Head kit, cylinder, Black - stock pattern SS, .630" lift - 1994-2002 Buell ....................................................................... $1,067.20

90-1805F Head assembly, front cylinder, Black - stock pattern SS, .630" lift - 1994-2002 Buell ...................................................... $640.30

90-1805R Head assembly, rear cylinder, Black - stock pattern SS, .630" lift - 1994-2002 Buell ....................................................... $640.30

90-1810 Head kit, cylinder, Black - stock pattern SS, .630" lift - 1991-2003 XL ........................................................................... $1,073.00

90-1810F Head assembly, front cylinder, Black - stock pattern SS, .630" lift - 1991-2003 XL........................................................... $643.80

90-1810R Head assembly, rear cylinder, Black - stock pattern SS, .630" lift - 1991-2003 XL & Buell ............................................... $643.80

90-1907 Gasket kit, cylinder - 3 1 ⁄

2

" XL................................................................................................................................................. $26.35

90-1908 Gasket kit, cylinder - 3 5 ⁄

8

" XL................................................................................................................................................. $26.35

90-2077 Spring kit, valve - .640" lift steel top collar - 1984-up V 2 , 1999-up TC, TCB BT................................................................. $111.45

90-2078 Spring kit, valve - .640" lift tit. top collar - 1984-up V 2 , 1999-up TC, TCB BT .................................................................... $164.30

90-4006 Shaft, rocker arm - all V 2 (HD#17611-83) .............................................................................................................................. $7.35

90-4014 Bushing, rocker arm - V 2 ........................................................................................................................................................ $2.50

90-4036 Shaft set, rocker arm - 1984-up V 2 ...................................................................................................................................... $29.20

90-4049 Gasket set, rocker cover - billet - 1984-up V 2 ...................................................................................................................... $44.85

90-4050 Kit, rocker cover - chrome billet - 1984-'99 V 2 ................................................................................................................... $866.85

90-4055 Kit, rocker cover - plain billet - 1984-'99 V 2 ....................................................................................................................... $624.25

90-4065 Arm set, roller rocker - 1984-up V 2 .................................................................................................................................... $389.95

90-4065F Arm assembly, roller rocker - FE/RI - 1984-up V 2 .............................................................................................................. $116.95

90-4065R Arm assembly, roller rocker - RE/FI - 1984-up V 2 .............................................................................................................. $116.95

90-4080 Kit, rocker cover - polished billet - 1984-'99 V 2 ................................................................................................................. $735.75

90-4083 Kit, rocker cover - plain die cast - 1984-'99 V 2 .................................................................................................................. $281.65

90-4090 Kit, rocker cover - polished die cast - 1984-'99 V 2 ............................................................................................................. $387.05

90-4091 Gasket set, rocker cover - die cast - 1984-'99 V 2 ................................................................................................................. $48.65

90-4095 Kit, rocker cover - chrome die cast - 1984-'99 V 2 .............................................................................................................. $559.95

90-4104 Kit, rocker arm rebuild (90-4065) ...................................................................................................................................... $102.95

90-4119 Arm set, rocker - 1984-up V 2 ............................................................................................................................................. $174.95

90-4119F Arm assembly, rocker - FE/RI - 1984-up V 2 ......................................................................................................................... $52.50

90-4119R Arm assembly, rocker - RE/FI - 1984-up V 2 ......................................................................................................................... $52.50

91-3002 Cylinder kit, 79" SW - 3 13/16", 9.2:1 or 11.0:1 CR F (92-1940) - 1986-2003 XL ............................................................. $668.40

91-3012 Cylinder kit - 3 1 ⁄

2

" x 3 13/16" 10.5:1CR (4.650") SSF (92-2056) - 1986-2003 883 XL ........................................................ $759.10

91-3014 Cylinder kit - 3 1 ⁄

2

" x 3 13/16" 10.5:1CR (4.650") SSF (92-2016) - 1986-2003 XL ............................................................... $712.80

46 email us at [email protected]

Suggested Retail Pricing

Suggested Retail Pricing in the Continental United States

Part No.

Description Suggested Retail Price

91-3204 SW kit, 89" - 4 5 ⁄

16

", 9.5:1 or 10.2:1CR F (92-1940) - 1986-'90 XL ................................................................................... $1,774.95

91-3206 SW kit, 89" - 4 5 ⁄

16

", 9.5:1 or 10.2:1CR F (92-1940) - 1991-2003 XL ................................................................................ $1,774.95

91-3504 SW kit, 103" - 5", 10.5:1 or 11.8:1CR F (92-1940) - 1986-'90 XL .................................................................................. $1,784.95

91-3506 SW kit, 103" - 5", 10.5:1 or 11.8:1CR F (92-1940) - 1991-2003 XL ............................................................................... $1,784.95

91-3906 Cylinder kit, Black - 3 1 ⁄

2

" x 3 13 ⁄

16

" 10.5:1CR (4.650") SSF (92-2056) - 1986-2003 883 XL.................................................... $844.10

91-3908 Cylinder kit, Black - 3 1 ⁄

2

" x 3 13 ⁄

16

" 10.5:1CR (4.650") SSF (92-2016) - 1986-2003 XL........................................................... $797.80

92-2016 Piston set, 3

1

2

" std. - 4

5

8

",12.5:1 – 3

13

16

",10.5:1 SSFDF - 1984-up V 2 .................................................................................. $236.45

92-20165 Piston set, 3 1 ⁄

2

" +.005" - 4 5 ⁄

8

",12.5:1 – 3 13 ⁄

16

",10.5:1 SSFDF - 1984-up V 2 .............................................................................. $236.45

92-2017 Piston set, 3 1 ⁄

2

" +.010" - 4 5 ⁄

8

",12.5:1 – 3 13 ⁄

16

,10.5:1 SSFDF - 1984-up V 2 ............................................................................... $236.45

92-2018 Piston set, 3 1 ⁄

2

" +.020" - 4 5 ⁄

8

",12.5:1 – 3 13 ⁄

16

",10.5:1 SSFDF - 1984-up V 2 .............................................................................. $236.45

92-2019 Piston set, 3

1

2

" +.030" - 4

5

8

",12.5:1 – 3

13

16

",10.5:1 SSFDF - 1984-up V 2 .............................................................................. $236.45

92-2036 Piston set, 3 1 ⁄

2

" std. - 4 5 ⁄

8

",10.9:1 – 3 13 ⁄

16

",9.2:1 SSRDF - 1984-up V 2 ................................................................................... $244.60

92-20565 Piston set, 3 1 ⁄

2

" +.005" - 883,10.5:1 SSFDF - 1986-up XL................................................................................................... $288.70

92-2056 Piston set, 3 1 ⁄

2

" std. - 883,10.5:1 SSFDF - 1986-up XL....................................................................................................... $288.70

92-2057 Piston set, 3

1

2

" +.010" - 883,10.5:1 SSFDF - 1986-up XL................................................................................................... $288.70

92-2058 Piston set, 3 1 ⁄

2

" +.020" - 883,10.5:1 SSFDF - 1986-up XL................................................................................................... $288.70

92-2059 Piston set, 3 1 ⁄

2

" +.030" - 883,10.5:1 SSFDF - 1986-up XL................................................................................................... $288.70

92-2446 Piston kit, 3 1 ⁄

2

" std. - 883,9.25:1 RDC - 1986-up XL ........................................................................................................... $214.15

92-24465 Piston kit, 3

1

2

" +.005" - 883,9.25:1 RDC - 1986-up XL....................................................................................................... $214.15

92-2447 Piston kit, 3 1 ⁄

2

" +.010" - 883,9.25:1 RDC - 1986-up XL....................................................................................................... $214.15

92-2448 Piston kit, 3 1 ⁄

2

" +.020" - 883,9.25:1 RDC - 1986-up XL....................................................................................................... $214.15

92-2449 Piston kit, 3 1 ⁄

2

" +.030" - 883,9.25:1 RDC - 1986-up XL....................................................................................................... $214.15

92-3701 Piston set, 3

3

16

" +.010" - 4

7

16

"-4

13

16

", 7.25:1-9:1 F - 1972-'85 XL ......................................................................................... $226.55

92-3702 Piston set, 3 3 ⁄

16

" +.020" - 4 7 ⁄

16

"-4 13 ⁄

16

", 7.25:1-9:1 F - 1972-'85 XL ......................................................................................... $226.55

92-3703 Piston set, 3 3 ⁄

16

" +.030" - 4 7 ⁄

16

"-4 13 ⁄

16

", 7.25:1-9:1 F - 1972-'85 XL ......................................................................................... $226.55

92-3704 Piston set, 3 3 ⁄

16

" +.040" - 4 7 ⁄

16

"-4 13 ⁄

16

", 7.25:1-9:1 F - 1972-'85 XL ......................................................................................... $226.55

92-3705 Piston set, 3

3

16

" +.050" - 4

7

16

"-4

13

16

", 7.25:1-9:1 F - 1972-'85 XL ......................................................................................... $226.55

92-3706 Piston set, 3 3 ⁄

16

" +.060" - 4 7 ⁄

16

"-4 13 ⁄

16

", 7.25:1-9:1 F - 1972-'85 XL ......................................................................................... $226.55

92-3707 Piston set, 3 3 ⁄

16

" +.070" - 4 7 ⁄

16

"-4 13 ⁄

16

", 7.25:1-9:1 F - 1972-'85 XL ......................................................................................... $226.55

92-3708 Piston set, 3 3 ⁄

16

" +.080" - 4 7 ⁄

16

"-4 13 ⁄

16

", 7.25:1-9:1 F - 1972-'85 XL ......................................................................................... $226.55

93-4059 Mount, isolator to head, stock engine height - 1996-2002 Buell ...................................................................................... $321.45

93-4060 Mount, isolator to head, S&S 100" engine height - 1996-2002 Buell ............................................................................... $321.45

93-4061 Mount, isolator to head, special order - 1996-2002 Buell.................................................................................................. $321.45

93-4062 Mount, top motor, slotted steel - 1996-2002 Buell .............................................................................................................. $83.65

93-5022 Pushrod set, adjustable - steel +

7

16

" 1986-'90 XL/std. 1991-up XL ...................................................................................... $86.95

93-5025 Pushrod set, adjustable - +1.100" steel - 1986-'90 XL......................................................................................................... $86.95

93-5033 Pushrod set, adjustable - std. steel - 1986-'90 XL............................................................................................................... $86.95

93-5036 Pushrod set, adjustable - Special Order steel - 1986-up XL .............................................................................................. $103.40

93-5037 Pushrod set, non-adjustable - std. steel - 1957-'85 XL ....................................................................................................... $38.55

93-5038 Pushrod set, non-adjustable - Special Order steel - 1957-'85 XL ........................................................................................ $55.00

93-5088 Pushrod set, adjustable - +1.100" steel - 1991-up XL.......................................................................................................... $86.95

93-5089 Pushrod set, adjustable - + 7 ⁄

16

" steel - 1991-up XL ............................................................................................................... $86.95

93-5130 Pushrod set, quickee - 883-89" - 1991-up V 2 XL ............................................................................................................... $169.95

93-5131

93-5132

Pushrod set, quickee - 883-89" - 1989-'90 V

Pushrod set, quickee - 103" - 1984-'99 V 2

2 XL .............................................................................................................. $169.95

BT, 1986-'90 V2 XL ......................................................................................... $169.95

93-5133 Pushrod set, quickee - 103" - 1991-up V 2 XL..................................................................................................................... $169.95

93-5135 Pushrod set, quickee - special order.................................................................................................................................. $199.95

visit us at www.sscycle.com

47

S&S 11-Second club

Here's how you can join some fast company.

First, go fast -- after breaking in your engine according to the manufacturer's instructions.

Next, provide the documentation listed below.

Then, toss everything in an envelope and send it to S&S.

We’ll send you an official 11-Second Club patch for your leathers or denims, a certificate authorizing braggin' rights, and a free 11-Second Club T-shirt.

Here's what we need from you:

1.

Proof that your street-ridden motorcycle (D.O.T. tires, full charging system, no wheelie bars or air shifts) equipped with one of our carburetors and, hopefully, numerous other S&S products, has turned an 11.99 or quicker quarter-mile time. We'll need an official timing slip from a sanctioned dragstrip dated after June 1, 1997 and signed by the timekeeper. (A good photocopy will do.) We don't care if you trailer the bike to the track, so long as it sees more action on the street than off.

2.

A photograph of yourself, anyone else you'd care to include, and the motorcycle. Action shots are preferred if sharp and clear, but the carburetor MUST be in plain view.

3.

A signed copy of this statement:

Please tell us a little about yourself and your motorcycle.

Included the model and year, a list of all engine and frame modifications, the type of exhaust, and tire brand and model.

Be sure to mention all S&S products used!

Submitted materials may be used for promotional purposes.

Members will receive a 11- Second Club certificate, patch, and T-shirt, but no payment or other considerations.

I do hereby attest that I have fulfilled all membership requirements of the S&S Cycle 11-Second Club as outlined above and that my motorcycle is fully licensed for use on all city, state and federal highways. I also attest that starting is self-contained or by kickstart, requiring no external mechanical devices, and that this motorcycle is ridden more often on the street than the racetrack. I understand that some risk to rider and equipment is present in all forms of motorcycle racing and do hereby accept all risks and liabilities associated therewith.

____________________________________ ___________________ _________________

Signature Date T-Shirt Size

48

Please include a few words about yourself and your motorcycle. Include the model and year, a list of engine and frame modifications, displacement, compression ratio, type of exhuast, and tire brand. Be sure to mention any S&S products used!

Send inquiries and membership applications to: 11-Second Club, Attention: Carla Langyel

S&S Cycle, Inc. • 14025 County Hwy. G Box 215 • Viola, Wisconsin 54664 USA

Please allow 4 weeks for processing.

email us at [email protected]

S&S 10-Second club

Continuing in the spirit of the 11-Second Club...

The 10-Second Club is for registered and licensed street motorcycles with S&S carbs. No wheelie bars are permitted. D.O.T. tires, full charging systems, lighting, and self-contained starters are required. Any chassis or engine modifications compatible with legitimate street-use are permitted.

Mufflers are between you and the authorities, but the motorcycle must be street-ridden on a regular basis.

Here’s what we need to welcome you in:

1. Proof that your street-ridden motorcycle is equipped with one of our carburetors and, hopefully, other S&S products as well, has turned a 10.999 or quicker quarter mile. Send either the original or a good photocopy of an official timing slip from a sanctioned dragstrip; it must be dated after 01/01/99 and signed by the timekeeper. The registered owner must ride the motorcycle for the qualifying pass.

2. Your t-shirt size and a photograph of yourself and the motorcycle. The carburetor must be in plain view.

3. A signed and dated copy of the statement below.

Please tell us a little about yourself and your motorcycle.

Included the model and year, a list of all engine and frame modifications, the type of exhaust, and tire brand and model.

Be sure to mention all S&S products used!

Submitted materials may be used for promotional purposes. Members will receive a certificate, club patch, and t-shirt, but no payment or other considerations

I do hereby attest that I have fulfilled all membership requirements of the S&S Cycle 10-Second Club as outlined above and that my motorcycle is fully licensed for use on all city, state and federal highways. I also attest that starting is self-contained or by kickstart, requiring no external mechanical devices, and that this motorcycle is ridden more often on the street than the racetrack. I understand that some risk to rider and equipment is present in all forms of motorcycle racing and do hereby accept all risks and liabilities associated therewith.

____________________________________ ___________________ _________________

Signature Date T-Shirt Size

Please include a few words about yourself and your motorcycle. Include the model and year, a list of engine and frame modifications, displacement, compression ratio, type of exhuast, and tire brand. Be sure to mention any S&S products used!

Send inquiries and membership applications to: 11-Second Club, Attention: Carla Langyel

S&S Cycle, Inc. • 14025 County Hwy. G Box 215 • Viola, Wisconsin 54664 USA

Please allow 4 weeks for processing.

#51-1503

© S&S Cycle 2005

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals

Download PDF

advertisement