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EnginEs 1-2 4 stEps to pErformancE 1-8 Exhaust 1-12 ... - S&S Cycle

EnginEs 1-2 4 stEps to pErformancE 1-8 Exhaust 1-12 ... - S&S Cycle

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Engines 1-2<br />

4 Steps <strong>to</strong> Performance 1-8<br />

<strong>Exhaust</strong> 1-<strong>12</strong><br />

Power Kits 1-22<br />

Fuel Systems 1-30<br />

Tuned Induction System<br />

Teardrop Air Cleaners<br />

Air Filters<br />

Fuel Injection Sytem<br />

Carbure<strong>to</strong>r Kits<br />

Manifolds<br />

Top End 1-52<br />

Cylinder Heads<br />

Cylinder and Pis<strong>to</strong>ns<br />

Valve Train 1-62<br />

Camshafts<br />

Tappets<br />

Pushrods<br />

Valve Springs<br />

Rocker Arms/Covers<br />

Transmission<br />

Lower End 1-83<br />

Crankcases<br />

Gearcover<br />

Flywheels<br />

Mainshaft Assemblies<br />

Connecting Rod Assemblies<br />

Oil Pumps<br />

Breather Reed Valves


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

S&S ® T<strong>12</strong>4 ENGINE<br />

S&S T<strong>12</strong>4 engines provide a whole new riding experience! A huge<br />

displacement increase, high lift gear driven cams and a high performance<br />

billet oil pump provides a level of performance that must be experienced.<br />

The optional S&S Single Bore Tuned Induction System adds more horsepower<br />

and style (see page 1-30).<br />

FITMENT<br />

❚❚ The T<strong>12</strong>4 can only be sold as a closed course competition engine<br />

for 1999-’05 fuel injected engines and 1999-’06 carbureted engines<br />

S&S does not offer full replacement engines for 2006 Dyna® models,<br />

any 2007-up models, or any counterbalanced engines, such as Twin<br />

Cam 88B. However, see our Power Kits starting on page 1-22 for<br />

power-enhancing modifications <strong>to</strong> these models.<br />

FEATURES AND BENEFITS<br />

❚❚ Bolt-in<br />

❚ ❚ Increased power & <strong>to</strong>rque (see Dyno Chart on next page)<br />

❚❚ Long pis<strong>to</strong>n stroke and high performance gear driven cams result<br />

in large horsepower increase over s<strong>to</strong>ck engine<br />

❚❚ Chrome plated 2.00" stainless steel intake and 1.605" inconel<br />

exhaust valve<br />

❚❚ Chrome gearcover, tappet covers and rocker covers<br />

❚❚ Natural, wrinkle black powdercoat, or polished finish. Diamond<br />

cut finish is available, but has a longer lead time<br />

FUEL INJECTED ENGINES (2002–’05)<br />

❚❚ Delphi® style S&S Variable Fuel Injection (VFI) module with<br />

built-in three stage engine overheat protection<br />

❚❚ Closed loop fuel system, dual oxygen sensors provide air-fuel<br />

ratio feedback for correct fuel delivery under any condition<br />

❚❚ Included S&S ProTune II software CD provides base fuel maps for<br />

most aftermarket exhaust systems<br />

❚ ❚ Delphi style knock sensor module eliminates knock – prolonging<br />

engine life<br />

❚❚ Break-in rev-limiter prevents high RPM during break-in<br />

❚❚ Single bore throttle body with teardrop air cleaner<br />

❚❚ One-year warranty<br />

Displacement Bore Stroke Camshaft<br />

Pis<strong>to</strong>n<br />

Type<br />

Compression<br />

Ratio<br />

S&S® T<strong>12</strong>4 engine shown with polished finish and optional chrome single<br />

bore tuned induction system. All engines come standard with a teardrop<br />

air cleaner. Tuned induction system must be purchased separately, see page<br />

1-30.<br />

Chassis Style Fuel Delivery Ignition<br />

Now with<br />

Easy Start<br />

Cams!<br />

Warranty<br />

Period<br />

Finish<br />

Silver Black Polished<br />

Warranty &<br />

Company Policy<br />

<strong>12</strong>4" 4 1⁄8" 4 5/8" 640GP<br />

S&S<br />

forged<br />

Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />

10.8:1<br />

1999-'06 Carb S&S® Super G Carbure<strong>to</strong>r IST® 2 Years 106-4328 31-9895 31-9896<br />

2002-'05 FI Delphi® style VFI<br />

106-4323 106-0402 106-0403<br />

VFI 1 Year<br />

1999-'01 FI Magneti Marelli® style VFI 106-4322 106-0399 106-0400<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-2


CONTINUED -<br />

S&S® T<strong>12</strong>4 Engine<br />

Parts for<br />

Twin Cam 88®<br />

FUEL INJECTED ENGINES (1999–’01)<br />

❚❚ Magneti Marelli® style S&S Variable Fuel Injection (VFI) module<br />

with built-in three stage engine overheat protection<br />

❚❚ Closed loop fuel system, dual oxygen sensors provide air-fuel<br />

ratio feedback for correct fuel delivery under any condition<br />

❚❚ Included S&S ProTune II software CD provides base fuel maps for<br />

most aftermarket exhaust systems<br />

❚❚ Single bore throttle body with teardrop air cleaner<br />

❚❚ One-year warranty<br />

CARBURETED ENGINES (1999–’06)<br />

❚❚ S&S Super G carbure<strong>to</strong>r with slotted “Desperado” air cleaner cover<br />

❚❚ Knock sensing ignition control prolongs engine life by<br />

au<strong>to</strong>matically adjusting timing <strong>to</strong> eliminate knock by learning<br />

and s<strong>to</strong>ring ignition requirements of the engine<br />

❚❚ Guardian feature protects engine with a 3 step break-in rev-limiter<br />

❚❚ Two-year warranty<br />

CONTENTS<br />

❚❚ Complete S&S engine<br />

❚❚ Fuel delivery/ignition system<br />

❚❚ Instructions<br />

❚❚ Mobil 1® 20W-50 and an S&S oil filter<br />

140<br />

130<br />

<strong>12</strong>0<br />

110<br />

100<br />

90<br />

80<br />

70<br />

60<br />

50<br />

Dyno Comparison<br />

S&S® T<strong>12</strong>4 w/Single Bore Throttle Body - Tuned Induction vs Teardrop Air Cleaner<br />

S&S T<strong>12</strong>4 w/Single Bore - Tuned Induction<br />

Peak Corrected HP 139.9<br />

Peak Corrected Torque 137.7<br />

S&S T<strong>12</strong>4 w/Single Bore - Air Cleaner<br />

Peak Corrected HP 135.8<br />

Peak Corrected Torque 132.1<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

40<br />

2500 3000 3500<br />

4000 4500 5000 5500 6000 6500<br />

EngSpd RPM<br />

This dyno chart shows performance of a fuel injected T<strong>12</strong>4 with a teardrop air<br />

cleaner and with a single bore tuned induction system.<br />

NOTE:<br />

1999–’05 Dyna® requires oil line installation kit part # 31-0424 , includes special transmission <strong>to</strong>p cover.<br />

2000–’06 FLT requires oil line installation kit part #31-0425.<br />

If a different exhaust or intake system is used, the fuel maps must be modified. It is highly recommended that this tuning be done by a certified S&S® VFI tuning center. Visit our<br />

website at www.sscycle.com <strong>to</strong> locate your nearest certified S&S VFI tuning center or <strong>to</strong> download maps for the S&S VFI system.<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-3 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

S&S ® T111 ENGINE<br />

The new T111 is a powerful yet quiet engine perfect for <strong>to</strong>uring riders. A<br />

practical stroke, less aggressive <strong>to</strong>uring cam, and nearly silent valve train<br />

create a <strong>to</strong>rquey, smooth power band – making your bike a pleasure <strong>to</strong> ride<br />

for long distances. Lower cost and superior engine life.<br />

FITMENT<br />

❚❚ The T111 will only fit in place of 1999-’05 fuel injected engines<br />

and 1999-’06 carbureted engines<br />

S&S does not offer full replacement engines for 2006 Dyna® models,<br />

any 2007-up models, or any counterbalanced engines, such as Twin<br />

Cam 88B. However, see our Power Kits starting on page 1-22 for<br />

power-enhancing modifications <strong>to</strong> these models.<br />

FEATURES AND BENEFITS<br />

❚❚ Installs easily in<strong>to</strong> s<strong>to</strong>ck frames<br />

❚❚ “Square” mo<strong>to</strong>r configuration (equal bore and stroke) produces<br />

excellent <strong>to</strong>rque, greatly increases engine life, and reduces<br />

mechanical engine noise<br />

❚❚ S&S 585GP gear driven cams and lightweight single coil<br />

Sidewinder® valve springs further reduce valve train noise<br />

❚❚ Silver powdercoat or wrinkle black powdercoat finish<br />

❚❚ Chrome gearcover and tappet covers<br />

❚❚ Trademark S&S teardrop air cleaner<br />

FUEL INJECTED ENGINES (2002-’05)<br />

❚❚ Delphi® style S&S Variable Fuel Injection (VFI) module with<br />

built-in three stage engine overheat protection<br />

❚❚ Closed loop fuel system, dual oxygen sensors provide air-fuel<br />

ratio feedback for correct fuel delivery under any condition<br />

❚❚ Included S&S ProTune II software CD provides base fuel maps for<br />

most aftermarket exhaust systems<br />

❚❚ Delphi style knock sensor module eliminates knock and prolongs<br />

engine life<br />

❚❚ Break-in rev-limiter prevents high RPM during break-in<br />

❚❚ Single bore throttle body with teardrop air cleaner<br />

❚❚ Three-year warranty<br />

Displacement Bore Stroke Camshaft Pis<strong>to</strong>n Type<br />

Compression<br />

Ratio<br />

111" 4 1⁄8" 4 1⁄8" 585GP S&S Forged 9.8:1<br />

Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />

Chassis<br />

Style<br />

Fuel Delivery<br />

Now with<br />

Easy Start<br />

Cams!<br />

Ignition<br />

Warranty<br />

Period<br />

Silver<br />

Finish<br />

Black<br />

1999-'06 Carb S&S® Super E Carbure<strong>to</strong>r IST®<br />

106-4431 106-4430<br />

3 Years<br />

2002-'05 FI<br />

Delphi® style VFI<br />

106-4433 106-4432<br />

VFI<br />

1999-'01FI Magneti Marelli® style VFI 2 Year 106-4435 106-4434<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-4


CONTINUED -<br />

S&S® T111 Engine<br />

Parts for<br />

Twin Cam 88®<br />

FUEL INJECTED ENGINES (1999-’01)<br />

❚❚ Single bore throttle body with teardrop air cleaner<br />

❚❚ Magneti Marelli® style S&S Variable Fuel Injection (VFI) module<br />

with built-in three stage engine overheat protection<br />

❚❚ Closed loop fuel system, dual oxygen sensors provide air-fuel<br />

ratio feedback for correct fuel delivery under any condition<br />

❚❚ Included S&S ProTune II software provides base fuel maps for<br />

most aftermarket exhaust systems<br />

❚❚ Two-year warranty<br />

CARBURETED ENGINES<br />

❚❚ S&S Super E carbure<strong>to</strong>r with teardrop air cleaner cover<br />

❚❚ Knock sensing ignition control prolongs engine life by<br />

au<strong>to</strong>matically adjusting timing <strong>to</strong> eliminate knock by learning<br />

and s<strong>to</strong>ring ignition requirements of the engine<br />

❚❚ Guardian feature protects engine with a 3 step break-in rev-limiter<br />

❚❚ Three-year warranty<br />

CONTENTS<br />

❚❚ Complete S&S engine<br />

❚❚ Fuel delivery/ignition system<br />

❚❚ Intake manifold<br />

❚❚ Instructions<br />

❚❚ Mobil 1® 20W-50 and an S&S oil filter<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Those used <strong>to</strong> looking at dyno charts of high performance engines may wonder<br />

why the T111 does not make more horsepower on the <strong>to</strong>p end. That’s because<br />

it is a bona fide <strong>to</strong>uring engine. Thanks <strong>to</strong> the S&S® Super E carb, moderate<br />

compression ratio, and mild cams, it has a lot of <strong>to</strong>rque and a broad power curve<br />

making passing vehicles, climbing hills, and accelerating up <strong>to</strong> highway speed as<br />

simple as twisting the throttle. We recommend the S&S T<strong>12</strong>4 engine for cus<strong>to</strong>mers<br />

who are looking for big horsepower numbers.<br />

NOTE:<br />

If a different exhaust or intake system is used, the fuel maps must be modified. It is highly<br />

recommended that this tuning be done by a certified S&S® VFI tuning center. Visit our<br />

website at www.sscycle.com <strong>to</strong> locate your nearest certified S&S VFI tuning center, or <strong>to</strong><br />

download updated fuel maps for the system.<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-5 Visit us at www.sscycle.com


Warranty &<br />

Company Policy<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

S&S ® T<strong>12</strong>4 TÜV APPROVED ENGINES<br />

These modified T<strong>12</strong>4 high performance engines exceed European Union<br />

Chapter 9 standards. Equipped with a high flow billet oil pump and gear<br />

driven cams, they include instructions, and all required certification and<br />

documentation <strong>to</strong> verify their emissions compliance.<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

FITMENT<br />

❚❚<br />

The T<strong>12</strong>4 TÜV can only be sold as a replacement engine for:<br />

1999-’05 fuel injected engines and 1999-’06 carbureted engines<br />

S&S does not offer full replacement engines for 2006 Dyna® models,<br />

any 2007-up models, or any counterbalanced engines, such as Twin<br />

Cam 88B. However, see our Power Kit starting on page 1-22 for<br />

power-enhancing modifications <strong>to</strong> these models.<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

FEATURES AND BENEFITS<br />

❚❚ Meets EU Chapter 9 standards 2002/51/EC for exhaust,<br />

97/24/EC for noise<br />

❚❚ Bolt-in<br />

❚❚ Increased power & <strong>to</strong>rque (see Dyno Chart on next page)<br />

❚❚ Long pis<strong>to</strong>n stroke and high performance gear driven cams result<br />

in large horsepower increase over s<strong>to</strong>ck engine<br />

❚❚ Chrome plated 2.00" stainless steel intake and 1.605" inconel<br />

exhaust valve<br />

❚❚ Chrome gearcover, tappet covers and rocker covers<br />

❚❚ Natural, wrinkle black powdercoat, or polished finish. Diamond<br />

cut finish is available, but has a longer lead time<br />

T<strong>12</strong>4 with teardrop air cleaner<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Displacement Bore Stroke Camshaft<br />

Pis<strong>to</strong>n<br />

Type<br />

Compression<br />

Ratio<br />

<strong>12</strong>4" 4 1⁄8" 4 5/8" 546GP S&S Forged 9.5:1<br />

Chassis<br />

Style<br />

Fuel Delivery<br />

Ignition<br />

Warranty<br />

Period<br />

Finish<br />

Silver Black Polished<br />

1999-'06 Carb S&S® Super G Carb IST® 2 Years 106-4329 31-9965 –<br />

1999-'05 FI Delphi® style VFI VFI 1 Year 106-4327 106-2356 106-2395<br />

Dealer Services<br />

& Promo Items<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-6


Racing<br />

Products<br />

CONTINUED -<br />

S&S® T<strong>12</strong>4 TÜV Approved Engines<br />

Parts for<br />

Twin Cam 88®<br />

FUEL INJECTED ENGINES (1999-’05)<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

Single bore throttle body with teardrop air cleaner<br />

Modified Delphi® style S&S Variable Fuel Injection (VFI) module<br />

with built-in three stage engine overheat protection<br />

Closed loop fuel system, dual oxygen sensors provide air-fuel<br />

ratio feedback for correct fuel delivery under any condition<br />

Delphi style knock sensor module eliminates knock, prolonging<br />

engine life<br />

Break-in rev-limiter prevents high RPM during break-in<br />

One-year warranty<br />

Meets Euro III exhaust emissions limits<br />

CARBURETED ENGINES (1999-'06)<br />

❚❚ S&S® Super G, EC carbure<strong>to</strong>r with chrome teardrop air cleaner<br />

❚❚ Knock sensing ignition control prolongs engine life by<br />

au<strong>to</strong>matically adjusting timing <strong>to</strong> eliminate knock by learning<br />

and s<strong>to</strong>ring ignition requirements of the engine<br />

❚❚ Guardian feature protects engine with a 3 step break-in rev-limiter<br />

❚❚ Two-year warranty<br />

❚❚ Meets Euro II exhaust emissions limits<br />

CONTENTS<br />

❚❚ Complete S&S engine<br />

❚❚ Fuel delivery/ignition system<br />

❚❚ Instructions<br />

❚❚<br />

Certificates and documentation of TÜV approval<br />

❚❚ Mobil 1® 20W-50 and an S&S oil filter<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

NOTE:<br />

1999-'01 EFI bikes will require conversion <strong>to</strong> Delphi® style single bore EFI fuel tank & wiring harness.<br />

1999-’05 Dyna® requires oil line installation kit part #31-0424 , includes special transmission <strong>to</strong>p cover.<br />

2000-’06 FLT, requires oil line installation kit part #31-0425.<br />

In order <strong>to</strong> be compliant with EU Chapter 9 standards, all S&S® TÜV engines must be used with s<strong>to</strong>ck Harley-Davidson® exhaust, specified gearing, and the provided S&S ignition system.<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-7 Visit us at www.sscycle.com


Tools &<br />

Shop Supplies<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Four steps <strong>to</strong> better performance<br />

For 1999-Up Big Twins<br />

If you have a new bike and are considering high performance modifications, the expense can seem pretty daunting. However, if done one step at a time, these<br />

modifications can be pretty affordable. Here is a series of performance upgrades that can help you go fast and will fit any budget. The idea is <strong>to</strong> install some key<br />

components that will give you more power right now. Later, installing additional parts <strong>to</strong> what you already have will produce even more power. That way, you<br />

can build up <strong>to</strong> a respectable level of performance without having <strong>to</strong> make a large investment all at once. Of course, you can start at any step you want. If you<br />

want the big numbers right away, just go for it and get everything at once.<br />

Step 1 Intake and <strong>Exhaust</strong><br />

One of the most cost effective ways <strong>to</strong> improve performance is a high flowing<br />

air cleaner kit and a set of high performance slip on mufflers from S&S. These<br />

parts are required components of any serious performance package.<br />

More intake information starting on page 1-30.<br />

More exhaust information starting on page 1-<strong>12</strong>.<br />

Replacement<br />

Parts<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Racing<br />

Products<br />

X-Wedge®<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Choose the S&S Single<br />

Bore Tuned Induction System for<br />

even more power!<br />

This dyno chart shows a s<strong>to</strong>ck 2009 FLHT and the performance improvement with a set of<br />

S&S slip-on bagger mufflers and a teardrop air cleaner or an S&S tuned induction system.<br />

NEXT UPGRADE: SEE STEP 2<br />

<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-8


Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

CONTINUED -<br />

Four Steps <strong>to</strong> Better Performance For 1999-up Big Twins<br />

Step 2 Cams<br />

The addition of cams is the next step <strong>to</strong>ward higher performance. Several types of<br />

cams are available, and it is important <strong>to</strong> decide what cams are best suited <strong>to</strong> your<br />

immediate needs and what cams will be needed <strong>to</strong> achieve your long-term goals.<br />

For more <strong>to</strong>rque, we recommend the S&S 551 cams for dressers, and the S&S 583<br />

cam for Dyna® and Softail® models. For more <strong>to</strong>p end horsepower, we suggest<br />

the S&S 585 cams. Dealer installation of cams is recommended, and EFI tuning is<br />

generally required. We recommend the Harley-Davidson® Super Tuner, Dynojet®<br />

Power Commander®, or S&S VFI module for EFI tuning.<br />

More cam information starting on page 1-62.<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

This dyno chart shows a s<strong>to</strong>ck 2009 FLHT as a base line and the performance<br />

improvement with a set of S&S slip-on bagger mufflers, a teardrop air cleaner, and a<br />

set of S&S 551 cams. The cams provide a significant increase in both <strong>to</strong>rque and hp.<br />

NEXT UPGRADE: SEE STEP 3<br />

<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-9 Visit us at www.sscycle.com


Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Tools &<br />

Shop Supplies<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

CONTINUED -<br />

Four Steps <strong>to</strong> Better Performance For 1999-up Big Twins<br />

Step 3 106" Big Bore Kit<br />

The next step is <strong>to</strong> increase the displacement of your engine. The S&S 106" Big Bore Kit is an easy and cost effective way <strong>to</strong> do it. Simply replace the s<strong>to</strong>ck<br />

pis<strong>to</strong>ns and cylinders with the S&S 106" kit. No machining or flywheel rebalancing required. Cams, exhaust, and intake components from steps 1 and 2 will<br />

work great with the 106" kits. Dealer installation recommended. Larger fuel injec<strong>to</strong>rs, such as the Screamin' Eagle®, may be required. Big bore kits are also<br />

available for 1999-'06 big twins (see page 1-22).<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Racing<br />

Products<br />

Replacement<br />

Parts<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

X-Wedge®<br />

This dyno chart shows a s<strong>to</strong>ck 2009 FLHT compared <strong>to</strong> the same bike with an S&S<br />

106" big bore kit, along with the set of S&S Slip-on Power-Tour mufflers, a teardrop<br />

air cleaner, and a set of S&S 551 cams installed in steps 1 and 2. This combination is<br />

extremely useful for bagger applications because of the great increase in <strong>to</strong>rque. For<br />

lighter bikes, or if more horsepower is your goal, the 585 cam will result in somewhat<br />

less <strong>to</strong>rque, but more horsepower.<br />

NEXT UPGRADE: SEE STEP 4<br />

<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-10


CONTINUED -<br />

Four Steps <strong>to</strong> Better Performance For 1999-up Big Twins<br />

Step 4 CNC Ported Heads<br />

After the displacement of an engine has been increased, and high<br />

performance intake, exhaust and cams have been installed, the next step<br />

is <strong>to</strong> make the heads flow better. For this, S&S offers several options. The<br />

most economical route is <strong>to</strong> have S&S CNC port your s<strong>to</strong>ck heads. This can<br />

be done on an exchange or rework basis (see page 1-20). The other option<br />

is <strong>to</strong> purchase new S&S cylinder heads or new H-D® heads from S&S. Either<br />

way, the increased flow of the intake and exhaust ports will allow you <strong>to</strong><br />

take advantage of the extra displacement by filling it with more air. Dealer<br />

installation is recommended and EFI tuning is required. We recommend<br />

the S&S VFI modules, Harley-Davidson® Super Tuner, or Dynojet® Power<br />

Commander® for EFI tuning. Larger fuel injec<strong>to</strong>rs, such as the high flow<br />

injec<strong>to</strong>rs from Screamin' Eagle®, will be required.<br />

For even more horsepower, consider a set of cams with more radical lift and<br />

timing such as the Crane 296 cam.<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

The CNC Difference: The dyno chart compares a s<strong>to</strong>ck 2009 FLHT (black curves) with<br />

the same bike after an S&S 106" Big Bore Top End Kit, 585 cams and S&S slip on mufflers,<br />

and an S&S teardrop AC were installed (blue curves). The <strong>to</strong>p (red curves) show the same<br />

engine after the heads were CNC ported and a 58mm throttle body was installed. Both<br />

106" engines perform much better than s<strong>to</strong>ck, and are pretty comparable <strong>to</strong> each other<br />

until about 3500 rpm. At that point the engine with CNC heads continues <strong>to</strong> increase in<br />

<strong>to</strong>rque and horsepower because it can still get enough air.<br />

Where Do I Find This Stuff?<br />

The parts you will need for any of these performance steps are in this catalog.<br />

S&S air cleaner kits ....................................... Page 1-31<br />

S&S tuned induction systems .............................. Page 1-30<br />

Slip-on mufflers for 1995-up big twins ...................... Page 1-<strong>12</strong><br />

Gear drive and chain drive cams for 1995-up big twins ......... Page 1-62<br />

S&S 106" big bore kits .................................... Page 1-22<br />

How <strong>to</strong> get your s<strong>to</strong>ck heads CNC ported by S&S .............. Page 1-20<br />

<strong>12</strong>0<br />

110<br />

100<br />

90<br />

Dyno Comparison<br />

S<strong>to</strong>ck 2009 FLHT vs S&S 106” Kit, Slip-On’s, Intake, CNC Porting. With 551 & 585 Cams<br />

S&S 106”, Slip-On’s, 585 Cams, CNC, & SE 58<br />

Peak Rear Wheel HP 115.2<br />

Peak Rear Wheel To rque 1<strong>12</strong>.0<br />

130<br />

80<br />

70<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

0<br />

1000 2000 3000<br />

S&S 106”, Slip-On’s,551 Cams CNC, S&S AC<br />

Peak Rear Wheel HP 96.9<br />

Peak Rear Wheel To rque 113.4<br />

S<strong>to</strong>ck 2009 FLHT<br />

Peak Rear Wheel HP 68.6<br />

Peak Rear Wheel To rque 84.7<br />

4000 5000 6000<br />

7000<br />

EngSpd RPM<br />

Choose The Right Cam For You: This dyno chart compares a s<strong>to</strong>ck 96" 2009 FLHT on<br />

the same bike with an S&S 106" Big Bore Top End Kit with CNC ported heads, S&S slipon<br />

mufflers, performance intake, and two different cams. The blue curves represent the<br />

106 with S&S 551 <strong>to</strong>uring cams and S&S teardrop air cleaner on the s<strong>to</strong>ck 50mm throttle<br />

body. Great <strong>to</strong>rque for performance <strong>to</strong>uring applications. The red curves show the S&S<br />

585 cams with a 58mm throttle body. The increased duration of the 585 reduces low<br />

and midrange <strong>to</strong>rque, but the combination of more aggressive valve timing, higher lift<br />

and a larger throttle body significantly increases usable rpm and <strong>to</strong>p end horsepower.<br />

A good choice for lighter bikes and racing applications. Both engines were tuned with<br />

Screamin' Eagle® Race Tuner.<br />

Notes:<br />

If your final goal is a really big inch engine like our <strong>12</strong>4" Hot Set Up Kit®, it is not<br />

practical <strong>to</strong> build that engine in steps.<br />

S&S CNC ported heads are only available through S&S dealers.<br />

CNC ported heads are not available for Harley-Davidson® CVO vehicles.<br />

It should be noted that more radical cams will produce more <strong>to</strong>p end horsepower,<br />

but may reduce low and midrange <strong>to</strong>rque. Consider which is more important <strong>to</strong> your<br />

personal style of riding.<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-11 Visit us at www.sscycle.com


Tools &<br />

Shop Supplies<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Racing<br />

Products<br />

X-Wedge®<br />

S&S ® SPO ® <strong>to</strong>uring MUFFLERS<br />

Touring mufflers restyled<br />

With their unique oval shape, the newly restyled S&S SPO mufflers give your<br />

dresser a distinctive cus<strong>to</strong>m look, enhanced midrange <strong>to</strong>rque, and a sound<br />

reminiscent of the low rumble of a late 1960’s muscle car. These mufflers<br />

feature sculpted alloy end-caps in your choice of show chrome finish or<br />

coated with high-temp black Xylan®. Double walled construction and show<br />

quality chrome virtually eliminate bluing.<br />

Fitment<br />

❚❚ 1995-up Harley-Davidson® <strong>to</strong>uring models<br />

(except 2010 Road Glide Cus<strong>to</strong>m and Street Glide only)<br />

Features and benefits<br />

❚❚ Modern styling<br />

❚❚ Double walled construction<br />

❚❚ Sculpted alloy end-caps with machined-in S&S logo<br />

❚❚ Great looking show chrome finish<br />

❚ ❚ Increased performance – works best with S&S air cleaner and/or<br />

camshaft upgrade<br />

❚❚ Utilizes fac<strong>to</strong>ry mounting locations and hardware<br />

❚ ❚ Made in the U.S.A.<br />

Options<br />

❚❚ Xylan® black alloy end-cap<br />

❚❚ Chrome alloy end-cap<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

S&S® SPO® Touring Mufflers<br />

Fitment End-cap Style Part Number<br />

1995-up H-D® <strong>to</strong>uring<br />

(except 2010 Road Glides and<br />

Street Glides only)<br />

SEE SPECIAL NOTES: ON PAGE 1-13 FOR DISCLAIMERS<br />

Xylan® Black 550-0002<br />

Chrome 550-0001<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-<strong>12</strong>


Replacement<br />

Parts<br />

S&S ® 80db SPO ® MUFFLERS<br />

S&S 80db SPO mufflers are designed <strong>to</strong> look and sound great, and are EPA<br />

compliant! Great for <strong>to</strong>uring models, these mufflers are sure <strong>to</strong> leave your<br />

hearing intact after a long day of riding.<br />

FITMENT<br />

❚❚ 1995-up Harley-Davidson® <strong>to</strong>uring models<br />

(except 2010-up Road Glides and Street Glides)<br />

FEATURES AND BENEFITS<br />

❚❚ More power than s<strong>to</strong>ck Harley-Davidson® mufflers throughout<br />

the midrange<br />

❚❚ Made from stainless steel so they’ll never rust, pit, or corrode<br />

❚❚ Highly polished finish looks great on any bike<br />

❚❚ Legal replacement for 2007-up models without catalyst in<br />

mufflers (no recalibration required)<br />

KIT CONTENTS<br />

❚❚ Installation instructions<br />

❚❚ Two mufflers<br />

❚❚ Utilizes fac<strong>to</strong>ry mounting hardware and locations<br />

PART NUMBER<br />

S&S 80db SPO Mufflers ...............................55-6634<br />

NOTES:<br />

55-6634<br />

LISTEN & COMPARE AT<br />

SSCYCLE.COM/AUDIO<br />

Baffles are riveted in place <strong>to</strong> meet EPA tamper proof requirements.<br />

Use on any other engine configurations are not covered by this certification.<br />

Does not meet California or TÜV standards.<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

This EPA compliance statement is a quick way <strong>to</strong> tell the difference between<br />

our 80db SPO® mufflers and our standard performance SPO mufflers. The<br />

other difference is that the standard version has a replaceable baffle, while<br />

the 80db version’s baffle is permanently riveted in place.<br />

Notice the increase in midrange <strong>to</strong>rque after installing the S&S® 80db<br />

SPO® mufflers. This means more power for passing, climbing hills, and<br />

accelerating <strong>to</strong> highway speed.<br />

SPECIAL NOTES:<br />

It may be necessary <strong>to</strong> re-jet the carbure<strong>to</strong>r or recalibrate the fuel injection system for best performance when a change is made in the exhaust system.<br />

Dyno results are from tests performed at the S&S® Research and Development facility in Viola, Wisconsin.<br />

Emissions Notice: S&S <strong>Cycle</strong>, Inc. exhaust systems and slip-on mufflers are legal for sale and use on U.S. EPA and California pollution controlled mo<strong>to</strong>rcycles not originally equipped<br />

with a catalyst in the exhaust system. In addition S&S slip-on mufflers are legal for sale and use on U.S. EPA and California pollution controlled mo<strong>to</strong>rcycles that have the catalyst<br />

located in the header pipes upstream of the muffler. Removing a catalytic converter from a pollution-controlled mo<strong>to</strong>rcycle is considered tampering and can lead <strong>to</strong> substantial fines<br />

and penalties. Unless otherwise noted additional S&S components shown are restricted <strong>to</strong> closed course competition use only.<br />

<strong>Exhaust</strong> Noise Disclaimer: Unless noted, S&S exhaust components do not meet U.S. EPA noise standards and may be restricted <strong>to</strong> closed course competition use. Check local noise<br />

ordinances before use.<br />

All reference <strong>to</strong> Harley-Davidson® part numbers is for identification purposes only. We are in no way implying that any of S&S <strong>Cycle</strong>'s products are original equipment parts or that they<br />

are equivalent <strong>to</strong> the corresponding H-D part number shown.<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-13 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

S&S ® 3 1 /2" <strong>to</strong>uring MUFFLERS<br />

A New Line Of Bagger Mufflers From S&S<br />

This new line of slip-on performance <strong>to</strong>uring mufflers from S&S has just the<br />

right muffler for almost any style and/or budget. These mufflers fit on the<br />

s<strong>to</strong>ck header pipes of 1995-up Harley-Davidson® bagger models and are<br />

perfect for s<strong>to</strong>ck or modified engines. A great complement <strong>to</strong> an S&S air<br />

cleaner kit, camshaft, or any other performance upgrade. See dyno charts.<br />

For the budget minded rider, we have three styles <strong>to</strong> choose from: 31/2"<br />

diameter chromed steel mufflers, with a slash-down, slash-back, or a tapered<br />

end. The slash-down, and slash-back styles are available in a quieter version<br />

that we call Quiet-Tour, and in a louder performance version that we call<br />

Power-Tour. The tapered version is only available in the Quiet-Tour version.<br />

If you are looking for a little more style, we have mufflers that feature a billet<br />

end cap, which are also available in Quiet-Tour and Power-Tour versions.<br />

The billet end-caps are engraved with the S&S logo, and are available<br />

chrome plated or coated with black Xylan®.<br />

Fitment<br />

❚❚ 1995-up Harley-Davidson® <strong>to</strong>uring models<br />

(except 2010 Road Glides and Street Glides only)<br />

106-5979<br />

Black Xylan® Billet End Cap Style<br />

LISTEN & COMPARE AT<br />

SSCYCLE.COM/AUDIO<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Features and benefits<br />

❚❚ Great looking show chrome finish<br />

❚❚ Great sounding<br />

❚❚<br />

Increased performance – works best with an<br />

S&S air cleaner and/or camshaft upgrade<br />

❚ ❚ Double layered packing – Basalt wool over stainless steel wool<br />

❚❚ Utilizes fac<strong>to</strong>ry mounting locations and hardware<br />

❚❚ Made in the U.S.A.<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Options<br />

❚❚ Slash-back end<br />

❚❚ Slash-down end<br />

❚❚ Tapered end<br />

❚❚<br />

End cap – available chrome plated or black Xylan® coated<br />

❚❚ Quiet-Tour or Power-Tour versions available<br />

S&S 31/2"Touring Mufflers<br />

Style Quiet-Tour Power-Tour<br />

Slash-back 106-5977 106-5982<br />

Slash-down 106-5976 106-5981<br />

Tapered 106-5978 –<br />

Billet End-cap Black Xylan® 106-5979 106-5983<br />

Billet End-cap Chrome 106-5980 106-5984<br />

SEE SPECIAL NOTES: ON PAGE 1-13 FOR DISCLAIMERS<br />

This dyno chart shows the improvement a set of S&S 31/2" slash-back Power-<br />

Tour mufflers and an S&S air cleaner kit (middle curves) and an S&S tuned<br />

induction kit (<strong>to</strong>p curves) made on a s<strong>to</strong>ck 96" 2009 FLHT (bot<strong>to</strong>m curves).<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-14


Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Replacement<br />

Parts<br />

Racing<br />

Products<br />

Continued<br />

S&S® Touring Mufflers<br />

LISTEN & COMPARE AT<br />

SSCYCLE.COM/AUDIO<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

106-5980<br />

Chrome Billet End Cap Style<br />

106-5978<br />

Tapered Style<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

106-5977<br />

Slash-back Style<br />

Tools &<br />

Shop Supplies<br />

To really wake up this s<strong>to</strong>ck 96" 2009 FLHT (bot<strong>to</strong>m curves) we added a set<br />

of S&S 551 cams <strong>to</strong> the S&S slash-back mufflers and air cleaner kit shown in<br />

the previous dyno chart. S&S performance mufflers will enhance the results<br />

of any performance modifications made <strong>to</strong> the engine. See the Four Steps <strong>to</strong><br />

Better Performance, starting on page 1-8, for more performance upgrade<br />

information for late model baggers.<br />

106-5976<br />

Slash-down Style<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-15 Visit us at www.sscycle.com


Tools &<br />

Shop Supplies<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

X-Wedge®<br />

S&S ® SLIP-ON PERFORMANCE MUFFLERS<br />

One of the most popular and cost effective performance upgrades you can<br />

make <strong>to</strong> a Harley-Davidson® mo<strong>to</strong>rcycle is <strong>to</strong> replace the s<strong>to</strong>ck exhaust with<br />

a set of low restriction, high performance mufflers. The s<strong>to</strong>ck exhaust pipes<br />

and S&S performance mufflers make a great high performance exhaust<br />

system with a low price tag.<br />

FITMENT<br />

❚❚ 1999 –up big twins<br />

FEATURES AND BENEFITS<br />

❚❚ Best horsepower/dollar ratio<br />

❚❚ Slip-on mufflers maintain a smooth power curve while delivering<br />

excellent low and midrange <strong>to</strong>rque, making adjustments <strong>to</strong> the<br />

fuel delivery system minimal and straightforward<br />

❚❚ Show chrome finish<br />

OPTIONS<br />

❚❚ Slash-cut<br />

❚❚ Tapered<br />

LISTEN & COMPARE AT<br />

SSCYCLE.COM/AUDIO<br />

106-6016<br />

Slash-cut Style<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

S&S Slip-on Performance Mufflers<br />

Application Slash-cut Tapered<br />

1995-up Harley-Davidson® Dyna® Models (except 2008-up FatBob® and 2010-up Wide Glide®) 106-5769 106-5770<br />

2000-'06 Softail®, Softail Standard, and Heritage Softail® Models - Shorty* 106-5757 106-5763<br />

2000-'06 Softail, Fatboy® and Duece Models - Shotgun* 106-5762 106-5761<br />

2007-up Softail Standard Model - Shorty* 55-6041 55-6040<br />

2007-up Softail Fatboy and Duece Models - Shotgun* 55-6043 55-6042<br />

2007-up Softail Deluxe Model - Shotgun* 55-6045 55-6044<br />

2008-up Fat Bob®, 2010 Dyna® Wide Glide®* 106-6016 –<br />

*Not intended for mo<strong>to</strong>rcycles orginally equipped with a catalyst.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-16


Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Continued<br />

S&S® Slip-on Performance Mufflers<br />

90<br />

80<br />

70<br />

60<br />

50<br />

40<br />

Dyno Comparison<br />

S<strong>to</strong>ck H-D® Twin Cam 88® Engine vs w/S&S Slip-On vs w/S&S Slip-On, 510 Cam, & Super E<br />

Twin Cam 88 w/S&S Exh, 510 Cam, E Carb<br />

Peak Corrected HP 83.7<br />

Peak Corrected Torque 87.8<br />

Twin Cam 88 w/S&S <strong>Exhaust</strong><br />

Peak Corrected HP 68.7<br />

Peak Corrected Torque 79.3<br />

Twin Cam 88 S<strong>to</strong>ck<br />

Peak Corrected HP 60.9<br />

Peak Corrected Torque 68.7<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

30<br />

20<br />

2000 2500 3000 3500 4000 4500 5000 5500 6000<br />

EngSpd RPM<br />

Vintage<br />

Engines<br />

This dyno chart shows the difference between s<strong>to</strong>ck mufflers and S&S®<br />

mufflers (quite a lot), and the difference between S&S slash-cut and S&S<br />

tapered mufflers (not much).<br />

Bot<strong>to</strong>m curves: S<strong>to</strong>ck 88" Harley-Davidson® Twin Cam 88® engine with<br />

s<strong>to</strong>ck exhaust. Middle curves: S<strong>to</strong>ck 88" Twin Cam 88 engine with S&S® slipon<br />

mufflers on s<strong>to</strong>ck header pipes. Top curves: S<strong>to</strong>ck Twin Cam 88 engine<br />

with S&S slip-on mufflers on s<strong>to</strong>ck header pipes, S&S Super E carbure<strong>to</strong>r,<br />

and S&S 510 bolt-in cams.<br />

X-Wedge®<br />

55-6043<br />

Slash-cut Style<br />

55-6042<br />

Tapered Style<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

55-6019<br />

REPLACEMENT INTERCONNECT GASKETS<br />

Fits 2000-up Softail® Shotgun<br />

(H-D#65826-90A) ..................................55-6019<br />

Fits 2000-up Softail Shorty<br />

(H-D#65927-00) ....................................55-6020<br />

SPECIAL NOTES:<br />

See page 1-13 for disclaimers.<br />

All reference <strong>to</strong> Harley-Davidson® part numbers is for identification purposes only. We are in no way implying that any of S&S <strong>Cycle</strong>'s products are original equipment parts or that they<br />

are equivalent <strong>to</strong> the corresponding H-D part number shown.<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-17 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

S&S ® Power Tune Duals<br />

Parts for<br />

Sportster® '86-'06<br />

Dealer Services<br />

& Promo Items<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Parts for<br />

Evolution®<br />

Fitment<br />

❚❚<br />

1995-up Harley-Davidson® <strong>to</strong>uring models<br />

Features and benefits<br />

❚❚ Adds 8 horsepower over s<strong>to</strong>ck header pipes<br />

❚❚ Independent dual look with hidden crossover<br />

❚❚ Moves the rear cylinder header under the bike <strong>to</strong> reduce<br />

radiated heat <strong>to</strong> the passenger<br />

❚❚ Full chrome heat shielding with 220º coverage<br />

❚❚ Updated styling <strong>to</strong> give the bike a modern look<br />

❚❚ Oxygen sensor bungs*<br />

❚❚ Durable16 gauge construction<br />

❚❚ Spherical inlet design for improved sealing and exhaust gasket<br />

durability<br />

❚❚ Hardware included <strong>to</strong> mount crossover pipe<br />

❚❚ Compatible with all slip-on mufflers<br />

❚❚ Made in the U.S.A.<br />

Part number<br />

S&S Power Tune Duals, 1995-’08 bt....................................550-0003<br />

* Has 18mm sensor fittings in the s<strong>to</strong>ck locations for 2007-’08 bikes. If not equipped with oxygen<br />

sensors, the ports can be used for tuning. Caps are included if ports are not used.<br />

S&S Power Tune Duals, 2009-up bt.....................................550-0004<br />

* Has both <strong>12</strong>mm and 18mm oxygen sensor fittings in the s<strong>to</strong>ck locations. Caps are included for<br />

both sets of ports.<br />

Warranty &<br />

Company Policy<br />

Power Tune Duals: Fitment on 2010-up model year <strong>to</strong>uring mo<strong>to</strong>rcycles is limited <strong>to</strong> closed course competition use only. All 2010-up <strong>to</strong>uring mo<strong>to</strong>rcycles contain a catalyst in the head pipe<br />

and removing the catalyst from a highway mo<strong>to</strong>rcycle is a violation of pollution control laws.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-18


Proven Performance ®<br />

S&S <strong>Cycle</strong> has a well equipped, modern R&D facility and a professional<br />

staff of technicians and engineers. Every product S&S sells is thoroughly<br />

tested for reliability and performance.<br />

During the development process of the latest S&S exhaust product line,<br />

our team of engineers <strong>to</strong>ok on the first major task of finding an exhaust<br />

manufacturer that S&S could partner with and co-develop new products.<br />

After contacting most of the major exhaust manufacturers, S&S decided<br />

DS Manufacturing is best suited for the job.<br />

With a mot<strong>to</strong> like "Proven Performance®", which is in fact a registered<br />

trademark of S&S® <strong>Cycle</strong> Inc., it is very important that we be able <strong>to</strong> back<br />

up our claims regarding performance. It is also vitally important <strong>to</strong> be able<br />

<strong>to</strong> evaluate new designs in our development process. One of the <strong>to</strong>ols we<br />

depend on for both of these functions is the chassis dynamometer.<br />

Development<br />

There are 3 significant additions <strong>to</strong> our exhaust line up:<br />

31/2" Touring Mufflers. When S&S started the exhaust re-launch over<br />

a year ago, we <strong>to</strong>ok a look at our current exhaust product offerings and<br />

quickly found that we had some holes in what we offered. The most<br />

obvious was the round mufflers for the <strong>to</strong>uring bikes... we didn’t have<br />

any. This was a good project <strong>to</strong> begin with because DS Manufacturing<br />

already had some very good <strong>to</strong>uring mufflers <strong>to</strong> use for a starting point.<br />

In order <strong>to</strong> make our mufflers unique, we decided <strong>to</strong> do a round muffler<br />

with a styled end cap. After an end cap design was choosen, S&S worked<br />

with in-house manufacturing <strong>to</strong> produce the parts.<br />

Two baffles, a “loud” (Power-Tour) and a “quiet” (Quiet-Tour), were<br />

created because the personal preference with the Harley-Davidson®<br />

crowd is as diverse as you can get, so we felt that these two designs<br />

would allow for more options. We did multiple dyno runs with both of<br />

these mufflers. Many of the best dyno runs shown in the catalog are with<br />

the Power-Tour mufflers. The Quiet-Tour mufflers also perform extremely<br />

well, especially with a smaller displacement bike. One major advantage<br />

<strong>to</strong> the Quiet Tour mufflers is the great sound. They are less restrictive<br />

than the s<strong>to</strong>ck mufflers and provide a great sounding exhaust note.<br />

Redesigned SPO Mufflers. Once the 31/2" mufflers went in<strong>to</strong> production,<br />

we turned our attention <strong>to</strong> the SPO mufflers. We’ve been making them<br />

in-house for quite a few years. We needed <strong>to</strong> give our “flagship” muffler<br />

a major revamping – working with the same designer who did the end<br />

caps for the 31/2" mufflers. After we agreed on a new exterior design for<br />

the muffler, the hard part of actually producing the muffler went <strong>to</strong> DS<br />

Manufacturing. We wanted <strong>to</strong> keep the same general size of the muffler<br />

but give it some updates such as a styled end cap and updated shape.<br />

The end cap comes with a choice of finishes, chrome or Xylan® black. The<br />

updated shape gives the muffler an attractive modern look, plus provides<br />

additional cornering clearance. In addition <strong>to</strong> the new look, we wanted <strong>to</strong><br />

retain much of the sound and performance of the early style SPO muffler.<br />

After trying dozens of different baffle combinations, we decided on using<br />

a baffle based on our current Dyna®/Softail®/Sportster® muffler baffle.<br />

Power Tune Duals Header System. DS Manufacturing was working on<br />

developing a header system for a while and S&S had visions of creating a<br />

complete header system. After testing a few pro<strong>to</strong>types and seeing how<br />

well they work on the dyno (and how good they looked), we decided that<br />

DS Manufacturing designed the header system we were looking for. The<br />

performance is excellent, especially compared <strong>to</strong> the 2008 and earlier<br />

s<strong>to</strong>ck header systems.<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-19 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

CNC Ported Cylinder Heads From S&S ®<br />

S&S® now offers a CNC porting service for s<strong>to</strong>ck cylinder heads for 1999-up<br />

Harley-Davidson® big twin engines. This is an economical way <strong>to</strong> get a<br />

substantial horsepower increase while maintaining a s<strong>to</strong>ck appearance.<br />

S&S has developed high flowing intake port, exhaust port, and combustion<br />

chamber shapes for s<strong>to</strong>ck cylinder heads. S&S then digitally reproduces<br />

them in a s<strong>to</strong>ck head casting with our 5-axis CNC machining centers. After<br />

CNC porting, heads are assembled with new one-piece, forged racing grade<br />

stainless steel alloy, valves, valve guides and high performance conical high<br />

silicon alloy valve springs.<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Fitment<br />

❚❚ Available for 1999-up big twin engines<br />

❚❚ Ideal for 95" - 106" engines<br />

Features and benefits<br />

❚❚ CNC machined ports for a consistent performance increase from<br />

s<strong>to</strong>ck heads<br />

❚❚ Great throttle response, high velocity port without losing low<br />

RPM <strong>to</strong>rque<br />

❚❚ Assembled with performance valves and springs ready <strong>to</strong> bolt-on<br />

❚❚ Slight increase in compression<br />

Service options<br />

❚❚ Exchange Service<br />

• CNC ported heads are available for immediate delivery, core<br />

charge of $450 per set must be paid<br />

• S<strong>to</strong>ck heads sent <strong>to</strong> S&S<br />

• Core charge credited if cus<strong>to</strong>mer's returned heads pass<br />

inspection (see notes)<br />

• No turn-around delay<br />

❚❚ Rework Service<br />

• S<strong>to</strong>ck heads sent <strong>to</strong> S&S<br />

• Get the same set of heads back with CNC machined ports<br />

• The best option for heads with a special cosmetic treatment<br />

• Allow 2 week turn-around<br />

❚❚ Cus<strong>to</strong>m CNC Port Duplication<br />

• S&S can digitize your port design and machine it in your<br />

heads, ask an S&S cus<strong>to</strong>mer service representative for details<br />

Part Number<br />

S&S CNC Porting Service for S<strong>to</strong>ck Heads ..................... 106-5880<br />

Shown is the S&S CNC machined intake port before the valve guide is installed.<br />

Notice the raised vane ahead of the valve guide hole. The purpose of this vane<br />

is <strong>to</strong> split the air stream ahead of the valve guide <strong>to</strong> reduce turbulence and<br />

increase flow.<br />

Digitized port shapes are faithfully reproduced in any s<strong>to</strong>ck Harley-<br />

Davidson® cylinder head on our 5-axis CNC machining center. Intake port,<br />

exhaust port and combustion chamber are all modified. This head will be<br />

assembled with new forged stainless steel valves and high lift valve springs<br />

<strong>to</strong> complete the package.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-20


Continued<br />

CNC Ported Cylinder Heads from S&S®<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Valve Size<br />

Max TDC Lift<br />

Port Flow*<br />

Compression<br />

Ratio<br />

S<strong>to</strong>ck Harley-Davidson®<br />

CNC Ported by S&S®<br />

Intake 1.805" 1.900"<br />

<strong>Exhaust</strong> 1.575" 1.610"<br />

Max Valve Lift .585" .650"<br />

Intake – .230"<br />

<strong>Exhaust</strong> – .215"<br />

Intake 216.2 cfm 248.6 cfm<br />

<strong>Exhaust</strong> 191.8 cfm 209.7 cfm<br />

88" 9.0:1 9.2:1<br />

95" 9.2:1 9.4:1<br />

96" 9.2:1 9.4:1<br />

97" 9.7:1 9.9:1<br />

103" 10.1:1 10.3:1<br />

106" Big Bore 10.0:1 10.2:1<br />

106" Stroker 10.1:1 10.3:1<br />

<strong>12</strong>4" DD Pis<strong>to</strong>n 10.7:1 10.9:1<br />

Chamber Volume 85cc 83cc<br />

*Flow testing performed on a SuperFlow® 1020 flow bench at 28” of water test pressure at .600"<br />

lift. Heads tested are 2006-up style.<br />

Notes:<br />

Only cylinder heads that are in good condition and have “like new” appearance, may be exchanged. Heads with superficial damage, peeling or discolored paint, or other cosmetic<br />

alterations are not acceptable for exchange, but may be reworked. Rework will take slightly longer than exchange service. Cus<strong>to</strong>mer will be contacted <strong>to</strong> review options if heads do not<br />

pass inspection.<br />

CNC porting is not available for previously ported heads, heads that have been structurally damaged, or heads that are determined <strong>to</strong> be unserviceable during initial inspection. These<br />

heads will be returned <strong>to</strong> the cus<strong>to</strong>mer without modification. In these cases, the cus<strong>to</strong>mer will be notified and options will be reviewed. New, CNC ported s<strong>to</strong>ck heads or S&S heads are<br />

available for purchase.<br />

Due <strong>to</strong> variations in s<strong>to</strong>ck cylinder head castings, all inside surfaces of the ports may not “clean up” during machining. As a result, the inside of one or more ports may not appear <strong>to</strong> be<br />

completely machined. This does not effect performance and is not considered a defect.<br />

CNC porting is not currently available for Harley-Davidson® CVO engines.<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

The CNC Difference<br />

See dyno charts on page 1-11.<br />

Replacement parts<br />

See page 7-74.<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-21 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

S&S ® 97" & 106" BIG BORE KITS<br />

With no need <strong>to</strong> rebalance flywheels, bore crankcases, or bore cylinders,<br />

this kit is about as easy as it gets. Consisting of the largest bore we feel can<br />

safely be used in a cylinder with a s<strong>to</strong>ck spigot diameter, this kit brings a new<br />

definition <strong>to</strong> the term ‘big bore’.<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

FITMENT<br />

❚❚<br />

1999-up big twins<br />

FEATURES AND BENEFITS<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

Bolt-on 9 <strong>to</strong> 10 cubic inches<br />

Pis<strong>to</strong>n weight for 97" & 106" kits are the same as s<strong>to</strong>ck, requiring<br />

no flywheel rebalancing<br />

Cylinders do not require crankcase machining <strong>to</strong> install<br />

Forged coated pis<strong>to</strong>ns are compatible with s<strong>to</strong>ck or S&S Super<br />

S<strong>to</strong>ck® 89cc heads<br />

Valve pocket recessed in S&S pis<strong>to</strong>ns are enlarged for oversize<br />

valves and higher lift cams<br />

Silver or black wrinkle powdercoat cylinder finish color matches<br />

s<strong>to</strong>ck Harley-Davidson® finish<br />

KIT CONTENTS<br />

❚❚ Pis<strong>to</strong>n set<br />

❚ ❚ Top end gasket kit (not shown)<br />

❚❚ S&S cylinders<br />

❚❚<br />

Instructions<br />

S&S® 97" & 106" BIG BORE KITS<br />

Specifications Compression Ratio Part No.<br />

Year Displacement Stroke Bore Cylinder Length Pis<strong>to</strong>n Type S<strong>to</strong>ck Heads 89cc S&S Heads Silver Powdercoat Finish Black Powdercoat Finish<br />

2007 - '09 106" 4 3/8"<br />

10.0:1 9.7:1 106-3747 106-3760<br />

3.927" 4.937" Forged<br />

1999 - '06 97" 4" 9.7:1 9.4:1 106-5974 106-5975<br />

Cylinder w/ pis<strong>to</strong>n kits include fitted pis<strong>to</strong>ns and cylinders that require no boring or honing.<br />

SPECIAL NOTES:<br />

S&S® highly recommends installing a performance cam for easier starting and better engine performance.<br />

S&S high flow cylinder heads will provide further horsepower gains and are machined for installation of manual/electric compression releases.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-22


Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

CONTINUED -<br />

S&S® 97" & 106" Big Bore Kits<br />

Parts for<br />

Twin Cam 88®<br />

<strong>12</strong>0<br />

110<br />

100<br />

90<br />

Dyno Comparison<br />

S<strong>to</strong>ck 2009 FLHT vs S&S 106” Kit, Slip-On’s, Intake, CNC Porting. With 551 & 585 Cams<br />

S&S 106”, Slip-On’s, 585 Cams, CNC, & SE 58<br />

Peak Rear Wheel HP 115.2<br />

Peak Rear Wheel To rque 1<strong>12</strong>.0<br />

130<br />

80<br />

70<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

0<br />

1000 2000 3000<br />

S&S 106”, Slip-On’s,551 Cams CNC, S&S AC<br />

Peak Rear Wheel HP 96.9<br />

Peak Rear Wheel To rque 113.4<br />

S<strong>to</strong>ck 2009 FLHT<br />

Peak Rear Wheel HP 68.6<br />

Peak Rear Wheel To rque 84.7<br />

4000 5000 6000<br />

7000<br />

EngSpd RPM<br />

This dyno chart compares a s<strong>to</strong>ck 96" 2009 FLHT on the same bike with an S&S 106" Big Bore<br />

Top End Kit with CNC ported heads, S&S slip-on mufflers, performance intake, and two different<br />

cams. The blue curves represent the 106 with S&S 551 <strong>to</strong>uring cams and S&S teardrop air cleaner<br />

on the s<strong>to</strong>ck 50mm throttle body. Great <strong>to</strong>rque for performance <strong>to</strong>uring applications. The red<br />

curves show the S&S 585 cams with a 58mm throttle body. The increased duration of the 585<br />

reduces low and midrange <strong>to</strong>rque, but the combination of more aggressive valve timing, higher<br />

lift and a larger throttle body significantly increases usable rpm and <strong>to</strong>p end horsepower. A good<br />

choice for lighter bikes and racing applications. Both engines were tuned with Screamin' Eagle®<br />

Race Tuner.<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

1-23 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

CTO<br />

S&S ® <strong>12</strong>4" HOT SET UP KIT ®<br />

Keep your s<strong>to</strong>ck crankcases and take the horsepower output of your late<br />

model big twin <strong>to</strong> the max with an S&S <strong>12</strong>4" Hot Set Up Kit! Configured<br />

specifically for your application, this kit is sure <strong>to</strong> exceed your performance<br />

expectations!<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

FITMENT<br />

❚❚ 1999 - up big twins<br />

FEATURES AND BENEFITS<br />

❚❚ Huge displacement increase means huge power increase<br />

❚❚ S<strong>to</strong>ck crankcases, cylinder heads, oil pump, and cam cover can be<br />

reused, saving hundreds of dollars<br />

❚❚ Original engine serial numbers are retained, meaning no hassles<br />

registering or insuring<br />

❚❚ Silver or wrinkle black powdercoat finish heads match fac<strong>to</strong>ry<br />

finish, giving bike a “sleeper” advantage<br />

PART NUMBER<br />

S&S <strong>12</strong>4" Hot Set Up Kit® ........................... 106-5752<br />

Year Stroke Displacement Bore Cylinder Length<br />

S&S® <strong>12</strong>4" HOT SET UP KIT® SPECIFICATIONS<br />

Pis<strong>to</strong>n Type/Compression Ratio<br />

91cc S&S Heads 89cc S&S Heads S<strong>to</strong>ck Heads<br />

1999-up 4 5/8" <strong>12</strong>4" 4 1/8" 5.013" Flat <strong>to</strong>p forged/10.8:1 Flat <strong>to</strong>p forged/11:1 Forged, 10.9cc dish/10.4:1<br />

Cylinder w/ pis<strong>to</strong>n kits include fitted pis<strong>to</strong>ns and cylinders that require no boring or honing.<br />

ORDERING INFORMATION<br />

Please provide the following information when ordering a <strong>12</strong>4" Hot Set Up Kit®.<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

OPTIONS<br />

The following three options are examples of the most commonly ordered<br />

kits. Available in silver or black wrinkle powdercoat finish.<br />

Option 1 (10.8:1 compression ratio) includes:<br />

❚❚ S&S 91cc high flow Super S<strong>to</strong>ck® heads<br />

❚❚ Flat <strong>to</strong>pped pis<strong>to</strong>ns<br />

Option 2 (11:1 compression ratio, works with previously<br />

purchased S&S 89cc high flow Super S<strong>to</strong>ck heads) includes:<br />

❚❚ Flat <strong>to</strong>pped pis<strong>to</strong>ns<br />

Option 3 (10.4:1 compression ratio, works with s<strong>to</strong>ck cylinder<br />

heads) includes:<br />

Dished pis<strong>to</strong>ns<br />

Year of engine, crankcase type<br />

Oil pump <strong>to</strong> be used<br />

Head and cylinder finish desired (Silver or wrinkle black powdercoat)<br />

Type of cams desired. Chain drive or gear drive<br />

Fuel and induction system desired<br />

Pushrods desired<br />

Other parts desired (tappets, pushrod covers, rocker arms, intake manifold, exhaust, manual/electric compression releases)<br />

Any special information that S&S should know <strong>to</strong> make sure the correct parts are shipped<br />

S&S can provide quality, professional machine shop and engine building service through our remanufacturing program. We can handle any job from fitting a set of pis<strong>to</strong>ns in your cylinders,<br />

<strong>to</strong> complete installation of any engine kit. Contact your S&S cus<strong>to</strong>mer service representative for details.<br />

❚❚<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-24


Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Tools &<br />

Shop Supplies<br />

CONTINUED -<br />

S&S® <strong>12</strong>4" Hot Set Up Kit®<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

X-Wedge®<br />

Dyno Results (Above): Carbureted S&S <strong>12</strong>4" Hot Set Up Kit® with S&S Super S<strong>to</strong>ck®<br />

cylinder heads. NOTE: Kits using s<strong>to</strong>ck cylinder heads will produce substantially<br />

less power unless professional headwork is performed. Test bike is a 1999 FXDL<br />

with Super G carbure<strong>to</strong>r, S&S IST® ignition, and S&S mufflers.<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

SPECIAL NOTES:<br />

S<strong>to</strong>ck crankcases need <strong>to</strong> be machined <strong>to</strong> accept new cylinders. S&S can provide this service for you!<br />

S&S Easy Start Cams can save you money – no need <strong>to</strong> buy compression releases or S&S rocker covers. Note when using 1999-'06 chain drive cams: For lifts over .510", S&S strongly<br />

recommends that the s<strong>to</strong>ck chain drive be upgraded <strong>to</strong> the S&S gear drive or <strong>to</strong> the H-D® #25284-08 hybrid plate. This kit updates the problematic spring loaded chain tensioners <strong>to</strong><br />

reliable hydraulic tensioners and also upgrades the oil pump.<br />

2008-up <strong>to</strong>uring models with electronic throttle control require Screamin' Eagle® 58mm throttle body and Harley-Davidson® race tuner.<br />

Main Bearing Note: S&S flywheel assemblies for 1999-up big twin engines are designed for use with Timken® style sprocket shaft bearings. They will fit directly in s<strong>to</strong>ck Harley-<br />

Davidson® 1999-’02 crankcases and in all S&S crankcases for Twin Cam 88® engines with no modifications. S&S does not produce a set of flywheels that is a direct replacement for<br />

the 2003 and later big twin engines. S<strong>to</strong>ck 2003 and later engines use the same roller type bearing for the sprocket shaft that is used on the pinion shaft. However, S&S flywheels<br />

may be used in 2003 and later engines with the installation of the Harley-Davidson® bearing kit #24004-03A. These crankcases use a roller type bearing for the sprocket shaft. Verify<br />

that the bearing kit contains the 24604-00D or 24607-07 sprocket shaft bearing. Do not use a 24604-00, 24604-00A, 24604-00B or 24604-00C bearing.<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-25 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

CTO<br />

S&S ® 106" Stroker KIT<br />

Delivering real performance gains at a reasonable price, the heart of this 106"<br />

stroker kit is an S&S 41/2" stroke flywheel assembly. Installation requires no<br />

crankcase machining or modification, and s<strong>to</strong>ck cylinders can be reused <strong>to</strong><br />

further reduce cost. Select S&S Super S<strong>to</strong>ck® heads for the maximum power<br />

output. 106" stroker kit is recommended for 1999-up engines.<br />

FITMENT<br />

❚❚ 1999-up big twins<br />

FEATURES AND BENEFITS<br />

❚❚ Up <strong>to</strong> 50% horsepower increase<br />

❚❚ Strong S&S 41/2" stroke pressed <strong>to</strong>gether flywheel assembly<br />

❚❚ No crankcase modifications required!<br />

❚❚ High lift cams are available <strong>to</strong> maximize performance<br />

❚❚ High performance hydraulic tappets assure accurate valve timing<br />

❚❚ S<strong>to</strong>ck cylinders can be bored <strong>to</strong> 37/8" and reused <strong>to</strong> reduce cost<br />

❚❚ 9.8:1 compression ratio means reliable performance<br />

❚❚ S&S pushrods are made from high strength chromoly tubing<br />

❚❚ Valve pocket recesses in S&S pis<strong>to</strong>ns are enlarged for oversize<br />

valves and higher lift cams<br />

❚❚ Installation instructions and all necessary hardware and<br />

gaskets are included<br />

Please provide the following information when ordering a 106" stroker kit:<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

PART NUMBER<br />

S&S® 106" STROKER KIT SPECIFICATIONS<br />

Year Stroke Displacement Bore Cylinder Length Pis<strong>to</strong>n Type<br />

S&S 106" stroker kit ............................... 106-5745<br />

Compression Ratio<br />

89cc S&S Heads (included) 79cc S&S Heads S<strong>to</strong>ck Heads<br />

1999-up 41/2" 106" 37/8" 4.937" Flat Top Forged 9.8:1 10.8:1 10.1:1<br />

Cylinder w/ pis<strong>to</strong>n kits include fitted pis<strong>to</strong>ns and cylinders that require no boring or honing.<br />

ORDERING INFORMATION<br />

After installing the pictured 106” S&S® stroker kit horsepower output<br />

increased by 50%!<br />

Year of engine, crankcase type<br />

Oil pump <strong>to</strong> be used<br />

Pis<strong>to</strong>n oversize required<br />

Head finish desired (silver or wrinkle black powdercoat)<br />

Cylinders <strong>to</strong> be used<br />

Fuel system <strong>to</strong> be used<br />

Optional parts desired (cams, tappets, cylinders, valve springs, pushrods, pushrod covers, rocker arms, rocker covers, electric/manual<br />

compression releases, induction system, intake manifold, carbure<strong>to</strong>r/VFI module, exhaust)<br />

Any special information that S&S should know <strong>to</strong> make sure the correct parts are shipped<br />

S&S can provide quality, professional machine shop and engine building service through our remanufacturing program. We can handle any job from fitting a set of pis<strong>to</strong>ns in your cylinders,<br />

<strong>to</strong> complete installation of any engine kit. Contact your S&S cus<strong>to</strong>mer service representative for details.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-26


Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

CONTINUED -<br />

S&S® 106" Stroker Kit<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

X-Wedge®<br />

Replacement<br />

Parts<br />

SPECIAL NOTES:<br />

For 106" stroker kits ordered without cylinders, pis<strong>to</strong>ns must be measured and cylinders bored/honed accordingly. Recommended pis<strong>to</strong>n fitment:<br />

Close: 0.0020" – 0.0025"<br />

Loose: 0.0032" – 0.0045"<br />

S&S Easy Start Cams can save you money – no need <strong>to</strong> buy compression releases or S&S rocker covers.<br />

Note: Unless professional headwork is done, kits using s<strong>to</strong>ck, un-ported cylinder heads will produce significantly less power compared <strong>to</strong> S&S heads.<br />

Example of a typical 106” stroker kit configuration.<br />

S&S® recommends its 106” big bore kit for 2007-up bikes as it yields the same displacement as the 106" stroker kit, uses the s<strong>to</strong>ck flywheel assembly, and requires no engine<br />

disassembly below the base gasket. Turn <strong>to</strong> page 1-22 of this section for more details on 106" Big Bore Kits.<br />

Main Bearing Note: S&S flywheel assemblies for 1999-up big twin engines are designed for use with Timken® style sprocket shaft bearings. They will fit directly in s<strong>to</strong>ck<br />

Harley-Davidson® 1999-’02 crankcases and in all S&S crankcases for Twin Cam 88® engines with no modifications. S&S does not produce a set of flywheels that is a direct<br />

replacement for the 2003 and later big twin engines. S<strong>to</strong>ck 2003 and later engines use the same roller type bearing for the sprocket shaft that is used on the pinion shaft.<br />

However, S&S flywheels may be used in 2003 and later engines with the installation of the Harley-Davidson® bearing kit #24004-03A. These crankcases use a roller type<br />

bearing for the sprocket shaft. Verify that the bearing kit contains the 24604-00D or 24607-07 sprocket shaft bearing. Do not use a 24604-00, 24604-00A, 24604-00B or<br />

24604-00C bearing.<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-27 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

CTO<br />

S&S ® 95" & 103" HOT SET UP KIT ®<br />

S&S 95" and 103" Hot Set Up Kits are an excellent way <strong>to</strong> increase the<br />

displacement of late model big twin engines. S<strong>to</strong>ck cylinders and heads can<br />

be reused, making this a very economical way <strong>to</strong> increase horsepower.<br />

FITMENT<br />

❚❚ 1999-up big twins<br />

FEATURES AND BENEFITS<br />

❚ ❚ Up <strong>to</strong> 25 hp increase! (when combined with upgraded fuel system<br />

and a performance exhaust)<br />

❚❚ No crankcase modifications required. Uses your s<strong>to</strong>ck flywheels!<br />

❚❚ S&S high lift cams are available for maximum power increase<br />

❚❚ S&S Easy Start cams are highly recommended<br />

❚❚ S&S pushrods are made from high strength chromoly tubing<br />

❚❚ S<strong>to</strong>ck cylinders can be bored <strong>to</strong> 37/8", honed, and reused<br />

❚❚ S&S pis<strong>to</strong>n weight for 95" & 103" kits are the same as s<strong>to</strong>ck,<br />

requiring no flywheel rebalancing<br />

❚❚ High performance hydraulic tappets assure accurate valve timing<br />

❚❚ Pop-up dome pis<strong>to</strong>ns increase compression and add horsepower<br />

❚❚ Valve pocket recesses in S&S pis<strong>to</strong>ns are enlarged for oversize<br />

valves and higher lift cams<br />

❚❚ Installation instructions and all necessary hardware and gaskets<br />

are included<br />

Year<br />

Displacement<br />

S<strong>to</strong>ck<br />

Stroke<br />

ORDERING INFORMATION<br />

PART NUMBER<br />

S&S® 95" & 103" HOT SET UP KIT® SPECIFICATIONS<br />

Bore Cylinder Length Pis<strong>to</strong>n Type<br />

S&S 95" & 103" Hot Set Up Kit ..............................106-5744<br />

Compression Ratio<br />

S<strong>to</strong>ck Heads 89cc S&S Heads 79cc S&S Heads<br />

2007 - up 103" 4 3/8"<br />

Forged, 5cc pop-up dome 10.1:1 9.8:1 10.8:1<br />

3 7/8" 4.937"<br />

1999 - '06 95" 4" Forged, 5.3cc pop-up dome 9.7:1 9.3:1 10.3:1<br />

Cylinder w/ pis<strong>to</strong>n kits include fitted pis<strong>to</strong>ns and cylinders that require no boring or honing.<br />

92-<strong>12</strong>00<br />

Pis<strong>to</strong>ns work with 4" stroke<br />

flywheels in 88" engines <strong>to</strong><br />

produce 95 cubic inches<br />

106-0432<br />

Pis<strong>to</strong>ns are designed for 43/8" stroke<br />

flywheels in 2007-up 96" engines<br />

and are coated <strong>to</strong> reduce friction.<br />

Please provide the following information when ordering a 95"/103" Hot Set Up Kit®:<br />

❚❚ Year of engine and crankcase type<br />

❚❚ Oil pump <strong>to</strong> be used<br />

❚❚ Pis<strong>to</strong>n oversize required<br />

❚❚ Cylinders and heads <strong>to</strong> be used<br />

❚❚ Fuel system <strong>to</strong> be used<br />

❚❚ Optional parts desired (cams, tappets, cylinders, valve springs, pushrods, pushrod covers, rocker arms, rocker covers, electric/manual<br />

compression releases, induction system, intake manifold, carbure<strong>to</strong>r/VFI module, exhaust)<br />

❚❚ Any special information that S&S should know <strong>to</strong> make sure the correct parts are shipped<br />

S&S can provide quality, professional machine shop and engine building service through our remanufacturing program. We can handle any job from fitting a set of pis<strong>to</strong>ns in your cylinders,<br />

<strong>to</strong> complete installation of any engine kit. Contact your S&S cus<strong>to</strong>mer service representative for details.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-28


Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

CONTINUED -<br />

S&S® 95" & 103" Hot Set Up Kit®<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

X-Wedge®<br />

Lower curves show completely s<strong>to</strong>ck 1999 FXDL. Upper curves represent 1999<br />

FXDL with 95" Hot Set Up Kit® (Super E carbure<strong>to</strong>r, 570G cams, high performance<br />

tappets, .640” triple valve springs, adjustable pushrods), s<strong>to</strong>ck heads, Screamin’<br />

Eagle® 6200 rpm ignition module, and Khrome Werks® mufflers. Installation of<br />

S&S® Super S<strong>to</strong>ck® heads will result in nearly triple digit horsepower output!<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

SPECIAL NOTES:<br />

S<strong>to</strong>ck cylinders must either be bored <strong>to</strong> 37/8" or replaced with S&S® 37/8" bore<br />

cylinders.<br />

S&S recommends either porting s<strong>to</strong>ck cylinder heads or purchasing Super<br />

S<strong>to</strong>ck® heads <strong>to</strong> maximize the effect of higher lift cams.<br />

Unless professional headwork is done, kits using s<strong>to</strong>ck, un-ported cylinder<br />

heads will produce significantly less power.<br />

S&S can CNC port your heads, for an economical increase in power.<br />

For 95" kits ordered without cylinders, pis<strong>to</strong>ns must be measured and cylinders<br />

bored/honed accordingly. Recommended pis<strong>to</strong>n fitment:<br />

Close: 0.0020” – 0.0025”<br />

Loose: 0.0032” – 0.0045”<br />

S&S 37/8" pis<strong>to</strong>ns for 103" kits are machined <strong>to</strong> such close <strong>to</strong>lerances that it<br />

is not necessary <strong>to</strong> measure the pis<strong>to</strong>n. Additionally, the low friction coating<br />

on the pis<strong>to</strong>n skirt makes taking measurements very difficult. Therefore, bore<br />

cylinders <strong>to</strong> nominal diameter +/- 0.0005” for correct clearance.<br />

An example of a 95" Hot Set Up Kit for a carbureted big twin with pushrods,<br />

covers, hydraulic tappets, teardrop air cleaner, gear drive cams, Super E<br />

carbure<strong>to</strong>r, intake manifold, and valve spring kit. Select S&S cylinder heads<br />

when ordering for more horsepower.<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-29 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

CTO<br />

S&S ® SINGLE BORE TUNED INDUCTION SYSTEM<br />

Offering over twice the filtering area of s<strong>to</strong>ck intake systems, the tuned<br />

runner increases horsepower and <strong>to</strong>rque across the rpm range using air<br />

column inertia and carefully timed gas dynamic pressure waves.<br />

FITMENT<br />

❚❚ 1999–up big twin<br />

❚❚ S&S T-Series engines<br />

FEATURES AND BENEFITS<br />

❚❚ Bolt-on performance<br />

❚❚ Large increase in filtering area over s<strong>to</strong>ck air cleaner<br />

❚❚ Smooth intake tract of carefully selected tuned lengths<br />

increases performance<br />

❚❚ High flow washable and reusable cot<strong>to</strong>n media provides<br />

performance, protection, and economy<br />

OPTIONS<br />

❚❚ Chrome, wrinkle black powdercoat, or natural finish<br />

❚❚ Red or blue filters<br />

❚❚ Nylon air filter covers<br />

PART NUMBER<br />

Specify the year and model of your mo<strong>to</strong>rcycle, as well as the runner finish<br />

and filter color desired.<br />

S&S Single Bore Tuned Induction System .................... 106-5337<br />

Replacement Filters (each sold with clamp)<br />

Red ..................................................... 17-1020<br />

Blue .....................................................17-1023<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Washable nylon air filter covers are water resistant and<br />

filter out large debris, allowing the filter media <strong>to</strong> s<strong>to</strong>p<br />

small dirt particles from getting in<strong>to</strong> your engine<br />

S&S Nylon Air Filter Cover ................106-0247<br />

Dealer Services<br />

& Promo Items<br />

Renew the color of your air filter with an 8 oz.<br />

bottle of S&S Air Filter Oil. Choice of red or blue oil.<br />

S&S Air Filter Oil, Red ....................106-1163<br />

S&S Air Filter Oil, Blue. . . . . . . . . . . . . . . . . . . . 106-1164<br />

Warranty &<br />

Company Policy<br />

Billet adap<strong>to</strong>r brackets make<br />

single bore tuned induction<br />

compatible with many engines and<br />

mo<strong>to</strong>rcycles.<br />

SPECIAL NOTES:<br />

Does not fit Screamin' Eagle 58mm throttle bodies on 2008-up <strong>to</strong>uring models.<br />

Tuned induction will not fit on mo<strong>to</strong>rcycles equipped with fairing lower glove boxes.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-30


S&S ® Teardrop AIR Cleaner Kit<br />

Add performance and style <strong>to</strong> any bike without breaking the bank! The<br />

trademark S&S teardrop shaped filter assembly offers riders an efficient and<br />

free flowing intake that can add two <strong>to</strong> five horsepower, or even more with<br />

a set of S&S slip-on mufflers.<br />

FITMENT<br />

❚❚ 1999 - up big twins<br />

FEATURES AND BENEFITS<br />

❚❚ Uniquely designed back plate has air horn style radiused entryway<br />

<strong>to</strong> reduce turbulence<br />

❚❚ Dimpled cover with directional air cone on inside creates smooth<br />

path for air<br />

❚❚ Great addition <strong>to</strong> performance exhaust or cams<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

KIT CONTENTS<br />

❚❚ Filter<br />

❚❚ Backing plate<br />

❚❚ All mounting hardware<br />

❚❚ Instructions<br />

Optimize your s<strong>to</strong>ck carBure<strong>to</strong>r<br />

Jet,Kit,CV Carb,1999-2006 bt .................... 11-5203<br />

Jet,Kit,CV Carb,1995-2006 bt. . . . . . . . . . . . . . . . . . . . . 11-5202<br />

S&S® high flow air cleaner kit offers improved flow with classic S&S styling.<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

SPECIAL NOTES:<br />

Fuel delivery (carbureted or EFI) may need <strong>to</strong> be modified <strong>to</strong> maintain the correct<br />

air and fuel mixture.<br />

A respectable gain in both horsepower and <strong>to</strong>rque can be seen in this graph<br />

comparing a s<strong>to</strong>ck big twin <strong>to</strong> one equipped with an S&S® air cleaner and SPO®<br />

<strong>to</strong>uring mufflers.<br />

Model/Engine S<strong>to</strong>ck Carbure<strong>to</strong>r/EFI: S&S® Super E or G:<br />

S&S 41/8" bore engines – 17-0416<br />

2008-up <strong>to</strong>uring models with electronic throttle control, except Screamin' Eagle® 58mm 106-2091 –<br />

2001-up Softail EFI, All 2002-Up EFI (Delphi®) 17-0450 –<br />

1999-'01 EFI big twin (Magneti Marelli®) 106-4589 –<br />

1999-'06 Carbureted 17-0450 17-0403<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-31 Visit us at www.sscycle.com


Warranty &<br />

Company Policy<br />

Dealer Services<br />

& Promo Items<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

S&S ® DESPERADO AIR CLEANER COVER<br />

17-0004<br />

NOSTALGIC S&S ® CYCLE AIR CLEANER COVERS<br />

Available <strong>to</strong> S&S dealers only, these limited edition reproductions of the old<br />

style air cleaner covers have a mirror like polished finish and are sure <strong>to</strong> bring<br />

back memories. With raised letters that say “S&S <strong>Cycle</strong>”, these covers are a<br />

perfect fit for an old school chopper!<br />

FITMENT<br />

❚❚ S&S teardrop air cleaners for Super E & G carbs and S&S EFI<br />

throttle bodies<br />

❚❚ S&S air cleaner kits for s<strong>to</strong>ck fuel systems<br />

❚❚ Super B carbs<br />

PART NUMBER<br />

Polished Nostalgic S&S <strong>Cycle</strong> Air Cleaner Cover<br />

E & G carbs ........................................ 17-0071<br />

Super B carbs .......................................17-0070<br />

While developing the 41/8" bore series of engines, we found that having an<br />

easier breathing intake tract further increased its power output by 1–2 hp!<br />

Thus the Desperado air cleaner cover was born. Slots strategically cut around<br />

the perimeter of the cover allow a more direct path <strong>to</strong> the air filter. On <strong>to</strong>p of<br />

good looks and better performance, the best part is that this quick swap will<br />

require no jetting change <strong>to</strong> a properly jetted carbure<strong>to</strong>r.<br />

FITMENT<br />

❚❚ S&S teardrop air cleaners for Super E & G carbs<br />

and S&S EFI throttle bodies<br />

❚❚ S&S air cleaner kits for s<strong>to</strong>ck fuel systems<br />

PART NUMBER<br />

Desperado Cleaner Cover ............................17-0004<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-32


S&S ® HIGH FLOW AIR FILTER KIT<br />

With large street engines becoming more and more popular, S&S developed<br />

a high flow air filter kit for its teardrop style air intake.<br />

Parts for<br />

Twin Cam 88®<br />

FITMENT<br />

❚❚ S&S teardrop air cleaners for Super E & G carbs<br />

and S&S EFI throttle bodies<br />

FEATURES AND BENEFITS<br />

❚❚ Low restriction filter element comes pre-oiled for true plug and<br />

play installation<br />

❚❚ 1" wider filtration area provides up <strong>to</strong> 37% more airflow over<br />

standard S&S filters<br />

❚❚ Resulting band of exposed filter material imparts a high<br />

performance look<br />

KIT CONTENTS<br />

❚❚ Wide filter<br />

❚❚ Filter spacers<br />

17-0045<br />

PART NUMBERS<br />

High Flow Air Cleaner Kit ............................17-0045<br />

Replacement Filter ..................................17-0055<br />

Replacement Filter Spacers .........................50-5009-S<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

S&S ® HIGH PERFORMANCE FILTERS<br />

FOR STOCK Air Cleaners<br />

Made <strong>to</strong> directly replace the s<strong>to</strong>ck Harley-Davidson® filter assembly, these<br />

high performance filters are washable and reusable and save you money in<br />

the long run.<br />

FITMENT<br />

❚❚<br />

1999 - ‘10 carbureted and EFI big twins<br />

FEATURES AND BENEFITS<br />

❚❚<br />

❚❚<br />

Cost effective upgrade that pays for itself over time<br />

Great by itself or complement <strong>to</strong> performance exhaust or cams<br />

Application<br />

Part No.<br />

1999 - '06 Carbureted Twin Cam 88®,<br />

2001-'10 Softail® EFI (except Cross Bones),<br />

106-4630<br />

2002-'07 FL EFI, 2004-'07 EFI Dyna®<br />

1999-2001 EFI big twin 106-4631<br />

106-4630– Twin Cam 88® (carb),<br />

2001-‘09 Softail® EFI (except Cross Bones),<br />

2002-'07 FL EFI and 2004-‘07 EFI Dyna®<br />

– Replaces H-D #29461-99<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

SPECIAL NOTES:<br />

All reference <strong>to</strong> H-D® part numbers is for identification purposes only. We in no<br />

way are implying that any of S&S® <strong>Cycle</strong>'s products are original equipment parts<br />

or that they are equivalent <strong>to</strong> the corresponding H-D part number shown.<br />

106-4631– Twin Cam 88® FL EFI 1999-‘01 – Replaces H-D #29462-99<br />

Warranty &<br />

Company Policy<br />

1-33 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

S&S ® VARIABLE FUEL INJECTION MODULES (VFI)<br />

S&S VFI systems offer tuners the ultimate in adjustability. They directly<br />

replace s<strong>to</strong>ck Harley-Davidson® fuel injection modules and since the systems<br />

connect <strong>to</strong> the s<strong>to</strong>ck wiring harness and use fac<strong>to</strong>ry sensors, they can be<br />

installed in minutes. Optional closed loop sensor kit and knock sensor kit<br />

extend module capabilities.<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

FEATURES AND BENEFITS<br />

❚❚ Plugs directly in<strong>to</strong> s<strong>to</strong>ck wiring harness<br />

❚❚ Includes ProTune II software and can be updated on the<br />

S&S website sscycle.com/protune<br />

❚❚ Three stage engine overheat protection eliminates possible engine<br />

catastrophes caused by improper modifications <strong>to</strong> fuel maps<br />

❚❚ Altitude compensation au<strong>to</strong>matically adjusts for altitude<br />

variations<br />

❚❚ Live tuning allows manual changes <strong>to</strong> maps while the engine<br />

is running<br />

❚❚ Self diagnostics and actua<strong>to</strong>r test functions help tuning and<br />

verify proper installation/operation<br />

❚❚ Engine light can be programmed <strong>to</strong> function as a shift light<br />

❚❚ Close loop capable<br />

❚❚ Knock sensing ignition control<br />

OPTIONS: CLOSED LOOP CAPABILITY<br />

When equipped with a dual closed loop sensor kit and running in closed<br />

loop mode, VFI tuning becomes a breeze! S&S supplies base maps for several<br />

displacement groups, creating a starting point <strong>to</strong> get bikes up and running.<br />

Utilizing dual oxygen sensors (sold separately) placed in the exhaust, the<br />

S&S closed loop system modifies the base fuel map <strong>to</strong> meet the specific<br />

requirements of your engine!<br />

❚❚<br />

❚❚<br />

❚❚<br />

Au<strong>to</strong>matic tuning on the street or on the dyno<br />

Each cylinder is tuned individually<br />

Fuel map changes are saved <strong>to</strong> the tune file and can be<br />

merged with the pre-loaded base map<br />

Closed loop VFI can also au<strong>to</strong>matically compensate fuel delivery for<br />

modifications creating up <strong>to</strong> a 20 hp gain, such as changes in:<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

Displacement<br />

Cams<br />

<strong>Exhaust</strong><br />

Head porting or installation of aftermarket heads<br />

Gear ratios<br />

559-0001<br />

Magneti Marelli ® style S&S VFI module<br />

FITMENT<br />

❚❚ 1999–‘01 big twins (except 2001 Softail®)<br />

KIT CONTENTS<br />

❚❚ Magneti Marelli® style S&S VFI module<br />

❚❚ ProTune II software<br />

❚❚ Barometric pressure sensor relocation kit part #55-1599<br />

❚❚ Installation instructions<br />

PART NUMBERS<br />

Magneti Marelli style VFI module ................... 559-0001<br />

Magneti Marelli style VFI Closed Loop Sensor Kit ....... 106-2067<br />

106-2067<br />

SPECIAL NOTES:<br />

Due <strong>to</strong> the extreme range of control offered by the S&S VFI modules, they are<br />

only available from S&S Certified VFI Tuning Centers. Check www.sscycle.com <strong>to</strong><br />

find a tuning center near you.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-34


Continued<br />

S&S® VARIABLE FUEL INJECTION MODULES<br />

Delphi ® style S&S VFI module<br />

FITMENT<br />

❚❚<br />

❚❚<br />

❚❚<br />

KIT CONTENTS<br />

❚❚<br />

❚❚<br />

❚❚<br />

2001-up Softail®<br />

2002-up big twins<br />

Not available for 2008-up <strong>to</strong>uring with electronic throttle control<br />

One Delphi® style S&S VFI module<br />

ProTune II software and USB cable<br />

Installation instructions<br />

PART NUMBERS<br />

55-5090<br />

Delphi style VFI module ..............................55-5090<br />

S&S Delphi style VFI closed loop sensor kit ............ 106-2066<br />

Knock Sensor Kit (Delphi style only) ................. 106-0810<br />

S&S Sensor Kits and Replacement Parts<br />

S&S VFI Closed Loop Sensor Kit<br />

Magneti Marelli® Style ..............................106-2067<br />

Delphi® Style ......................................106-2066<br />

Knock Sensor Kit (Delphi style only) ...................106-0810<br />

Service Kit, O 2<br />

Sensor ...............................106-2061<br />

Wiring Harness Extension 16" .........................55-1595<br />

Service Kit, Connec<strong>to</strong>r, DTM, 4-Position Receptacle ........55-1592<br />

Service Kit, DTM Pins ................................55-1521<br />

Service Kit, Oxygen Sensor Boss .....................55-6071-S<br />

Service Kit, Subharness – Magneti Marelli Style. . . . . . . . . . 55-1588<br />

Service Kit, Subharness – Delphi Style ..................55-1595<br />

Service Kit, Electrical Tap (10 Pack) ......................55-1596<br />

Barometric Sensor Relocation Kit ......................55-1599<br />

Hardware Kit (USB Cover) ............................55-5091<br />

Installation of the oxygen sensors on the back or underside of the pipes<br />

makes them unobtrusive in nearly all applications. The wiring sub-harness<br />

installation requires minor wiring harness modifications. Complete<br />

installation instructions are included.<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

NOTES:<br />

All current production S&S modules are closed loop compatible, and all older S&S modules can be updated with current calibration by simply downloading software from the<br />

S&S website at www.sscycle.com/protune.<br />

Please note that maps created for older versions of the ECU operating software are not compatible with the new closed loop ECU software, however they can be converted<br />

if desired.<br />

Optional Delphi® style knock sensor adjusts timing <strong>to</strong> eliminate spark knock, prolonging engine life.<br />

S&S VFI systems installed on 2004–up bikes incorporate a speedometer calibration feature.<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-35 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

S&S ® VFI Closed Loop Fuel Injection Kit<br />

S&S Variable Fuel Injection (VFI) modules for 2001-’03 Harley-Davidson® big<br />

twins with Delphi® style fuel injection are now available. Comes packaged<br />

with a dual oxygen sensor kit so they can be run in closed loop mode for<br />

au<strong>to</strong>matic fine-tuning of fuel delivery – that brings older bikes up <strong>to</strong> 2007<br />

and later technology. The S&S VFI module offers almost unlimited tuning<br />

capacity and can handle just about any performance upgrade possible. Once<br />

a base map for a particular configuration is installed, the oxygen sensor<br />

kit continuously fine-tunes the engine. To save time getting started, the<br />

module is pre-loaded with a fuel map for a <strong>to</strong>uring bike with a 95" engine<br />

and the CD includes easily changed calibrations for other models. With<br />

the oxygen sensor kit included with the module, this map can be used as<br />

a starting point for this very popular engine configuration. Maps for several<br />

other engine configurations are on the software CD that is included with<br />

this VFI closed loop fuel injection kit. Maps are also available for download<br />

at www.sscycle.com/protune.<br />

The S&S VFI modules are easy <strong>to</strong> install. They directly replace the s<strong>to</strong>ck<br />

Harley-Davidson fuel injection module, and plug in<strong>to</strong> the s<strong>to</strong>ck wiring<br />

harness. Minor wiring modifications are required for the oxygen sensor<br />

kit and <strong>to</strong> retain the “tip over” safety feature of the s<strong>to</strong>ck system. Also,<br />

oxygen sensor bungs must be welded in<strong>to</strong> the existing exhaust pipes. Full<br />

instructions are included.<br />

Fitment<br />

❚❚ 2001-’03 big twins with Delphi® style fuel injection<br />

Features and Benefits<br />

❚❚<br />

Easy installation – module plugs in<strong>to</strong> the s<strong>to</strong>ck wiring harness<br />

❚❚<br />

Altitude compensation – au<strong>to</strong>matically adjusts for altitude<br />

variations<br />

❚❚<br />

Live Tuning – make manual changes <strong>to</strong> maps while the engine<br />

is running<br />

❚❚ Self diagnostics and actua<strong>to</strong>r test functions<br />

❚❚ Engine light can be programmed <strong>to</strong> function as a shift light<br />

❚❚<br />

ProTune II software included with each module – updates can<br />

be downloaded from sscycle.com/protune<br />

❚❚ Engine overheat protection<br />

❚❚ Oxygen sensor kit continuously fine-tunes the engine<br />

❚❚ Module is pre-loaded with a fuel map for a <strong>to</strong>uring bike with a<br />

95" engine<br />

*A Serial <strong>to</strong> USB adap<strong>to</strong>r is required for this module when using computers that do not have a serial port.<br />

Save a bundle on this S&S VFI closed loop fuel injection kit. You get<br />

an S&S VFI module and closed loop dual oxygen sensor kit for a<br />

great price. It’s almost like getting the sensor kit for free!<br />

Part Number<br />

S&S VFI Closed Loop Fuel Injection Kit ................... 550-0010<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-36


S&S ® EZFI MODULE<br />

Sometimes all you need is a little bit of adjustment. Great for modifying fuel<br />

delivery <strong>to</strong> s<strong>to</strong>ck engines equipped with power enhancers like high flow air<br />

cleaners, exhaust systems or performance cams, and the EZFI plugs directly<br />

in<strong>to</strong> the s<strong>to</strong>ck ECM. With simple adjustments, you can add fuel where your<br />

bike needs it and remove fuel where it does not.<br />

FITMENT<br />

❚❚ 2001-up Softail®<br />

❚❚ 2002-up big twins<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

FEATURES AND BENEFITS<br />

❚❚ Provides economical tuning for s<strong>to</strong>ck or mildly modified engines<br />

❚❚ Plugs in<strong>to</strong> s<strong>to</strong>ck ECM<br />

❚❚ Does not adjust timing, only modifies fuel delivery<br />

❚❚ S<strong>to</strong>ck TSSM functions such as turn signals, safety functions, and<br />

instruments are not affected<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

KIT CONTENTS<br />

❚❚ EZFI module<br />

❚❚ Tuning software<br />

❚❚ Install Instructions<br />

❚❚ Velcro®<br />

PART NUMBERS<br />

2002-up EZFI module kit<br />

(excludes 2008-up <strong>to</strong>uring models) ................... 106-0890<br />

OPTIONS<br />

An optional wiring harness allows for quick and easy bypass of the EZFI<br />

module in order <strong>to</strong> return the fuel system <strong>to</strong> s<strong>to</strong>ck for diagnostic or<br />

comparison reasons. ............................... 106-0891<br />

106-0891<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

SPECIAL NOTES:<br />

Since the S&S EZFI module does not control ignition timing, it is not recommended for engines with higher than s<strong>to</strong>ck compression ratios.<br />

Warranty &<br />

Company Policy<br />

1-37 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

S&S ® CALIFORNIA APPROVED EZFI-C MODULE<br />

The 50-state legal EZFI-C module is now available. That means California<br />

residents can legally enjoy the benefits of better tuning. The EZFI-C module<br />

functions in the same way the original EZFI module does, except that<br />

emissions in critical areas of the fuel map are locked and cannot be changed.<br />

However, these locked areas are limited <strong>to</strong> 0–4000 rpm and under 50%<br />

throttle position. Significant increases in drivability can be attained with this<br />

module for a bike fitted with approved aftermarket exhaust and induction.<br />

FITMENT<br />

❚❚ 2001–‘09 Softail®<br />

❚❚ 2002–‘08 big twins<br />

FEATURES AND BENEFITS<br />

❚❚ Provides legal, economical tuning for s<strong>to</strong>ck or mildly<br />

modified engines<br />

❚❚ Plugs in<strong>to</strong> s<strong>to</strong>ck ECM<br />

❚❚ Modifies fuel delivery only, timing is not adjusted<br />

❚❚ S<strong>to</strong>ck TSSM functions such as turn signals, safety functions,<br />

and instruments are not affected<br />

KIT CONTENTS<br />

❚❚ EZFI module<br />

❚❚ Tuning software<br />

❚❚ Install Instructions<br />

❚❚ Velcro®<br />

PART NUMBERS<br />

EZFI-C module ................................... 106-3796<br />

Diagnostic cable ....................................55-<strong>12</strong>71<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

106-0891<br />

OPTIONS<br />

An optional wiring harness allows for quick and easy bypass of the EZFI<br />

module in order <strong>to</strong> return the fuel system <strong>to</strong> s<strong>to</strong>ck for diagnostic or<br />

comparison reasons. .............................. 106-0891<br />

Warranty &<br />

Company Policy<br />

SPECIAL NOTES:<br />

Since the S&S EZFI module does not control ignition timing, it is not recommended for engines with higher than s<strong>to</strong>ck compression ratios.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-38


S&S ® SINGLE BORE EFI THROTTLE BODIES<br />

52mm:Offering a 30% larger cross sectional area than s<strong>to</strong>ck throttle<br />

bodies, the S&S 52mm bore throttle body flows more than enough air for all but<br />

the most demanding street engines.<br />

58mm:In response <strong>to</strong> constant requests for something bigger, S&S<br />

also offers a huge 58mm bore throttle body! Strictly for large displacement<br />

competition engines, this throttle body allows your engine <strong>to</strong> breathe easy and<br />

make more power!<br />

FITMENT<br />

❚❚ 1999-up big twins<br />

(except 2008-up <strong>to</strong>uring models with electronic throttle control)<br />

FEATURES AND BENEFITS<br />

❚❚ Excellent performance<br />

❚❚ Compatible with:<br />

• S&S VFI<br />

• Harley-Davidson® Super Tuner software<br />

❚❚ Cruise control compatible with no extra bracket<br />

OPTIONS<br />

❚❚ 52mm<br />

❚❚ 58mm<br />

KIT CONTENTS<br />

❚❚ Throttle body assembly<br />

❚❚ Fuel injec<strong>to</strong>rs<br />

❚❚ Fuel rail<br />

❚❚ Harness adap<strong>to</strong>rs<br />

❚❚ All necessary hardware, gaskets, and hoses<br />

PART NUMBERS AND SPECIFICATIONS<br />

S&S® 52mm Single Bore EFI Throttle Body/Fuel Rail Kits<br />

1995–’01 EFI big twin (except Softail® models) ..........17-5068<br />

2002– ‘05 EFI big twin & 2001 Softail models .........17-5067<br />

2006–up EFI big twin* .............................. 17-5070<br />

S&S® 58mm Single Bore EFI Throttle Body/Fuel Rail Kits<br />

1999–’01 EFI big twin (except Softail models) ......... 106-4406<br />

2002–‘05 EFI big twin & 2001 Softail models ........ 106-4407<br />

2006–up EFI big twin* ............................. 106-4408<br />

* except 2008–up <strong>to</strong>uring models with electronic throttle control.<br />

SPECIAL NOTES:<br />

SuperFlow® SF1020 Super Bench flow bench shows the difference in flow<br />

between the S&S 52mm (2 1/16”) EFI throttle body and the new S&S 58mm<br />

throttle body. The peak numbers at WOT are pretty impressive, but what<br />

may not be as apparent is that the percentage of increase in air flow is<br />

greatest right off idle, between 5° and 25°. The increase in this area is as<br />

high as 23%, which translates in<strong>to</strong> better off-idle response.<br />

If you plan <strong>to</strong> use another programmable fuel injection module, it is best <strong>to</strong> consult the manufacturer <strong>to</strong> be certain that it is compatible with the S&S single bore system and has<br />

enough tuning capability for your engine configuration.<br />

Installation of S&S throttle body on 1995-'01 bikes requires S&S ECU. Single bore throttle bodies are not compatible with s<strong>to</strong>ck Magneti Marelli® ECU<br />

S<strong>to</strong>ck<br />

S&S 52mm<br />

S&S 58mm<br />

Seeing is believing. It’s pretty easy <strong>to</strong> see the differences in the bore sizes<br />

of a s<strong>to</strong>ck Harley-Davidson® throttle body and the S&S® 52mm or 58mm<br />

throttle bodies. How big do you want <strong>to</strong> go?<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-39 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

BUILDING A COMPLETE<br />

S&S ® FUEL INJECTION SYSTEM<br />

Select one kit in each step in order <strong>to</strong> create a complete fuel system. If you<br />

already have items from any of the steps, verify their compatibility and move<br />

<strong>to</strong> the next step.<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Step 1: Select an S&S VFI module<br />

1999-'01 (except 2001 Softail® models)<br />

(Replaces s<strong>to</strong>ck Magneti Marelli® module) . . . . . . . . . . . . 559-0001<br />

2001-up Harley-Davidson® Softail models and all 2002-up models<br />

(except 2008-up <strong>to</strong>uring)<br />

(Replaces s<strong>to</strong>ck 36-pin Delphi® module) ...............55-5090<br />

Step 2: Select a throttle body kit<br />

55-5090<br />

559-0001<br />

S&S 52mm Single Bore EFI Throttle Body/Fuel Rail Kits:<br />

X-Wedge®<br />

1999-’01 EFI big twin (except Softail models) ............17-5068<br />

2002-‘05 EFI big twin & 2001 Softail Models ............17-5067<br />

2006-up EFI big twin ................................17-5070<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

S&S 58mm Single Bore EFI Throttle Body/Fuel Rail Kits:<br />

1999-’01 EFI big twin (except Softail models) .......... 106-4406<br />

2002-‘05 EFI big twin & 2001 Softail Models .......... 106-4407<br />

2006-up EFI big twin .............................. 106-4408<br />

17-5067<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Step 3: Select the correct intake manifold<br />

Engine Displacement<br />

Cylinder<br />

Length<br />

Order <strong>to</strong>ll free 866-244-2673<br />

Manifold<br />

Size<br />

2006-Up Big twins with S<strong>to</strong>ck or S&S Heads<br />

Part No.<br />

88", 95", 96" 103" & 106" 4.937" 405 16-5134<br />

<strong>12</strong>4" Hot Set Up Kit®<br />

All Except 2008-up Touring Models 5.013” 417 16-5139<br />

w/S<strong>to</strong>ck or S&S Heads<br />

<strong>12</strong>4" Hot Set Up Kit®<br />

2008-up Touring Models<br />

5.013” 405 16-5134<br />

w/S&S Heads Only<br />

1999-’05 Big twins With S<strong>to</strong>ck or S&S Heads<br />

88", 95", 103" & 106" 4.937" 410 16-5141<br />

<strong>12</strong>4" Hot Set Up Kit<br />

w/ S<strong>to</strong>ck or S&S Heads<br />

5.013" 417 16-5139<br />

S&S 41/8" Bore T-Series Engines<br />

117" 4.888" 408 16-5138<br />

<strong>12</strong>4" 5.013" 417 16-5139<br />

Special Order (All Styles) Specify 389-428 16-5142<br />

1-40<br />

S&S tuned induction systems give increased<br />

performance with more aggressive styling.<br />

Kits include the red filters. Blue filters are<br />

available separately. See page 1-30 for details<br />

on single bored tuned induction systems.<br />

Single bore<br />

induction bracket


Racing<br />

Products<br />

CONTINUED<br />

BUILDING A COMPLETE S&S® FUEL INJECTION SYSTEM<br />

Step 4: Select an induction system<br />

Air cleaner kits for 52mm Throttle Bodies<br />

Application: Filter Style: Finish: Part No.<br />

S<strong>to</strong>ck Harley-Davidson®<br />

Heads or S&S® Heads for s<strong>to</strong>ck<br />

or 4" bore<br />

S&S Heads for 41/8" Bore<br />

S<strong>to</strong>ck Harley-Davidson®<br />

Heads or S&S® Heads for s<strong>to</strong>ck<br />

or 4" bore<br />

Teardrop Natural 17-0498<br />

Desperado Natural 17-0497<br />

Tuned<br />

induction<br />

runner<br />

Chrome<br />

Black Powdercoat<br />

Natural<br />

106-2067<br />

106-5337*<br />

Desperado Natural 17-0496<br />

Tuned<br />

induction<br />

runner<br />

Chrome<br />

Black Powdercoat<br />

Natural<br />

Air cleaner kits for 58mm Throttle Bodies<br />

106-5337*<br />

Teardrop Natural 106-4669<br />

S&S Heads for 41/8" Bore Teardrop Natural 106-4668<br />

*Tuned induction kits are special order items that allow your choice of application, runner finish and<br />

filter color<br />

S&S closed loop sensor kit for Magneti Marelli® style S&S VFI module.<br />

Kit for Delphi® style module is similar but the wiring harness adapter is<br />

slightly different.<br />

17-0498<br />

S&S teardrop air cleaner kits give excellent performance<br />

with a traditional look.<br />

Closed Loop Sensor Kit:<br />

(For S&S VFI Modules only)<br />

The kit includes two oxygen sensors, two weld-in exhaust bosses, an<br />

oxygen sensor wiring sub-harness, all required connec<strong>to</strong>rs, and instructions.<br />

Everything needed for closed loop operation on systems with current S&S<br />

VFI modules.<br />

For use with Magneti Marelli® style S&S modules ...... 106-2067<br />

For use with Delphi® style S&S modules . ............. 106-2066<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Knock Sensor Kit:<br />

(For Delphi® Style S&S VFI Module only)<br />

Kit includes knock sensor and all hardware and wiring required for<br />

installation. Software update needed for VFI modules purchased before<br />

Oc<strong>to</strong>ber 2007.<br />

Compatible with USB equipped VFI modules only ...... 106-0810<br />

106-0810<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-41 Visit us at www.sscycle.com


Tools &<br />

Shop Supplies<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

S&S ® EFI WIRING HARNESS<br />

The S&S cus<strong>to</strong>m EFI wiring harness was designed specifically for the<br />

installation of fuel injected S&S engines in<strong>to</strong> frames with less than 2" of<br />

backbone stretch.<br />

FITMENT<br />

❚❚ S&S T-Series engines with Delphi® style VFI modules<br />

❚❚ Harley-Davidson® engines with fac<strong>to</strong>ry Delphi modules<br />

❚❚ Does not support J18S0 devices<br />

FEATURES AND Benefits<br />

❚❚ Plugs directly in<strong>to</strong> Delphi® style S&S VFI modules and s<strong>to</strong>ck Delphi<br />

modules used in late model Harley-Davidson® mo<strong>to</strong>rcycles<br />

❚❚ Compatible with most s<strong>to</strong>ck and aftermarket components for<br />

Harley-Davidson Softail® models including:<br />

• Tip-over sensor<br />

• Oxygen sensors<br />

• Includes provisions for a knock sensor, which is utilized in<br />

the newest S&S VFI modules<br />

106-0478<br />

OPTIONS<br />

S&S is also offering an optional matching connec<strong>to</strong>r set specifically for the<br />

S&S EFI wiring harness. The set contains the correct connec<strong>to</strong>rs <strong>to</strong> allow<br />

cus<strong>to</strong>m builders <strong>to</strong> make tight, waterproof connections from electrical<br />

components <strong>to</strong> the S&S harness. Set includes connec<strong>to</strong>rs for:<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

Speedometer<br />

Headlights<br />

Fuel gauge<br />

Left and right handlebar controls<br />

Indica<strong>to</strong>r lights<br />

Front turn signals<br />

Extra DT and DTM replacement terminals and sealing plugs<br />

PART Numbers<br />

Cus<strong>to</strong>m wiring harness kit .......................... 106-0478<br />

Connec<strong>to</strong>r set ..................................... 106-2857<br />

When connecting S&S T-Series engines <strong>to</strong> this EFI harness, a K-<strong>to</strong>-B style fuel<br />

injec<strong>to</strong>r adap<strong>to</strong>r must be used.<br />

Injec<strong>to</strong>r adap<strong>to</strong>r .....................................55-5074<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

55-5074<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-42


Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

S&S ® SPEEDOMETER CALIBRATOR<br />

Quite simply, the S&S speedometer calibra<strong>to</strong>r is the easiest way <strong>to</strong> adjust<br />

s<strong>to</strong>ck Harley-Davidson® electronic speedometers. No more worrying about<br />

the effects of changing gear ratios, tire size, or wheel size. Installation is as<br />

simple as unplugging the connection between the transmission sensor and<br />

speedometer, and connecting it <strong>to</strong> the S&S calibration module.<br />

FITMENT<br />

❚❚ 2006 and earlier Harley-Davidson® big twin models equipped<br />

with OEM electronic speedometer (except 2006 Dyna®)<br />

FEATURES AND BENEFITS<br />

❚❚ Allows precise adjustments in 1% increments between<br />

-29% and + 69%<br />

❚❚ Compact size (2.25" x 1.50" x 1.10") permits neat, unobtrusive<br />

installation<br />

❚❚ Sensitive components are sealed in epoxy for protection from<br />

vibration and weather<br />

PART NUMBER<br />

S&S Speedometer Calibra<strong>to</strong>r ..........................55-1007<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

SPECIAL NOTES:<br />

Not compatible with Rev Tech® transmissions.<br />

Calculating the difference between actual and indicated speeds/mileage requires only that the rider compare odometer readings <strong>to</strong> a known distance. Highway mile markers are<br />

usually accurate enough <strong>to</strong> use for calibration, although the test should be repeated between several different markers for confirmation. The S&S speedometer calibra<strong>to</strong>r can then<br />

be adjusted <strong>to</strong> increase or decrease the speed and mileage indicated by the speedometer. In most cases it is possible <strong>to</strong> achieve accuracy within 0.5%.<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-43 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

S&S ® SUPER E & G COMPLETE Carbure<strong>to</strong>r KITS<br />

Whether it’s for a big twin with s<strong>to</strong>ck or aftermarket cylinders, or a cus<strong>to</strong>m<br />

application, S&S has a carbure<strong>to</strong>r kit for it! Built <strong>to</strong> last, these high flow<br />

butterfly type carbure<strong>to</strong>rs are easily tuned for maximum performance and<br />

drivability. Both Super E & G carbs have an adjustable accelera<strong>to</strong>r pump and an<br />

adjustable enrichment system for easy starting. The Super E’s 17/8" bore is more<br />

than adequate for street engines up <strong>to</strong> about 100" displacement. The huge<br />

21/16" bore on the Super G is recommended for engines 100" and larger.<br />

FITMENT<br />

❚❚ 1999–’06 Twin Cam 88® engines<br />

Models Super E Complete Kit Super G Complete Kit<br />

1999-'05 big twin 11-0450 11-0451<br />

2006 big twin 106-0874 106-0875<br />

Models Super E (Carb only) Super G (Carb only)<br />

All Years & Models 11-0420 11-0421<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

FEATURES AND BENEFITS<br />

❚❚ Increased air flow for more power<br />

❚❚ Accelera<strong>to</strong>r pump for quick throttle response<br />

❚❚ Utilization of the fac<strong>to</strong>ry dual cable system ensures<br />

safe operation<br />

❚❚ Direct replacement and high quality fit and finish means<br />

less down time and better performance<br />

❚❚ Variable position enrichment starting system<br />

OPTIONS<br />

Optional cruise control adapter kits allows riders <strong>to</strong> keep fac<strong>to</strong>ry cruise<br />

feature on 1999-’06 models ..........................11-2927<br />

KIT CONTENTS<br />

FULL KIT (For engines with s<strong>to</strong>ck length cylinders):<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

❚❚<br />

Super E/G carbure<strong>to</strong>r<br />

S&S intake manifold<br />

Teardrop air cleaner kit<br />

Mounting hardware<br />

Gaskets, seals and hoses<br />

Instructions<br />

11-2927<br />

Cruise Control Adapter<br />

11-0450<br />

Super E Carbure<strong>to</strong>r complete kit for<br />

1999-'05 big twin<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

SPECIAL NOTES:<br />

S&S® does not recommend polishing or chrome plating Super E & G carbure<strong>to</strong>rs. Our repair department has seen many carbs with plugged passages due <strong>to</strong> polishing compounds,<br />

and some carbs that have been destroyed because the polishing or chrome plating had altered critical machined surfaces.<br />

Recommended for closed circuit use only—S&S Super E & G carbure<strong>to</strong>rs shown in this catalog section are not approved for use on mo<strong>to</strong>r vehicles operated on California public<br />

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<br />

in connection therewith.<br />

Replacement parts for S&S Super E & G carbure<strong>to</strong>rs can be found on page 7-10.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-44


TÜV APPROVED S&S ® SUPER E CARBURETOR KITS<br />

Riders in the European Union can now replace their s<strong>to</strong>ck Harley-Davidson®<br />

carbure<strong>to</strong>r with the attractive and reliable S&S Super E. With the included<br />

single bore intake manifold and teardrop air cleaner assembly, this carbure<strong>to</strong>r<br />

kit is sure <strong>to</strong> turn heads. Before being shipped, carbure<strong>to</strong>rs are jetted for the<br />

specific year of bike they are going <strong>to</strong> be installed on.<br />

FITMENT<br />

❚❚ 1999–’06 carbureted Twin Cam 88®<br />

KIT CONTENTS<br />

❚❚ Documentation proving TÜV approval<br />

❚❚ 17/8" bore Super E carbure<strong>to</strong>r<br />

❚❚ Polished intake manifold<br />

❚❚ Teardrop air cleaner cover<br />

❚❚ Air filter<br />

❚❚ All mounting hardware and gaskets<br />

❚❚ Complete instructions<br />

TÜV Approved S&S Super E Carbure<strong>to</strong>r Kit ............. 106-2482<br />

S&S ® SINGLE BORE EFI MANIFOLDS<br />

Specifically designed for S&S Single Bore EFI applications, these S&S manifolds<br />

include fuel injec<strong>to</strong>r mounting ports and provisions for installation of a s<strong>to</strong>ck<br />

style MAP sensor.<br />

FITMENT<br />

❚❚ S<strong>to</strong>ck height or taller than s<strong>to</strong>ck 1999-up big twins<br />

❚❚ S&S 52mm or 58mm throttle bodies<br />

❚❚ S<strong>to</strong>ck or S&S heads<br />

❚❚ S&S T-Series engines<br />

NOTE:<br />

S&S style o-rings must be used with these manifolds. S&S o-rings are slightly<br />

thinner <strong>to</strong> accommodate the larger S&S port diameter. Use of s<strong>to</strong>ck o-rings may<br />

damage the manifold.<br />

106-2482<br />

Engine Displacement<br />

Cylinder Length<br />

Manifold<br />

Size<br />

2006-Up Big twins with STock or S&S Heads<br />

Part No.<br />

88", 95", 96" 103" & 106" 4.937" 405 16-5134<br />

<strong>12</strong>4" Hot Set Up Kit®<br />

All Except 2008-up Touring Models 5.013” 417 16-5139<br />

w/S<strong>to</strong>ck or S&S Heads<br />

<strong>12</strong>4" Hot Set Up Kit®<br />

2008-up Touring Models<br />

5.013” 405 16-5134<br />

w/S&S Heads Only<br />

1999-’05 Big twins With S<strong>to</strong>ck or S&S Heads<br />

88", 95", 103" & 106" 4.937" 410 16-5141<br />

<strong>12</strong>4" Hot Set Up Kit<br />

w/ S<strong>to</strong>ck or S&S Heads<br />

5.013" 417 16-5139<br />

S&S 41/8" Bore T-Series Engines<br />

111" 4.763" 398 16-5136<br />

117" 4.888" 408 16-5138<br />

<strong>12</strong>4" 5.013" 417 16-5139<br />

Special Order (All Styles) Specify 389-428 16-5142<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-45 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Parts for<br />

Evolution®<br />

X-Wedge®<br />

Manifolds for Carbureted big twin Engines<br />

These manifolds have provisions for mounting the s<strong>to</strong>ck MAP sensor directly<br />

<strong>to</strong> the manifold, and are primarily designed for Harley-Davidson® Twin Cam<br />

88® engines. These manifolds may also be used on engines for 1984-'99 big<br />

twins which require a MAP sensor, such as S&S engines equipped with the<br />

S&S Intelligent Spark Technology® (IST®) ignition. Available in 17⁄8" and 21/16"<br />

bore sizes and for 40–48mm CV carbure<strong>to</strong>rs.<br />

FITMENT<br />

❚❚ 1999–’06 big twins<br />

FEATURES AND BENEFITS<br />

❚❚ Fits s<strong>to</strong>ck or S&S heads<br />

❚❚ Fits s<strong>to</strong>ck or engines with taller cylinders<br />

S&S® Manifolds for Harley-Davidson® Twin Cam 88® Big twin<br />

Engines (Requiring MAP Sensor* Machining)<br />

Engine Style<br />

and Displacement<br />

Cylinder<br />

Length<br />

Manifold<br />

Size<br />

Super E<br />

Part No.<br />

Super G<br />

88", 95", 106"<br />

Twin Cam 88<br />

4.937" 410 16-1718 16-2588<br />

100" Twin Cam 88 &<br />

S<strong>to</strong>ck 2006 Models<br />

4.850" 405 16-1717 16-2587<br />

107" Twin Cam 88 4.975" 414 16-1716 16-2586<br />

111" Twin Cam 88 47.763" 398 – 16-2604<br />

116" Twin Cam 88 5.160" 428 16-1719 16-2589<br />

117" Twin Cam 88 4.888" 408 – 16-2603<br />

<strong>12</strong>4" Twin Cam 88 5.013" 417 – 16-2598<br />

Special Order Specify – 16-1639 16-2549<br />

* All S&S engines for 1984-'06 and 1999-up big twins equipped with S&S IST ignition system.<br />

16-0242<br />

S&S CV Manifolds – 1999-2005 big twin<br />

(40-45mm)<br />

Style/Displacement Manifold Size Part No.<br />

88", 95", 106" Twin Cam 88 410 16-1722<br />

100" Twin Cam 88 405 16-1721<br />

107" Twin Cam 88 414 16-1723<br />

116" Twin Cam 88 428 16-1724<br />

Special order – 16-1725A<br />

(48mm)<br />

96 s<strong>to</strong>ck 410 160-0001<br />

Special order – 16-1725A<br />

S&S CV Manifolds – 2006 & up big twin<br />

(40-45mm)<br />

Style/Displacement Manifold Size Part No.<br />

96 s<strong>to</strong>ck 405 16-1721<br />

Special order – 16-1725A<br />

(48mm)<br />

96 s<strong>to</strong>ck 405 160-0002<br />

Special order – 16-1725A<br />

U-Rings for Constant Velocity Carbs<br />

U-ring, 40-42mm ...................................16-0242<br />

U-ring, 44-48mm ...................................16-0241<br />

16-0241<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Manifold for S&S carbure<strong>to</strong>rs<br />

See replacement parts for Intake manifold o-rings and mounting<br />

flanges, page 7-46.<br />

Manifold for CV carbure<strong>to</strong>r<br />

SPECIAL NOTES:<br />

S&S manifolds require S&S style manifold seals.<br />

S&S style o-rings must be used with these manifolds. S&S o-rings are slightly<br />

thinner <strong>to</strong> accommodate the larger S&S port diameter. Use of s<strong>to</strong>ck o-rings may<br />

damage the manifold.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-46


S&S ® IST ® Guardian Diagnostic System<br />

On <strong>to</strong>p of a 3-step break-in rev-limiter function, the Guardian Diagnostic<br />

System offers engine builders and tuners some powerful diagnostic <strong>to</strong>ols <strong>to</strong><br />

use with the S&S IST ignition module.<br />

FITMENT<br />

❚❚ 1999–‘03 big twins with S&S IST ignition modules manufactured<br />

after 10/01/03 (serial number begins with “E” or higher letter)<br />

❚❚ 2004–’06 big twins with S&S IST ignition modules manufactured<br />

after 10/01/05 (serial number begins with “G” or higher letter)<br />

❚❚ All new S&S IST ignition modules<br />

FEATURES AND BENEFITS<br />

❚❚ Adjust the rev-limiter. Modules are fac<strong>to</strong>ry set <strong>to</strong> 6,250 rpm<br />

rev-limit, but this can be set <strong>to</strong> any value up <strong>to</strong> 7,200 rpm<br />

❚❚ Scan <strong>to</strong>ol function allows you <strong>to</strong> view diagnostic test codes (DTCs)<br />

or clear his<strong>to</strong>ry DTCs<br />

❚❚ Calibrate the speedometer in 2004-'06 H-D® models<br />

❚❚ Look at live data (rpm, manifold absolute pressure, engine<br />

temperature, battery voltage, spark timing, dwell, and coil<br />

current) for both cylinders while the engine is running, <strong>to</strong> aid in<br />

service work or performance development<br />

❚❚ Look at his<strong>to</strong>ry information (number of starts, number of revlimiter<br />

hits after the break-in rev-limit has expired, amount<br />

of time spent in various operating conditions, maximum<br />

temperature reached, current rev-limit, <strong>to</strong>tal engine cycles and<br />

running time)<br />

KIT CONTENTS<br />

❚❚ PC software CD<br />

❚❚ Transla<strong>to</strong>r unit<br />

❚❚ Adap<strong>to</strong>r cables<br />

Hours of Operation<br />

break-in rev-limits schedule<br />

Rev-Limit<br />

0 <strong>to</strong> 8 4,250<br />

8 <strong>to</strong> 16 5,<strong>12</strong>5<br />

16 <strong>to</strong> 24 6,025<br />

24+ 6,250*<br />

* The final rev-limit can be set <strong>to</strong> any value up <strong>to</strong> 7200 rpm using S&S IST Guardian Diagnostic<br />

software. Available for modules sold separately only.<br />

PART NUMBER<br />

S&S IST Guardian Diagnostic System ...................55-5075<br />

Replacement Cables:<br />

Harness, transla<strong>to</strong>r <strong>to</strong> data link ....................... 55-5062<br />

Cable, RS-232, PC <strong>to</strong> transla<strong>to</strong>r . . . . . . . . . . . . . . . . . . . . . . . .55-5063<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

System Requirements<br />

❚❚ Microsoft® Windows® 2000 or higher operating system<br />

❚❚ Pentium II 350 MHz processor or faster/equivalent, Pentium III<br />

500 MHz processor or faster/equivalent preferred<br />

❚❚ Minimum 64 MB RAM, <strong>12</strong>8 MB or more recommended<br />

❚❚ At least 300 MB of free hard drive space<br />

❚❚ CD-ROM or DVD-ROM drive required for installation<br />

❚❚ Keyboard and mouse (or equivalent pointing device)<br />

❚❚ 9-pin serial port for communication with ignition modules or<br />

serial <strong>to</strong> USB adapter<br />

Note:<br />

PC must have 9-pin serial port for communication with ignition module.<br />

Otherwise, a serial <strong>to</strong> USB adapter must be used.<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-47 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

S&S ® IST ® IGNITION SYSTEM<br />

Truly revolutionary, the Intelligent Spark Technology (IST) system moni<strong>to</strong>rs<br />

s<strong>to</strong>ck crank position, cam position (if equipped), MAP, and cylinder<br />

temperature sensors, in addition <strong>to</strong> the exclusive S&S Knock Sensor. If<br />

knock or de<strong>to</strong>nation occurs, the IST system adjusts timing until it s<strong>to</strong>ps. It<br />

then s<strong>to</strong>res information about conditions that cause the engine <strong>to</strong> knock. In<br />

effect, the system “learns” the ignition requirements of a particular engine,<br />

and creates a fully cus<strong>to</strong>m ignition map for it. Requires two coils or dual coil<br />

package.<br />

FITMENT<br />

❚❚ 1999–’06 carbureted big twins<br />

❚❚ Requires installation kit (see below)<br />

FEATURES AND BENEFITS<br />

❚❚ Protects your engine from damaging de<strong>to</strong>nation or knock<br />

❚❚ Au<strong>to</strong>matically adjusts <strong>to</strong> lower grade fuel<br />

❚❚ Installation kits plug in<strong>to</strong> s<strong>to</strong>ck wiring harnesses<br />

❚❚ 6250 rpm preset rev-limiter<br />

❚❚ High output au<strong>to</strong>matically maximizes coil output<br />

❚❚ Au<strong>to</strong>matic dwell adjust will optimize current for any<br />

0.5Ω <strong>to</strong> 3.0Ω coil<br />

❚❚ Short circuit and reverse polarity protected<br />

IST will au<strong>to</strong>matically adjust ignition timing for modifications such as:<br />

❚❚ Increased displacement from stroker or big bore kits<br />

❚❚ Bigger cams<br />

❚❚ Performance exhaust<br />

❚❚ Head porting or installation of aftermarket heads<br />

❚❚ Gear ratios<br />

55-<strong>12</strong>21<br />

PART NUMBER<br />

S&S Intelligent Spark Technology Ignition Module .............55-<strong>12</strong>21<br />

Installation kit (required):<br />

1999–’03 carburated big twins . .............................55-10<strong>12</strong><br />

2004–’06 carburated big twins . .............................55-<strong>12</strong>20<br />

KIT CONTENTS<br />

❚❚ Wiring harness adapter<br />

❚❚ Knock sensor<br />

❚❚ Temperature sensor<br />

Racing<br />

Products<br />

55-10<strong>12</strong><br />

Installation Kit<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Exclusive S&S knock sensor installed on cylinder head <strong>to</strong>p mo<strong>to</strong>r mount. No<br />

other ignition system for v-twin mo<strong>to</strong>rcycles uses knock sensing <strong>to</strong> control<br />

ignition timing.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-48<br />

NOTE:<br />

Do not use a dual fire coil with the S&S ignition module.<br />

This kit will NOT work with vehicles equipped with flat slide carbs, open primaries,<br />

and dry clutches. If you want <strong>to</strong> use IST with these configurations, contact S&S – we<br />

can help set-up IST.


Tools &<br />

Shop Supplies<br />

CONTINUED<br />

S&S® IST® IGNITION SYSTEM<br />

S&S High Output 3.0Ω Single Fire Coil:<br />

The perfect complement for S&S IST® or Super S<strong>to</strong>ck® ignition systems.<br />

This single fire coil is actually two separate coils in a single package. Coil<br />

impedance is 3Ω per coil. Not compatible with the S&S Variable Fuel Injection<br />

(VFI) System.<br />

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-1571<br />

S&S High Output 0.5Ω Single Fire Coil:<br />

High output 0.5Ω single fire coil for S&S IST ignition, Delphi® style VFI<br />

modules and cus<strong>to</strong>m applications requiring a 0.5Ω coil. Not compatible with<br />

S&S Super S<strong>to</strong>ck ignition. ...................................55-1576<br />

Replacement Parts For Installation Kits<br />

Cylinder Head Temperature Sensors<br />

For Twin Cam 88® ..................................... 55-1014<br />

S&S 41/8" Bore Engines ................................. 55-1014<br />

Knock Sensor Kit. ........................................ 55-1015<br />

Crank Position Sensor .................................... 55-1051<br />

MAP Sensor. ............................................ 55-1037<br />

Cam Position Sensor Kit .................................. 55-1023<br />

Cam Position Ro<strong>to</strong>r Assembly. ............................. 55-1034<br />

Cam Position Sensor Assembly. ............................ 55-1024<br />

Replacement Parts for<br />

Wiring Harness Adapters<br />

Harley-Davidson® Twin Cam 88® 2004-'06 .................. 55-1499<br />

Harley-Davidson® Twin Cam 88® 1999-'03 .................. 55-1017<br />

Cam Harness Kit ......................................... 55-1530<br />

Power Harness Kit ....................................... 55-1540<br />

Scan Tool Harness ....................................... 55-1550<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

55-1576<br />

55-1571<br />

Replacement<br />

Parts<br />

Racing<br />

Products<br />

NOTE:<br />

The S&S IST Ignition System is not recommended for kick start applications unless<br />

a cam position sensor is used. Engines using crankshaft position sensors will be<br />

difficult <strong>to</strong> kick start. We recommend our Super S<strong>to</strong>ck® ignition system for kick<br />

start applications.<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-49 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

S&S ® COMPRESSION RELEASES<br />

Better batteries and high-<strong>to</strong>rque starters have helped, but starting big inch<br />

mo<strong>to</strong>rs can still be troublesome.<br />

S&S <strong>Cycle</strong>’s compression release system eliminates high compression starting<br />

problems. Designed exclusively for S&S cylinder heads, the compression<br />

release system consists of a small valve that opens during starting and<br />

allows a portion of the cylinder pressure <strong>to</strong> escape in<strong>to</strong> the exhaust port. The<br />

reduced cylinder pressure makes it easier for the starter <strong>to</strong> turn the engine.<br />

When the engine starts, the valve closes and the engine runs normally, with<br />

full compression. With the S&S compression release kit, a s<strong>to</strong>ck starter is able<br />

<strong>to</strong> start almost any engine. These compression releases are a good solution<br />

for engines using other manufacturer's cams, which do not have built-in<br />

compression releases.<br />

FITMENT<br />

❚❚ S&S cylinder heads for big twin<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

OPTIONS<br />

❚❚ Manual release:<br />

Activated by a cable similar <strong>to</strong> a choke control, this slick system<br />

can be used with any style rocker cover.<br />

❚ ❚ Electric release:<br />

Solenoid operated, this system au<strong>to</strong>matically opens and closes<br />

when the starter but<strong>to</strong>n is pressed and released. Convenient<br />

and simple, this is the best setup for big displacement high<br />

compression bikes. Requires S&S die cast rocker covers,<br />

see page 1-78.<br />

PART NUMBERs<br />

S&S Electric Compression Release Kit ..................90-4915<br />

S&S Manual Compression Release Kit ..................90-4925<br />

S&S Cable Knob: Special billet accessory knob for manual compression<br />

release (see picture) .................................50-8701<br />

S&S Two-Piece Socket Kit:<br />

Special S&S two-piece compression release socket kit allows in-frame<br />

installation of S&S compression releases and protects wiring from damage<br />

during installation. .................................53-0045<br />

S&S Compression Release Hole Plug ...................90-4916<br />

Replacement Parts for S&S Electric Compression Releases:<br />

Silicone Solenoid Caps ...............................55-1009<br />

Wiring Harness .....................................55-1010<br />

Compression Release Assembly .......................90-4914<br />

90-4915– Electric Compression Release Kit<br />

90-4916<br />

50-8701<br />

50-1009<br />

53-0045<br />

NOTES:<br />

S&S rocker covers must be used with electric compression releases due <strong>to</strong> clearance<br />

requirements for the solenoids.<br />

Rocker covers must be removed when installing S&S® compression releases. If lack<br />

of frame clearance prevents removal of rocker covers, engine must be removed from<br />

frame for compression release installation.<br />

All S&S heads for 1999-up big twins are machined for S&S compression releases.<br />

In most cases, S&S compression releases can be installed while the engine is in the<br />

frame with the special S&S two-piece socket kit, part #53-0045 .<br />

If cylinder heads are machined for S&S compression releases, but compression<br />

releases are not used, special plug part #90-4916 (two required) must be installed<br />

<strong>to</strong> seal the machined hole.<br />

S<strong>to</strong>ck cylinder heads cannot be machined for S&S compression releases because<br />

there is not enough material in critical areas.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-50


Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

champion ® spark plugs<br />

Replace Your Spark Plugs For Maximum Performance and Fuel<br />

Economy. S&S® now offers the same high quality Champion® spark plugs<br />

that we include with our engines for replacement in S&S and s<strong>to</strong>ck engines<br />

alike. These long reach resis<strong>to</strong>r spark plugs are available in <strong>12</strong>mm and 14mm<br />

sizes. They are the correct heat range for all S&S engines and also fit 1977<br />

and later Harley-Davidson® engines. Compatible with any ignition system.<br />

Champion® Spark Plugs<br />

Size<br />

Part No.<br />

<strong>12</strong>mm Long Reach (2 Pack) 55-1322<br />

14mm Long Reach (2 Pack) 55-1323<br />

U S A<br />

55-1322<br />

TÜV<br />

USA<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

5,6<br />

55-1323<br />

2,3<br />

X-Wedge®<br />

1-51 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

S&S ® SUPER STOCK ® 79c c & 89c c CYLINDER HEADS<br />

S&S 79cc cylinder heads are intended for s<strong>to</strong>ck engines and other small<br />

displacement applications. These heads are compatible with s<strong>to</strong>ck Harley-<br />

Davidson® rocker covers. Must use S&S valve cover gasket kit part #90-4<strong>12</strong>4<br />

with s<strong>to</strong>ck rocker covers. They are a very economical performance upgrade<br />

designed for use with other performance enhancers and are machined <strong>to</strong><br />

accept S&S® compression releases.<br />

Intended for larger displacement engines, S&S 89cc heads have a<br />

whopping 264cfm flow rate (compared <strong>to</strong> 182cfm for s<strong>to</strong>ck H-D® heads),<br />

larger valves and .640" lift valve springs. S&S recommends S&S Easy<br />

Start cams or manual or electric compression release system in order <strong>to</strong><br />

maintain reliable engine starting on high compression applications.<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

FITMENT<br />

❚❚ 1999–up big twins<br />

❚❚ S<strong>to</strong>ck rocker covers<br />

FEATURES AND BENEFITS<br />

❚❚ Heads can be decked up <strong>to</strong> .060" <strong>to</strong> increase compression<br />

❚❚ 79cc heads 1.940" intake and 1.575" exhaust valves<br />

❚❚ 89cc heads have 2.000" intake and 1.605" exhaust valves<br />

❚❚ S&S .640" lift valve springs<br />

❚❚ S<strong>to</strong>ck Harley-Davidson® rocker boxes can be retained if S&S<br />

manual compression release or S&S Easy Start cams are used.<br />

Must use S&S valve cover gasket kit part #90-4<strong>12</strong>0 with s<strong>to</strong>ck rocker covers<br />

❚❚ 2006-up heads are machined for 2008-up <strong>to</strong>p mo<strong>to</strong>r mount<br />

OPTIONS<br />

❚❚ Silver powdercoat or wrinkle black powdercoat finish<br />

Compression Ratios for S&S® Super S<strong>to</strong>ck® Cylinder Heads for<br />

1999-UP Big twins<br />

Engine Displacement and<br />

Configuration<br />

79cc<br />

Chamber Volume<br />

89cc<br />

88" 9.1 8.3<br />

95" 9.6/10.3* 8.7/9.3*<br />

S<strong>to</strong>ck 2007-up 96" 9.8 8.9<br />

97" Big Bore 10.3 9.4<br />

103" 10.2/11.1* 9.3/10.1*<br />

106" Stroker 10.7 9.8<br />

106" Top End Kit 10.6 9.7<br />

* S&S pop-up pis<strong>to</strong>n<br />

110" 10.8 9.8<br />

S&S® Super S<strong>to</strong>ck® Cylinder Head Kits for 1999-'05 Big twins<br />

Chamber Volume Finish Part No.<br />

79cc<br />

89cc<br />

Silver 106-4277<br />

Black 90-<strong>12</strong>93<br />

Silver 106-4270<br />

Black 90-1106<br />

S&S® Super S<strong>to</strong>ck® Cylinder Head Kits for 2006-UP Big twins<br />

79cc<br />

89cc<br />

Silver 106-3227<br />

Black 106-3233<br />

Silver 106-3255<br />

Black 106-3240<br />

Special Order 1 – 90-1060<br />

1<br />

Use the Special Order part number <strong>to</strong> order front or rear replacement cylinder head assemblies<br />

and for special finish.<br />

Replacement heads are only available assembled, complete with valves and springs.<br />

S&S® Head Bolt Packages for Cylinder Heads 1999-UP Big twin<br />

Engine Displacement<br />

90-<strong>12</strong>90<br />

Part No.<br />

88", 95", 100", 106", 107", 110", 111" 93-3070<br />

116", 117" 93-3071<br />

<strong>12</strong>4" 93-3072<br />

S&S® Gasket Kits for 1999-UP Big twins<br />

S&S heads for Harley-Davidson®<br />

engines are now available in silver<br />

powdercoat finish. This is a perfect<br />

match for the finish on s<strong>to</strong>ck<br />

cylinders and crankcases.<br />

33/4" Bore 37/8" Bore 3.927" Bore 4" Bore 41/8" Bore*<br />

90-1911 90-19<strong>12</strong> 106-3763 90-1913 90-1914<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-52


Continued<br />

S&S® Super S<strong>to</strong>ck® 79cc & 89cc Cylinder Heads<br />

Parts for<br />

Twin Cam 88®<br />

NOTES:<br />

79cc heads<br />

When 79cc s<strong>to</strong>ck compatible heads are used with s<strong>to</strong>ck H-D® pis<strong>to</strong>ns, TDC lifts of up <strong>to</strong> .186” for intake and .179” for exhaust and can be used without additional valve pocket<br />

clearancing. This allows the use of S&S® 510, 570, and 585 camshafts. If cams with higher TDC lifts are used, or if the heads are decked, pis<strong>to</strong>n valve pocket machining will be<br />

required.<br />

79cc heads may be decked as much as .060” <strong>to</strong> increase compression. If heads are decked, pis<strong>to</strong>n valve pockets must be re-machined.<br />

Moderate valve spring force in S&S Super S<strong>to</strong>ck® cylinder heads allows the use of camshafts designed for the s<strong>to</strong>ck style chain cam drive system. However, for maximum reliability<br />

and performance we recommend the S&S gear drive cams.<br />

Must use S&S valve cover gasket kit part #90-4<strong>12</strong>0 with s<strong>to</strong>ck rocker covers.<br />

89cc heads<br />

If 89cc heads are used with s<strong>to</strong>ck pis<strong>to</strong>ns, valve reliefs must be machined in the pis<strong>to</strong>ns due <strong>to</strong> larger valve size.<br />

89cc heads may be decked as much as .060” <strong>to</strong> increase compression. If heads are decked, valve-<strong>to</strong>-pis<strong>to</strong>n clearance must be checked. If s<strong>to</strong>ck pis<strong>to</strong>ns are used, valve pockets must<br />

be re-machined.<br />

Moderate valve spring force in S&S® Super S<strong>to</strong>ck® cylinder heads allows the use of camshafts designed for the s<strong>to</strong>ck style chain cam drive system. However, for maximum reliability<br />

and performance we recommend the S&S gear drive cams.<br />

A larger intake manifold is recommended <strong>to</strong> supplement the heads in order <strong>to</strong> let them flow <strong>to</strong> their full potential.<br />

Must use S&S valve cover gasket kit part #90-4<strong>12</strong>0 with s<strong>to</strong>ck rocker covers.<br />

MANIFOLD RECOMMENDATIONS<br />

S&S® manifolds for 1999-’06 carbureted engines are available <strong>to</strong> fit s<strong>to</strong>ck CV<br />

carbure<strong>to</strong>rs and S&S Super E and G carbs. Note that 2006 models require a slightly<br />

shorter manifold. (See "Important Manifold Information")<br />

S&S single bore throttle body and manifold are recommended for engines with<br />

Magneti Marelli® and Delphi® fuel injection.<br />

S&S single bore throttle body and manifold are recommended for 2006-up, except<br />

2008-up <strong>to</strong>uring models. Due <strong>to</strong> the change in manifold flange mounting bolt<br />

pattern, s<strong>to</strong>ck flanges and S&S seal part #16-0235 must be used. The Screamin’<br />

Eagle® 58mm throttle body/manifold may also be used on 2006-'09 engines.<br />

We recommend the s<strong>to</strong>ck 50 mm throttle body or Screamin’ Eagle 58mm throttle<br />

body/manifold for 2008-up <strong>to</strong>uring models with Electronic Throttle Control (ETC).<br />

These engines can be tuned with the Harley-Davidson® Super Tuner package,<br />

Pro EFI Super Tuner, Power Commander® or an aftermarket EFI tuning module<br />

or software tuner.<br />

IMPORTANT MANIFOLD INFORMATION<br />

In 2006, Harley-Davidson® changed the bolt pattern of the flanges that connect<br />

the manifold <strong>to</strong> the cylinder heads for all big twin engines. The pattern was<br />

changed from an offset bolt pattern <strong>to</strong> a symmetrical bolt pattern, so flanges can<br />

fit either the front or rear cylinder head. In addition, the intake port was moved<br />

slightly <strong>to</strong>ward the drive side of the engine, making the port-<strong>to</strong>-port distance of the<br />

90-4<strong>12</strong>0<br />

S&S valve cover gasket kit.<br />

Must be used with s<strong>to</strong>ck rocker<br />

covers.<br />

intake manifold slightly shorter. S&S® heads for 2006-up big twins are machined<br />

with the symmetrical bolt pattern and relocated port <strong>to</strong> allow for the fitment of<br />

s<strong>to</strong>ck manifolds. In 2008, Harley-Davidson <strong>to</strong>uring models were equipped with<br />

electronic throttle control (ETC). The throttle body and manifold used on these<br />

engines is a one-piece unit that contains a servomechanism <strong>to</strong> control the position<br />

of the throttle plate. S&S does not offer a throttle body for this application, so<br />

the s<strong>to</strong>ck 50mm throttle body or a Screamin’ Eagle® 58mm throttle body is<br />

recommended. This limits the cylinder length of engines using an ETC manifold/<br />

throttle body <strong>to</strong> s<strong>to</strong>ck length because the ETC manifold/throttle body units are only<br />

available in s<strong>to</strong>ck length. However, S&S does supply specially machined cylinder<br />

heads for our <strong>12</strong>4” Hot Set Up Kit® for 2008 and later baggers, which allows the<br />

use of a s<strong>to</strong>ck length manifold on these longer-than-s<strong>to</strong>ck engines.<br />

Ordering Notes:<br />

Select the cylinder head kit that is correct for your application.<br />

Select a gasket kit for the bore size of your engine. (Refer <strong>to</strong> “S&S Gasket Kit” chart<br />

on previous page)<br />

Select an S&S manifold for your engine size or cylinder length and fuel system.<br />

(Optional)<br />

Select head bolt package. (Refer <strong>to</strong> “S&S Head Bolt Packages” chart on previous page)<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-53 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

S&S ® Replacement CYLINDER HEADS FOR<br />

4 1 /8" BORE T-Series ENGINES & <strong>12</strong>4" Hot Set Up Kit ®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Cylinder heads shown on this page are replacements for S&S 41/8" bore<br />

engines and <strong>12</strong>4" Hot Set Up Kits. Heads for S&S engines are machined with<br />

the S&S head bolt pattern, for use with S&S crankcases. Heads for the <strong>12</strong>4"<br />

Hot Set Up Kit are machined with the s<strong>to</strong>ck head bolt pattern, for use with<br />

s<strong>to</strong>ck crankcases.<br />

OPTIONS<br />

❚❚ S&S or s<strong>to</strong>ck head bolt pattern<br />

❚❚ Natural, silver powdercoat, black powdercoat, or polished finish<br />

Special Order OPTIONS<br />

❚❚ Individual front or rear heads<br />

❚❚ Head bolt pattern<br />

❚❚ Diamond cut or full polished finishes<br />

❚❚ Heads with the old fin profile may be special ordered <strong>to</strong> match<br />

an existing engine<br />

S&S Replacement cylinder heads for S&S bore T-Series engines<br />

for 1999-up big twins - S&S Bolt pattern<br />

Description Finish Kit<br />

91cc 41/8" Bore<br />

S&S Replacement cylinder heads for S&S <strong>12</strong>4" Hot Set Up Kit®<br />

for 1999-up big twins - S<strong>to</strong>ck bolt pattern<br />

Description Finish Kit<br />

1999-up (except ‘08-up Touring)<br />

91cc 41/8" Bore<br />

‘08-up Touring<br />

91cc 41/8" Bore<br />

Natural 90-1370<br />

Silver 106-4275<br />

Black 90-1371<br />

Polished 90-1372<br />

Special Order 1 - 90-1060<br />

1<br />

Use the Special Order part number <strong>to</strong> order front or rear replacement cylinder head assemblies.<br />

Replacement heads are only available assembled, complete with valves and springs.<br />

Silver 106-4272<br />

Black 90-1163<br />

Silver 106-4278<br />

Black 106-3249<br />

Special Order 1 Specify 90-1060<br />

1<br />

Use the Special Order part number <strong>to</strong> order front or rear replacement cylinder head assemblies.<br />

Replacement heads are only available assembled, complete with valves and springs.<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

90-1370<br />

USA<br />

3<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

NOTES:<br />

By changing the profile and shape of the cooling fins on our heads for 41/8” bore engines, a large reduction in the transmission of mechanical noise was found. This not only benefits<br />

our TÜV certified engines and our EPA approved engines, but our performance engines as well!<br />

Since April 1, 2007, these redesigned heads have been installed on all S&S 41/8” bore engines and Hot Set Up Kits.<br />

Replacement heads of the old style are available by special order.<br />

TÜV<br />

6<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-54


S&S ® 4 1 /8" BORE CYLINDERS AND PISTONS<br />

S<strong>to</strong>ck Bolt Pattern for<br />

S&S <strong>12</strong>4" & 117" Hot Set up kits<br />

Replacements for cylinders included in the S&S <strong>12</strong>4" Hot Set Up Kit®, these<br />

cylinders are made of superior materials and has a thicker casting than<br />

s<strong>to</strong>ck cylinders. Other than being machined with a s<strong>to</strong>ck stud pattern, these<br />

cylinders are identical <strong>to</strong> the ones used in S&S <strong>12</strong>4" engines.<br />

FITMENT<br />

❚❚ 1999-'09 big twins with S&S <strong>12</strong>4" or 117" Hot Set Up Kit<br />

❚❚ Compatible with s<strong>to</strong>ck or S&S Super S<strong>to</strong>ck® heads<br />

106-4158<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

FEATURES AND BENEFITS<br />

❚❚ Forged, coated pis<strong>to</strong>ns and S&S cylinders provide consistent<br />

performance and reliability<br />

❚❚ Valve pocket recesses in S&S pis<strong>to</strong>ns are enlarged for oversize<br />

valves and higher lift cams<br />

OPTIONS<br />

❚❚ Silver powdercoat or wrinkle black powdercoat finish<br />

Special Order OPTIONS<br />

❚❚ Diamond cut<br />

❚❚ Full polished<br />

Displacement<br />

Stroke<br />

Cylinder<br />

Length<br />

GASKETS, DOWELS, AND HARDWARE<br />

Description<br />

Part No.<br />

Head Gasket<br />

93-1043-S<br />

Base Gasket<br />

93-1050-S<br />

Base O-ring 50-8049<br />

<strong>Exhaust</strong> Gasket 106-5029<br />

Oil Return O-ring 50-8008<br />

Cylinder Dowels 50-8177<br />

Center Case Bolt (waisted) 50-0327<br />

Flat Washer 50-7026<br />

Nut 5/16" - 24 50-5023<br />

Center Case Bolt Seal<br />

50-8063-S<br />

S&S® 41/8" BORE CYLINDERS FOR <strong>12</strong>4" and 117" HOT SET UP KITS<br />

Part No.<br />

Compression Ratio<br />

Cylinders Only (pair)<br />

Cylinders w/ Pis<strong>to</strong>ns (pair)<br />

S<strong>to</strong>ck 91cc S&S 89cc S&S<br />

Silver<br />

Silver<br />

Black<br />

Heads Heads Heads<br />

Silver Black<br />

(for S&S<br />

(for (for S&S 89cc/91cc<br />

89cc/91cc heads) s<strong>to</strong>ck heads) heads)<br />

Black<br />

(for<br />

s<strong>to</strong>ck heads)<br />

<strong>12</strong>4" 45/8" 5.013" 10.4:1 10.8:1 11:1 106-4158 91-7252 106-4159 – 91-7257 –<br />

<strong>12</strong>4" dish 45/8" 5.013" 10.8:1 10.2:1 10.4:1 106-4158 91-7252 – 106-4163 – 91-7253<br />

117" 43/8" 4.888 10.9:1 10.3:1 10.5:1 910-0030 91-7365 910-0033 – 91-7367 –<br />

Cylinder w/ pis<strong>to</strong>n kits include cylinders, pis<strong>to</strong>n kit, head gaskets, base gaskets, and exhaust gaskets<br />

Heads<br />

S&S<br />

89cc/91cc<br />

S<strong>to</strong>ck<br />

S&S<br />

84cc/91cc<br />

Deck<br />

Height<br />

Stroke<br />

1.050" 4 5/8"<br />

1.050" 43/8"<br />

Pis<strong>to</strong>n<br />

Type<br />

Flat<br />

<strong>to</strong>pped<br />

10.9cc<br />

dished<br />

Flat<br />

<strong>to</strong>pped<br />

Pis<strong>to</strong>n kits include set of pis<strong>to</strong>ns, rings, wristpins, and clips<br />

S&S® 41/8" BORE PISTONS FOR <strong>12</strong>4" HOT SET UP KITS<br />

Forged Pis<strong>to</strong>n Kits<br />

Rings, chromoly faced<br />

Standard +.010" +.020" +.030" Standard +.010" +.020" +.030"<br />

92-1556 92-1557 92-1558 92-1559<br />

92-1575 92-1576 92-1577 –<br />

92-1550 92-1551 92-1552 92-1553<br />

.927"<br />

Wristpin<br />

SPECIAL NOTES<br />

S&S 41/8" pis<strong>to</strong>ns are machined <strong>to</strong> such close <strong>to</strong>lerances that it is not necessary <strong>to</strong> measure the pis<strong>to</strong>n. Additionally, the low friction coating on the pis<strong>to</strong>n skirt makes taking<br />

measurements very difficult. Therefore, bore cylinders <strong>to</strong> nominal diameter +/- 0.0005” for correct clearance.<br />

Special<br />

Order<br />

91-7506<br />

Keeper<br />

94-1400X 94-1401X 94-1402X 94-1403X 94-9277 94-9278-S<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-55 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

S&S ® 4 1 /8" BORE CYLINDERS AND PISTONS<br />

Replacements for cylinders included in S&S T-Series 41/8" bore engines,<br />

these cylinders are made of superior materials and has a thicker casting<br />

than s<strong>to</strong>ck cylinders.<br />

FITMENT<br />

❚❚ S&S T<strong>12</strong>4, T117 and T111<br />

❚❚ 1999-'06 big twins<br />

FEATURES AND BENEFITS<br />

❚❚ Forged, coated pis<strong>to</strong>ns and S&S cylinders provide consistent<br />

performance and reliability<br />

❚❚ Valve pocket recesses in S&S pis<strong>to</strong>ns are enlarged for oversize<br />

valves and higher lift cams<br />

91-7099<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

OPTIONS<br />

❚❚ Silver, wrinkle black powdercoat, or polished finish<br />

Special Order OPTIONS<br />

❚❚ Natural<br />

❚❚ Diamond cut<br />

❚❚ Individual cylinders<br />

Displacement<br />

Stroke<br />

Cylinder<br />

Length<br />

Compression<br />

Ratio<br />

41/8" BORE CYLINDERS FOR S&S® ENGINES<br />

Part No.<br />

Cylinders Only (Set) Cylinders w/ Pis<strong>to</strong>ns (Set) Special<br />

Order<br />

Silver Black Polished Silver Black Polished<br />

<strong>12</strong>4" 4 5/8" 5.013" 10.8:1 106-4157 91-7079 91-7165 106-4161 91-7099 –<br />

117" 4 3/8" 4.888" 10.2:1 106-4151 – – 106-4152 91-7098 –<br />

111" 4 1/8" 4.763" 9.7:1 106-4150 – – 106-4149 – 91-7290<br />

Cylinder w/ pis<strong>to</strong>n kits include fitted pis<strong>to</strong>ns and cylinders, head gaskets, base, and exhaust gaskets<br />

Displacement<br />

<strong>12</strong>4"<br />

Deck<br />

Height<br />

Forged Pis<strong>to</strong>n Kits<br />

41/8" BORE PISTONS FOR S&S® ENGINES<br />

Rings, chromoly faced<br />

Stroke Standard +.010" +.020" +.030" Standard +.010" +.020" +.030"<br />

4 5/8" 92-1556 92-1557 92-1558 92-1559<br />

117" 1.050" 4 3/8" 92-1550 92-1551 92-1552 92-1553<br />

111" 4 1/8" 92-1560 92-1561 92-1562 92-1563<br />

Pis<strong>to</strong>n kits include set of pis<strong>to</strong>ns, rings, wristpins, and clips<br />

Description<br />

Head Gasket<br />

Base Gasket<br />

GASKETS, DOWELS, AND HARDWARE<br />

Part No.<br />

93-1091-S<br />

93-1092-S<br />

<strong>Exhaust</strong> Gasket 106-5029<br />

Cylinder Dowels 50-8177<br />

0.927"<br />

Wristpin<br />

91-7506<br />

Keeper<br />

94-1400X 94-1401X 94-1402X 94-1403X 94-9277 94-9278-S<br />

SPECIAL NOTES<br />

S&S 41/8” pis<strong>to</strong>ns are machined <strong>to</strong> such close <strong>to</strong>lerances that it is not necessary <strong>to</strong> measure the pis<strong>to</strong>n. Additionally, the low friction coating on the pis<strong>to</strong>n skirt makes taking<br />

measurements very difficult. Therefore, bore cylinders <strong>to</strong> nominal diameter +/- 0.0005” for correct clearance.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-56


S&S ® 4" BORE REPLACEMENT<br />

CYLINDERS AND PISTONS<br />

Made as replacements for S&S Super Sidewinder® kits, these cylinders are made<br />

of superior materials and has a thicker casting than s<strong>to</strong>ck cylinders. Excellent<br />

wear resistance will maintain horsepower and reliability for years <strong>to</strong> come.<br />

FITMENT<br />

❚❚ 116" Super Sidewinder kit for 1999-’09 models<br />

❚❚ 100" Super Sidewinder kit for 1999-’06 models<br />

FEATURES AND BENEFITS<br />

❚❚ Forged, coated pis<strong>to</strong>ns and S&S cylinders provide<br />

dependable performance<br />

❚❚ Compatible with s<strong>to</strong>ck or S&S Super S<strong>to</strong>ck® heads<br />

❚❚ Valve pocket recesses in S&S pis<strong>to</strong>ns are enlarged for<br />

oversize valves and higher lift cams<br />

❚❚ Pis<strong>to</strong>n weight for 100” kits are the same as s<strong>to</strong>ck,<br />

requiring no flywheel rebalancing<br />

❚❚ S<strong>to</strong>ck stud pattern<br />

OPTIONS<br />

❚❚ Silver or wrinkle black powdercoat finish<br />

Special Order OPTIONS<br />

❚❚ Natural<br />

❚❚ Diamond cut<br />

❚❚ Polished<br />

Displacement<br />

Displacement<br />

Stroke<br />

Cylinder<br />

Length<br />

S&S® 4" BORE PISTONS<br />

Forged Pis<strong>to</strong>n Kits Rings, chromoly faced 0.927"<br />

Deck Height Stroke Standard +.010" +.020" +.030" Standard +.010" +.020" +.030" Wristpin<br />

116"<br />

4 5/8" 92-1436 92-1437 92-1438 92-1439<br />

1.200"<br />

100" 4" – 92-1431 92-1432 92-1433<br />

Pis<strong>to</strong>n kits include set of pis<strong>to</strong>ns, rings, wristpins, and clips<br />

Compression Ratio<br />

S&S® 4" BORE CYLINDERS<br />

Cylinders Only (Set)<br />

Part No.<br />

Cylinders w/Pis<strong>to</strong>ns (Set)<br />

S<strong>to</strong>ck Heads 89cc S&S Heads 79cc S&S Heads Silver Silver Black<br />

116" 4 5/8" 5.160" 11:1 10.4:1 11.5:1 106-4145 106-4146 91-7227<br />

100" 4" 4.850" 9.7:1 9.2:1 10.1:1 106-4141 106-4142 91-7019<br />

Cylinder w/ pis<strong>to</strong>n kits include cylinders, pis<strong>to</strong>n kit, head gaskets, base gaskets, and exhaust gaskets<br />

Description<br />

Head Gasket<br />

Base Gasket<br />

GASKETS, DOWELS, AND HARDWARE<br />

Part No.<br />

93-1043-S<br />

93-1050-S<br />

Base O-ring 50-8049<br />

<strong>Exhaust</strong> Gasket 106-5029<br />

Oil Return O-ring 50-8008<br />

Cylinder Dowels 50-8177<br />

Center Case Bolt (waisted) 50-0119<br />

Flat Washer 50-7026<br />

Nut 5/16" - 24 50-5023<br />

Center Case Bolt Seal<br />

106-4141<br />

50-8063-S<br />

Special Order<br />

91-7506<br />

Keepers<br />

94-1306X 94-1307X 94-1308X 94-1309X 94-9277 94-9278-S<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

SPECIAL NOTES:<br />

For 100” and 116” ‘cylinder only’ kits, pis<strong>to</strong>ns must be measured and cylinders<br />

bored/honed accordingly. Recommended pis<strong>to</strong>n fitment:<br />

Close: 0.0020” – 0.0025” Loose: 0.0032” – 0.0045”<br />

NOTE:<br />

S<strong>to</strong>ck crankcases must be bored <strong>to</strong> accept the larger S&S 4” cylinders<br />

Early S&S 4” bore kits used o-rings <strong>to</strong> seal the cylinder base. Later kits use a<br />

base gasket. Use the correct sealing method for your kit<br />

Warranty &<br />

Company Policy<br />

1-57 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

S&S ® 3 7 /8" BORE REPLACEMENT<br />

CYLINDERS AND PISTONS<br />

These 3 7/8" bore cylinders are a good choice for installation and repair of 95" and<br />

103" kits. Superior materials, thicker casting in critical areas and bigger cooling<br />

fins, combined with excellent wear resistance ensure excellent engine life.<br />

FITMENT<br />

❚❚ Cylinders can be used for s<strong>to</strong>ck replacement<br />

❚❚ 95" kit for 1999-’06 models – pis<strong>to</strong>ns have 5.3cc pop up dome<br />

❚❚ 103" kit for 2007-’09 models – pis<strong>to</strong>ns have 5cc pop up dome<br />

❚❚ 106" stroker kit for 1999-’09 models – pis<strong>to</strong>ns have flat <strong>to</strong>ps<br />

106-4137 Cylinders<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

FEATURES AND BENEFITS<br />

❚❚ Installation of S&S cylinders instead of boring s<strong>to</strong>ck cylinder saves<br />

time and labor when installing 95" or 103" kits<br />

❚❚<br />

S&S 37/8" bore cylinders require no crankcase machining <strong>to</strong> install<br />

❚❚ Pis<strong>to</strong>n weight for 95" & 103" kits are the same as s<strong>to</strong>ck, requiring<br />

no flywheel rebalancing<br />

❚❚ Forged, coated pis<strong>to</strong>ns and S&S cylinders are compatible with<br />

s<strong>to</strong>ck or S&S Super S<strong>to</strong>ck® heads<br />

❚❚ Valve pocket recesses in S&S pis<strong>to</strong>ns are enlarged for oversize<br />

valves and higher lift cams<br />

OPTIONS<br />

❚❚ Silver or wrinkle black powdercoat finish<br />

92-<strong>12</strong>00 Series Pis<strong>to</strong>n<br />

Silver powdercoat S&S cylinders with pis<strong>to</strong>ns<br />

Special Order OPTIONS<br />

❚❚ Natural<br />

❚❚ Diamond cut<br />

❚❚ Polished<br />

❚❚ Individual cylinders<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Displacement Stroke Cylinder Length<br />

S&S® 37/8" BORE CYLINDERS<br />

Compression Ratio<br />

Cylinders Only (Set)<br />

Part No.<br />

Cylinders w/Pis<strong>to</strong>ns (Set)<br />

S<strong>to</strong>ck Heads 89cc S&S Heads 79cc S&S Heads Silver Black Silver Black<br />

106" 4 1/2"<br />

106-4140 91-7061<br />

10.1:1 9.8:1 10.8:1<br />

103" 4 3/8" 4.937"<br />

106-4137 91-7045<br />

– –<br />

95" 4" 9.7:1 9.3:1 10.3:1 106-4138 91-7047<br />

Cylinder w/ pis<strong>to</strong>n kits include fitted pis<strong>to</strong>ns and cylinders, head gaskets, base, and exhaust gaskets<br />

Displacement<br />

Deck<br />

Height<br />

Forged Pis<strong>to</strong>n Kits<br />

S&S® 37/8" BORE PISTONS<br />

Rings, chromoly faced<br />

Stroke Standard +.005" +.010" +.020" Standard +.005" +.010" +.020"<br />

0.927"<br />

Wristpin<br />

106" 1.020" 4 1/2" 92-<strong>12</strong>10 92-<strong>12</strong>14 92-<strong>12</strong>11 92-<strong>12</strong><strong>12</strong> 94-<strong>12</strong>95X 94-<strong>12</strong>99X 94-<strong>12</strong>96X 94-<strong>12</strong>97X 94-9277<br />

103" 1.083" 4 3/8" 106-0432 106-0433 106-0434 – 106-1581 106-1582 106-1583 – 106-1052<br />

95" 1.270" 4" 92-<strong>12</strong>00 92-<strong>12</strong>04 92-<strong>12</strong>01 92-<strong>12</strong>02 94-<strong>12</strong>90X 94-<strong>12</strong>94X 94-<strong>12</strong>91X 94-<strong>12</strong>92X 94-9277<br />

Pis<strong>to</strong>n kits include set of pis<strong>to</strong>ns, rings, wristpins, and clips<br />

Special Order<br />

91-7506<br />

Keeper<br />

94-9278-S<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-58


Vintage<br />

Engines<br />

Continued-<br />

S&S® 37/8” Bore Replacement Cylinders and Pis<strong>to</strong>ns<br />

Parts for<br />

Twin Cam 88®<br />

91-7045<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Wrinkle black powdercoat S&S cylinders<br />

X-Wedge®<br />

106-0432 Series Pis<strong>to</strong>n<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Description<br />

Gaskets & Dowels<br />

Part No.<br />

Head Gaskets 106-2947<br />

Base O-ring 50-8048<br />

<strong>Exhaust</strong> Gaskets 106-5029<br />

Oil Return O-ring 50-8008<br />

Cylinder Dowels 50-8177<br />

SPECIAL NOTES:<br />

For 95” and 106” ‘cylinder only’ kits, pis<strong>to</strong>ns must be measured and cylinders bored/honed accordingly. Recommended pis<strong>to</strong>n fitment:<br />

Close: 0.0020” – 0.0025”<br />

Loose: 0.0032” – 0.0045”<br />

S&S 3 7/8” pis<strong>to</strong>ns for 103” kits are machined <strong>to</strong> such close <strong>to</strong>lerances that it is not necessary <strong>to</strong> measure the pis<strong>to</strong>n. Additionally, the low friction coating on the pis<strong>to</strong>n skirt makes<br />

taking measurements very difficult. Therefore, bore cylinders <strong>to</strong> nominal diameter +/- 0.0005” for correct clearance.<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-59 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

S&S ® 3.927" BORE REPLACEMENT<br />

CYLINDERS AND PISTONS<br />

Superior materials, thicker casting in critical areas and bigger cooling fins are<br />

what make S&S cylinders the best! Improved cooling and strength combined<br />

with excellent wear resistance will maintain horsepower and reliability for<br />

years <strong>to</strong> come. Replacement cylinders for S&S 97" and 106" <strong>to</strong>p end kits.<br />

FITMENT<br />

❚❚ 106" <strong>to</strong>p end kit for 2007-’09 models<br />

❚❚ 97" <strong>to</strong>p end kit for 1999-’06 models<br />

FEATURES AND BENEFITS<br />

❚❚ Pis<strong>to</strong>n weight for 97" & 106" kits are the same as s<strong>to</strong>ck, requiring<br />

no flywheel rebalancing.<br />

❚❚ S&S 3.927" bore cylinders require no crankcase machining <strong>to</strong> install<br />

❚❚ Forged, coated pis<strong>to</strong>ns and S&S cylinders are compatible with<br />

s<strong>to</strong>ck or S&S Super S<strong>to</strong>ck® 89cc heads<br />

❚❚ Valve pocket recesses in S&S pis<strong>to</strong>ns are enlarged for oversize<br />

valves and higher lift cams<br />

❚❚ Pis<strong>to</strong>ns compatible with tapered or standard rods<br />

OPTIONS<br />

❚❚ Silver or wrinkle black powdercoat finish<br />

Special Order OPTIONS<br />

❚❚ Natural<br />

❚❚ Diamond cut<br />

❚❚ Polished<br />

Displacement Stroke Cylinder Length<br />

NOTE:<br />

S&S® 3.927" BORE CYLINDERS for 97" & 107" Top end kits<br />

S<strong>to</strong>ck Heads<br />

Compression Ratio<br />

89cc S&S Heads<br />

106" 43/8"<br />

10:1 9.7:1<br />

4.937"<br />

97" 4" 9.7 9.4<br />

Since front and rear cylinders are interchangeable they are not sold in pairs.<br />

Displacement<br />

Description<br />

S&S® 3.927" BORE PISTONS 97" & 107" Top end kits<br />

Forged Pis<strong>to</strong>n Kits<br />

Part No.<br />

Cylinders Only<br />

Special Order<br />

S&S 3.927” pis<strong>to</strong>ns are machined <strong>to</strong> such close <strong>to</strong>lerances that it is not necessary <strong>to</strong> measure the pis<strong>to</strong>n. Additionally, the low friction coating on the pis<strong>to</strong>n skirt makes taking<br />

measurements very difficult. Therefore, bore cylinders <strong>to</strong> nominal diameter +/- 0.0005” for correct clearance.<br />

Silver<br />

GASKETS<br />

Black<br />

Part No.<br />

Head Gasket 106-3714<br />

Base O-ring 50-8048<br />

Gasket Kit 106-3763<br />

106-3765 106-3767 91-7506<br />

Rings, chromoly faced<br />

Deck Height Stroke Standard +.010" Standard +.010"<br />

0.927" Wristpin Keeper<br />

106" 1.083" 43/8" 106-3690 106-4416 106-3709 106-4422 106-1052 94-9278-2<br />

97" 1.270" 4" 106-3688 106-4414 106-3709 106-4422 106-1052 94-9278-2<br />

Pis<strong>to</strong>n kits include set of pis<strong>to</strong>ns, rings, wristpins, and clips<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-60


S&S ® Head BOLTS WITH WASHERS<br />

Thickness<br />

head bolt washers<br />

Part No.<br />

.100" 50-7088<br />

.150" 50-0418-S<br />

.250" 50-7091<br />

S&S® head bolt-information chart<br />

Length w/ Washer 1.690" 1.840" 1.920" 2.070" 2.220" 2.370" 3.134" 3.284" 3.501" 3.651"<br />

Washer Thickness .250" .100" .250" .100" .250" .100" .250" .100" .250" .100"<br />

Head Bolt w/Washer 93-3028 93-3027 93-3036 93-3031 93-3038 93-3032 93-3029 93-3030 93-3037* 93-3033*<br />

Washers Only 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088<br />

* Drilled & tapped deeper <strong>to</strong> allow shortening for cus<strong>to</strong>m lengths.<br />

S&S® head bolts for Harley-Davidson® twin cam 88® and Twin Cam 96 engines<br />

Engine Displacement Stroke Cylinder Length Cylinder Head Type Short Bolt w/Washer Long Bolt w/Washer Head Bolt Kit<br />

88", 95" 4" 4.935"<br />

100" 4" 4.850"<br />

106" 41⁄2" 4.935"<br />

107" 41⁄4" 4.975"<br />

111" 41⁄8" 4.763"<br />

116" 45⁄8" 5.160"<br />

117" 43⁄8" 4.888"<br />

<strong>12</strong>4" 45⁄8" 5.013"<br />

CALCULATING CUSTOM HEAD BOLT LENGTHS<br />

See instructions in the Replacement Parts section page 7-75..<br />

50-0333<br />

S<strong>to</strong>ck H-D® 93-3031 93-3030 93-3014<br />

S&S® – 93-3030 93-3070<br />

S<strong>to</strong>ck H-D® 93-3036 93-3030 93-3014<br />

S&S® – 93-3030 93-3070<br />

S<strong>to</strong>ck H-D® 93-3031 93-3030 93-3014<br />

S&S® – 93-3030 93-3070<br />

S<strong>to</strong>ck H-D® 93-3031 93-3030 93-3014<br />

S&S® – 93-3030 93-3070<br />

S<strong>to</strong>ck H-D® 93-3027 93-3030 93-3010<br />

S&S® – 93-3030 93-3070<br />

S<strong>to</strong>ck H-D® 93-3038 93-3037 93-3016<br />

S&S® – 93-3037 93-3071<br />

S<strong>to</strong>ck H-D® 93-3036 93-3030 93-3014<br />

S&S® – 93-3030 93-3070<br />

S<strong>to</strong>ck H-D® 93-3038 93-3037 93-3016<br />

S&S® – 93-3030 93-3070<br />

S&S ® Chrome Head Bolt Covers<br />

Dress up your engine with these magnetic chrome head bolt covers. Easy<br />

installation, no <strong>to</strong>ols, no messy adhesives. A powerful magnet holds cover<br />

in place, yet allows easy removal. Chrome plated steel looks great on any<br />

engine, but is a must for polished engines. For S&S head bolts only.<br />

(Set of 4) ............................................50-0333<br />

U S A<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-61 Visit us at www.sscycle.com


Warranty &<br />

Company Policy<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

X-Wedge®<br />

S&S ® CAMSHAFT OVERVIEW<br />

S&S offers a variety of cam grinds for 1999-up big twin engines in both chain<br />

drive and gear drive versions. S&S 475, 509 and 510 camshafts are bolt-in<br />

cams for 1999-’04. S&S 551, 570, 583, 585 cams are bolt-in cams for 2005-up<br />

engines. Cams that exceed the limits of the s<strong>to</strong>ck valve springs require the<br />

use of special high lift springs. Most S&S cams have higher lift than s<strong>to</strong>ck<br />

and are designed <strong>to</strong> take advantage of the extra flow of ported s<strong>to</strong>ck heads<br />

or S&S Super S<strong>to</strong>ck® heads. Due <strong>to</strong> the high lift of these cams, S&S adjustable<br />

pushrods are recommended. Not all grinds are available in the chain drive<br />

version. To get the best performance from a performance cam installation, a<br />

high flow intake and exhaust system is also recommended.<br />

EASY START CAMS<br />

The most innovative S&S product since the electric compression<br />

release system, these cams will revolutionize the starting of late<br />

model big twins. Regardless of displacement or compression<br />

ratio, a s<strong>to</strong>ck starter and battery will now easily turn over any<br />

engine. These cams also install just as easily as non compression<br />

release versions and require no extra parts or machining!<br />

Available in both chain and gear drive S&S cams.<br />

HOW Do Easy Start Cams WORK?<br />

The heart of our Easy Start cams is a centrifugally retracted, spring loaded,<br />

compression release lobe milled in<strong>to</strong> the heel of each exhaust lobe. At<br />

cranking speeds, the lobe bumps the exhaust valve open slightly during the<br />

compression stroke, making the engine much easier <strong>to</strong> turn over. Once the<br />

engine fires and reaches 800 RPM, the lobe swings out of the tappet roller<br />

path, allowing the engine <strong>to</strong> run normally and with full compression.<br />

Recommended applications for S&S Cams<br />

475: A bolt-in replacement cam designed for riders with s<strong>to</strong>ck engines<br />

that want <strong>to</strong> eliminate the fac<strong>to</strong>ry chain drive system, but are not necessarily<br />

looking for more power.<br />

509 (NEW!): Designed as a bolt-in, high <strong>to</strong>rque cam for 1999-'06<br />

models. 180 psi cranking compression, no need for compression releases.<br />

For 88 CID engines with s<strong>to</strong>ck compression ratio. Idle-4500 rpm.<br />

510: Designed as a bolt-in cam for 88, 95, and 96 CID engines with<br />

compression ratios below 9.7:1, it is primarily intended for use with s<strong>to</strong>ck,<br />

un-ported heads. 3000-5500 rpm.<br />

551: Designed for engines with 96 <strong>to</strong> 106 CID and 9:1 <strong>to</strong> 9:9 compression<br />

this is a bolt-in cam set designed for s<strong>to</strong>ck or mildly modified <strong>to</strong>uring bikes.<br />

551 cams are not recommended for compression ratios of 10:1 or greater.<br />

Greatly improves low-end and midrange <strong>to</strong>rque, strongest from idle-<br />

4000rpm.<br />

570: Designed for 88 <strong>to</strong> 96 CID engines with compression ratios between 9:1<br />

and 10:1 this cam will provide a nice power increase across the entire power<br />

band. 3200-5700 rpm.<br />

583: Optimized for use in the Softail®/Dyna® lines, this cam makes<br />

horsepower and <strong>to</strong>rque that you can feel all the way through the rpm range,<br />

making the most power right where you need it:1500–5000rpm<br />

585: Designed for 88 <strong>to</strong> 96 CID engines with compression ratios from 9:1 <strong>to</strong><br />

10:1 and 100 <strong>to</strong> 111 CID engines from 9.7:1 <strong>to</strong> 10.5:1 compression. Provides<br />

massive horsepower and <strong>to</strong>rque increases starting at 3000rpm and holds<br />

steady all the way <strong>to</strong> redline. 3500-6000 rpm for 88" - 96" engines and 2500-<br />

5500 for larger engines.<br />

625: Cam set designed for 95” or larger engines with compression ratios<br />

between 10.0 and 10.75:1. 3000-6000 rpm.<br />

640: Used in S&S T<strong>12</strong>4 engines, this cam is designed <strong>to</strong> make horsepower.<br />

Intended for engines of 95 CID or more with compression ratios between<br />

10.5:1 and 11.5:1. 3000-6000 rpm.<br />

675: A high lift monster, this cam set is designed for <strong>12</strong>0” or larger engines<br />

with at least 11:1 compression ratio. 4500-6500 rpm.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-62


Continued<br />

S&S® Camshaft Overview<br />

Parts for<br />

Twin Cam 88®<br />

Specifications For S&S Camshafts For 1999-up Big Twins<br />

The chart below shows the specifications for S&S camshafts by cam name (grind). The specifications for a particular cam name are the same for chain drive and<br />

gear drive cams. Note that not all cam grinds are available in all styles.<br />

Cam Name<br />

Specifications of S&S® Chain Drive and Gear Drive Camshafts for 1999-UP Big twin<br />

Valve Timing (open/close)<br />

Valve Duration<br />

Centerline<br />

Lift @ TDC<br />

Valve Lift<br />

Intake <strong>Exhaust</strong> Intake <strong>Exhaust</strong> Intake <strong>Exhaust</strong> Intake <strong>Exhaust</strong><br />

475 2˚/34˚ 36˚/4˚ 216˚ 220˚ .475" 106˚ 106˚ .060" .060"<br />

509 18˚/18˚ 46˚/11˚ 216˚ 237˚ .509" 90˚ 107.5˚ .174" .140"<br />

510 20˚/38˚ 52˚/20˚ 238˚ 252˚ .510" 99˚ 106˚ .187" .178"<br />

550 14°/17° 44°/11° 211° 235° .500" 91.5˚ 106.5˚ .156" .133"<br />

551** 17°/19° 41°/17° 216° 238° .550" 91˚ 102˚ .178" .170"<br />

570 20˚/40˚ 55 ˚/20˚ 240˚ 255˚ .570" 100˚ 107.5˚ .187" .179"<br />

583 5˚/18˚ 58˚/24˚ 203˚ 262˚ .583" 96.5˚ 107˚ .113" .206"<br />

585 20˚/45˚ 60˚/20˚ 245˚ 260˚ .585" 102.5˚ 110˚ .186" .179"<br />

625 20˚/55˚ 60˚/20˚ 255˚ 260˚ .625" 107.5˚ 110˚ .189" .184"<br />

640 25˚/60˚ 65˚/25˚ 265˚ 270˚ .640" 107.5˚ 110˚ .228" .214"<br />

675 25˚/64˚ 70˚/25˚ 269˚ 275˚ .675" 109.5˚ 1<strong>12</strong>.5˚ .235" .205"<br />

*Note: Although several cam grinds were used in s<strong>to</strong>ck engines from 1999-’06, the timing specs of the 475G cams is most similar <strong>to</strong> cams used in 1999-’03 EFI engines.<br />

**551 cams are not recommended with compression ratio of 10:1 or higher.<br />

Compare S&S Cams To Other Popular Cams<br />

If you have been using cams from another manufacturer and would like <strong>to</strong> know what S&S has <strong>to</strong> offer that is similar, the chart below lists a number of popular<br />

cams along with the S&S cams that work well in similar applications.<br />

Application CROSS REFERENCE CHART<br />

S&S Cam Name H-D® Screamin' Eagle® Cam Andrews® Cam Most Fitting Application<br />

551 SE-203/255 21H/26H Touring Models<br />

570 – 54H All Big Twin Models<br />

583 SE-203/255 21H/26H Softail®/Dyna® Models<br />

585 SE-211/251/257 31H/32H/50H/55H/67H All Big Twin Models<br />

625 SE-258/260 60H All Big Twin Models<br />

640 SE-264 59H All Big Twin Models<br />

675 – 64H All Big Twin Models<br />

Note:<br />

S<strong>to</strong>ck valve springs in 1999-’04 big twin models can handle cam s with valve lifts as high as .515”. S<strong>to</strong>ck valve springs in 2005-up engines can accommodate valve lifts up <strong>to</strong> .590”.<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-63 Visit us at www.sscycle.com


Tools &<br />

Shop Supplies<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

S&S ® CHAIN DRIVE CAM KITS<br />

FEATURES AND BENEFITS<br />

❚❚ Great way <strong>to</strong> increase performance at an affordable price<br />

❚❚ Quick installation – reuse many s<strong>to</strong>ck components<br />

❚❚ Easy Start Cams allow s<strong>to</strong>ck starter <strong>to</strong> start any engine<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

KIT CONTENTS<br />

❚❚ Cams<br />

❚❚ Gearcover gasket<br />

❚❚ Cam bearings<br />

❚❚ Instructions<br />

S&S CHAIN DRIVE CAM Kits FOR 2007-up MODELS<br />

Cam Name Easy Start Cam Kit Standard Cam Kit<br />

510 – 106-4380<br />

551 106-4947 106-4858<br />

570 106-5234 106-4381<br />

583 106-5807 –<br />

585 106-5233 106-4382<br />

625 106-5239 106-4383<br />

640 106-5235 106-4399<br />

Note: 2006 Dyna® uses 2007-up style cams.<br />

33-5182A<br />

S&S® 510C chain drive camshafts for 1999-’06 use the s<strong>to</strong>ck Harley-<br />

Davidson® chain drive mechanism and offers an economical option for<br />

engines with mild performance upgrades.<br />

S&S CHAIN DRIVE CAM KITS FOR 1999-'06 MODELS<br />

Cam Name Standard Cam Kit Easy Start Cam Kit<br />

509 330-0016 –<br />

510 33-5182A –<br />

551 330-0002 106-5293<br />

570 330-0003 106-5296<br />

583 330-0004 106-5289<br />

585 330-0005 106-5299<br />

625 330-0006 106-5302<br />

640 330-0007 106-5305<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Replacement<br />

Parts<br />

Easy Start Chain Drive Cams for 2007-up<br />

Warranty &<br />

Company Policy<br />

33-5175<br />

Installation kits are<br />

included with cam kits.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-64


Vintage<br />

Engines<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Continued-<br />

S&S® Chain Drive Cam Kits<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

2007–up<br />

standard chain drive cams<br />

Parts for<br />

Sportster® '86-'06<br />

X-Wedge®<br />

106-5929<br />

INSTALLATION KITs for S&S CHAIN DRIVE CAM (recommended)<br />

Models<br />

Standard Cam Kit<br />

1999-'06 (except 2006 Dyna® models) 33-5175<br />

2006 Dyna and all 2007-up 106-5929<br />

Includes a gearcover gasket, cam bearings and instructions.<br />

106-5723 Oil passage block-off kit<br />

Use this kit <strong>to</strong> block oil passages in cam plate when hydraulic cam chain<br />

tensioners are removed <strong>to</strong> install gear drive cams. Fits any cam plate designed<br />

for hydraulic tensioners. This oil passage block-off kit is included in the cam<br />

installation kit, part #106-5929 for 2007-up big twins.<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

NOTE:<br />

If 475, 509 or 510C cams are used with the s<strong>to</strong>ck chain drive system in Twin Cam 88® engines, it is recommended <strong>to</strong> use cylinder heads with s<strong>to</strong>ck valve springs or performance valve<br />

springs with no more than 160 lb. of seat force. For more demanding applications, we recommend the S&S gear drive cams.<br />

When using 1999-'06 chain drive cams for lifts over .510", S&S strongly recommends that the s<strong>to</strong>ck chain drive be upgraded <strong>to</strong> the S&S gear drive of <strong>to</strong> the H-D® #25284-08 hybrid<br />

plate. This kit updates the problematic spring loaded chain tensioners <strong>to</strong> reliable hydraulic tensioners and also upgrades the oil pump.<br />

551 cams are not recommended with compression ratio of 10:1 or higher.<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-65 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

S&S ® GEAR DRIVE CAM KITS<br />

FEATURES AND BENEFITS<br />

❚❚<br />

❚❚<br />

❚❚<br />

Improves valve timing accuracy by eliminating timing<br />

chain lash<br />

Easy Start Cams allow s<strong>to</strong>ck starter <strong>to</strong> start any engine<br />

No tensioner shoes <strong>to</strong> wear out or fail<br />

Cam Name<br />

Complete Kit<br />

S&S GEAR DRIVE CAMS FOR 1999-'06 MODELS<br />

Easy Start<br />

OPTIONS<br />

Which S&S Gear Drive Cam Kit <strong>to</strong> Order?<br />

If updating from the s<strong>to</strong>ck chain drive system, it is easiest <strong>to</strong> order<br />

a complete kit which includes:<br />

• Camshafts with inner gears<br />

• Outer cam drive gear kit<br />

• Camshaft installation kit<br />

Standard<br />

Cams w/ Inner Gears Complete Kit Cams w/ Inner Gears<br />

S<strong>to</strong>ck Oil Pump S&S Oil Pump S<strong>to</strong>ck Oil Pump S&S Oil Pump<br />

475 – – – 106-4033 106-4385 –<br />

509 – – – 330-0017 330-0018 –<br />

510 – – – 33-5177 33-5174 33-5220<br />

546 – – – 33-5230 – 33-5226<br />

551 106-5442 106-5441 – – – –<br />

570 106-5243 106-5242 106-4751 33-5178 33-5166 33-5221<br />

583 106-5859 106-5858 – – – –<br />

585 106-5247 106-5246 106-4771 33-5179 33-5168 33-5222<br />

625 106-5251 106-5250 106-52<strong>12</strong> 33-5180 33-5170 33-5223<br />

640 106-4840 106-4839 106-4781 33-5181 33-5172 33-5224<br />

675 106-5255 106-5254 106-5215 33-5231 33-5237 33-5225<br />

Cam Name<br />

S&S GEAR DRIVE CAMS FOR 2007-up MODELS<br />

Easy Start<br />

❚❚<br />

❚❚<br />

❚❚<br />

If replacing cams in an engine already equipped with S&S gear<br />

drive cams, order cams with inner gears and reuse the existing<br />

outer gears. Camshaft installation kit for the appropriate model<br />

year is recommended.<br />

If installing a gear drive cam set without inner gears from another<br />

cam manufacturer, cam gear drive kit for the appropriate model<br />

year provides the inner cam gears as well as an outer cam drive<br />

gear kit. Camshaft installation kit for the appropriate model year<br />

is recommended.<br />

Standard<br />

Complete Kit Cams w/ Inner Gears Complete Kit Cams w/ Inner Gears<br />

510 – – 33-5266 33-5246<br />

551 106-5737 106-5736 106-4868 106-4870<br />

570 106-5221 106-5220 33-5267 33-5247<br />

583 106-5811 106-5810 – –<br />

585 106-5225 106-5224 33-5268 33-5248<br />

625 106-5229 106-5228 33-5269 33-5249<br />

640 106-4850 106-4849 33-5270 33-5250<br />

675 106-5741 106-5740 – –<br />

Note: 2006 Dyna® uses 2007-up style cams.<br />

Gear Drive Easy<br />

Start Cams<br />

for early models<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-66


Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Continued-<br />

S&S® Gear Drive Cam Kits<br />

Parts for<br />

Twin Cam 88®<br />

106-4781<br />

Easy Start Cams for S&S Oil Pump<br />

Vintage<br />

Engines<br />

106-5723 Oil passage block-off kit<br />

Use this kit <strong>to</strong> block oil passages in cam<br />

plate when hydraulic cam chain tensioners<br />

are removed <strong>to</strong> install gear drive cams.<br />

Fits any cam plate designed for hydraulic<br />

tensioners. This oil passage block-off kit is<br />

included in the cam installation kit, part<br />

#106-6086.<br />

SPECIAL NOTES:<br />

Pinion shaft run-out must be checked before installing S&S® gear drive cams.<br />

A hydraulic press and other professional <strong>to</strong>ols are required <strong>to</strong> install S&S gear<br />

drive cams. Additionally, material must be removed from the inner surface of<br />

the s<strong>to</strong>ck gearcover. The s<strong>to</strong>ck crankcase will require clearancing for S&S .625”,<br />

.640”, and .675” lift cams. S&S recommends that gear drive cams be installed by<br />

a professional mechanic.<br />

New cam bearings and a new gearcover gasket are required <strong>to</strong> complete cam<br />

installation. Gear drive cams for 1999-' 06 models require the use of ball bearing<br />

style cam bearing rather than the s<strong>to</strong>ck roller bearing. Roller bearings have more<br />

internal clearance which can cause excessive gear lash and increased noise. The<br />

correct parts are provided in S&S Camshaft Installation Kit, part #106-5896.<br />

Due <strong>to</strong> the inherent characteristics of gear drives, you may experience more valve<br />

train noise with gear driven cams. Oversized and undersized gears are available<br />

<strong>to</strong> help achieve correct gear lash. We have found that with 160 lb. of valve seat<br />

force, the S&S gear drive cams will perform well up <strong>to</strong> 6200 rpm. If higher rpm is<br />

anticipated, valve springs that provide higher seat force should be used.<br />

106-5896<br />

Camshaft installation kit for 1999-'06 models provides parts needed <strong>to</strong><br />

install S&S® gear drive cam sets. Included with complete cam kits.<br />

106-6068<br />

INSTALLATION KITS for S&S Gear DRIVE CAM (recommended)<br />

Models<br />

Standard Cam Kit<br />

1999-'06 (except 2006 Dyna® models) 106-5896<br />

2006 Dyna and all 2007-up 106-6068<br />

Includes a gearcover gasket, cam bearings and instructions.<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-67 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

S&S ® Cam Related Repair Parts<br />

Cam gear drive kits:<br />

(Includes front and rear inner cam gears, pinion gear, and outer cam gear)<br />

Fits 1999-‘06 models .......................................33-4275<br />

Fits 2006 Dyna® and all 2007-up models ......................33-4285<br />

Outer cam drive gear kit:<br />

Fits 1999-‘06 models .......................................33-4276<br />

Fits 2006 Dyna and all 2007-up models .......................33-4268<br />

Replacement hardware pack for outer<br />

cam drive gear:<br />

Fits 1999-up models ......................................33-4271P<br />

Replacement key ..........................................106-1348<br />

33-4276<br />

Outer cam drive gear kit<br />

for Twin Cam 88® engine<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Replacement gears, oversized & undersized<br />

Due <strong>to</strong> machining variations in the s<strong>to</strong>ck cam plate, oversized or<br />

undersized gears may be needed <strong>to</strong> achieve correct gear lash.<br />

Cam drive gear set:<br />

1999-up ..................................................33-4293<br />

Outer cam drive gear only:<br />

1999-‘06 (except 2006 Dyna) .................................33-4271<br />

2006 Dyna and all 2007-up models ...........................33-4269<br />

Front inner cam gear:<br />

1999-‘06 (except 2006 Dyna) ...............................33-4272F<br />

2006 Dyna and all 2007-up models ...........................33-4273<br />

Rear inner cam gear, standard:<br />

1999-‘06 (except 2006 Dyna) ...............................33-4272R<br />

2006 Dyna and all 2007-up models ...........................33-4274<br />

Rear inner cam gear, undersized:<br />

1999-‘06 (except 2006 Dyna) ..............................33-4272RX<br />

2006 Dyna and all 2007-up models ...........................33-4277<br />

Rear inner cam gear, oversized:<br />

1999-‘06 (except 2006 Dyna) ...............................33-4272RZ<br />

2006 Dyna and all 2007-up models ...........................33-4278<br />

Pinion Gears 1999-up:<br />

Standard size ..............................................33-4160<br />

Undersized ...............................................33-4160X<br />

Double under ............................................33-4160XX<br />

Oversized ................................................33-4160Z<br />

Double over .............................................33-4160ZZ<br />

S&S heavy duty cam bearing plate<br />

Fits 1999-‘06 models .......................................33-52<strong>12</strong><br />

Cam Needle Bearings Assemblies<br />

Inner cam bearing Harley-Davidson® Twin Cam 88® and 1999-'06<br />

(except 2006 Dyna®) .........................................31-4080<br />

Inner cam bearing for Harley-Davidson® Twin Cam 96, 2006 Dyna<br />

and all 2007-up models ......................................... 31-4199-S<br />

31-4080<br />

NOTE:<br />

All reference <strong>to</strong> H-D® part numbers is for identification purposes only. We in no way<br />

are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they<br />

are equivalent <strong>to</strong> the corresponding H-D® part number shown. Use of brand names<br />

such as Harley-Davidson® Sportster® are also for reference only.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-68


S&S ® High Performance Hydraulic Tappets<br />

Standard equipment in S&S T-Series engines and every Hot Set Up Kit® for<br />

Harley-Davidson® Twin Cam 88® and 96, these tappets are a great choice<br />

for any s<strong>to</strong>ck or high performance application. Only the finest materials and<br />

precision machining techniques are used in the manufacture of these lifters,<br />

and strict quality control insures that they will work flawlessly every time, no<br />

matter what the application. Whether you have a s<strong>to</strong>ck 88 incher or the most<br />

outrageous big inch engine with a radical cam and spring combination, S&S<br />

tappets are built <strong>to</strong> take it.<br />

FITMENT<br />

❚❚<br />

❚❚<br />

1999–up big twins<br />

S&S T-Series engines<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

OPTIONS<br />

Tappets are available with the HL 2<br />

T Limited Travel Kit for improved cold<br />

starts and high rpm valve timing accuracy.<br />

KIT CONTENTS<br />

❚❚<br />

Four hydraulic tappets<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

PART NUMBER<br />

Without HL 2<br />

T Kit ....................................33-5350<br />

With HL 2<br />

T Kit .......................................33-5351<br />

S&S ® Hydraulic Lifter Limited Travel Spacer (HL 2<br />

T)<br />

Designed <strong>to</strong> limit the range of travel of the hydraulic tappet plunger in Twin<br />

Cam 88® engines, HL 2<br />

T spacers do not allow the tappets <strong>to</strong> collapse, meaning<br />

both high rpm performance and starting are improved. A great addition <strong>to</strong> s<strong>to</strong>ck<br />

applications, the S&S HL 2<br />

T kit is highly recommended for engines equipped<br />

with stronger valve springs and aggressive cam profiles. Now you can have<br />

solid lifter performance and retain the benefits of low noise, low maintenance<br />

hydraulic tappets.<br />

NOTE:<br />

S&S tappets with HL 2<br />

T Kit require the use of adjustable pushrods.<br />

33-5338<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

FITMENT<br />

❚❚ S<strong>to</strong>ck 2003 – ’06 big twin<br />

❚❚ Harley-Davidson® replacement tappets 1999-up bt<br />

❚❚ All S&S tappets<br />

FEATURES AND BENEFITS<br />

❚❚ Low noise and positive valve train activation<br />

❚❚ More horsepower at higher RPM’s<br />

❚❚ Easier starting<br />

KIT CONTENTS<br />

❚❚ Set of four spacers<br />

PART NUMBER<br />

(fits tappets with .6<strong>12</strong>" I.D.) ..........................33-5338<br />

Note:<br />

Will not fit fac<strong>to</strong>ry tappets in 1999-'02 engines.<br />

EXTRA PARTS NEEDED:<br />

Adjustable pushrods must be used with HL 2<br />

T kit in order <strong>to</strong> obtain proper<br />

plunger position.<br />

If replacing lifters in a 1999-'02 with H-D #18538-99B, order S&S part #33-5338.<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-69 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

S&S ® Tappet Covers<br />

The perfect finishing <strong>to</strong>uch for any s<strong>to</strong>ck or cus<strong>to</strong>m engines, these S&S<br />

tappet covers are CNC machined from billet aluminum and polished <strong>to</strong> a<br />

show finish. The CNC machining assures dimensional accuracy, while the<br />

billet material provides extra strength and dimensional stability over a wide<br />

temperature range.<br />

FITMENT<br />

❚❚ Twin Cam 88® and Twin Cam 88B<br />

❚❚ Twin Cam 96® and Twin Cam 96B<br />

❚❚ S&S crankcases<br />

FEATURES AND BENEFITS<br />

❚❚ Unlike cast aluminum, billet has no internal voids or impurities<br />

❚❚ No residual strain from thermal contraction or expansion means<br />

no cracking or changes in shape<br />

❚❚ Simple <strong>to</strong> install upgrade that looks great<br />

KIT CONTENTS<br />

❚❚ Covers<br />

❚❚ Gaskets<br />

❚❚ Installation hardware<br />

33-5601<br />

PART NUMBERs<br />

Polished ...........................................33-5601<br />

Chrome ......................................... 106-3883<br />

S&S ® PUSHROD COVERS AND RELATED PARTS<br />

S&S pushrod cover kits include all of the parts required for four pushrods<br />

except keepers. Keepers are sold separately because of the different<br />

length requirements of some engines. These covers are a must when using<br />

adjustable pushrods.<br />

FITMENT<br />

❚❚ 1999–up big twins<br />

Pushrod cover parts<br />

Top cover (H-D#17935-79B) ............................93-4016<br />

Bot<strong>to</strong>m cover (H-D#17938-83) .........................93-4015<br />

Cover cap (H-D#17945-36B) ............................93-4017<br />

Cover spring (H-D#17947-36) ..........................93-4018<br />

Cover cap washer (H-D#6762B)<br />

Bot<strong>to</strong>m cover washer (H-D#6737)<br />

Top o-ring (H-D#11157 & 11190)<br />

Middle o-ring (H-D#11132)<br />

Bot<strong>to</strong>m o-ring (H-D#11145)<br />

Quad Seal<br />

Pushrod o-ring kits (includes <strong>to</strong>p, middle, and bot<strong>to</strong>m o-rings<br />

for four pushrods) ...................................93-4022<br />

106-1340<br />

PART NUMBER<br />

Pushrod cover kits (includes <strong>to</strong>p and bot<strong>to</strong>m covers, cover cap, cover spring,<br />

and spring washer for four pushrods) ................ 106-1340<br />

NOTE:<br />

All reference <strong>to</strong> H-D® part numbers is for identification purposes only. We in no way<br />

are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that<br />

they are equivalent <strong>to</strong> the corresponding H-D® part number shown.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-70


Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

S&S ® Adjustable Pushrod and COVER KITS<br />

Everything you need <strong>to</strong> convert a Twin Cam 88® or Twin Cam 96 <strong>to</strong><br />

adjustable pushrods. Standard pushrod kit is for s<strong>to</strong>ck engines. Quickee kit<br />

will accommodate all displacements. Will need longer keepers for taller<br />

than s<strong>to</strong>ck engines.<br />

KIT CONTENTS<br />

❚❚ S&S pushrod kit (standard or Quickee)<br />

❚❚ Chrome pushrod covers<br />

❚❚ Gaskets<br />

❚❚ Tappet cover gaskets<br />

❚❚ O-rings<br />

❚❚ Cover keepers<br />

PART NUMBERS<br />

S&S standard adjustable pushrod kit ...................93-5095<br />

S&S Quickee pushrod kit ........................... 106-6051<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Replacement parts on page 7-99.<br />

106-6051<br />

Quickee Pushrod Kit<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

93-5095<br />

Standard Pushrod Kit<br />

Warranty &<br />

Company Policy<br />

1-71 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

S&S ® QUICKEE PUSHRODS<br />

These pushrods can be both installed and removed easily. The S&S design<br />

permits a simple, trouble-free installation that does not require removal of<br />

the gas tank, rocker assemblies, or even the rocker box cover! OEM pushrods<br />

may be cut <strong>to</strong> permit removal without rocker disassembly. The threaded<br />

adjuster screws in<strong>to</strong> the pushrod until the threads disengage and the<br />

adjuster simply slides in<strong>to</strong> the pushrod, making installation or removal a<br />

snap. Once the pushrod is installed and adjusted, the locknut prevents the<br />

adjuster from moving. 1984-'99 style pushrods covers required.<br />

FITMENT<br />

❚❚ 1999-up big twin w/displacement: 88"- <strong>12</strong>4"<br />

FEATURES AND BENEFITS<br />

❚❚ Easy <strong>to</strong> install – removal of rocker box not needed<br />

❚❚ Adjustable <strong>to</strong> accommodate all tappets and cam base circle<br />

diameters and engine heights<br />

❚❚<br />

Perfect for S&S HL 2<br />

❚❚ No threads on wrench flats<br />

PART NUMBERS<br />

1999-up big twin ...................................93-5<strong>12</strong>2<br />

Special Order .......................................93-5135<br />

EXTRA PARTS NEEDED:<br />

1984-'99 style pushrod covers are required for access <strong>to</strong> the Quickee Pushrod adjusters<br />

in 1999-up big twins. See page 1-71 of this catalog for pushrod & cover kits.<br />

S&S ® Standard ADJUSTABLE PUSHROD SETS<br />

To assure consistent valve train operation under all conditions, S&S<br />

adjustable pushrods are manufactured from rigid chromoly steel tubing. The<br />

S&S design permits a simple, trouble-free installation that does not require<br />

removal of the gas tank, rocker assemblies, or even the rocker box cover!<br />

OEM pushrods may be cut <strong>to</strong> permit removal without rocker disassembly.<br />

1984-'99 style pushrod covers required.<br />

FITMENT<br />

❚❚ 1999–up big twins<br />

❚❚ Lengths available for various displacements<br />

93-5<strong>12</strong>2<br />

Replacement parts on page 7-99.<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

FEATURES AND BENEFITS<br />

❚❚ Adjustable <strong>to</strong> accommodate all tappets & cam base circle diameters<br />

❚❚<br />

Perfect for HL 2<br />

EXTRA PARTS NEEDED:<br />

1984-'99 style pushrod covers are required for access <strong>to</strong> the Quickee Pushrod adjusters<br />

in 1999-up big twins. See page 1-71 of this catalog for pushrod & cover kits.<br />

Replacement parts on page 7-99.<br />

S&S® Standard adjustable Pushrod Sets for<br />

Harley-Davidson® Twin Cam 88® and Twin Cam 96<br />

Displacement<br />

Engine<br />

Height<br />

Cylinder<br />

length<br />

Pushrod<br />

Set<br />

Pushrod<br />

Clip<br />

Pushrod<br />

Covers<br />

88", 95", 96", 103", 106" S<strong>to</strong>ck 4.937" 93-5096 93-4100 106-1340<br />

100" -.070" 4.850" 93-5099 93-4100 106-1340<br />

107" +.055" 4.975" 93-5100 93-4101 106-1340<br />

116" +.243" 5.160" 93-5098 93-4115 106-1340<br />

<strong>12</strong>4" +.080" 5.013" 93-5098 93-4115 106-1340<br />

Special Order Specify Specify 93-5102 93-4109* –<br />

* Extra long stainless steel, cut <strong>to</strong> required length.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-72


Dealer Services<br />

& Promo Items<br />

S&S ® SIDEWINDER ® .585" Lift VALVE SPRINGS<br />

Lighter and simpler than our previous valve springs, S&S Sidewinder springs<br />

are made from special ovate spring wire and have only one progressively<br />

wound coil. Since they do not add as much mass <strong>to</strong> the valve train as multicoil<br />

spring packs, they offer high rpm capability with less spring pressure for<br />

cams up <strong>to</strong> .585" lift.<br />

FITMENT<br />

❚❚<br />

❚❚<br />

1999–up big twins with s<strong>to</strong>ck heads<br />

All S&S Super S<strong>to</strong>ck® heads<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

FEATURES AND BENEFITS<br />

❚❚ Lower spring force results in reduced valve train noise, increased<br />

valve stability, and longer valve train component life<br />

❚❚ Excellent upgrade for s<strong>to</strong>ck rebuilds and mild performance cams<br />

KIT CONTENTS<br />

❚❚ Valve keepers<br />

❚❚ Springs<br />

❚❚ Top collars<br />

❚❚ Bot<strong>to</strong>m collars<br />

❚❚ Shims<br />

PART NUMBER<br />

S&S Sidewinder .585" Lift Valve Springs for 1999-'04 ...........90-2069<br />

S&S Sidewinder .585" Lift Valve Springs for 2005-up ..........900-0049<br />

Lift<br />

S&S® Sidewinder® Valve Springs Specifications<br />

Installed<br />

Height<br />

Seat Force<br />

Force @ Max<br />

Lift<br />

Max RPM<br />

.585" 1.800" <strong>12</strong>5 lb. 332 lb. 6500<br />

Not recommended for cams with over 0.585” lift<br />

90-2069<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Replacement parts on page 7-100.<br />

Warranty &<br />

Company Policy<br />

1-73 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

S&S ® HIGH PERFORMANCE .640" LIFT<br />

TRIPLE VALVE SPRING KITS<br />

Not only designed <strong>to</strong> increase spring force and reduce the risk of valve float,<br />

S&S valve springs also eliminate most of the complicated procedures and<br />

specialized <strong>to</strong>ols required <strong>to</strong> prepare cylinder heads for high lift cams up <strong>to</strong><br />

.640" lift.<br />

FITMENT<br />

❚❚ 1999–’04 Twin Cam 88®/88B with s<strong>to</strong>ck heads<br />

❚❚ All S&S Super S<strong>to</strong>ck® heads<br />

FEATURES AND BENEFITS<br />

❚❚ Patented steel <strong>to</strong>p collars are drilled for lightness and <strong>to</strong> increase<br />

cooling oil flow over valve springs<br />

❚❚ For very high performance applications, kits with low mass<br />

titanium <strong>to</strong>p collars are also available<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

KIT CONTENTS<br />

❚❚ Valve keepers<br />

❚❚ Top collars<br />

❚❚ Bot<strong>to</strong>m collars<br />

❚❚ Outer springs<br />

❚❚ Middle springs<br />

❚❚ Inner springs<br />

PART NUMBERS<br />

Kit w/ steel <strong>to</strong>p collars .............................. 90-2077<br />

Kit w/ titanium <strong>to</strong>p collars ............................90-2078<br />

S&S® Sidewinder® Valve Springs Specifications<br />

Lift Installed Height Seat Force Force @ Max Lift<br />

.640" 1.800" 170 lb. 390 lb.<br />

Not recommended for cams with over 0.640” lift<br />

90-2078<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Application Notes:<br />

Use with shoulderless-style valve guides.<br />

Special keepers included fit valves with s<strong>to</strong>ck 5⁄16" stems and S&S collars only.<br />

Spring seat force is typically 170 lbs. at s<strong>to</strong>ck 1.800" installed height.<br />

Open force is 390 lbs. at .560" lift, 415 lbs. at .630" lift.<br />

May also be used in any other heads that require s<strong>to</strong>ck O.D. outer spring.<br />

S&S springs will not fit 2005 - later s<strong>to</strong>ck heads because of the change in valve<br />

spring and valve diameter.<br />

Replacement parts on page 7-100.<br />

Warranty &<br />

Company Policy<br />

Installation NOTE:<br />

High lift cams may require the engine builder <strong>to</strong> obtain additional clearance between the pis<strong>to</strong>n and valves, the intake and exhaust valves and the upper spring collar and rocker cover.<br />

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<br />

clearances and check for spring coil bind, even when using parts specifically designed for high performance. Most valve train failures can be traced <strong>to</strong> over-revving or failure <strong>to</strong> confirm correct<br />

clearances during assembly.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-74


Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

S&S .650" Lift Beehive Valve Spring Kit<br />

FITMENT<br />

❚❚ 1999-up big twins with s<strong>to</strong>ck heads<br />

FEATURES AND BENEFITS<br />

❚❚ Manufactured from ultra clean high silicon Kobe alloy wire<br />

then micro shot peened and nitrided<br />

❚❚ CNC machined 9˚ locks<br />

❚❚ High performance conical single wire spring<br />

❚❚ Chromoly forged retainers<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

KIT CONTENTS<br />

❚❚ Valve keepers<br />

❚❚ Top collars<br />

❚❚ Bot<strong>to</strong>m collars<br />

❚❚ Springs<br />

❚❚ Shims<br />

PART NUMBERS<br />

S&S Beehive Valve Spring Kit for 1999-'04 ........... 900-0050<br />

S&S Beehive Valve Spring Kit for 2005-up ........... 106-5909<br />

Lift<br />

S&S® BEEHIVE Valve Springs Specifications<br />

Installed<br />

Height<br />

Seat Force<br />

Force @ Max<br />

Lift<br />

Max RPM<br />

.650" 1.860" 178 lb. 376 lb. 6500<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

NOTE:<br />

S&S recommends roller rocker arms be used when lifting over .585"<br />

Replacement parts on page 7-100.<br />

Warranty &<br />

Company Policy<br />

1-75 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

S&S ® FORGED ROLLER ROCKER ARMS<br />

Forged from 8620 steel, heat-treated, and then shot-peened for additional<br />

strength and protection from fatigue, our roller rocker arms were designed<br />

<strong>to</strong> eliminate failure-prone stress areas found in some other rockers. Most<br />

rockers come equipped with 1⁄2" long bushings or needle bearings, however<br />

ours utilize 3⁄4" long bronze bushings. The end result is what we believe <strong>to</strong> be<br />

the finest rocker arm available anywhere, for any price.<br />

FITMENT<br />

❚❚ 1999-up big twins<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

FEATURES AND BENEFITS<br />

❚❚ Extremely durable rollers reduce side thrusting with<br />

high lift cams<br />

❚❚ Superior wear and fatigue resistance even in the most<br />

demanding applications<br />

❚❚ 3⁄4" long bushings provide 50% more bushing support area<br />

than 1⁄2" long bushings – eliminating the risk of engine damage<br />

associated with failed needle bearings<br />

900-4065A<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

90-4036<br />

S&S rocker arm shaft set<br />

KIT CONTENTS<br />

❚❚ 2 front and 2 rear rocker arms<br />

PART NUMBERS<br />

Set of 4 rocker arms ..............................900-4065A<br />

Replacement parts:<br />

Front exhaust or rear intake ......................900-4065FA<br />

Rear exhaust or front intake ......................900-4065RA<br />

Rebuild kits (rebuilds 4 rocker arms) ...................90-4104<br />

Rocker arm bushing (3/4" long) ........................90-4014<br />

Rocker arm shafts:<br />

Set (includes 4) .....................................90-4036<br />

Individual (H-D#17611-83) ...........................90-4006<br />

NOTE:<br />

Adjustable pushrods must be used with S&S roller rocker arms <strong>to</strong> obtain proper valve clearance.<br />

New rocker arm shafts are recommended for maximum performance and rocker life.<br />

All reference <strong>to</strong> H-D® part numbers is for identification purposes only. We in no way are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are equivalent<br />

<strong>to</strong> the corresponding H-D® part number shown.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-76


Racing<br />

Products<br />

S&S ® STANDARD FORGED ROCKER ARMS<br />

S&S now offers an economical solution for s<strong>to</strong>ck rebuilds, and mild<br />

performance upgrades. S&S standard rocker arms are forged from 8620 steel<br />

for greater strength than s<strong>to</strong>ck forged or cast steel rocker arms. In addition,<br />

they feature the same 3/4" long rocker shaft bushings that our S&S roller<br />

rocker arms do. Thousands of hours of engine testing have proved them <strong>to</strong><br />

be superior <strong>to</strong> other non-roller rocker arms.<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

FITMENT<br />

❚❚<br />

1999-up big twins<br />

Parts for<br />

Sportster® '86-'06<br />

FEATURES AND BENEFITS<br />

❚❚<br />

3/4" long bronze bushings provide 50% more load bearing area<br />

than the 1/2" long bushings used in s<strong>to</strong>ck and other aftermarket<br />

rocker arms<br />

TÜV<br />

4,5<br />

900-4119A<br />

Vintage<br />

Engines<br />

KIT CONTENTS<br />

❚❚<br />

2 front and 2 rear rocker arms<br />

X-Wedge®<br />

PART NUMBERS<br />

Standard forged rocker arms .......................900-4119A<br />

Replacement parts:<br />

Front exhaust or rear intake ......................900-4119FA<br />

Rear exhaust or front intake ......................900-4119RA<br />

Rocker arm bushing 3/4" long ..........................90-4014<br />

Rocker arm shafts:<br />

Set (includes 4) .....................................90-4036<br />

Individual (H-D#17611-83) ............................90-4006<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

NOTE:<br />

S&S roller rocker arms are recommended for use with cams of more than 0.585" of lift.<br />

New rocker arm shafts are recommended for maximum performance and rocker life.<br />

All reference <strong>to</strong> H-D® part numbers is for identification purposes only. We in no way are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are equivalent<br />

<strong>to</strong> the corresponding H-D® part number shown.<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-77 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

S&S ® Die Cast ROCKER COVERS<br />

Produced using the die-casting manufacturing process and then machined<br />

with computer controlled equipment. S&S die cast rocker covers for 1999-<br />

up Harley-Davidson® Twin Cam 88® and 96 engines include Vi<strong>to</strong>n® o-ring<br />

style cover seals for leak-free operation. Our proven two-piece design makes<br />

installation simple.<br />

FITMENT<br />

❚❚ 1999–up big twins<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

FEATURES AND BENEFITS<br />

❚❚ Special rocker arm supports are included<br />

❚❚ S&S rocker covers are finished with show-quality chrome<br />

❚❚ Installation on s<strong>to</strong>ck and most comparable sized engines can be<br />

performed without removing the engine from the frame<br />

❚❚ Clearanced <strong>to</strong> permit valve lifts up <strong>to</strong> .640" using S&S valve spring<br />

packages and s<strong>to</strong>ck rocker arms or S&S roller rocker arms<br />

❚❚ S&S rocker covers accept valve springs up <strong>to</strong> 1.660" O.D. without<br />

modification<br />

❚❚ Exclusive one way valve built in<strong>to</strong> the rocker cover gasket <strong>to</strong><br />

control oil carry over<br />

KIT CONTENTS<br />

❚❚ Front and rear covers<br />

❚❚ All necessary gaskets and o-rings<br />

❚❚ Mounting hardware<br />

PART NUMBER<br />

S&S rocker cover ....................................90-4110<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Notes:<br />

If using valve spring packages with taller than s<strong>to</strong>ck installed height, some minor<br />

clearancing may be required.<br />

Cylinder heads must be set up correctly for high lift cams, and it remains the<br />

builder’s responsibility <strong>to</strong> confirm all clearances.<br />

In most instances, only minor clearancing is required <strong>to</strong> use S&S rocker covers with<br />

valve springs larger than 1.660” O.D.<br />

EXTRA PARTS NEEDED:<br />

S&S® rocker covers are required if S&S cylinder heads are used with S&S electric<br />

compression releases.<br />

90-4110<br />

Any Job is easy with the right <strong>to</strong>ols<br />

S&S Rocker Cover Wrench Set, see page 8-7.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-78


Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

Exclusive S&S ® Inner Primary Bearing Race<br />

Saving You a Lot of Money and Trouble!<br />

Parts for<br />

Twin Cam 88®<br />

High performance applications often reveal problems with s<strong>to</strong>ck power train<br />

components that were never anticipated by the designers. One such problem<br />

is the tendency of the s<strong>to</strong>ck inner primary bearing race on late model big<br />

twins <strong>to</strong> shift on the transmission mainshaft under high <strong>to</strong>rque loads. This<br />

“walking” of the race can result in the destruction of the transmission<br />

mainshaft seal, and ultimately the mainshaft seal, output gear and output<br />

gear bearing. The result: costly repairs and annoying down time.<br />

A unique modification <strong>to</strong> the design of the mainshaft inner primary bearing<br />

race, positively prevents it from "walking" in<strong>to</strong> the mainshaft seal and output<br />

gear. The S&S bearing race features an extra step on the inside diameter that<br />

acts as a s<strong>to</strong>p on the transmission mainshaft. When the race is pressed on<br />

<strong>to</strong> the shaft, the step will not allow the race <strong>to</strong> move inward <strong>to</strong>ward the<br />

mainshaft seal. The improved S&S bearing race is a must for any high<br />

performance application. It is included as a part of all S&S high performance<br />

clutch kits, and can be retrofitted <strong>to</strong> s<strong>to</strong>ck and aftermarket transmissions for<br />

all 1991-'06 big twins (except '06 Dyna®).<br />

Fitment<br />

❚ ❚ All 1991-'06 big twins (except '06 Dyna®)<br />

Features and benefits<br />

❚❚ Will not "walk" on transmission mainshaft<br />

❚❚ Prevents costly damage <strong>to</strong> mainshaft seal, output gear & output<br />

gear bearing<br />

❚❚ Simple <strong>to</strong> install<br />

Part number<br />

All 1991-'06 big twins (except '06 Dyna®)<br />

S&S Inner Primary Bearing Race .............................56-5089<br />

56-5089<br />

The S&S inner primary bearing race positively eliminates bearing race<br />

movement that can cause costly damage <strong>to</strong> the mainshaft seal, output gear<br />

and output bearing. A must for high performance applications.<br />

U S A<br />

Any Job is easy with the right <strong>to</strong>ols<br />

S&S Inner Primary Bearing Race Installer, see page 8-6.<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

1-79 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

S&S ® Chrome plated Billet Transmission Side<br />

Covers For Mechanical and Hydraulic Clutches<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

S&S offers two chrome plated billet transmission side covers that fit our six speed<br />

transmissions, as well as s<strong>to</strong>ck and aftermarket left side drive transmissions for<br />

1987-‘06 big twins (except 2006 Harley-Davidson® Dyna® and all FXR models).<br />

The first version is cable actuated and is compatible with all s<strong>to</strong>ck and aftermarket<br />

cables. The second, is a hydraulic version designed <strong>to</strong> convert a cable actuated<br />

clutch <strong>to</strong> hydraulic actuation without changing the clutch pressure plate,<br />

throw-out bearing or pushrod. The hydraulic side cover has a pis<strong>to</strong>n diameter<br />

of 1.550", and is compatible with s<strong>to</strong>ck and aftermarket master cylinders with<br />

11⁄16" diameter pis<strong>to</strong>ns.<br />

Billet Transmission Side Covers<br />

Cable Actuated, Chrome ...................................106-4035<br />

Hydraulic, Chrome ........................................106-3885<br />

S&S chrome billet side covers fit 1987-'06 big twins except 2006 Dyna® and<br />

all FXR models. Available for cable and hydraulically actuated clutches.<br />

Note:<br />

If replacing a Harley-Davidson® Screamin’ Eagle® hydraulic side cover, a three piece<br />

pushrod with the thrust bearing on the right hand side must be used. (Oil slinger removal<br />

required on s<strong>to</strong>ck H-D® right-side pushrods.)<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

S&S Transmission Top Covers<br />

The S&S transmission <strong>to</strong>p covers are made of chrome plated die-cast or<br />

polished billet aluminum, so naturally, they look great. The two versions are<br />

for different applications.<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

S&S Chrome Die Cast Transmission Top Cover<br />

For 1991-’99 Softail ® and 1991-'00 FLT Models<br />

This cover may be used as s<strong>to</strong>ck replacement for 1991-’99 Harley-Davidson®<br />

Softail® and 1991-'00 FLT Models ............................ 56-5115<br />

S&S Chrome Billet Transmission Top Cover<br />

For 1999-‘05 Dyna ® Models<br />

This cover is required for proper oil line connection in 1999-’05 Dyna models<br />

when installing an S&S T<strong>12</strong>4 engine or when installing S&S replacement<br />

crankcases. This <strong>to</strong>p cover may also be used as s<strong>to</strong>ck replacement for 1999-'05<br />

Dyna models..............................................106-3886<br />

56-5115<br />

This chrome plated die-cast <strong>to</strong>p cover can be used <strong>to</strong> replace <strong>to</strong>p covers on<br />

1991-’99 Harley-Davidson® Softail® and 1991-'00 FLT models.<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

NOTE:<br />

All reference <strong>to</strong> H-D® part numbers is for identification purposes only. We in no way are<br />

implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are<br />

equivalent <strong>to</strong> the corresponding H-D® part number shown.<br />

This chrome billet transmission <strong>to</strong>p cover is required in order <strong>to</strong> install an S&S<br />

T<strong>12</strong>4 engine or S&S replacement crankcases in 1999-’05 Harley-Davidson®<br />

Dyna® models. This cover is included in oil line kit, part #31-0424.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-80


S&S ® /Gates ® High Strength Final Drive Belts<br />

How many final drive belts have S&S engines broken? Yes, a lot of power<br />

can break things, so what’s the solution? The solution that we are offering<br />

is stronger belts! S&S has teamed up with the Gates® Corporation, a leading<br />

manufacturer of power transmission belts, <strong>to</strong> offer a series of secondary<br />

drive belts for many popular v-twin models. These belts feature Gates’<br />

super strong X3N carbon cord material which is significantly stronger than<br />

the Aramid material used in many OEM final drive belts.<br />

S&S final drive belts by Gates are available with 14mm pitch in 11/2" and<br />

11/8" widths. See the chart below and match the width and number of teeth<br />

required for your vehicle. You can find this information in the vehicle service<br />

manual.<br />

106-0361<br />

Secondary Drive Belts (14m m pitch)<br />

Teeth 11/8" Wide 11/2" Wide<br />

<strong>12</strong>5 106-0357 –<br />

<strong>12</strong>6 – 106-0348<br />

<strong>12</strong>7 – 106-0349<br />

<strong>12</strong>8 106-0358 106-0350<br />

130 106-0359 106-0351<br />

132 106-0360 106-0352<br />

133 106-0361 106-0353<br />

135 106-0362 106-0354<br />

136 – 106-0355<br />

139 106-0363 106-0356<br />

149 106-1338 –<br />

156 – 106-2827<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Attention Cus<strong>to</strong>m Bike Manufacturers!<br />

Special Order Belts From S&S ® and Gates ®<br />

Special belt sizes, private brand labeling, and assistance with belt drive<br />

design, are available <strong>to</strong> cus<strong>to</strong>m performance OEM's and aftermarket bike<br />

builders, through S&S. These products and services are available for licensed<br />

mo<strong>to</strong>rcycle manufacturers only, and a minimum order quantity may be<br />

required.<br />

Drive belts with your company name imprinted on them are a perfect way <strong>to</strong><br />

show off your brand. Any belt size currently available in the S&S catalog, as<br />

well as the special ordered sizes, can be specially branded. Minimum order<br />

quantities would apply.<br />

Whether you’re designing a completely new chassis, or simply need a<br />

replacement belt, S&S can help you find the belt you’re looking for. Through<br />

the combined efforts of Gates and S&S, S&S can now provide cus<strong>to</strong>mers with<br />

the technical assistance they need for designing new secondary belt drive<br />

systems. In addition, S&S can help you determine required <strong>to</strong>oth count for<br />

your existing chassis design, based on the pulley center-<strong>to</strong>-center distances<br />

and pulley <strong>to</strong>oth counts.<br />

All belts have a 14mm <strong>to</strong>oth pitch, and are made of the super strong Gates<br />

Carbon X3N material. Belts are available in three standard widths of 1.<strong>12</strong>5",<br />

1.5"and 1.181" (30mm), but can be special ordered in nearly any width for a<br />

nominal charge. If you want a belt with a special <strong>to</strong>oth count, they are also<br />

available (see the special order chart for availability).<br />

Contact your S&S Cus<strong>to</strong>mer Support Representative for more information.<br />

Belts Available By Special Order (14m m Pitch)<br />

Tooth Count 1.181" (30mm) Width* 1.25" Width*<br />

<strong>12</strong>5 •<br />

<strong>12</strong>6 • •<br />

<strong>12</strong>7 • •<br />

<strong>12</strong>8 •<br />

130 •<br />

131 • •<br />

132 •<br />

133 •<br />

135 •<br />

136 • •<br />

137 • •<br />

139 •<br />

140 • •<br />

149 •<br />

150 • •<br />

151 • •<br />

152 • •<br />

156 •<br />

*Minimum order required: 1.181” (30mm) – 16 belts; 1.25” – 17 belts.<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-81 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

S&S ® High Performance Clutch<br />

The S&S high performance clutch offers more gripping power with more<br />

friction surfaces and a larger friction centerline diameter. This clutch is able<br />

<strong>to</strong> handle over 150 horsepower. For competition applications, stronger<br />

pressure plate springs are available that increase the power handling<br />

capacity <strong>to</strong> nearly 200 horsepower. Fits in s<strong>to</strong>ck primary cases with only<br />

minor clearancing operations, which are not visible when the primary is<br />

assembled.<br />

Fitment<br />

❚ ❚ Available for 1991-'06 big twin models (except 2006 Dyna®)<br />

U S A<br />

56-5152<br />

The S&S high performance hydraulically actuated clutch is compatible with<br />

Harley-Davidson® hydraulic clutch, pushrod, and bearing.<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Features and benefits<br />

❚❚ Superior <strong>to</strong> competitively priced high performance clutches<br />

❚❚ Fits in s<strong>to</strong>ck primary with minor modification<br />

❚❚ With supplied springs, lever effort is slightly less than a s<strong>to</strong>ck<br />

Harley-Davidson® clutch, but handles engines up <strong>to</strong> 150 hp<br />

❚❚ Optional high pressure clutch springs, available for competition<br />

applications, increases power handling capacity <strong>to</strong> nearly 200 hp<br />

❚❚ Light duty springs for light clutch pull in less demanding s<strong>to</strong>ck<br />

street applications<br />

❚❚ 11 friction plate, 10 steel plate design – narrow friction rings<br />

increase contact diameter for increased <strong>to</strong>rque capacity<br />

❚❚ Supplied with early style 66-<strong>to</strong>oth ring gear for increased strength<br />

and reduced <strong>to</strong>oth breakage<br />

❚❚ Perfect for use with the S&S six-speed transmission<br />

Options<br />

❚❚ Mechanical or hydraulic actuation<br />

❚❚ 36 or 37-<strong>to</strong>oth sprocket<br />

❚❚ Early style starter pinion gear required for 1994-'99 models <strong>to</strong><br />

match 66-<strong>to</strong>oth ring gear supplied<br />

S&S High Performance Clutch<br />

Mechanical Actuation<br />

With 36-Tooth Sprocket ................................... 56-5150A<br />

With 37-Tooth Sprocket ................................... 56-5151A<br />

Hydraulic Actuation<br />

With 36-Tooth Sprocket ................................... 56-5152A<br />

With 37-Tooth Sprocket ................................... 56-5153A<br />

Optional Parts<br />

Starter Pinion Gear – 9-Tooth ................................56-1037<br />

High Pressure "Competition" Clutch Springs ....................56-5106<br />

Low Pressure "Touring" Clutch Springs. ........................56-5109<br />

Loctite® Epoxy, .<strong>12</strong> ounce ..................................51-9007-S<br />

S&S high performance cable actuated<br />

clutch is compatible with s<strong>to</strong>ck and<br />

aftermarket cable style transmission<br />

side covers. See page 1-80 for<br />

S&S chrome billet transmission<br />

side covers.<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

Kit Contents<br />

❚❚ Clutch assembly<br />

❚❚ Special inner transmission mainshaft bearing race<br />

❚❚ Installation hardware<br />

❚❚ Instructions<br />

This S&S inner primary bearing race, which is<br />

included in S&S clutch kits, positively will not<br />

move on the transmission mainshaft. This<br />

prevents damage <strong>to</strong> the mainshaft seal, output<br />

gear and output gear bearing.<br />

U S A<br />

56-5089<br />

U S A<br />

56-5150A<br />

Replacement parts on page 7-78.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-82


Racing<br />

Products<br />

S&S ® CRANKCASES<br />

For high performance applications or just the replacement of a worn out or<br />

broken engine, these cases are compatible with the s<strong>to</strong>ck primary, charging<br />

system and all other s<strong>to</strong>ck components and bolt directly <strong>to</strong> the s<strong>to</strong>ck<br />

transmission on all models.<br />

FITMENT<br />

❚ ❚ 1999–'06 Harley-Davidson® Twin Cam 88® (except 2006 Dyna®)<br />

FEATURES AND BENEFITS<br />

❚❚ Much stronger than s<strong>to</strong>ck crankcases in every aspect, extra large<br />

front mo<strong>to</strong>r mount for increased strength<br />

❚❚ Large cam chest allows cam lift up <strong>to</strong> .675" without clearancing<br />

❚❚ Timken® style sprocket shaft bearings withstand the most<br />

demanding applications<br />

❚❚ Includes S&S crankcase breather reed valve <strong>to</strong> eliminate oil<br />

carry-over and oil scavenging problems<br />

❚❚ Clearanced for strokes up <strong>to</strong> 5"<br />

❚❚ All passages between crankcase cam support plate are o-ring sealed<br />

❚❚ Includes pinion bearing<br />

OPTIONS<br />

❚❚ Available in s<strong>to</strong>ck bore, 4" bore, and 41⁄8" bore versions<br />

❚❚ Silver powdercoat, black wrinkle powdercoat, or polished finish<br />

KIT CONTENTS<br />

❚❚ S&S crankcase<br />

❚❚ Pinion bearing<br />

❚❚ S&S breather reed valve<br />

❚❚ Bearings and hardware<br />

NOTES:<br />

Oil line installation kit part #31-0424 is required for installation in 1999-’05<br />

Dyna® models. This kit includes a special transmission <strong>to</strong>p cover and oil lines.<br />

Oil line installation kit part #31-0425 is required for installation in 2000-'06 FLT<br />

models. S<strong>to</strong>ck transmission <strong>to</strong>p cover may be used.<br />

S&S® Crankcase for 1999-'06 Big twin Engines<br />

(except 2006 Dyna®)<br />

Crankcase Bore Size Silver Finish Black Finish Polished Finish<br />

S<strong>to</strong>ck Bore<br />

(S<strong>to</strong>ck Stud Pattern)<br />

4" Bore<br />

(S<strong>to</strong>ck Stud Pattern)<br />

41/8" Bore<br />

(S<strong>to</strong>ck Stud Pattern)<br />

41/8" Bore<br />

(S&S Stud Pattern)<br />

106-4039 31-0172 –<br />

106-4041 31-0175 –<br />

106-4057 31-0181 31-0182<br />

106-4043 31-0178 31-0179<br />

Special Order 31-0<strong>12</strong>0<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

31-0425<br />

Oil line installation kit<br />

for 2000-'06 FLT models<br />

Replacement parts on page 7-86.<br />

31-0424<br />

Oil line installation kit<br />

1999-'05 Dyna® models<br />

Any Job is easy with the right <strong>to</strong>ols<br />

S&S Degree Wheel Kit, page 8-14 and S&S Anti-Rotation Bracket, page 8-15.<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-83 Visit us at www.sscycle.com


Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Dealer Services<br />

& Promo Items<br />

Racing<br />

Products<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

S&S ® BILLET Gearcovers AND OIL FILTER BRACKETS<br />

Looking through this catalog, you will probably have noticed that S&S is<br />

offering more and more billet components. Billet offers a lot of structural<br />

and engineering advantages over cast parts, but the thing that makes<br />

everyone sit up and take notice is the beauty of polished billet aluminum. If<br />

you are replacing a cam or tappets, consider installing an S&S polished billet<br />

gearcover at the same time. While you’re at it, a billet oil filter bracket would<br />

really look great <strong>to</strong>o.<br />

FITMENT<br />

❚ ❚ 1999-'06 Twin Cam 88® only (except '06 Dyna®)<br />

PART NUMBER<br />

S&S Billet Gearcover (polished)........................31-6516<br />

X-Wedge®<br />

S&S Billet oil filter bracket<br />

These billet oil filter brackets were originally created <strong>to</strong> complete our S&S<br />

T<strong>12</strong>4 dual cam engines, but they are an excellent upgrade for s<strong>to</strong>ck Harley-<br />

Davidson® Twin Cam 88® engines as well. The bracket places the filter slightly<br />

farther from the crankcase <strong>to</strong> allow just that little bit of extra clearance that<br />

makes installation and removal of the filter a lot easier. However, what<br />

really makes this filter bracket useful is that it allows oil <strong>to</strong> be routed <strong>to</strong> an oil<br />

cooler right from the filter mounting bracket.<br />

S&S Billet Oil Filter Bracket<br />

Polished ........................................31-6510<br />

Chrome ...................................... 106-3884<br />

31-6516<br />

31-6510<br />

Warranty &<br />

Company Policy<br />

Replacement parts on page 7-110.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-84


S&S ® FLYWHEEL ASSEMBLIES<br />

Recommended for performance applications, S&S flywheel assemblies are<br />

made of forged steel and have pressed-in shafts. A 1.5" diameter crankpin<br />

means that, unlike s<strong>to</strong>ck flywheel assemblies, lower connecting rod bearing<br />

races are replaceable.<br />

FITMENT<br />

❚❚ 1999-up big twins<br />

KIT CONTENTS<br />

Assembled:<br />

❚❚ Flywheel assembled with rods<br />

❚❚ Instructions<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Engine Displacement<br />

Stroke<br />

EXTRA PARTS NEEDED:<br />

2003–up big twins require installation of Harley-Davidson® bearing kit<br />

H-D#24004–03A, containing sprocket shaft bearing H-D#24604–00D<br />

or H-D#24607–07. Do not use a H-D# 24604–00, H-D#2460 –00A,<br />

H-D#24604–00B, or H-D#24604–00C bearing.<br />

S&S® Flywheel Assemblies<br />

1999-'06 H-D® big twin models<br />

Trying <strong>to</strong> identify an S&S ® Flywheel?<br />

See Flywheel I.D. Chart in the Replacement Parts section page 7-2..<br />

2007-Up H-D® big twin models<br />

Twin Cam 88® Twin Cam 88B Twin Cam 96 Twin Cam 96B<br />

88", 95", 97", 100" 4" 32-2293 32-2241 – –<br />

96", 103"*, 106" big bore, 110",117" 4 3/8" 32-23<strong>12</strong> 32-2314 32-2310 32-2311<br />

S<strong>to</strong>ck 96"** 4 3/8" – – 106-3363 106-3364<br />

106" stroker 4 1/2" 32-2242 32-2243 32-2294 106-0<strong>12</strong>7<br />

107" 4 1/4" 32-2244 32-2245 – –<br />

111" 4 1/8" 106-47<strong>12</strong> 106-6052 106-6053 106-6054<br />

116", <strong>12</strong>4" 4 5/8" 32-2246 32-2247 32-2295 32-2313<br />

Special Order Specify 32-2141<br />

S&S flywheels for unbalanced engines may also be used in 2006 Harley-Davidson® Dyna® models.<br />

*Not compatible with s<strong>to</strong>ck 2007-up pis<strong>to</strong>ns<br />

**Compatible with s<strong>to</strong>ck 2007-up pis<strong>to</strong>ns<br />

***For 2006 Dyna® models<br />

Any Job is easy with the right <strong>to</strong>ols<br />

S&S Flywheel Balancing Kits, see page 8-2.<br />

NOTE:<br />

Engines with strokes over 4" may require S&S® pis<strong>to</strong>n oiling jets and pis<strong>to</strong>n <strong>to</strong> jet<br />

clearance notches in the pis<strong>to</strong>n skirt <strong>to</strong> avoid contact.<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-85 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

S&S ® PRESS-IN PINION & Sprocket<br />

SHAFT ASSEMBLIES<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

These press-in style pinion and sprocket shafts are for use in S&S flywheels<br />

only for 1999–up Harley-Davidson® big twin engines and S&S T-Series<br />

engines. These are intended as replacement parts when rebuilding flywheel<br />

assemblies. Many shops may not have the equipment needed <strong>to</strong> repair this<br />

style of flywheel. We suggest that these flywheels be sent back <strong>to</strong> S&S for<br />

rebuilding.<br />

FITMENT<br />

❚❚ Twin Cam 88®/88B with S&S flywheel assembly<br />

❚❚ Twin Cam 96/96B with S&S flywheel assembly<br />

❚❚ S&S T-Series engines<br />

33-2042<br />

33-2030<br />

X-Wedge®<br />

KIT CONTENTS<br />

❚❚ All shaft assemblies come complete with matching nuts<br />

and keys<br />

TÜV<br />

1,2,7<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

PART NUMBERS<br />

Pinion Shafts<br />

1999-up Twin Cam 88® and 96 ..................... 33-2030<br />

2000-up Twin Cam 88B and 96B ....................33-2042<br />

Sprocket Shafts<br />

2006 Harley-Davidson® Dyna® and All 2007-up with S&S flywheels<br />

Press-In Sprocket Shaft ..............................33-2011<br />

1999-'06 Big Twin – Press-In Sprocket Shaft<br />

Fits S&S® SF, SGX, AND SM flywheels only ...............33-2009<br />

S&S®Pinion SHAFT ASSEMBLIES FOR BIG TWIN ENGINES<br />

Model Year Flywheel Type *Pinion Shaft<br />

S&S® SPROCKET SHAFT ASSEMBLIES FOR BIG TWIN ENGINES<br />

Model Year Flywheel Type *Sprocket Shaft<br />

*Sprocket Shaft<br />

Key (5 pack)<br />

1999-'06 Press-In S&S SM and SG 33-2009 50-1013<br />

2006 Dyna® and All 2007-Up S&S SM and SG 33-2011 50-1013<br />

* Parts included with kit.<br />

*Sprocket Shaft<br />

Key (5 pack)<br />

1999 – up Twin Cam 88 and 96 S&S SM and SG 33-2030 50-1013<br />

2000 – up Twin Cam 88B and 96B S&S SM and SG 33-2042 50-1013<br />

* Parts included with kit.<br />

33-2011<br />

33-2009<br />

Any Job is easy with the right <strong>to</strong>ols<br />

S&S Sprocket Shaft Bearing and Seal Installation Tool, see page 8-5.<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-86


S&S ® CONNECTING ROD ASSEMBLIES<br />

Made <strong>to</strong> be used with S&S flywheels, these connecting rod assemblies<br />

are not compatible with s<strong>to</strong>ck components. The 1.5" diameter crankpin is<br />

smaller than s<strong>to</strong>ck, allowing the crankpin end of the rods <strong>to</strong> be smaller and<br />

lighter, and also allows replaceable bearing races.<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

FITMENT<br />

❚❚ 1999–up big twins with S&S flywheels<br />

FEATURES AND BENEFITS<br />

❚❚ Heavy duty rods are made of heat treated 4140 chromoly steel<br />

❚❚ Bearing clearance is pre-fit so rods come ready <strong>to</strong> install<br />

❚❚ Crankpins have two oil distribution holes located between the<br />

roller bearing paths for continuous oil distribution <strong>to</strong> the bearing<br />

❚❚ Thrust faces on crankpin end of rear rods are grooved <strong>to</strong> distribute oil<br />

and help maintain lubrication between the rod and flywheel<br />

❚❚ Designed with additional rod-<strong>to</strong>-rod clearance <strong>to</strong> accommodate<br />

strokes up <strong>to</strong> and including 5"<br />

❚❚<br />

1.5" crankpin – less rotating mass and replaceable bearing races<br />

KIT CONTENTS<br />

❚❚ Connecting rods<br />

❚❚ Crankpin with end plugs<br />

❚❚ Bearings with steel retainers<br />

❚❚ Bearing retainers<br />

❚ ❚ Nuts (if required)<br />

PART NUMBERS<br />

Connecting rod set for use with s<strong>to</strong>ck 2007–up pis<strong>to</strong>ns<br />

(tapered wristpin ends) ............................ 106-3373<br />

Connecting rod set for use with aftermarket big bore pis<strong>to</strong>n<br />

(straight wristpin ends) ..............................34-7405<br />

SPECIAL NOTES:<br />

Due <strong>to</strong> different crankpin diameters, S&S® connecting rod assemblies cannot be<br />

used with s<strong>to</strong>ck Harley-Davidson® flywheels.<br />

S&S flywheels for Harley-Davidson® Twin Cam 88® and Twin Cam 96 engines are<br />

pressed <strong>to</strong>gether as opposed <strong>to</strong> using the traditional tapered shafts and crankpin.<br />

Assembly and truing requires special equipment. If you do not have the capability<br />

of servicing pressed <strong>to</strong>gether flywheel assemblies, S&S will remanufacture your<br />

S&S flywheel assembly <strong>to</strong> like new specifications. See Section 10: Dealer Services<br />

or call your S&S cus<strong>to</strong>mer support representative for more information.<br />

Rebuild parts for S&S® Connecting Rods<br />

for 1999-up big twin engines<br />

Description<br />

Part No.<br />

Steel Cage & Bearing Set 34-4011<br />

Front Rod Race 34-4008<br />

Rear Rod Race 34-4013<br />

Wristpin Bushing 34-40<strong>12</strong><br />

Race & Bushing Set –<br />

For S&S connecting rods only. Will not fit s<strong>to</strong>ck 1999-up connecting rods.<br />

Model Year<br />

Replacement crankpins for S&S® Connecting rods<br />

for 1999-Up big twin<br />

Standard<br />

(1.500")<br />

+.001"<br />

(1.501")<br />

+.002"<br />

(1.502")<br />

+.003"<br />

(1.503")<br />

1999-Up 34-2175* 34-2176 34-2177 34-2178<br />

*For S&S rods only. Not s<strong>to</strong>ck replacement.<br />

34-7405<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services Warranty &<br />

& Promo Items Company Policy<br />

1-87 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

S&S ® OIL PUMPS<br />

S&S oil pumps use the drive gears on special S&S gear drive cams <strong>to</strong> pump oil<br />

<strong>to</strong> the engine. Unlike s<strong>to</strong>ck pumps, S&S oil pumps regulate oil pressure after<br />

it gets filtered, providing more consistent oil pressure at all temperatures.<br />

Crankcase scavenging is increased while oil carryover and drag on the<br />

flywheels is reduced. Oil temperature can also drop by as much as 20° F.<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

Warranty &<br />

Company Policy<br />

FITMENT<br />

❚ ❚ 2002 - ’06 carbureted & EFI big twins (except 2006 Dyna®)<br />

❚❚ May be used in 1999-'01 engines with aftermarket ignition or EFI<br />

(see note below)<br />

❚❚ Fits all engines built with S&S T-Series crankcases<br />

FEATURES AND BENEFITS<br />

❚❚ Replaces s<strong>to</strong>ck oil pump, cams, cam support plate, bearing<br />

plate, bearings and decorative gearcover<br />

❚❚ Uses drive gears of special S&S gear drive cams <strong>to</strong> pump oil<br />

❚ ❚ Oil pressure is regulated after the oil filter – more consistent<br />

pressure <strong>to</strong> the engine<br />

❚❚ Increased scavenging capacity results in:<br />

• Less oil in the crankcase<br />

• Less power loss<br />

• Less heat build up<br />

• Less oil carryover<br />

❚ ❚ Excess oil from pressure control valve is filtered – longer pump life<br />

PART NUMBERS<br />

Polished ...........................................31-6503<br />

Chrome .......................................... 106-3887<br />

SPECIAL NOTES:<br />

Requires installation of gear drive cams, see chart.<br />

The S&S oil pump is not compatible with 1999-’01 engines with s<strong>to</strong>ck fuel injection<br />

or ignition systems which require a cam position sensor in the gearcover. May be<br />

used in 1999-’01 engines if an aftermarket ignition or fuel injection system, that<br />

does not require a cam position sensor, is installed.<br />

S&S® GEAR DRIVE CAMS FOR USE With S&S OIL PUMPS<br />

FOR 1999-'06 Big twin (EXCEPT 2006 DYNA® MODELS)<br />

Cam*<br />

Easy Start Cams<br />

with Drive Gears<br />

Cams with Drive<br />

Gears<br />

510GP – 33-5220<br />

546GP – 33-5226<br />

570GP 106-4751 33-5221<br />

585GP 106-4771 33-5222<br />

625GP 106-52<strong>12</strong> 33-5223<br />

640GP 106-4781 33-5224<br />

675GP 106-5215 33-5225<br />

* See Camshafts starting on page 1-62 of this catalog for further information on cam<br />

recommendations for different applications.<br />

Replacement parts on page 7-110.<br />

31-6503<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-88


Warranty &<br />

Company Policy<br />

S&S ® CRANKCASE BREATHER REED VALVES<br />

Besides offering improved oil scavenging and reduced oil carryover, S&S<br />

crankcase breather reed valves make your bike run better and provide a<br />

more enjoyable riding experience.<br />

How Do They Work?<br />

The functional part of S&S crankcase breather reed valves consists of steel<br />

reeds that are normally in the closed position. When the pis<strong>to</strong>ns travel<br />

downward in the cylinders, pressure in the crankcase below the pis<strong>to</strong>ns<br />

causes the reeds <strong>to</strong> open, allowing the air and oil mist in the crankcase <strong>to</strong><br />

escape in<strong>to</strong> the cam chest. When the pis<strong>to</strong>ns change direction and begin<br />

traveling back upward in the cylinders, a vacuum is created in the crankcase.<br />

The vacuum causes the reeds <strong>to</strong> close, preventing air from entering the<br />

crankcase. The effect is that a slight vacuum is maintained in the crankcase,<br />

and oil scavenging is greatly improved.<br />

FITMENT<br />

❚❚ Twin Cam 88®<br />

❚❚ S&S T-Series engines<br />

PART NUMBERS<br />

For Engines with S<strong>to</strong>ck Oil Pump<br />

1999-’02 ...........................................31-2070<br />

2003-up ...........................................31-2071<br />

S&S special application crankcases .....................31-2086<br />

Engines with S&S Oil Pump<br />

Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Evolution®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

1999-’02 s<strong>to</strong>ck crankcases ............................31-2093<br />

31-2071<br />

S&S ® T-Series Service Manual<br />

These manuals are created <strong>to</strong> help you maintain your S&S engine. They<br />

outline the procedures necessary for both the home mechanic and shop<br />

technician <strong>to</strong> ensure maximum performance and longevity.<br />

S&S T-Series engines ................................61-1002<br />

2003-up s<strong>to</strong>ck crankcases & all S&S crankcases ..........31-2094<br />

Spring Adapter<br />

(For S&S SA crankcases)* .............................31-2103<br />

*Required <strong>to</strong> accommodate the extra .375" case width of S&S Special Application big bore crankcases.<br />

Replacement parts on page 7-116.<br />

X-Wedge®<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Replacement<br />

Parts<br />

Tools &<br />

Shop Supplies<br />

Racing<br />

Products<br />

Dealer Services<br />

& Promo Items<br />

1-89 Visit us at www.sscycle.com


Parts for<br />

Twin Cam 88®<br />

Parts for<br />

Sportster® '86-'06<br />

Vintage<br />

Engines<br />

Replacement<br />

Parts<br />

Parts for Vic<strong>to</strong>ry®,<br />

Off-road & Metric<br />

Tools &<br />

Shop Supplies<br />

Dealer Services<br />

& Promo Items<br />

Racing<br />

Products<br />

Warranty &<br />

Company Policy<br />

X-Wedge®<br />

Parts for<br />

Evolution®<br />

Order <strong>to</strong>ll free 866-244-2673<br />

1-90

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