SECTION 2: 1999-2006 BIG TWINS - S&S Cycle

When the Harley-Davidson® Twin Cam 88® and Twin Cam 88B engines were first introduced in 

1999 and 2000, it was apparent that they had a lot of potential for performance improvement. S&S set 

about tackling the job of creating products that made them go a lot faster and made them even more 

dependable too. 

Owners of 1999 - ‘06 Twin Cam 88 equipped big twins should be aware that even though 2007 and later 

models have bigger engines from the factory, your 88" motor has the same potential for upgrade. S&S 

has been making performance kits for these bikes for over 12 years and we have a lot to offer. Some of 

these performance solutions are much less expensive than you might think! 

S&S 4 Step Performance Upgrade Program 

The S&S 4-Step program is the easiest way to get immediate gratification, and even more performance 

as your budget allows. 

Step 1 S&S slip-on muffler, Power Tune Duals header, and an S&S Air Cleaner. Now even more 

options are available with the new S&S Super Stock® air cleaners (See Page 2-2) 

Step 2 S&S bolt-in performance cams and pushrods 

Step 3 S&S 95" and 97" bolt-in big bore kit 

Step 4 Let S&S CNC port your stock heads! 

S&S 95" or 97" Hot Set Up Kit® 

The fast track to steps 3 and 4. If you want to get it all at once, a 95" or 97" Hot Set Up Kit is the perfect 

solution. Hot Set Up Kits contain everything you need in one easy-to-install package of components that 

have been tested and proven to work together…every time. A typical Hot Set Up Kit contains S&S Easy 

Start gear drive cams and pushrods for outstanding performance. Kits are even available that include CNC 

ported stock heads. (See Page 2-18) 

124" Hot Set Up Kit 

This proven big bore/stroker Hot Set Up Kit is for the rider who wants to go for the gusto! It features 41/8" 

bore pistons and cylinders, an S&S 45/8" stroke flywheel assembly, and S&S heads. Also includes S&S 

Easy Start .640 gear drive cams, pushrods, and required gaskets and hardware. Cases must be bored to 

accommodate bigger cylinders, but it’s worth it! (See Page 2-30) 

S&S Complete Engines – The Ultimate Upgrade! 

There is no doubt that a complete S&S engine is the best way to get the power and reliability you want. 

Replace your entire stock engine with a new S&S power plant. Available in 111 and 124 cubic inch 

displacements…S&S quality all the way! (See engines starting on page 2-32) 

Note: Not available for 2006 Dyna® models 

Performance Guide 

STEP 1: INTAKE & EXHAUST 2-2 

Air Cleaners 2-2 

Headers 2-6 

Mufflers 2-7 

STEP 2: CAMS & PUSHRODS 2-11 

Cams 2-11 

Pushrods 2-14 

Tuners 2-15 

STEP 3: BIG BORE KIT 2-16 

97" Big Bore Kit 2-16 

STEP 4: CNC PORTED HEADS 2-19 

Performance Kits 

PERFORMANCE KIT OVERVIEW 2-20 

BIG BORE KITS 2-22 

HOT SET UP KITS® 2-24 

STROKER KITS 2-27 

PERFORMANCE ENGINES 2-32 

Performance Parts 

CRANKCASES 2-35 

FLYWHEELS 2-37 

OIL PUMPS 2-38 

CAMS 2-39 

GEARCOVERS 2-43 

CYLINDERS & PISTONS 2-45 

CYLINDER HEADS 2-49 

TAPPETS 2-53 

PUSHRODS 2-54 

ROCKER ARMS 2-57 

VALVE SPRINGS 2-58 

ROCKER COVERS 2-61 

FUEL SYSTEMS 2-62 

ELECTRONICS 2-72 

TRANSMISSION 2-78 

CLUTCH 2-79 

BELTS 2-80 

Replacement Parts 2-81 

SECTION 2: 1999-2006 BIG TWINS

S e ction 2: 

S&S ® Step 1: Intake and Exhaust 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 

Twin Cam 88 ® 

1999-2006 

1999-2006 BIG TWINS 

Super Stock ® Stealth Air Cleaner Kits 

The Power Of Style! 

High performance intake systems have been an important part of the S&S product 

line since the early 1960’s. These new S&S Super Stock Stealth air cleaner kits make a 

powerful statement about style and performance. 

Parts for 

Evolution ® 

1984-1999 

Parts for 

Sportster ® & Buell ® 

1986-2012 

Parts for 

Vintage Engines 

1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Features and Benefits 

• For the rider who likes to go fast, but doesn’t like to advertise 

• Air directional stinger cone in the filter 

• Use with your stock Harley-Davidson® Twin Cam 88®, 96, 103 air cleaner cover 

– the word "sleeper" comes to mind 

• Can also be used with any of several S&S designed covers 

• High flow (1" taller) filter kit available 

Cut-away showing a stock Twin Cam 88®, 96 or 103 cover on S&S Stealth air cleaner kit. 

S&S Super Stock® Air Cleaner KitS 

AIR STREAM BOBBER-DISHED BOBBER-DOMED MUSCLE 

Application Fuel System STEALTH* 

Chrome Finish 

Stock CV/EFI, except 1999 Softail® carb 170-0060 170-0056 170-0104 170-0105 170-0106 

1999-’06 bt 

S&S Super E & G Carbs 170-0058 170-0063 170-0110 170-0111 170-0112 

*These kits do not contain covers – use your stock Twin Cam 88®, 96 or 103 cover or choose an S&S cover Not legal for sale or use on CA pollution controlled vehicles. 

Parts for 

Victory®, Off-road 

& Metric 

Dyno Comparison 

2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ Airstream Cover vs Stock Air Cleaner 

100 

90 

S&S Super Stock Stealth w/ Airstream Cover 

Peak Corrected HP 71.4 

Peak Corrected Torque 87.5 

Stock Air Cleaner 



100 

90 


2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ Bobber Cover vs Stock Air Cleaner 

S&S Super Stock Stealth w/ Bobber Cover 






80 

80 

Racing 

Products 

70 

60 

70 

60 

50 

40 

50 

40 

Tools & Shop 

Supplies 

30 

20 

10 

30 

20 

10 

Dealer Services 

& Promo Items 

1000 2000 

3000 

4000 5000 6000 

EngSpd RPM 

1000 2000 

3000 

4000 5000 6000 

EngSpd RPM 

These dyno charts compare the performance of a totally stock 2012 FLHX to the same bike with an S&S Stealth air cleaner, fitted with the S&S Airstream and S&S Bobber air cleaner covers. In 

both cases, the S&S Stealth air cleaner out-performs the stock air cleaner. With more filter exposure, the S&S Bobber cover delivers the largest increase in torque of 1.5 ft/lb over stock! For even 

more power add S&S performance mufflers. Both were tuned with Dynojet® Power Vision® Tuner. 

Warranty & 

Company Policy 

OEM Cross Reference 

Appendix & Index 

2-2 

High Flow replacement Air filters 

Standard (Filter only) ............... 170-0126 

1" Taller Kit* (includes 2 spacers) .... 170-0127 

(Filter only). .................. 170-0154 

* 1” taller filter kit does not fit Muscle air cleaner kit 

Order toll free 866-244-2673 

170-0126 

Standard high flow air flilter 

170-0127 

1" taller high flow air filter kit 

This built-in stinger cone is featured in all 

Super Stock air cleaner kits except the tuned 

induction systems. 

• Directs air smoothly into the bore of the 

carburetor or EFI throttle body 

• Reduced turbulence and increased flow 

• Featured in S&S teardrop air cleaners 

since the early 1970’s



Super Stock ® Stealth Air Cleaner Covers 

S&S Air Stream Air Cleaner Cover 

• Fits the new S&S Stealth air cleaner kits 

• An updated version of the speed inspired S&S teardrop shape 

• Screened vent for more air without sucking in rain/road debris 

• Steel construction with your choice of chrome or Black Jack (wrinkle black powdercoat) 

Air Stream 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Part numbers 

Air Stream Air Cleaner Cover 

Parts for 

Evolution ® 


Chrome ............................................. 170-0118 

Black Jack ........................................... 170-0122 

S&S Bobber Billet Air Cleaner Covers 

170-0118 

Bobber Dished 

Parts for 


1986-2012 


• Minimalist air cleaner cover that really delivers the goods! 

• Fits over the end of the air filter and leaves the filter element exposed 

• Choose from the Dished Bobber or the Domed Bobber covers 

Parts for 


1926-1984 

• CNC machined from billet aluminum in chrome or Black Jack 

(wrinkle black powdercoat) 

Parts for 

X-Wedge® 

2007-2012 

Part numbers 

Bobber Dished Air Cleaner Cover 

Chrome ............................................. 170-0119 

Black Jack ........................................... 170-0123 

170-0119 

170-0123 

Bobber Domed 

Parts for 


& Metric 

Bobber Domed Air Cleaner Cover 

Chrome ............................................. 170-0120 

Black Jack ........................................... 170-0124 

Racing 

Products 

S&S muscle Billet Air Cleaner Covers 


• Similar to the Bobber covers 

• Leaves the entire air filter exposed for a raw hot rod look 

• Cover is held on with muscle car style hood pins 

• CNC machined from billet aluminum in chrome or Black Jack (wrinkle black powdercoat) 

Part numbers 

170-0120 

170-0124 

Muscle 

Tools & Shop 

Supplies 


& Promo Items 

Muscle Air Cleaner Cover 

Chrome ............................................. 170-0121 

Black Jack ........................................... 170-0125 

Warranty & 


170-0121 



170-0125 

Visit us at www.sscycle.com 

2-3

S e ction 2: 


Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 



SINGLE BORE TUNED INDUCTION SYSTEM 

FEATURES AND BENEFITS 

• Bolt-on performance – over twice the filtering area over stock intake system 

• Increases horsepower and torque across the rpm range using air column inertia 

and carefully timed gas dynamic pressure waves 

• Smooth intake tract of carefully selected tuned lengths increases performance 

• High flow washable and reusable cotton media provides performance, 

protection, and economy 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

S&S SINGLE BORE TUNED INDUCTION SYSTEM KITS 

Fitment Fuel Delivery Finish Part No. 

S&S Super E/G 

Chrome 170-0086 

1999-'06 big twins 

Runner 

and 

Stock CV & EFI Delphi® Red Filters 170-0087 

CTO 

Specify Specify 106-5337* 

*Use the Configure to Order (CTO) part number to order different finish and filter color. 

Not legal for sale or use on CA pollution controlled vehicles. 

Billet adaptor brackets make single 

bore tuned induction compatible 

with many engines and motorcycles. 

Parts for 


& Metric 

Replacement Filters (each sold with clamp) 

Red ............................................................17-1020 

Blue ...........................................................17-1023 

Racing 

Products 

Tools & Shop 

Supplies 

Renew the color of your air filter with an 8 oz. bottle of S&S Air 

Filter Oil. Choice of red or blue oil. 

S&S Air Filter Oil, Red .........................106-1163 

S&S Air Filter Oil, Blue ........................106-1164 


& Promo Items 

Warranty & 


Washable nylon air filter covers are water resistant and filter out 

large debris, allowing the filter media to stop small dirt particles 

from getting into your engine 

S&S Nylon Air Filter Cover 

each ..................................... 106-0247 

2 pack ................................... 106-0248 



NOTE: Tuned induction will not fit on motorcycles equipped with fairing lower glove boxes. 

2-4 

Order toll free 866-244-2673



Teardrop AIR Cleaner Kit 


• Efficient and free flowing intake that can add two to five horsepower 

• Uniquely designed back plate has air horn style radiused entryway to 

reduce turbulence 

• Dimpled cover with directional air cone on inside creates smooth path for air 

• Great addition to performance exhaust or cams 

KIT CONTENTS 

• Filter 

• Backing plate 

• All mounting hardware 

• Instructions 

Teardrop Air Cleaner Kits 

Model/Engine Stock Carb/EFI: S&S® Super E or G: 

2001-'12 Softail EFI, All 2002-Up EFI (Delphi®) 17-0450 – 

1999-'01 EFI big twin (Magneti Marelli®) 106-4589 – 

1999-'06 Carbureted 17-0450 17-0403 


Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Optimize your stock carBuretor 

Jet,Kit,CV Carb,1999-2006 bt ......11-5203 

Jet,Kit,CV Carb,1995-2006 bt .......11-5202 

11-5203 

A respectable gain in both horsepower and 

torque can be seen in this graph comparing 

a stock big twin to one equipped with an 

S&S® air cleaner and SPO® touring mufflers. 

S&S ® 

SUPER E & G COMPLETE Carburetor KITS 


• Increased air flow for more power 

• Adjustable accelerator pump for quick throttle response and easy starting 

• Utilization of the factory dual cable system ensures safe operation 

• Direct replacement and high quality fit and finish – less down time and better performance 

• Variable position enrichment starting system 

KIT CONTENTS 

• Super E or G carburetor 

• S&S intake manifold 

• Teardrop air cleaner kit 

• Mounting hardware, gaskets, seals and hoses 


Models 

S&S Carburetor Kits 

Super E 

Complete Kit 

Super G 

Complete Kit 

1999-'05 big twin 11-0450 11-0451 

2006 big twin 106-0874 106-0875 

Models 

Super E 

(Carb only) 

Super G 

(Carb only) 

All Years & Models 11-0420 11-0421 

Optional cruise control adapter kits allows 

riders to keep factory cruise feature. 

Cruise Control Adapter Kit ..11-2927 

NOTES: 

S&S® does not recommend polishing or chrome plating Super E & G carbs. Our repair department has seen many 

carbs with plugged passages due to polishing compounds, and some carbs that have been destroyed because the 

polishing or chrome plating had altered critical machined surfaces. 

Recommended for closed circuit use only—S&S Super E & G carbs shown are not approved for use on motor 

vehicles operated on California public highways, or in other states where similar pollution laws may apply. 

The user shall determine the suitability of the product for his or her use and shall assume all risk and liability in 

connection therewith. 

Replacement parts for S&S Super E & G carburetors can be found on page 2-96. 


Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-5

S e ction 2: 


Parts for 

Twin Cam 96 /103 

2007-2012 

Power Tune Duals 


Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Fitment 

• Harley-Davidson® touring models 

Features and benefits 

• Adds 8 horsepower over stock header pipes 

• Independent dual look with hidden crossover 

• Exclusive design moves the rear cylinder header away from the passenger 

to reduce radiated heat 

• Full chrome heat shielding with 220º coverage 

• Updated styling to give the bike a modern look 

• Oxygen sensor bungs* 

• Durable16 gauge construction 

• Spherical inlet design for improved sealing and exhaust gasket durability 

• Hardware included to mount crossover pipe 

• Compatible with all slip-on mufflers 

• Exhaust port gaskets included 

• Made in the U.S.A. 

Part numberS 

S&S Power Tune Duals, 1995-’08 bt.....................................550-0003 

* Has 18mm sensor fittings in the stock locations for 2007-’08 bikes. If not equipped with 

oxygen sensors, the ports can be used for tuning. Plugs are included if ports are not used. 

WATCH THE S&S POWER TUNE DUAL & SPO MUFFLER 

VIDEO AT SSCYCLE.COM/MEDIA/VIDEOS.PHP 



Warranty & 



& Promo Items 

Tools & Shop 

Supplies 

Racing 

Products 

2-6 




SPO ® touring MUFFLERS 

SPO Touring Mufflers have exhaust sound levels that are compliant with 

the SAE J2825 exhaust sound test when installed on a stock motorcycle. 

Touring mufflers restyled. With their unique oval shape, the restyled S&S SPO 

mufflers give your dresser a distinctive custom look, enhanced midrange torque, and a 

sound reminiscent of the low rumble of a late 1960’s muscle car. These mufflers feature 

sculpted alloy end-caps in your choice of show chrome finish or coated with high-temp 

black Xylan®. Double walled construction and show quality chrome virtually eliminate 

bluing. 

NEW! End caps are now available separately, so you can change up the look of your 

SPO mufflers. 

Fitment 

• Harley-Davidson® touring models with non-catalyst mufflers 

(except 2010 Road Glide® Custom and Street Glide® and all Tri Glide® models) 


• Modern styling 

• Double walled construction 

• Sculpted alloy end-caps with machined-in S&S logo 

• Great looking show chrome finish 

• Increased performance – works best with S&S air cleaner and/or 

camshaft upgrade 

• Utilizes factory mounting locations and hardware 


• 

Options 

• Xylan® black alloy end-cap 

• Chrome alloy end-cap 

550-0001 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Interactive Flipbook 

See mufflers installed on a variety of models. 

www.sscycle.com/exhaust 

Tools & Shop 

Supplies 

S&S® SPO® Touring Mufflers 

Fitment End-cap Style Part Number 

1995-’12 H-D® touring 

(except 2010 Road Glide & Street Glide 

and all Tri Glide models) 

WATCH THE S&S POWER TUNE DUAL & SPO MUFFLER 


Xylan® Black 550-0002 

Chrome 550-0001 

Replacement End Caps 

Chrome End Cap (set) ............................... 550-0106 

Black End Cap (set) ................................. 550-0107 

SEE SPECIAL NOTES: ON PAGE 2-9 FOR DISCLAIMERS 


& Promo Items 

Warranty & 





2-7

S e ction 2: 


Parts for 

Twin Cam 96 /103 

2007-2012 

3-1/2" touring MUFFLERS 

Fitment 

• 1995-'12 Harley-Davidson® touring models with non-catalyst mufflers 

(except 2010 Road Glide® Custom and Street Glide®) 


106-5979 

Black Xylan® Billet End Cap Style 

Parts for 



Parts for 

Evolution ® 



• Great looking show chrome finish 

• Great sounding rumble 

• Increased performance – works best with an S&S air cleaner and/or cam upgrade 

• Double layered packing – basalt wool over stainless steel wool 

• Fits on stock header pipes – utilizes factory mounting locations and hardware 


Parts for 


1986-2012 

Parts for 


1926-1984 

Options 

LISTEN & COMPARE AT 

• Slash-back end 

SSCYCLE.COM/AUDIO 

• Slash-down end 

• Tapered end 

• End cap – available chrome plated or black Xylan® coated 

• Quiet-Tour or Power-Tour versions available: 

• Quiet-Tour – increases performance with a mellow rumble 

• Power-Tour –gives you maximum performance with a louder rumble 

S&S 31/2"Touring Mufflers 

Parts for 

X-Wedge® 

2007-2012 

Style Quiet-Tour Power-Tour 

Slash-back 106-5977 106-5982 

Parts for 


& Metric 

Slash-down 106-5976 106-5981 

Tapered 106-5978 – 

Billet End-cap Black Xylan® 106-5979 106-5983 

Billet End-cap Chrome 106-5980 106-5984 

Chrome Tapered 

Chrome Slash-down 

Chrome Slash-back 

Racing 

Products 

Interactive Flipbook 

See mufflers installed on a variety of models. 

www.sscycle.com/exhaust 

Chrome Billet End Cap 

Xylan® Billet End Cap 

SEE SPECIAL NOTES: ON PAGE 2-9 FOR DISCLAIMERS 



Warranty & 



& Promo Items 

Tools & Shop 

Supplies 

2-8 

To really wake up this stock 96" 2009 FLHT (bottom curves) we added a set of S&S 551 cams 

to the S&S slash-back mufflers and air cleaner kit. S&S performance mufflers will enhance the 

results of any performance modifications made to the engine. 


This dyno chart shows the improvement a set of S&S 31/2" slash-back Power-Tour mufflers and 

an S&S air cleaner kit (middle curves) and an S&S tuned induction kit (top curves) made on a 

stock 96" 2009 FLHT (bottom curves).



80db SPO ® MUFFLERS 

EPA and SAE J2825 compliant when used on a stock motorcycle 

S&S 80db SPO mufflers are designed to look and sound great, and are EPA compliant! 

Great for touring models, these mufflers are sure to leave your hearing intact after a long 

day of riding. 

FITMENT 

• 1995-'12 Harley-Davidson® touring models with non-catalyst mufflers 

(except 2010 Road Glide® Custom, Street Glide® and all Tri Glide® models) 


• More power than stock Harley-Davidson® mufflers throughout the midrange 

• Made from stainless steel so they’ll never rust, pit, or corrode 

• Highly polished finish looks great on any bike 

• Legal replacement for models without catalyst in mufflers (no recalibration required) 

KIT CONTENTS 

• Installation instructions 

• Two mufflers 

• Utilizes factory mounting hardware and locations 

PART NUMBER 

S&S 80db SPO Mufflers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-6634 



55-6634 

NOTES: 

• Baffles are riveted in place to meet EPA tamper proof requirements. 

• Use on any other engine configurations are not covered by this certification. 

• Does not meet California or TÜV standards. 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

This EPA compliance statement is a quick way to tell the difference between our 80db 

SPO® mufflers and our standard performance SPO mufflers. The other difference is that the 

standard version has a replaceable baffle, while the 80db version’s baffle is permanently 

riveted in place. 

Notice the increase in midrange torque after installing the S&S® 80db SPO® mufflers. This 

means more power for passing, climbing hills, and accelerating to highway speed. 

SPECIAL NOTES: 

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

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

• Emissions Notice: S&S Cycle, Inc. exhaust systems and slip-on mufflers are legal for sale and use on U.S. EPA and California pollution controlled motorcycles not originally equipped 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 motorcycles that have the catalyst located in 

the header pipes upstream of the muffler. Removing a catalytic converter from a pollution-controlled motorcycle is considered tampering and can lead to substantial fines and penalties. 

Unless otherwise noted additional S&S components shown are restricted to closed course competition use only. 

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

ordinances before use. 

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

are equivalent to the corresponding H-D part number shown. 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-9

S e ction 2: 


Parts for 

Twin Cam 96 /103 

2007-2012 

SLIP-ON PERFORMANCE MUFFLERS 

FITMENT 

• Harley-Davidson® Softail® and Dyna® big twins with non-catalyst mufflers 


Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 


• Low restriction, high performance 

• Cost effective performance upgrade – best horsepower/dollar ratio 

• Maintains a smooth power curve while delivering excellent low and midrange torque 

– makes adjustments to the fuel delivery system minimal and straightforward 

• Show chrome finish 

OPTIONS 

• Slash-cut 

• Tapered 



Chrome Slash-cut 

106-6016 Slash-cut Style 

Chrome Tapered 


Stock H-D® Twin Cam 88® Engine vs w/S&S Slip-On vs w/S&S Slip-On, 510 Cam, & Super E 

Parts for 


1926-1984 

90 

80 

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



Twin Cam 88 w/S&S Exhaust 



Twin Cam 88 Stock 



70 

Parts for 

X-Wedge® 

2007-2012 

60 

50 

Parts for 


& Metric 

40 

30 

20 

2000 2500 3000 3500 4000 4500 5000 5500 6000 

EngSpd RPM 

Racing 

Products 

This dyno chart shows the difference between stock mufflers and S&S® mufflers, and the 

difference between S&S slash-cut and S&S tapered mufflers. 

Bottom curves: Stock 88" Harley-Davidson® Twin Cam 88® engine with stock exhaust. Middle 

curves: Stock 88" Twin Cam 88 engine with S&S® slip-on mufflers on stock header pipes. Top 

curves: Stock Twin Cam 88 engine with S&S slip-on mufflers on stock header pipes, S&S Super 

E carburetor, and S&S 510 bolt-in cams. 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




S&S Slip-on Performance Mufflers 

Application Slash-cut Tapered 

1995-'12 Harley-Davidson® Dyna® Models 

(except 2008-'12 FatBob® and 2010-'12 Wide Glide®) 

106-5769 106-5770 

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

2000-'06 Softail, Fatboy® and Deuce Models - Shotgun* 106-5762 106-5761 

*Not intended for motorcycles originally equipped with a catalyst. 


• See page 2-9 for disclaimers. 

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

are equivalent to the corresponding H-D part number shown. 

2-10 



S&S ® Step 2: Camshafts and Pushrods 

CAMSHAFT OVERVIEW 

S&S offers a variety of cam grinds for 1999-up big twin engines in both chain drive and 

gear drive versions. Cams that exceed the limits of the stock valve springs require the use 

of special high lift springs. Most S&S cams have higher lift than stock and are designed to 

take advantage of the extra flow of ported stock heads or S&S Super Stock® heads. Due 

to the high lift of these cams, S&S adjustable pushrods are recommended. Not all grinds 

are available in the chain drive version. To get the best performance from a performance 

cam installation, a high flow intake and exhaust system is also recommended. 

EASY START CAMS 

The most innovative S&S product since the electric compression release system, these 

cams will revolutionize the starting of late model big twins. Regardless of displacement 

or compression ratio, a stock starter and battery will now easily turn over any engine. 

These cams also install just as easily as non compression release versions and require no 

extra parts or machining! Available in both chain drive and gear drive. 

HOW Do Easy Start Cams WORK 

The heart of our Easy Start cams is a centrifugally retracted, spring loaded, compression 

release lobe milled into the heel of each exhaust lobe. At cranking speeds, the lobe 

bumps the exhaust valve open slightly during the compression stroke, making the 

engine much easier to turn over. Once the engine fires and reaches 800 RPM, the lobe 

swings out of the tappet roller path, allowing the engine to run normally and with full 

compression. 

Compare S&S Cams To Other Popular Cams 

If you have been using cams from another manufacturer and would like to know what 

S&S has to offer that is similar, the chart below lists a number of popular cams along 

with the S&S cams that work well in similar applications. 

Cam Name 

Application CROSS REFERENCE CHART 

S&S Cam 

Name 

H-D® Screamin' 

Eagle® Cam 

Andrews® Cam Most Fitting Application 

551 SE-203/255 21H/26H Touring Models 

570 – 54H All Big Twin Models 

583 SE-203/255 21H/26H Softail®/Dyna® Models 

585 SE-211/251/257 31H/32H/50H/55H/67H All Big Twin Models 

625 SE-258/260 60H All Big Twin Models 

640 SE-264 59H All Big Twin Models 


Recommended applications for S&S Cams 

475: A bolt-in replacement cam with stock cam timing is designed for riders 

with stock engines that want to eliminate the factory chain drive system, but are 

not necessarily looking for more power. Does not require tuning. Bolt-in stock. 

509: Designed as a bolt-in, high torque cam for 1999-'06 models. 180 psi cranking 

compression, no need for compression releases. For 88 CID engines with stock 

compression ratio. Idle-4500 rpm. Bolt-in torque. 

510: Designed as a bolt-in cam for 88, 95, and 96 CID engines with compression 

ratios below 9.7:1, it is primarily intended for use with stock, un-ported heads. 3000- 

5500 rpm. Bolt-in overall. 

546: Intended as a replacement part for S&S emissions certified engines, this is a 

short duration emissions cam with very little overlap to reduce emissions of unburned 

hydrocarbons. Requires high lift springs and normal clearance checks. 1000-4000 rpm 

551: Designed for engines with 96 to 106 CID and 9:1 to 9:9 compression this is a 

bolt-in cam set designed for stock or mildly modified touring bikes. 551 cams are not 

recommended for compression ratios of 10:1 or greater. Greatly improves low-end 

and midrange torque, strongest from idle-4000rpm. 

570: Designed for 88 to 103 CID engines with compression ratios between 9:1 and 

10:1 this cam will provide a nice power increase across the entire power band. 3200- 

5700 rpm. Excellent bolt-in for overall power on 103". 

583: Optimized for use in the Softail®/Dyna® lines, this cam makes horsepower 

and torque that you can feel all the way through the rpm range, making the most 

power right where you need it:1500–5000rpm 

585: Designed for 88 to 95 CID engines with compression ratios from 9.7:1 to 

10.5:1 and 100 to 124 CID engines from 9:1 to 10:1 compression. Provides massive 

horsepower and torque increases starting at 3000rpm and holds steady all the way 

to redline. 3500-6000 rpm for 88" - 103" engines and 2500-5500 for larger engines. 

625: Cam set designed for 95" or larger engines with compression ratios between 

10.0 and 10.75:1. 3000-6000 rpm. 

640: Used in S&S T124 engines, this cam makes horsepower! Intended for engines 

of 95 CID or more w/ compression ratios between 10.5:1 and 11.5:1. 3000-6000 rpm. 

675: A high lift monster, this cam set is designed for 120" or larger engines with at 

least 11:1 compression ratio. 4500-6500 rpm. 

Note: Stock valve springs in 1999-’04 big twin models can handle cams with valve lifts as high 

as .515". Stock valve springs in 2005-up engines can accommodate valve lifts up to .590". 

Specifications of S&S® Chain Drive and Gear Drive Camshafts for 1999-UP Big twin 

Valve Timing (open/close) 

Intake 

Exhaust 

Open BTDC/Close ABDC 

Open BBDC/Close ATDC 

Valve Duration 

Centerline 

Lift @ TDC 

Valve Lift 

Intake Exhaust Intake Exhaust Intake Exhaust 

475 2˚/34˚ 36˚/4˚ 216˚ 220˚ .475" 106˚ 106˚ .060" .060" 

509 18˚/18˚ 46˚/11˚ 216˚ 237˚ .509" 90˚ 107.5˚ .174" .140" 

510 20˚/38˚ 52˚/20˚ 238˚ 252˚ .510" 99˚ 106˚ .187" .178" 

546 5˚/55˚ 52˚/5˚ 240˚ 237˚ .546" 115˚ 113.5˚ .126" .106" 

551** 17°/19° 41°/17° 216° 238° .550" 91˚ 102˚ .178" .170" 

570 20˚/40˚ 55 ˚/20˚ 240˚ 255˚ .570" 100˚ 107.5˚ .187" .179" 

583 5˚/18˚ 58˚/24˚ 203˚ 262˚ .583" 96.5˚ 107˚ .113" .206" 

585 20˚/45˚ 60˚/20˚ 245˚ 260˚ .585" 102.5˚ 110˚ .186" .179" 

625 20˚/55˚ 60˚/20˚ 255˚ 260˚ .625" 107.5˚ 110˚ .189" .184" 

640 25˚/60˚ 65˚/25˚ 265˚ 270˚ .640" 107.5˚ 110˚ .228" .214" 

675 25˚/64˚ 70˚/25˚ 269˚ 275˚ .675" 109.5˚ 112.5˚ .235" .205" 

*Note: Although several cam grinds were used in stock engines from 1999-’06, the timing specs of the 475G cams is most similar to cams used in 1999-’03 EFI engines. 

**551 cams are not recommended with compression ratio of 10:1 or higher. 


Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-11

S e ction 2: 


Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

CHAIN DRIVE CAM KITS 


• Increase performance at an affordable price 

• Quick installation – reuse many stock components 

• Easy Start Cams allow stock starter 

to start any engine 

KIT CONTENTS 

• Cams 

• Gearcover gasket 

• Cam bearings 

• Thread lock 


WATCH THE S&S EASY START CAMS CRANK TEST 


33-5182A 

S&S CHAIN DRIVE CAM KITS FOR 1999-'06 MODELS (except 2006 Dyna®) 

Cam Name Standard Cam Kit Easy Start Cam Kit 

509 330-0016 – 

510 33-5182A – 

551 330-0002 106-5293 

570 330-0003 106-5296 

583 330-0004 106-5289 

585 330-0005 106-5299 

625 330-0006 106-5302 

640 330-0007 106-5305 

INSTALLATION KITs for S&S CHAIN DRIVE CAM (recommended) 

Models 

Standard Cam Kit 

1999-'06 (except 2006 Dyna® models)* 33-5175 

Includes a gearcover gasket, cam bearings and instructions. *2006 Dyna® cams are in Section 1. 


100 

90 

80 

70 

60 

50 

40 

30 

20 

100 

90 

80 

70 

60 

50 

40 

30 

20 

583 Cam 



1500 

2000 2500 3000 


2009 FLHT with S&S® 551 Touring Cam vs Stock Cam 

S&S 551 Touring Cam 




Fatboy® 583 Cam vs Stock Cam 

96 Stock Cam 



3500 4000 4500 5000 5500 6000 

EngSpd RPM 

96 Stock Cam 



Tools & Shop 

Supplies 

10 

1500 

2000 2500 3000 

3500 4000 4500 5000 5500 6000 

EngSpd RPM 


& Promo Items 

Warranty & 




33-5175 

Installation kits are included 

with cam kits. 

NOTE: 

• If 475, 509 or 510C cams are used with the stock chain drive system in Twin Cam 88® 

engines, it is recommended to use cylinder heads with stock valve springs or performance 

valve springs with no more than 160 lb. of seat force. For more demanding applications, 

we recommend the S&S gear drive cams. 

• When using 1999-'06 chain drive cams for lifts over .510", S&S strongly recommends 

that the stock chain drive be upgraded to the S&S gear drive or to the H-D® #25284-08 or 

#25284-11 hybrid plate. This kit updates the problematic spring loaded chain tensioners 

to reliable hydraulic tensioners and also upgrades the oil pump. 

• 551 cams are not recommended with compression ratio of 10:1 or higher. 

• S&S can do a special order cam. Contact your S&S Customer Service Representative for 

more information. 

100 

90 

80 

70 

60 

50 

40 

30 

20 

10 

1500 


2009 FLHT with S&S® 585 Performance Cam vs Stock Cam 




2000 2500 3000 

96 Stock Cam 



3500 4000 4500 5000 5500 6000 

EngSpd RPM 

2-12 




GEAR DRIVE CAM KITS 


• Improves valve timing accuracy by eliminating timing chain lash 

• Easy Start Cams allow stock starter to start any engine 

• No tensioner shoes to wear out or fail 

OPTIONS 

Which S&S Gear Drive Cam Kit to Order 

• If updating a stock chain drive system, it's easiest to order a complete kit. Includes: 

• Camshafts with inner gears 

• Outer cam drive gear kit 

• Camshaft installation kit 

• If replacing cams in an engine already equipped with S&S gear drive cams, order cams 

with inner gears and reuse the existing outer gears. Camshaft installation kit for the 

appropriate model year is recommended. 

• If installing a set of gear drive cams from another manufacturer, order S&S cam gear kits 

for the appropriate model year. Each kit provides the inner cam gear as well as an outer 

cam gear. Camshaft installation kit for the appropriate model year is recommended. 

Cam Name 

Complete Kit 

S&S GEAR DRIVE CAMS FOR 1999-'06 MODELS* 

Easy Start 

Cams w/ Inner Gears 

Stock Oil Pump 

Complete Kit 

Standard 


Stock Oil Pump 

475 – – 106-4033 106-4385 

509 – – 330-0017 330-0018 

510 – – 33-5177 33-5174 

546 – – 33-5230 – 

551 106-5442 106-5441 330-0100 330-0099 

570 106-5243 106-5242 33-5178 33-5166 

583 106-5859 106-5858 330-0107 330-0108 

585 106-5247 106-5246 33-5179 33-5168 

625 106-5251 106-5250 33-5180 33-5170 

640 106-4840 106-4839 33-5181 33-5172 

675 106-5255 106-5254 33-5231 33-5237 

*2006 Dyna® cams are in Section 1. 

INSTALLATION KITS for S&S Gear DRIVE CAM (recommended) 

Models 



Includes a gearcover gasket, cam bearings and instructions. *2006 Dyna® install kit is in Section 1. 

106-5896 

Camshaft installation kit for 1999-'06 models 

provides parts needed to install S&S® gear drive 

cam sets. Included with complete cam kits. 

Gear Drive Easy Start Cams 

for early models 



NOTES: 

• Pinion shaft run-out must be checked before installing S&S® gear drive cams. 

• A hydraulic press and other professional tools are required to install S&S gear drive 

cams. Additionally, material must be removed from the inner surface of the stock 

gearcover. The stock crankcase will require clearancing for S&S .625", .640", and 

.675" lift cams. S&S recommends that gear drive cams be installed by a professional 

mechanic. 

• New cam bearings and a new gearcover gasket are required to complete cam 

installation. Gear drive cams for 1999-' 06 models require the use of ball bearing style 

cam bearing rather than the stock roller bearing. Roller bearings have more internal 

clearance which can cause excessive gear lash and increased noise. The correct parts 

are provided in S&S Camshaft Installation Kit, part #106-5896. 

• Due to the inherent characteristics of gear drives, you may experience more valve 

train noise with gear driven cams. Oversized and undersized gears are available to 

help achieve correct gear lash. We have found that with 160 lb. of valve seat force, the 

S&S gear drive cams will perform well up to 6200 rpm. If higher rpm is anticipated, 

valve springs that provide higher seat force should be used. 

• S&S can do a special order cam. Contact your S&S Customer Service Representative 

for more information. 


Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-13

S e ction 2: 


Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Adjustable PUSHRODS 

S&S Quickee Adjustable Pushrods can be both installed and removed easily. The 

S&S design permits a simple, trouble-free installation that does not require removal 

of the gas tank, rocker assemblies, tappet covers or even the rocker box cover! OEM 

pushrods may be cut to permit removal without rocker disassembly. The threaded 

adjuster screws into the pushrod until the threads disengage and the adjuster simply 

slides into the pushrod, making installation or removal a snap. Once the pushrod is 

installed and adjusted, the locknut prevents the adjuster from moving. 1984-'99 style 

pushrod covers required. 

S&S Standard Adjustable Pushrods are an economical alternative to the S&S 

Quickee Adjustable pushrods, but require rocker cover removal to install or remove. To 

assure consistent valve train operation under all conditions, S&S adjustable pushrods 

are manufactured from rigid chromoly steel tubing. 

FITMENT 

• 1999-'12 Twin Cam 88® or 96 w/ stock engine height +/- .050" 


• Easy to install – removal of rocker box not needed 

• Adjustable to accommodate all tappets and 

cam base circle diameters and engine heights 

• Perfect for S&S HL 2 

T 

• No threads on wrench flats 

• Quickee Adjustable Pushrod Kit includes: 

• Pushrods 

• Chrome pushrod covers 

• O-rings 

• Cover keepers 


When a Quickee Adjustable is collapsed, it can easily be installed or removed from an assembled 

engine. 

93-5095 

Standard Adjustable Pushrod Kit 

Tools & Shop 

Supplies 

PART NUMBERS 

Quickee Adjustable Pushrod Kit .......................... 106-6051 

S&S Standard Adjustable Pushrod Kit .......................93-5095 


& Promo Items 

Warranty & 


Replacement parts on page 2-56 

WATCH THE PUSHROD INSTALLATION VIDEO AT 

SSCYCLE.COM/MEDIA/VIDEOS.PHP 

106-6051 

Quickee Adjustable Pushrod Kit 



EXTRA PARTS NEEDED: 

• Longer keepers are required for taller than stock engines. See page 2-50. 

2-14 




Dynojet ® Power vision ® tuner 

Power Vision is a performance tuner and data monitor that offers the latest 

flash tuning technology, data logging, and other industry exclusive 

features. Developed to tune any Harley-Davidson® motorcycle 

with the Delphi ECM, the Power Vision Product Suite includes 

a full color touch screen flash device, vehicle interface cable, and 

WinPV (Windows PC based tuning application). 

Fitment 

• 2001-’12 Harley-Davidson® models equipped with Delphi® ECM 


• Flash tune all H-D® models equipped with a Delphi ECM 

• Does NOT require the user to interface with a computer in order to flash a tune. 

Change rev limit, idle speed, and other parameters directly from the device 

• Display all H-D vehicle data as well as wide band AFR** and various calculated 

channels (such as Avg MPG) 

• Customizable virtual gauges allow data to be monitored live, and / or logged 

while riding 

• User defined visual alarms for any data channel 

• AutoTune Basic and Pro – calculates and stores fuel trims to help you optimize 

fuel curve utilizing the factory o2 sensors (Basic), or Dynojet’s Wide Band 2 

System (Pro)! 

• Check and clear diagnostic codes 

• Reset adaptive fuel trims and idle offset (with bike running) 

WinPV Software Features 

• Allows you to import Power Commander Maps 

• Tuning parameters laid out in a clear, concise manner utilizing a "tree view structure" 

• A viewing mode for every type of user, beginners or professionals 

• Individual tuning parameters are able to be saved as "value files". The value files can 

then be applied to other calibrations 

• Compare, restore, and undo features 

• Various math functions can be performed on any value 

• Synchronized editing of front and rear VE and / or Spark tables 

• Helpful tuning parameter descriptions 

• Automatic update client ensures you have the latest tuning application, firmware, 

and tune file database 

**when outfitted with a Dynojet Auto Tuner 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

The Power Vision Suite includes a highly flexible tuning / data logging device, as well 

as a productive tuning application (WinPV) that’s user friendly compared to other 

products on the market. 

Part Number 

Dynojet Power Vision Tuner 

2001-'12 H-D® models (except 2011 -'12 Softail® & 2012 Dyna®) MFR PIN PV-1 ..... 550-0087 

Parts for 

X-Wedge® 

2007-2012 


Dynojet ® Auto Tune 

for power Vision ® 

Want to get the most from your Power Vision Then upgrade with the Auto Tune Module 

kit. Exclusive to Power Vision, this exciting new accessory works in conjunction with your 

Power Vision to open the lines of communication simply not available through the narrow 

OEM band. 

FITMENT 

• 2001-’12 Harley-Davidson® models equipped with Delphi® ECM 

FEATURES & BENEFITS 

• Transmits wide band Air-Fuel Ratios (AFR) to Power Vision Data Recorder 

• Not an automatic tuning system. Requires Log Tuner software (free download) and 

user interaction. Process corrects fuel and spark requirements 

• Utilizes factory Ion Sense to precisely tune spark advance 

• Combine with Log Tuner software to tune like the pros 

• Kit includes Y-adapters for simultaneously interface with Power Vision and Auto Tuner 

module and oxygen sensors to provide more accurate tuning at all operating ranges 

PART NUMBERS 

Dynojet AutoTuner 

2001-'12 H-D® models (except 2011 -'12 Softail®, and 2012 Dyna®). ............550-0109 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-15

S e ction 2: 

S&S ® Step 3: Big Bore KIt 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

97" BIG BORE KITS 

FITMENT 

• 1999-'06 big twins 


• Largest bore that we feel can safely be used in a cylinder with a stock spigot O.D. 

• Bolt-on 9 to 10 cubic inches – cylinders do not require crankcase machining to install 

• Piston weight for 97" kits are the same as stock, requiring no flywheel rebalancing 

• Forged coated pistons are compatible with stock or S&S Super Stock® 79cc & 89cc heads 

• Valve pocket recessed in S&S pistons are enlarged for oversize valves and higher lift cams 

• Silver or wrinkle black powdercoat cylinder finish color matches stock Harley-Davidson® finish 

• Maintains stock engine height 

• Oversize pistons are available 

KIT CONTENTS 

• Piston set with rings 

• Top end gasket kit 

• S&S cylinders 



Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 



Warranty & 


Parts for 


& Metric 

S&S® 97" BIG BORE KITS 

Specifications Compression Ratio Part No. 

Year Displacement Stroke Bore Cylinder Length Piston Type 

1999 - '06 97" 4" 3.927" 4.937" 

Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or honing. 

Not legal for sale or use on CA or EPA pollution controlled vehicles. 

Forged 

3 cc Dome 

85cc Stock 

Heads 

79cc S&S Heads 


Silver 

Powdercoat 

Wrinkle Black 

Powdercoat 

9.7:1 10.3:1 9.4:1 106-5974 106-5975 

2-16 



Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

This dyno chart shows performance of a 2006 FLHR using stock heads with the S&S 97” Big Bore Kit, S&S performance mufflers and either an S&S 

551 cam or 585 cam. Compared to a completely stock FLHR, the output of horsepower increased 27.9 hp and torque increased to 18.4 ft/lb! 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

NOTES: 

• S&S® highly recommends installing a performance cam for easier starting and better engine performance. 

• S&S high flow cylinder heads will provide further horsepower gains. 

• For an additional .2 bump in compression, order .030" thick head gaskets #900-0216 (2 pack). Remember to check your 

clearances. 

• These kits require tuning. When used on EFI models, S&S recommends Dynojet® Power Vision flash tuner, for more information, 

see page 2-15. 


& Promo Items 

Warranty & 





2-17

S e ction 2: 

S&S ® Step 4: CNC Ported heads 

Parts for 

Twin Cam 96 /103 

2007-2012 


CNC Ported Cylinder Head sERVICES 

S&S® offers a CNC porting service for stock cylinder heads for 1999-’12 Harley-Davidson® 

big twin engines. This is an economical way to get a substantial horsepower increase 

while maintaining a stock appearance. 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




S&S has developed high flowing intake port, exhaust port, and combustion chamber 

shapes for stock cylinder heads. S&S then digitally reproduces them in a stock head 

casting with our 5-axis CNC machining centers. After CNC porting, heads are assembled 

with new one-piece, forged racing grade stainless steel alloy, valves, valve guides and 

high performance conical valve springs. 

Fitment 

• Available for 1999-’12 big twin engines 

• Ideal for 88" - 124" engines (must use Screamin’ Eagle® high flow injectors, HD 

#27796-08, with kits over 106") 


• CNC machined ports for a consistent performance increase from stock heads 

• Great throttle response, high velocity port without losing low RPM torque 

• Assembled with performance valves and springs ready to bolt-on 

• Choice of .585" or .650" lift valve springs 

• Combustion chambers are available in the following volumes: 

• 83cc-Generally used for stock 88" up to 106" engine displacements 

• 85cc- Same as stock Twin Cam 88" and 96" engine displacements 

• 89cc- Recommended for up to 117" engine displacements 

• 90cc- Generally used for 124" and up engine displacements 

• Available in factory black or silver 

Service options 

• Exchange Service 

• CNC ported heads are available for immediate delivery, core charge per set 

must be paid 

• Send your stock heads to S&S 

• Core charge credited if customer's returned heads pass inspection (see notes 

on next page) 

• No turn-around delay 

• Rework Service 

• Send your stock heads to S&S 

• Get the same set of heads back with CNC machined ports 

• The best option for heads with a special cosmetic treatment 

• Allow 2 week turn-around 

• Custom CNC Port Duplication 

• S&S can digitize your port design and machine it in your heads, ask an S&S 

customer service representative for details 

Part Number 

S&S CNC Porting Service for Stock Heads ............................. 106-5880 

WATCH THE S&S CNC PORTING VIDEOS AT 


Shown is the S&S CNC machined intake port before the valve guide is installed. Notice the 

raised vane ahead of the valve guide hole. The purpose of this vane is to split the air stream 

ahead of the valve guide to reduce turbulence and increase flow. 

Digitized port shapes are faithfully reproduced in any stock Harley-Davidson® cylinder 

head on our 5-axis CNC machining center. Intake port, exhaust port and combustion 

chamber are all modified. This head will be assembled with new forged stainless steel 

valves and high lift valve springs to complete the package. 

Stock 

Harley-Davidson® 

CNC Ported 

by S&S® 

Valve Size 

Intake 1.805" 1.900" 

Exhaust 1.575" 1.610" 

Max Valve Lift .585" .650" 

Max TDC Lift 

Intake – .230" 

Exhaust – .215" 

Port Flow* 

Intake 216.2 cfm 248.6 cfm 

Exhaust 191.8 cfm 209.7 cfm 

88" 9.0:1 9.2:1 

95" 9.2:1 9.4:1 

Compression 

97" 9.7:1 9.9:1 

Ratio 

103" 10.1:1 10.3:1 

106" Stroker 10.1:1 10.3:1 

124" DD Piston 10.7:1 10.9:1 

Chamber Volume 85cc 83cc** 

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

lift. Heads tested are 2006-up style. 

** As a general rule of thumb, for every 1cc decrease in chamber volume equals a .1 increase in 

compression ratio. 

2-18 



Continued 

CNC Ported Cylinder Heads from S&S® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

The CNC Difference: The dyno chart compares a stock 2009 FLHT (black curves) with the same 

bike after an S&S 106" Big Bore Top End Kit, 585 cams and S&S slip on mufflers, and an S&S 

teardrop AC were installed. The top curves show the same engine after the heads were CNC ported 

and a 58mm throttle body was installed. Both 106" engines perform much better than stock, and 

are pretty comparable to each other until about 3500 rpm. At that point, the engine with CNC 

heads continues to increase in torque and horsepower because it can still get enough air. 


Stock 2009 FLHT vs S&S 106” Kit, Slip-On’s, Intake, CNC Porting. With 551 & 585 Cams 

S&S 106”, Slip-On’s, 585 Cams, CNC, & SE 58 

Peak Rear Wheel HP 115.2 

Peak Rear Wheel Torque 112.0 

130 

120 

110 

100 

90 

80 

70 

60 

50 

40 

30 

20 

10 

0 

1000 2000 3000 

S&S 106”, Slip-On’s,551 Cams CNC, S&S AC 



Stock 2009 FLHT 



4000 5000 6000 

7000 

EngSpd RPM 

Choose The Right Cam For You: This dyno chart compares a stock 96" 2009 FLHT on the 

same bike with an S&S 106" Big Bore Top End Kit with CNC ported heads, S&S slip-on mufflers, 

performance intake, and two different cams. The blue curves represent the 106 with S&S 551 

touring cams and S&S teardrop air cleaner on the stock 50mm throttle body. Great torque for 

performance touring applications. The top curves show the S&S 585 cams with a 58mm throttle 

body. The increased duration of the 585 reduces low and midrange torque, but the combination of 

more aggressive valve timing, higher lift and a larger throttle body significantly increases usable 

rpm and top end horsepower. A good choice for lighter bikes and racing applications. Both engines 

were tuned with Screamin' Eagle® Race Tuner. 

Notes: 

• Only cylinder heads that are in good condition and have "like new" appearance may 

be exchanged. Heads with non-OEM compression release machining, superficial 

damage, peeling or discolored paint, or other cosmetic alterations are not acceptable 

for exchange, but may be reworked. Rework will take slightly longer than exchange 

service. Customer will be contacted to review options if heads do not pass inspection. 

• CNC porting is not available for previously ported heads, heads that have been 

structurally damaged, or heads that are determined to be unserviceable during initial 

inspection. These heads will be returned to the customer without modification. In 

these cases, the customer will be notified and options will be reviewed. New, CNC 

ported stock heads or S&S heads are available for purchase. 

• Due to variations in stock 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 to be completely machined. This does not effect performance and is not 

considered a defect. 

• CNC porting is not currently available for Harley-Davidson® CVO engines or Screamin' 

Eagle® cylinder heads. 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-19

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


PERFORMANCE 

KITS 

Performance Kit overview 

For harley-Davidson ® Twin Cam 88 ® 


There are many paths you can take on the road to performance. S&S offers many different types of kits to unlock the performance potential in your motorcycle. 

The following overview is intended to give you insight into the different ways that the performance you demand can be added to your ride. The contents, unique features, highlights 

and specifications are listed to help you understand the performance package that is best for your journey. 

97" Big Bore Kit 

Up the displacement of your Twin Cam® 88 to a whopping 97". This bolt-on cylinder kit adds significant displacement 

without any machining required to your engine. Stroke stays the same at 4.00". Bore increases from 3.750 to 3.927". This kit 

contains pistons, cylinders and all related parts, gaskets and instructions. See page 2-22 

Parts for 


1986-2012 

Parts for 


1926-1984 

106-5974 

95"/97" Hot Set Up Kit 

Looking to go further Consider the Hot Set Up Kits. Available in 95" or 97" displacements, these kits will put some stride in 

your glide. Your stock cylinders can be bored for 95" pistons or select 97" pistons and cylinders already sized. Pushrods, covers 

and hydraulic lifters are all included. Select from a variety of cylinder heads to achieve the compression ratio you desire or keep 

your stock heads. Kits include S&S Easy Start 570 or 585 chain drive camshafts. See page 2-24 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

106-0214 

106" Stroker Kit 

Stroke it! This performance package gives big displacement. The kit’s flywheel assembly increases your stroke from 4 3/8" 

to a hefty 4 ½" and bumps your 88" to 106". Oversize your stock cylinder bore from 3 ¾" to 3 7/8". No crankcase machining 

needed. Maintains stock engine height for easy installation. See page 2-27 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

32-2490 

106" Stroker Hot Set Up Kit 

Move beyond the Stroker Kit to the Stroker Hot Set Up Kit! Select the compression ratio you desire from a choice of cylinder 

heads. Kits come with S&S Easy Start chain drive cams or select the camshaft the best fits your riding style. Pushrods, covers, 

hydraulic lifters and gaskets are included. Realize up to a 50% horsepower increase! See page 2-28 

Warranty & 




2-20 

320-0015 

900-0220 


124" Hot Set- Up Kit 

Move to the ultimate in performance packages! Increase your bore to 41/8" and stroke to 45/8" to realize a massive 124 

cubic inches of pure performance. This kit includes flywheel assembly, cylinders and pistons, S&S Easy Start 640 lift chain 

drive camshafts, hydraulic lifters, pushrods, covers, valve springs and rocker arms. Comes complete with all gaskets and 

instructions. CTO options give you even more choices. Crankcases require boring to accept the larger cylinder spigots. 

See page 2-30


Continued 

S&S Performance Kit Overview 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

KITS 

KIT DESCRIPTION BORE STROKE 

Performance kit specifications for Harley-Davidson® Twin Cam 88® 

Stock 

Heads 

79cc 89cc 91cc 

COMPRESSION RATIO 

CNC Heads 

83cc 85cc 87cc 90cc 

CAMSHAFT 

HORSEPOWER 

(CNC Heads) 

97" Big Bore Kit 3.927" 4" 9.7:1 10.3:1 9.3:1 9.1:1 9.8:1 9.6:1 9.5:1 9.2:1 – 103 107 

95" Hot Set Up Kit 3 7/8" 4" 9.7:1 10.3:1 9.4:1 9.2:1 9.9:1 9.7:1 9.5:1 9.3:1 570 103 107 

97" Hot Set Up Kit 3.927" 4" 9.7:1 10.3:1 9.3:1 9.1:1 9.8:1 9.7:1 9.5:1 9.2:1 570 / 585 103 107 

106" Stroker Kit 3 7/8" 4 1/2" 10.1:1 10.7:1 9.7:1 9.6:1 10.3:1 10.1:1 9.9:1 9.7:1 585 109 115 

106" Stroker Hot Set Up Kit 3 7/8" 4 1/2" 10.1:1 10.8:1 9.8:1 9.6:1 10.3:1 10.1:1 9.9:1 9.7:1 585 110 119 

124" Hot Set Up Kit 4 1/8" 4 5/8" 10.9:1 * 11.1 10.8:1 11.6:1 11.4:1 11.2:1 10.9:1 640 127 130 

* Not Recommended 

KIT DESCRIPTION 

Performance kit contents, options and requirements for Harley-Davidson® twin Cam 88® 

Flywheels 

Cylinders 

Pistons 

w/ rings 

Rocker 

Arms 

PACKAGE CONTENTS 

Pushrods 

w/ covers 

Lifters 

Camshafts 

Valve 

Springs 

Heads w/ 

springs 

MACHINING 

REQUIRED 

CTO 

OPTIONS 

97" Big Bore Kit • • • • 

95" Hot Set Up Kit • • • • • 

97" Hot Set Up Kit • • • • • • • 

106" Stroker Kit • • 

106" Stroker Hot Set Up Kit • • • • • • 

124" Hot Set Up Kit • • • • • • • • • 

= Optional 

= Order separately 

= Bore & hone cylinders 

= Crankcase machining for center stud 

= Crankcase machining for cylinder spigots 

= Camshaft selection 

Gaskets 

= CNC heads 

= Combustion chamber size selection 

= Cylinder & piston set available 

*The CTO option column lists only the major items offered. Virtually any option can be selected from our product offerings through the Configure To Order (CTO) program. 

TORQUE 

REJETTING OR 

CALIBRATION 

CHANGE 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-21

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

97" BIG BORE KITS 


Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

PERFORMANCE 

KITS 

FITMENT 



• Largest bore that we feel can safely be used in a cylinder with a stock spigot O.D. 

• Bolt-on 9 to 10 cubic inches – cylinders do not require crankcase machining to install 

• Piston weight for 97" & 106" kits are the same as stock, requiring no flywheel rebalancing 

• Forged coated pistons are compatible with stock or S&S Super Stock® 79cc & 89cc heads 

• Valve pocket recessed in S&S pistons are enlarged for oversize valves and higher lift cams 

• Silver or wrinkle black powdercoat cylinder finish color matches stock Harley-Davidson® finish 


• Oversize pistons are available 

KIT CONTENTS 

• Piston set with rings 

• Top end gasket kit 

• S&S cylinders 


Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

S&S® 97" BIG BORE KITS 

Specifications Compression Ratio Part No. 

Year Displacement Stroke Bore Cylinder Length Piston Type 

1999 - '06 97" 4" 3.927" 4.937" 



Forged 

3 cc Dome 

85cc Stock 

Heads 



Silver 

Powdercoat 

Wrinkle Black 

Powdercoat 

9.7:1 10.3:1 9.4:1 106-5974 106-5975 



Warranty & 



& Promo Items 

2-22 



Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

KITS 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

This dyno chart shows performance of a 2006 FLHR using stock heads with the S&S 97” Big Bore Kit, S&S performance mufflers and 

either an S&S 551 cam or 585 cam. Compared to a completely stock FLHR, the output of horsepower increased 27.9 hp and torque 

increased to 18.4 ft/lb! 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

NOTES: 

• S&S® highly recommends installing a performance cam for easier starting and better engine performance. 

• S&S high flow cylinder heads will provide further horsepower gains. 

• For an additional .2 bump in compression, order .030" thick head gaskets #900-0216 (2 pack). Remember to check your clearances. 

• These kits require tuning. When used on EFI models, S&S recommends Dynojet® Power Vision flash tuner, for more information, see page 2-15. 


& Promo Items 

Warranty & 





2-23

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

PERFORMANCE 

KITS 

95" & 97" HOT SET UP KIT ® 

FITMENT 



• For 95" kits, stock cylinders can be bored to 3 7/8", honed and reused 

• .045" MLS head gaskets standard 

• Up to a 40 HP increase 

• True bolt on kit, no machining required 


• Wrinkle black or silver powdercoat match stock appearance 

• Kits include S&S 570 or 585 Easy Start chain drive cams – depending on resultant 

compression ratio 

• S&S pushrods are made of high strength chrome-moly tubing 

• Valve pocket recesses in S&S pistons are enlarged for oversize valves and high lift cams 


Stock Harley-Davidson® Twin Cam 88® vs S&S® 95” Super Stock® Hot Set Up Kit® 


Now with 

Easy Start 

Cams! 

900-0243 

This 97" Hot Set Up Kit includes chain drive easy start 

camshaft kit, cylinder kit, hydraulic tappet set, gasket kit, 

cylinder head kit with head bolts, and adjustable pushrod kit. 


Harley-Davidson® Twin Cam 88® with 97” Hot Set Up Kit® 79cc Heads vs 83cc CNC Heads 

Parts for 


& Metric 

110 

100 

90 

S&S 95” Super Stock Hot Set Up Kit 



Stock Twin Cam 88 Engine 



120 

100 

90 

80 

S&S 97” Hot Set Up Kit w/ 83cc CNC Heads 



S&S 97” Hot Set Up Kit w/ 79cc Heads 



Racing 

Products 

80 

70 

70 

60 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




60 

50 

40 

30 

Lower curves show completely stock 1999 FXDL. Middle and upper curves represent 1999 

FXDL with Screamin’ Eagle® 6200 rpm ignition module, and S&S performance mufflers and 

95" Hot Set Up Kit® (Super E carburetor, 570G cams, high performance tappets, .640" triple 

valve springs, adjustable pushrods), stock heads (middle) or Super Stock® heads (upper). 

Year 

2500 3000 3500 

Displacement 

4000 4500 5000 5500 6000 

EngSpd RPM 

Stock 

Stroke 

Bore 

Cylinder 

Length 

S&S® 95" & 97" HOT SET UP KIT® SPECIFICATIONS 

Piston Type 

85cc Stock 

Heads 


Compression Ratio 


83cc CNC Ported Stock 

Heads 

1999 - '06 95" 

37/8" 

Forged, 5.3cc pop-up dome 9.7:1 9.4:1 10.4:1 9.9:1 

1999-'06, 

4" 

4.937" 

97" 3.927" Forged, 3cc domed 9.7:1 9.3:1 10.3:1 9.8:1 

(except Dyna®) 


50 

40 

30 

20 

2000 2500 3000 

3500 4000 4500 5000 5500 6000 6500 7000 

EngSpd RPM 

2000 carbureted Dyna / S&S Teardrop / E series 2-1 exhaust / S&S IST ignition / 585 Easy 

Start cams 

2-24 



CONTINUED - 

S&S® 95" & 97" Hot Set Up Kit® 

Parts for 

Twin Cam 96 /103 

2007-2012 

S&S® 95" Super Stock® Hot Set Up Kits® for 88" Engines 

Includes S&S 37⁄8" bore cylinders and pistons, 585 Easy Start chain drive cams and 79cc heads 

Application Silver Black 

PERFORMANCE 

KITS 

Parts for 



S&S® 95" Hot Set Up Kits® 

900-0418 

106-0214 

These kits require special S&S pistons. 

Order the required piston oversize from these charts. 

92-1200 

Pistons work with 4" stroke flywheels in 

88" engines to produce 95 cubic inches 

1999-’06 (except 2006 Dyna® Models*) 900-0418 900-0419 

CTO 

*Kits for 2006 Harley-Davidson® Dyna models, use CTO part number. 

106-5744 

S&S® 95" Super Stock® Hot Set Up Kits® for 88" Engines 

Includes S&S 37⁄8" bore cylinders and pistons, 585 gear drive cams and 79cc heads 

Application Silver Black 

1999-’06 (except 2006 Dyna® Models*) 106-5744 106-0214 

CTO 


106-5744 

92-1200 Series Pistons for S&S® 95" Hot Set Up Kit® 

Oversize 

Part No. 

Standard 92-1200 

+.005 92-1204 

+.010 92-1201 

+.020 92-1202 

Cylinder & Piston Kit - Silver 106-4138 

Cylinder & Piston Kit - Black 91-7047 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

NOTES: 

• Fuel injected engines will require recalibration of the fuel injection system. The S&S VFI modules and closed loop sensor kits are highly recommended. Additionally, S&S recommends 

the Dynojet Power Vision Flash Tuner, see page 2-15 for more information. 

• Stock cylinders must either be bored to 37/8" or replaced with S&S® 37/8" bore cylinders. 

• S&S recommends either CNC porting stock cylinder heads or purchasing Super Stock® heads to maximize the effect of higher lift cams. Stock cylinder heads will produce significantly 

less power. S&S can CNC port your heads, for an economical increase in power. 

• For 95" kits ordered without cylinders, pistons must be measured and cylinders bored/honed accordingly. Recommended piston fitment: 

• Close: 0.0020" – 0.0025" 

• Loose: 0.0032" – 0.0045" 

• 92-1200 series pistons have a 1.270" deck height. 

• .030" MLS head gaskets optional: Part #900-0216 

• Not legal for sale or use on CA or EPA pollution controlled vehicles. 

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 pistons in your 

cylinders, to complete installation of any engine kit. Contact your S&S customer service representative for details. 

S&S® 97" Hot Set Up Kits® on next page 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-25

S e ction 2: 

CONTINUED - 

Parts for 

Twin Cam 96 /103 

2007-2012 

S&S® 95" & 97" Hot Set Up Kit® 


Parts for 



PERFORMANCE 

KITS 

S&S® 97" Hot Set Up Kits® With 79cc Super Stock® Heads, cylinders & Pistons 

Model Year Cam Compression 

Ratio 

Piston 

Type 

Valve 

Springs 

Wrinkle Black 

Part No. 

Silver 

Parts for 

Evolution ® 


1999-2006 bt 

(except 2006 Dyna®)* 

CTO 

585CE 10.3:1 106-3680 585” 900-0243 900-0244 

106-5744 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

S&S® 97" Hot Set Up Kits® 

900-0243 

900-0245 


Model Year 



CTO 

S&S® 97" Hot Set Up Kits® With 83cc CNC Ported Heads, cylinders & Pistons 

Cam 

Compression 

Ratio 

Piston 

Type 

Valve 

Springs 

Wrinkle Black 

Part No. 

Silver 

570CE 9.8:1 106-3680 585” 900-0245 900-0246 


106-5744 

S&S® 97" Hot Set Up Kits® With cylinders & Pistons Without Heads 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




900-0247 

Model Year 



CTO 

Cam 


with 85cc Stock Heads 

Piston 

Type 

570CE 9.7:1 106-3680 

Valve 

Springs 

Purchase 

Seperately 

Wrinkle Black 

Part No. 

Silver 

900-0247 900-0248 

106-5744 

S&S .585" lift dual valve spring kit must be used with stock heads. See page 2-58. 

S&S CNC ported stock cylinder heads are a perfect addition to this Hot Set Up kit. The .585" lift spring kit is not required if you are going 

to have S&S CNC port your heads. See page 2-18 for more details. 


NOTES: 

• S&S recommends either CNC porting stock cylinder heads or purchasing Super Stock® heads to maximize the effect of higher lift cams. Stock cylinder heads will produce 

significantly less power. 

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

strongly recommends that the stock chain drive be upgraded to the S&S gear drive or to the H-D® #25284-08 or #25284-11 hybrid plate. This kit updates the problematic spring 

loaded chain tensioners to more reliable hydraulic tensioners and also upgrades the oil pump. 

• S&S can CNC port your heads, for an economical increase in power. 


• Not legal for sale or use on CA or EPA pollution controlled vehicles. 

• Fuel injection tuning required. S&S offers fuel injection tuning solutions starting on page2-15. 

2-26 



S&S ® 

106" Stroker Kits 

for use with stock cylinders 

This kit combines an S&S 4½" stroke flywheel assembly with S&S 37⁄8" bore pistons for a 

displacement of 106 cubic inches. 

FITMENT 


PERFORMANCE 

KITS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 




• Installation of the kit does not require any special machining, other than fitting the 

pistons 

• S&S stroker pistons, which are sold separately, are available in all standard oversizes 

• Stock 88" cylinders can be bored from 3¾" bore to 37⁄8" to accommodate the S&S 

pistons, or a pre-fit S&S cylinder and piston kit may be installed 

• Engines with factory 95" kits require piston fitting only – stock or S&S cylinder 

heads can be used 

• Fuel injected engines will require recalibration of the fuel injection system – the S&S 

VFI modules and closed loop sensor kits are highly recommended 


To achieve the full potential of this engine configuration, we suggest that you 

consider the 106" Hot Set Up Kit® found on page 2-28. 

32-2490 

S&S® Stock Bore Stroker Kit shown here is only available with assembled 

flywheels. Pistons must be purchased separately, see below. Kit includes 

special S&S piston oiling jets. For Dyno chart see page 2-28.. 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Specification Chart 

S&S® 106" Stock Bore Stroker Kits For Harley-Davidson® Twin Cam 88® and Twin Cam 88B Engines 

Displacement Stroke Bore Compression Ratio* Piston Type Piston Deck Height Cylinder Length Application Engine Life 

106" 41⁄2" 37⁄8" 10.1:1 Flat Top 1.020" 4.937" Trips Very Good 

* Compression ratio with stock heads. Compression ratio with S&S 89cc heads 9.8:1. For additional compression use .030" MLS head gaskets- part #900-0216 

Includes S&S piston oiling jets 

S&S® 106" Stroker Kits 

For Harley-Davidson® Twin Cam 88® Engines with stock cylinders 

Application 

Part No. 

1999-’06 Twin Cam 88 Except 2006 Dyna® 32-2490 

2000-’06 Twin Cam 88B 32-2491 

2006 Dyna® 106-2189 

Custom Flywheels - Special Order* 32-2141* 

S&S piston oilers are supplied with this kit. 

Must be ordered separately with custom flywheels. 

* Special Order: Download the Special Order Form at sscycle.com/soforms 

92-1210 Series 

These kits require special S&S pistons. 

Order the required piston oversize from this chart. 


Oversize Piston Deck Height Part No. 

Standard 

92-1210 

+.005" 92-1214 

+.010" 92-1211 

1.020" 

+.020" 92-1212 

Cylinder & Piston Kit - Silver* 106-4140 

Cylinder & Piston Kit - Black* 91-7061 

*Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or 

honing. 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-27

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

KITS 

106" Stroker Hot Set Up ® KIT 

Delivering real performance gains at a reasonable price, the heart of this 106" stroker kit 

is an S&S 4½" stroke flywheel assembly. Installation requires no crankcase machining or 

modification, and stock cylinders can be reused to further reduce cost. Select S&S Super 

Stock® heads for the maximum power output. 106" stroker kit is recommended for 1999- 

'06 engines. 

FITMENT 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 


• Up to 75% horsepower increase 

• Strong S&S 4½" stroke pressed together flywheel assembly 

• No crankcase modifications required! 

• S&S 585 Easy Start chain drive cams to maximize performance 

• High performance hydraulic tappets assure accurate valve timing 

• Stock cylinders can be bored to 37/8" and reused to reduce cost 

• 9.8:1 compression ratio means reliable performance 

• S&S pushrods are made from high strength chromoly tubing 

• Valve pocket recesses in S&S pistons are enlarged for oversize valves and higher lift cams 

• Installation instructions and all necessary hardware and gaskets are included 


• Available in wrinkle black powdercoat or silver powdercoat 

Parts for 


& Metric 

Racing 

Products 

Parts for 

X-Wedge® 

2007-2012 

320-0015 Now with 

Easy Start 

Cams! 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




After installing the pictured 106" S&S® stroker kit, hp output increased by 75% when 

combined with a high flow air cleaner and performance exhaust! 

Year Stroke Displacement Bore 

Cylinder 

Length 

S&S® 106" STROKER KIT SPECIFICATIONS 

Piston Type 

Flat Top 

1999-'06 41/2" 106" 37/8" 4.937" 

Forged 




(included) 



85cc Stock Heads 

83cc CNC ported 

stock heads 

9.8:1 10.8:1 10.1:1 10.3:1 

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 pistons in your cylinders, to complete installation of any engine kit. Contact your S&S customer service representative for details. 

2-28 



CONTINUED - 

S&S® 106" Stroker Hot Set Up® Kit 

320-0015 

320-0021 

S&S® 106" Stroker Hot Set Up Kits® with 89cc Super Stock® Heads 

For Harley-Davidson® Twin Cam 88® Engines 

Engine Style Silver Powdercoat Black Powdercoat 

1999-2006 Twin Cam 88 Touring and Dyna® (except 2006 Dyna® models)* 320-0015 320-0018 

2001-2006 Twin Cam 88B Softail® w/Balancer 320-0016 320-0019 

CTO 

All kits include pushrod kit and chain drive Easy Start cams. 

Order pistons separately. * For 2006 Dyna®, see Section 1. 

106-5745 

The heads included in these kits have 89cc combustion chambers. 

S&S® 106" Stroker Hot Set Up Kits® without heads 

For Harley-Davidson® Twin Cam 88® Engines 

Engine Style 

Part No. 

1999-2006 Twin Cam 88 Touring and Dyna® (except 2006 Dyna® models)* 320-0021* 

2001-2006 Twin Cam 88B Softail® w/Balancer 320-0022* 

106-5745 

CTO 

This kit requires special S&S pistons. 

Order the required piston oversize from this chart. 

92-1210 Series 

All kits include pushrod kit and chain drive Easy Start cams. Order pistons separately. 

*S&S Sidewinder® .585" lift valve spring kit must be used with stock heads. See page 2-58. 

S&S CNC ported stock cylinder heads are a perfect addition to this stroker kit. The .585" lift spring kit is not required if you are going to have S&S 

CNC port your heads. See page 2-18 for more details. * For 2006 Dyna®, see Section 1. 


Oversize Piston Deck Height Part No. 

Standard 

92-1210 

+.005" 92-1214 

+.010" 92-1211 

1.020" 

+.020" 92-1212 

Cylinder & Piston Kit - Silver* 106-4140 

Cylinder & Piston Kit - Black* 91-7061 

*Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or honing. 

NOTES: 

• For 106" stroker kits ordered without cylinders, pistons must be measured and cylinders bored/honed accordingly. Recommended piston fitment: 

• Close: 0.0020" – 0.0025" 

Loose: 0.0032" – 0.0045" 

• S&S Easy Start Cams can save you money – no need to buy compression releases or S&S rocker covers. 

• Unless professional headwork is done, kits using stock, un-ported cylinder heads will produce significantly less power compared to S&S heads. 

• 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 stock flywheel assembly, and requires no 

engine disassembly below the base gasket. Turn to page 2-22 of this section for more details on 106" Big Bore Kits. 

• Fuel injected engines will require recalibration of the fuel injection system. The S&S VFI modules and closed loop sensor kits are highly recommended. Additionally, S&S 

recommends the Dynojet Power Vision Flash Tuner, see page 2-15 for more information. 

• 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 stock 

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 

replacement for the 2003 and later big twin engines. Stock 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 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 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. 


• S&S also recommends retrofitting a Timken bearing (31-4013) into 2003-'12 model crankcases with the use of a Timken sleeve, Screamin' Eagle #34822-08 or Jim's #956. S&S 

can provide this service for you. 

PERFORMANCE 

KITS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-29

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

PERFORMANCE 

KITS 

124" HOT SET UP KIT ® 

Keep your stock crankcases and take the horsepower output of your late model big twin 

to the max with an S&S 124" Hot Set Up Kit! Configured specifically for your application, 

this kit is sure to exceed your performance expectations! 

FITMENT 

• All big twin models 


• Huge displacement increase means huge power increase 

• Stock crankcases, cylinder heads, oil pump, and cam cover can be reused, saving 

hundreds of dollars 

• Original engine serial numbers are retained 

• Chain drive S&S 640 Easy Start Cams included! 

• Silver or wrinkle black powdercoat finish heads match factory finish, giving bike a 

"sleeper" advantage 

• .045" MLS head gaskets 

• Requires crankcase boring –S&S can provide quality, professional machine shop 

and engine building service through our remanufacturing program. Contact your 

S&S customer service representative for details. 

• Adds .096" to engine height 

OPTIONS 

The following three options are examples of the most commonly ordered kits. 

Option 1 (10.8:1 compression ratio) includes: 

• S&S 91cc high flow Super Stock® heads 

• Flat topped pistons 

Option 2 (without heads) Available only through CTO. Includes: 

• Flat topped pistons 

Option 3 (without heads, 10.4:1 compression ratio, works with stock cylinder heads) 

Includes: 

• 10.9cc Dished pistons 


900-0220 

Now with 

Easy Start 

Cams! 

Racing 

Products 

Tools & Shop 

Supplies 

S&S® 124" HOT SET UP KIT® SPECIFICATIONS 

Piston Type/Compression Ratio 

Year Stroke Displacement Bore Cylinder Length 

91cc S&S Heads 89cc S&S Heads 85cc Stock Heads 

1999-'06 4 5/8" 124" 4 1/8" 5.013" Flat top forged/10.8:1 Flat top forged/11:1 Forged, 10.9cc dish/10.4:1 



& Promo Items 

Warranty & 




NOTES: 

• Requires recalibration. 

• Stock crankcases need to be machined to accept new cylinders. S&S can provide this service for you! See page 10-6. 

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

recommends that the stock chain drive be upgraded to the S&S gear drive or to the H-D® #25284-08 or #25284-11 hybrid plate. This kit updates the problematic spring loaded chain 

tensioners to more reliable hydraulic tensioners and also upgrades the oil pump. 

• Main Bearing Note: S&S flywheel assemblies for 1999-'12 big twin engines are designed for use with Timken® style sprocket shaft bearings. They will fit directly in stock 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 replacement for the 

2003 and later big twin engines. Stock 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 may be 

used in 2003 and later engines with the installation of the Harley-Davidson® bearing kit #24004-03B. These crankcases use a roller type 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 24604-00C bearing. 

• S&S also recommends retrofitting a Timken bearing (314013) into 2003-'12 model crankcases with the use of a Timken sleeve, Screamin' Eagle #34822-08 or Jim's #956. S&S can 

provide this service for you. 

2-30 



CONTINUED - 

S&S® 124" Hot Set Up Kit® 


2009 FLHT with S&S® 124" Hot Set Up Kit vs Stock 

Parts for 

Twin Cam 96 /103 

2007-2012 

S&S 124 Hot Set Up Kit w/ Performance Exhaust System 



Stock 2009 FLHT 



PERFORMANCE 

KITS 

Parts for 



Parts for 

Evolution ® 


900-0220 

124" Hot Set Up kits® For Harley-Davidson® Twin Cam 88®/88B Engines 

(Kits include S&S® Super Stock® 91cc Cylinder Heads) (10.8:1 Compression) 

Model or Engine Type Finish Part No. 

1999-2006 Twin Cam 88 Touring and Dyna® (except 2006 Dyna® models)* 

2001-2006 Twin Cam 88B Softail® w/Balancer 

CTO 

This dyno chart compares a stock 96" 2009 FLHT with an S&S 124" Hot Set Up Kit 

with S&S® Stealth® air cleaner, Power Tune Duals and Power-Tour mufflers on the 

same bike. It is visibly clear that installing this performance kit dramatically increases 

power! The 124" Hot Set Up was tuned with a Dynojet® Power Vision Tuner. 

Not legal for sale or use on CA or EPA pollution controlled vehicles. *For 2006 Dyna® 124” Kits, see Section 1. 

Silver 900-0220 

Black 900-0221 

Silver 900-0222 

Black 900-0223 

Specify 106-5752 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

106-4294 

124" Hot Set Up kits® without Heads/Dished Pistons 

For Harley-Davidson® Twin Cam 88®/88B® Engines 

(10.4:1 Compression when used with 85cc stock heads) 

Model or Engine Type Finish Part No. 

1999-2006 Twin Cam 88 Touring and Dyna® (except 2006 Dyna® models)* 

2001-2006 Twin Cam 88B Softail® w/Balancer 

CTO 

Not legal for sale or use on CA or EPA pollution controlled vehicles. *For 2006 Dyna® 124” Kits, see Section 1. 

Silver 106-4294 

Black 106-0184 

Silver 106-4296 

Black 106-0188 

Specify 106-5752 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

900-0217 Gasket,Head,Stock Pattern,.030",4.125",2 Pack 

S&S now offers an MLS head gasket in .030" thickness for those engine builders who 

want tighter squish, higher compression, and who are willing to check their clearances. 

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 pistons in your cylinders, to complete installation of any engine kit. Contact your S&S customer service representative for details. 


Warranty & 




2-31

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

PERFORMANCE 

KITS 

T124 ENGINE 

FITMENT 

• The T124 can only be sold as a closed course competition engine for 1999-’05 fuel 

injected engines and 1999-’06 carbureted engines (except 2006 Dyna® models) 

For more 124" engine options on 2006-up Dyna® and 2007-up big twin models, call our toll 

free number and ask about our CTO options. Also, see our Power Kits starting on page 2-20 for 

power-enhancing modification options. 


• Bolt-in 

• Increased power & torque (see Dyno Chart) 

• Long piston stroke and high performance .640" lift gear driven cams 

• Chrome plated 2.00" stainless steel intake and 1.605" inconel exhaust valve 

• Chrome gearcover, tappet covers and rocker covers 

• Silver powdercoat, wrinkle black powdercoat, or polished finish. Diamond cut 

finish is available, but has a longer lead time 

• All engines have Easy Start camshafts for reliable starts and less starter motor wear 

FUEL INJECTED ENGINES (2002–’05)* 

• Delphi® style S&S Variable Fuel Injection (VFI) module with built-in three stage 

engine overheat protection 

• Closed loop fuel system, dual oxygen sensors provide air-fuel ratio feedback for 

correct fuel delivery under any condition 

• Included S&S ProTune II software CD provides base fuel maps for most 

aftermarket exhaust systems 

• Delphi style knock sensor module eliminates knock – prolonging engine life 

• Break-in rev-limiter prevents high RPM during break-in 

• Single bore throttle body with teardrop air cleaner 

• Two-year warranty 

*For 2006 touring models, use CTO part number for ordering 

FUEL INJECTED ENGINES (1999–’01) 

• Magneti Marelli® style S&S Variable Fuel Injection (VFI) module with built-in three 

stage engine overheat protection 



• Included S&S ProTune II software CD provides base fuel maps for most 

aftermarket exhaust systems 

• 52mm single bore throttle body with teardrop air cleaner 

• One-year warranty 

CARBURETED ENGINES (1999–’06) 

• S&S Super G carburetor with slotted "Slasher" air cleaner cover 

• Knock sensing ignition control prolongs engine life by automatically adjusting 

timing to eliminate knock by learning and storing ignition requirements of the 

engine 

• Guardian feature protects engine with a 3 step break-in rev-limiter 


CONTENTS 

• Complete S&S engine with fuel delivery/ignition system 


• Mobil 1® 20W-50 and an S&S oil filter 

Complete Engine Rebuild Gasket Kits 

S&S Engine Family Year Group Bore Size Part No 

T-Series 1999-’06 41/8" 106-0976 


S&S® T124 engine shown with 

optional chrome single bore tuned 

induction system. All engines come 

standard with a teardrop air cleaner. 

T124 engine specifications 

Displacement Bore Stroke Camshaft Piston Type Compression Ratio 

124" 4 1⁄8" 4 5/8" 640GP S&S forged 10.8:1 

140 

130 

120 

110 

100 

90 

80 

70 

60 

50 

40 


S&S® T124 w/Single Bore Throttle Body - Tuned Induction vs Teardrop Air Cleaner 

S&S T124 w/Single Bore - Tuned Induction 



2500 3000 3500 

S&S T124 w/Single Bore - Air Cleaner 



4000 4500 5000 5500 6000 6500 

EngSpd RPM 

This dyno chart shows performance of a fuel injected T124 with a teardrop air cleaner and with a 

single bore tuned induction system. Although the results are not typical, we wanted to show what is 

possible with an S&S 124” motor. Typically you should see around 124 hp or 1 hp/cubic inch. 

NOTE: 

• A high performance clutch must be used. See page 2-79 for more information. 

• 1999–’05 Dyna® requires oil line installation kit part #31-0424, includes special 

transmission top cover. 

• 2000–’06 FLT requires oil line installation kit part #31-0425. 

• 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 website at www.sscycle.com to locate your nearest certified S&S VFI tuning 

center or to download maps for the S&S VFI system. 

Warranty & 




2-32 

Chassis Style Fuel Delivery Ignition 

Warranty 

Period 



S&S® T124 Engines 

Diamond Cut 

Silver Black Polished Full Polished 

Black Full Polished 

106-4328 31-9895 31-9896 106-0830 106-0828 – 

1999-'03 Carb 

S&S® Super G Carburetor IST® 2 Years 

2004-'06 Carb 310-0200 310-0201 310-0202 310-0204 310-0203 310-0205 

2002-'03 FI 

106-4323 106-0402 106-0403 106-0800 – – 

Delphi® style VFI VFI 2 Years 

2004-'05 FI 310-0221 310-0216 310-0217 310-0219 – – 

1999-'01 FI Magneti Marelli® style VFI VFI 1 Year 106-4322 106-0399 106-0400 106-0831 106-0829 – 

CTO 

Specify Specify Varies 319-0010

S&S ® 

T111 ENGINE 

FITMENT 

• The T111 will only fit in place of 1999-’05 fuel injected engines and 

1999-’06 carbureted engines (except 2006 Dyna® models) 

For more 111" engine options on 2006-up Dyna® and 2007-up big twin models, call our toll free 

number and ask about our CTO options. Also, see our Power Kits starting on page 2-20 for powerenhancing 

modification options. 


• Bolt-in – installs easily into stock frames 

• "Square" motor configuration (equal bore and stroke) produces excellent torque, 

greatly increases engine life, and reduces mechanical engine noise 

• S&S 585GP Easy Start gear driven cams and lightweight conical Sidewinder® valve 

springs further reduce valve train noise 

• Silver powdercoat or wrinkle black powdercoat finish 

• Chrome gearcover and tappet covers 

• Trademark S&S teardrop air cleaner 

FUEL INJECTED ENGINES (2002-’05)* 

• Delphi® style S&S Variable Fuel Injection (VFI) module with built-in three stage 

engine overheat protection 



• Included S&S ProTune II software CD provides base fuel maps for most aftermarket 

exhaust systems 

• Delphi style knock sensor module eliminates knock – prolonging engine life 

• Break-in rev-limiter prevents high RPM during break-in 



*For 2006 touring models, use CTO part number for ordering 

FUEL INJECTED ENGINES (1999-’01) 

• Single bore throttle body with teardrop air cleaner 

• Magneti Marelli® style S&S Variable Fuel Injection (VFI) module with built-in three 

stage engine overheat protection 



• Included S&S ProTune II software provides base fuel maps for most aftermarket 

exhaust systems 


CARBURETED ENGINES 

• S&S Super E carburetor with teardrop air cleaner cover 

• Knock sensing ignition control prolongs engine life by automatically adjusting timing 

to eliminate knock by learning and storing ignition requirements of the engine 

• Guardian feature protects engine with a 3 step break-in rev-limiter 

• Three-year warranty 

CONTENTS 

• Complete S&S engine with fuel delivery/ignition system 






S&S® T111 Engines 


Those used to looking at dyno charts of high 

performance engines may wonder why the 

T111 does not make more horsepower on 

the top end. Thanks to the S&S® Super E carb, 

moderate compression ratio, and mild cams, 

it has a lot of torque and a broad power 

curve making passing vehicles, climbing 

hills, and accelerating up to speed as simple 

as twisting the throttle. 

T111 engine specifications 


111" 4 1⁄8" 4 1⁄8" 585GP S&S Forged 9.8:1 

Chassis Style Fuel Delivery Ignition Warranty Period Silver Black 


106-4431 106-4430 

S&S® Super E Carburetor IST® 3 Years 

2004-'06 Carb 310-0198 310-0199 

2002-'03 FI 

106-4433 106-4432 

Delphi® style VFI 

2004-'05 FI VFI 

2 Years 

310-0214 310-0213 

1999-'01FI Magneti Marelli® style VFI 106-4435 106-4434 

Specify Specify Varies 319-0010 

CTO 


NOTE: 

• A high performance clutch must be used. 

• 1999–’05 Dyna® requires oil line installation kit part #31-0424, which includes 

special transmission top cover. 

• 2000–’06 FLT requires oil line installation kit part #31-0425. 

• 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 website at www.sscycle.com to locate your nearest certified S&S 

VFI tuning center or to download maps for the S&S VFI system. 


PERFORMANCE 

KITS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-33

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

KITS 

T124 TÜV APPROVED ENGINES 

FITMENT 

• The T124 TÜV can only be sold as a replacement engine for 1999-’05 fuel 

injected engines and 1999-’06 carbureted engines 

S&S does not offer full replacement TUV engines for 2006 Dyna® models. 


• Similar to T124 but meets EU Chapter 9 standards 2002/51/EC for exhaust, 

97/24/EC for noise 


Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

FUEL INJECTED ENGINES (1999-’05) 


• Modified Delphi® style S&S Variable Fuel Injection (VFI) module with built-in 

three stage engine overheat protection 

• Closed loop fuel system, dual oxygen sensors provide air-fuel ratio feedback 

for correct fuel delivery under any condition 

• One-year warranty 

• Meets Euro III exhaust emissions limits 

CARBURETED ENGINES (1999-'06) 

• S&S® Super G, EC carburetor with chrome teardrop air cleaner 

• Knock sensing ignition control prolongs engine life by automatically adjusting 

timing to eliminate knock by learning and storing ignition requirements of 

the engine 

• Break-in rev limiter prevents high RPM during break-in 


• Meets Euro II exhaust emissions limits 

CONTENTS 

• Complete S&S engine 

• Fuel delivery/ignition system 


• Certificates and documentation of TÜV approval 





T124 TUV APPROVED ENgine SPECIFICAtiONS 


124" 4 1⁄8" 4 5/8" 546GP S&S Forged 9.5:1 

NOTE: 

• 1999-'01 EFI bikes will require conversion to Delphi® style single bore EFI fuel tank & 

wiring harness. 

• 1999-’05 Dyna® requires oil line installation kit part #31-0424 ,which includes special 

transmission top cover. 

• 2000-’06 FLT, requires oil line installation kit part #31-0425. 

• In order to be compliant with EU Chapter 9 standards, all S&S® TÜV engines must be used with 

stock Harley-Davidson® exhaust, specified gearing, and the provided S&S ignition system. 


& Promo Items 

Warranty & 




2-34 

Chassis Style Fuel Delivery Ignition Warranty Period Silver Black Polished 


106-4329 31-9965 – 

S&S® Super G Carb IST® 2 Years 

2004-'06 Carb 310-0209 310-0208 – 

1999-'05 FI Delphi® style VFI VFI 1 Year 106-4327 106-2356 106-2395 


S&S ® 

T-Series Service Manual 

These manuals were created to help you maintain your S&S engine. They outline the 

procedures necessary for both the home mechanic and shop technician to ensure 

maximum performance and longevity. 

S&S T-Series engines .....................................61-1002 



S&S ® 

CRANKCASES 

For high performance applications or just the replacement of a worn out or broken engine, 

these cases are compatible with the stock primary, charging system and bolts directly to 

the stock transmission on all models. 

FITMENT 

• 1999–'06 Harley-Davidson® Twin Cam 88® (except 2006 Dyna®) 


• Much stronger than stock crankcases in every aspect, extra large front motor mount 

for increased strength 

• Large cam chest allows cam lift up to .675" without clearancing 

• Timken® style sprocket shaft bearings withstand the most demanding applications 

• Includes S&S crankcase breather reed valve to eliminate oil carry-over and oil 

scavenging problems 

• Clearanced for strokes up to 5" 

• All passages between the crankcase and the cam support plate are o-ring sealed 

• Includes pinion and Timken® bearing 

OPTIONS 

• Available in stock bore, 4" bore, and 41⁄8" bore versions 

• Silver powdercoat, wrinkle black powdercoat, or polished finish 

KIT CONTENTS 

• S&S crankcase 

• S&S breather reed valve 

• Bearings and hardware 

NOTES: 

• Oil line installation kit part #31-0424 is required for installation in 1999-’05 

Dyna® models. This kit includes a special transmission top cover and oil lines. 

• Oil line installation kit part #31-0425 is required for installation in 2000-'06 FLT 

models. Stock transmission top cover may be used. 

S&S® Crankcase for 1999-'06 Big twin Engines 

(except 2006 Dyna®) 

Crankcase Bore Size Silver Finish Black Finish Polished Finish 

Stock Bore 

(Stock Stud Pattern) 

106-4039 31-0172 – 

4" Bore 


106-4041 31-0175 – 

41/8" Bore 


106-4057 31-0181 31-0182 

41/8" Bore 

(S&S Stud Pattern) 

106-4043 31-0178 31-0179 

Special Order 31-0120* 

Use the special order part number to order crankcases with a special finish or motor mount style. 

*Special Order: Download the Special Order Form at sscycle.com/soforms 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

31-0425 

Oil line installation kit 

for 1999-'06 FLT models 

Any Job is easy with the right tools 

S&S Degree Wheel Kit, page 9-13 and S&S Anti-Rotation Bracket, page 9-14 


31-0424 

Oil line installation kit 

1999-'05 Dyna® models 


& Promo Items 

Warranty & 





2-35

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 


CRANKCASE BREATHER REED VALVES 

Besides offering improved oil scavenging and reduced oil carryover, S&S crankcase breather 

reed valves make your bike run better and provide a more enjoyable riding experience. 

Parts for 



Parts for 

Evolution ® 


PERFORMANCE 

PARTS 

How Do They Work 

The functional part of S&S crankcase breather reed valves consists of steel reeds that 

are normally in the closed position. When the pistons travel downward in the cylinders, 

pressure in the crankcase below the pistons causes the reeds to open, allowing the air and 

oil mist in the crankcase to escape into the cam chest. When the pistons change direction 

and begin traveling back upward in the cylinders, a vacuum is created in the crankcase. 

The vacuum causes the reeds to close, preventing air from entering the crankcase. The 

effect is that camchest pressure waves are reduced improving oil return from the heads to 

the camchest and also a slight vacuum is maintained in the crankcase, improving ring seal. 

31-2071 

Parts for 


1986-2012 

FITMENT 

• Twin Cam 88®/96 (except "B" engines) 

• S&S T-Series engines 


Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

PART NUMBERS 

For Engines with Stock Oil Pump 

1999-’02 .................................................31-2070 

2003-’10 .................................................31-2071 

S&S special application crankcases ............................31-2086 

Engines with S&S Oil Pump 

1999-’02 stock crankcases ...................................31-2093 

2003-’10 stock crankcases & all S&S crankcases .................31-2094 

Spring Adapter 

(For S&S SA crankcases)* ....................................31-2103 

*Required to accommodate the extra .375" case width of S&S Special Application big bore crankcases. 

** Does not fit with Screamin’ Eagle® oil pumps. 

NOTES: 

• The crankcases breather valve for Twin Cam 88® engines was designed and 

developed for use with stock Harley-Davidson® or S&S oil pumps and tappets, 

and may not be compatible with some aftermarket components. 

• Not available for Twin Cam 88B or Twin Cam 96B engines with internal 

balancers. 



Warranty & 



& Promo Items 

Tools & Shop 

Supplies 

Racing 

Products 

2-36 



S&S ® 

FLYWHEEL ASSEMBLIES 

Recommended for performance applications, S&S flywheel assemblies are made of forged 

steel and have pressed-in shafts. A 1.5" diameter crankpin means that, unlike stock 

flywheel assemblies, lower connecting rod bearing races are replaceable. 

FITMENT 


KIT CONTENTS 

• Flywheel balanced and assembled with rods 


PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Trying to identify an S&S® Flywheel 

See Flywheel I.D. Chart in the Replacement Parts section page 12-2 


Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Engine Displacement 

Stroke 

S&S® Flywheel Assemblies 

1999-'06 H-D® big twin models 

Twin Cam 88® 

Twin Cam 88B 

USA 

USA 

88", 95", 97", 100" 4" 32-2240 32-2241 

(H-D® #23971-03) 

2006 H-D® Dyna® models 

32-2293 

(H-D® #23955-06) 

96", 103", 106" big bore, 110",117" 4 3/8" 32-2312 32-2314 32-2310 

Stock 96" 4 3/8" – – 106-3363 

106" stroker 4 ½" 32-2242 32-2243 32-2294 

107" 4 1/4" 32-2244 32-2245 – 

111" 4 1/8" 106-4712 106-6052 106-6053 

116", 124" 4 5/8" 32-2246 TÜV 2 32-2247 32-2295 

Special Order Specify 32-2141 

Use the special order part number to order flywheels assembled or unassembled, balanced or unbalanced, porkchop or with welded shafts. 

Special Order: Download the Special Order Form at sscycle.com/soforms 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 


• OPTION 1: 2003–up big twins require installation of Harley-Davidson® bearing kit H-D#24004–03B, containing sprocket shaft bearing H-D#24604–00D or H-D#24607–07. Do not use a 

H-D# 24604–00, H-D#2460 –00A, H-D#24604–00B, or H-D#24604–00C bearing. 

• OPTION 2: 2003–up crankcases can be retrofitted to accept a Timken® bearing by purchasing a Timken sleeve from Screamin' Eagle® (#34822-08) or Jims (#956) and a charging system spacer. 

Additional machining is required to install. S&S can provide this service. 

NOTE: Engines with strokes over 4" may require S&S® piston oiling jets and piston to jet clearance notches in the piston skirt to avoid contact. 


Warranty & 




2-37

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

PARTS 

OIL PUMPS 

S&S oil pumps use the drive gears on special S&S gear drive cams to pump oil to the engine. 

Unlike stock pumps, S&S oil pumps regulate oil pressure after it gets filtered, providing 

more consistent oil pressure at all temperatures. Crankcase scavenging is increased while 

oil carryover and drag on the flywheels are reduced. Oil temperature can also drop by as 

much as 20° F. 


Parts for 

Evolution ® 


FITMENT 

• 2002 - ’06 carbureted & EFI big twins (except 2006 Dyna®) 

• May be used in 1999-'01 engines with aftermarket ignition or EFI (see note below) 

• Fits all engines built with S&S T-Series crankcases 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 


• Replaces stock oil pump, cams, cam support plate, bearing plate, bearings and 

decorative gearcover 

• Uses drive gears of special S&S gear drive cams to pump oil 

• Oil pressure is regulated after the oil filter – more consistent pressure to the engine 

• Increased scavenging capacity results in: 

• Less oil in the crankcase 

• Less power loss 

• Less heat build up 

• Less oil carryover 

• Excess oil from pressure control valve is filtered – longer pump life 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 


PART NUMBERS 

S&S Oil Pump Kit without Cams 

Polished ..................................................31-6503 

Chrome ................................................. 106-3887 

S&S® GEAR DRIVE CAMS FOR USE With S&S OIL PUMPS 

FOR 1999-'06 Big twin (EXCEPT 2006 DYNA® MODELS) 

Cam* 

Easy Start Cams 

with Drive Gears 

Cams with Drive Gears 

510GP – 33-5220 

570GP 106-4751 – 

585GP 106-4771 33-5222 

625GP 106-5212 – 

640GP 106-4781 – 

675GP 106-5215 33-5225 

* See Camshafts starting on page 2-39 of this catalog for further information on cam 

recommendations for different applications. 


31-6503 




• Requires installation of gear drive cams, see chart. 

• The S&S oil pump is not compatible with 1999-’01 engines with stock fuel injection or ignition systems which require a cam position sensor in the gearcover. May be used in 1999-’01 

engines if an aftermarket ignition or fuel injection system, that does not require a cam position sensor, is installed. 

2-38 


S&S ® 

CAMSHAFT OVERVIEW 

S&S offers a variety of cam grinds for 1999-up big twin engines in both chain drive and 

gear drive versions. Cams that exceed the limits of the stock valve springs require the use 

of special high lift springs. Most S&S cams have higher lift than stock and are designed to 

take advantage of the extra flow of ported stock heads or S&S Super Stock® heads. Due 

to the high lift of these cams, S&S adjustable pushrods are recommended. Not all grinds 

are available in the chain drive version. To get the best performance from a performance 

cam installation, a high flow intake and exhaust system is also recommended. 

EASY START CAMS 

The most innovative S&S product since the electric compression release system, these 

cams will revolutionize the starting of late model big twins. Regardless of displacement 

or compression ratio, a stock starter and battery will now easily turn over any engine. 

These cams also install just as easily as non compression release versions and require no 

extra parts or machining! Available in both chain drive and gear drive. 

HOW Do Easy Start Cams WORK 

The heart of our Easy Start cams is a centrifugally retracted, spring loaded, compression 

release lobe milled into the heel of each exhaust lobe. At cranking speeds, the lobe 

bumps the exhaust valve open slightly during the compression stroke, making the 

engine much easier to turn over. Once the engine fires and reaches 800 RPM, the lobe 

swings out of the tappet roller path, allowing the engine to run normally and with full 

compression. 

Compare S&S Cams To Other Popular Cams 

If you have been using cams from another manufacturer and would like to know what 

S&S has to offer that is similar, the chart below lists a number of popular cams along 

with the S&S cams that work well in similar applications. 

Application CROSS REFERENCE CHART 

S&S Cam 

Name 

H-D® Screamin' 

Eagle® Cam 

Andrews® Cam Most Fitting Application 

551 SE-203/255 21H/26H Touring Models 


583 SE-203/255 21H/26H Softail®/Dyna® Models 

585 SE-211/251/257 31H/32H/50H/55H/67H All Big Twin Models 

625 SE-258/260 60H All Big Twin Models 

640 SE-264 59H All Big Twin Models 


Cam Name 


Recommended applications for S&S Cams 

475: A bolt-in replacement cam with stock cam timing is designed for riders 

with stock engines that want to eliminate the factory chain drive system, but are 

not necessarily looking for more power. Does not require tuning. Bolt-in stock. 

509: Designed as a bolt-in, high torque cam for 1999-’06 models. 180 psi cranking 

compression, no need for compression releases. For 88 CID engines with stock 

compression ratio. Idle-4500 rpm. Bolt-in torque. 

510: Designed as a bolt-in cam for 88, 95, and 96 CID engines with compression 

ratios below 9.7:1, it is primarily intended for use with stock, un-ported heads. 3000- 

5500 rpm. Bolt-in overall. 

546: Intended as a replacement part for S&S emissions certified engines, this is a 

short duration emissions cam with very little overlap to reduce emissions of unburned 

hydrocarbons. Requires high lift springs and normal clearance checks. 1000-4000 rpm 

551: Designed for engines with 96 to 106 CID and 9:1 to 9:9 compression this is a 

bolt-in cam set designed for stock or mildly modified touring bikes. 551 cams are not 

recommended for compression ratios of 10:1 or greater. Greatly improves low-end 

and midrange torque, strongest from idle-4000rpm. 

570: Designed for 88 to 103 CID engines with compression ratios between 9:1 and 

10:1 this cam will provide a nice power increase across the entire power band. 3200- 

5700 rpm. Excellent bolt-in for overall power on 103”. 

583: Optimized for use in the Softail®/Dyna® lines, this cam makes horsepower 

and torque that you can feel all the way through the rpm range, making the most 

power right where you need it:1500–5000rpm 

585: Designed for 88 to 95 CID engines with compression ratios from 9.7:1 to 

10.5:1 and 100 to 124 CID engines from 9:1 to 10:1 compression. Provides massive 

horsepower and torque increases starting at 3000rpm and holds steady all the way 

to redline. 3500-6000 rpm for 88” - 103” engines and 2500-5500 for larger engines. 

625: Cam set designed for 95” or larger engines with compression ratios between 

10.0 and 10.75:1. 3000-6000 rpm. 

640: Used in S&S T124 engines, this cam makes horsepower! Intended for engines 

of 95 CID or more w/ compression ratios between 10.5:1 and 11.5:1. 3000-6000 rpm. 

675: A high lift monster, this cam set is designed for 120” or larger engines with at 

least 11:1 compression ratio. 4500-6500 rpm. 

Note: Stock valve springs in 1999-’04 big twin models can handle cams with valve lifts as high as 

.515". Stock valve springs in 2005-up engines can accommodate valve lifts up to .590". 

Specifications of S&S® Chain Drive and Gear Drive Camshafts for 1999-UP Big twin 

Valve Timing (open/close) 

Intake 

Exhaust 

Open BTDC/Close ABDC 

Open BBDC/Close ATDC 

Valve Duration 

Centerline 

Lift @ TDC 

Valve Lift 

Intake Exhaust Intake Exhaust Intake Exhaust 

475 2˚/34˚ 36˚/4˚ 216˚ 220˚ .475" 106˚ 106˚ .060" .060" 

509 18˚/18˚ 46˚/11˚ 216˚ 237˚ .509" 90˚ 107.5˚ .174" .140" 

510 20˚/38˚ 52˚/20˚ 238˚ 252˚ .510" 99˚ 106˚ .187" .178" 

546 5˚/55˚ 52˚/5˚ 240˚ 237˚ .546" 115˚ 113.5˚ .126" .106" 

551** 17°/19° 41°/17° 216° 238° .550" 91˚ 102˚ .178" .170" 

570 20˚/40˚ 55 ˚/20˚ 240˚ 255˚ .570" 100˚ 107.5˚ .187" .179" 

583 5˚/18˚ 58˚/24˚ 203˚ 262˚ .583" 96.5˚ 107˚ .113" .206" 

585 20˚/45˚ 60˚/20˚ 245˚ 260˚ .585" 102.5˚ 110˚ .186" .179" 

625 20˚/55˚ 60˚/20˚ 255˚ 260˚ .625" 107.5˚ 110˚ .189" .184" 

640 25˚/60˚ 65˚/25˚ 265˚ 270˚ .640" 107.5˚ 110˚ .228" .214" 

675 25˚/64˚ 70˚/25˚ 269˚ 275˚ .675" 109.5˚ 112.5˚ .235" .205" 

*Note: Although several cam grinds were used in stock engines from 1999-’06, the timing specs of the 475G cams is most similar to cams used in 1999-’03 EFI engines. 

**551 cams are not recommended with compression ratio of 10:1 or higher. 


PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-39

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


PERFORMANCE 

PARTS 

CHAIN DRIVE CAM KITS 


• Increase performance at an affordable price 

• Quick installation – reuse many stock components 

• Easy Start Cams allow stock starter 

to start any engine 

KIT CONTENTS 

• Cams 

• Gearcover gasket 

• Cam bearings 

• Thread lock 


33-5182A 


100 

90 

80 

583 Cam 




Fatboy® 583 Cam vs Stock Cam 

96 Stock Cam 



Parts for 


1986-2012 



S&S CHAIN DRIVE CAM KITS FOR 1999-'06 MODELS (except 2006 Dyna®) 

Cam Name Standard Cam Kit Easy Start Cam Kit 

70 

60 

50 

40 

30 

Parts for 


1926-1984 

509 330-0016 – 

510 33-5182A – 

551 330-0002 106-5293 

20 

1500 

2000 2500 3000 

3500 4000 4500 5000 5500 6000 

EngSpd RPM 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

570 330-0003 106-5296 

583 330-0004 106-5289 

585 330-0005 106-5299 

625 330-0006 106-5302 

640 330-0007 106-5305 

INSTALLATION KITs for S&S CHAIN DRIVE CAM (recommended) 

Models 



100 

90 

80 

70 

60 


2009 FLHT with S&S® 551 Touring Cam vs Stock Cam 




96 Stock Cam 




50 

Racing 

Products 

40 

30 

20 

Tools & Shop 

Supplies 

10 

1500 

2000 2500 3000 

3500 4000 4500 5000 5500 6000 

EngSpd RPM 


& Promo Items 

Warranty & 




33-5175 

Installation kits are included 

with cam kits. 

NOTE: 

• If 475, 509 or 510C cams are used with the stock chain drive system in Twin Cam 88® 

engines, it is recommended to use cylinder heads with stock valve springs or performance 

valve springs with no more than 160 lb. of seat force. For more demanding applications, 

we recommend the S&S gear drive cams. 

• When using 1999-'06 chain drive cams for lifts over .510", S&S strongly recommends 

that the stock chain drive be upgraded to the S&S gear drive or to the H-D® #25284-08 or 

#25284-11 hybrid plate. This kit updates the problematic spring loaded chain tensioners 

to reliable hydraulic tensioners and also upgrades the oil pump. 

• 551 cams are not recommended with compression ratio of 10:1 or higher. 



100 

90 

80 

70 

60 

50 

40 

30 

20 

10 

1500 


2009 FLHT with S&S® 585 Performance Cam vs Stock Cam 




2000 2500 3000 

96 Stock Cam 



3500 4000 4500 5000 5500 6000 

EngSpd RPM 

2-40 



S&S ® 

GEAR DRIVE CAM KITS 


• Improves valve timing accuracy by eliminating timing chain lash 

• Easy Start Cams allow stock starter to start any engine 

• No tensioner shoes to wear out or fail 

OPTIONS 

Which S&S Gear Drive Cam Kit to Order 

• If updating a stock chain drive system, it's easiest to order a complete kit. Includes: 

• Camshafts with inner gears 

• Outer cam drive gear kit 

• Camshaft installation kit 

• If replacing cams in an engine already equipped with S&S gear drive cams, order cams 

with inner gears and reuse the existing outer gears. Camshaft installation kit for the 

appropriate model year is recommended. 

• If installing a set of gear drive cams from another manufacturer, order S&S cam gear kits 

for the appropriate model year. Each kit provides the inner cam gear as well as an outer 

cam gear. Camshaft installation kit for the appropriate model year is recommended. 

Cam Name 



Complete Kit 

S&S GEAR DRIVE CAMS FOR 1999-'06 MODELS 

Easy Start 

Standard 



Complete Kit 

Stock Oil Pump S&S Oil Pump Stock Oil Pump S&S Oil Pump 

475 – – – 106-4033 106-4385 – 

509 – – – 330-0017 330-0018 – 

510 – – – 33-5177 33-5174 33-5220 

546 – – – 33-5230 – – 

551 106-5442 106-5441 – 330-0100 330-0099 – 

570 106-5243 106-5242 106-4751 33-5178 33-5166 – 

583 106-5859 106-5858 – 330-0107 330-0108 – 

585 106-5247 106-5246 106-4771 33-5179 33-5168 – 

625 106-5251 106-5250 106-5212 33-5180 33-5170 – 

640 106-4840 106-4839 106-4781 33-5181 33-5172 – 

675 106-5255 106-5254 106-5215 33-5231 33-5237 – 

INSTALLATION KITS for S&S Gear DRIVE CAM (recommended) 

Models 




106-5896 

Camshaft installation kit for 1999-'06 models 

provides parts needed to install S&S® gear drive 

cam sets. Included with complete cam kits. 

106-4781 

Easy Start Cams for S&S Oil Pump 

Gear Drive Easy Start Cams 

for early models 

NOTES: 

• Pinion shaft run-out must be checked before installing S&S® gear drive cams. 

• A hydraulic press and other professional tools are required to install S&S gear drive cams. 

Additionally, material must be removed from the inner surface of the stock gearcover. 

The stock crankcase will require clearancing for S&S .625", .640", and .675" lift cams. 

S&S recommends that gear drive cams be installed by a professional mechanic. 

• New cam bearings and a new gearcover gasket are required to complete cam installation. 

Gear drive cams for 1999-' 06 models require the use of ball bearing style cam bearing 

rather than the stock roller bearing. Roller bearings have more internal clearance which 

can cause excessive gear lash and increased noise. The correct parts are provided in S&S 

Camshaft Installation Kit, part #106-5896. 

• Due to the inherent characteristics of gear drives, you may experience more valve train 

noise with gear driven cams. Oversized and undersized gears are available to help 

achieve correct gear lash. We have found that with 160 lb. of valve seat force, the S&S 

gear drive cams will perform well up to 6200 rpm. If higher rpm is anticipated, valve 

springs that provide higher seat force should be used. 




PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-41

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

PARTS 

Cam Related Repair Parts 

Cam gear drive kits: 

(Includes front and rear inner cam gears, pinion gear, and outer cam gear) 

Fits 1999-‘06 models ...............................................33-4275 

Outer cam drive gear kit: 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Replacement hardware pack for outer 

cam drive gear: 

Fits 1999-up models ............................................. 33-4271P 

Replacement key ................................................. 106-1348 

Replacement gears, oversized & undersized 

Due to machining variations in the stock cam plate, oversized or undersized gears may be 

needed to achieve correct gear lash. 

Cam drive gear set: 1999-up .......................................33-4293 

Outer rear cam drive gear only: 1999-‘06 (except 2006 Dyna) ......... 106-4882 

Front inner cam gear: 1999-‘06 (except 2006 Dyna) ..................33-4272F 

Rear inner cam gear, standard: 1999-‘06 (except 2006 Dyna) ........ 33-4272R 

Rear inner cam gear, undersized: 1999-‘06 (except 2006 Dyna) .....33-4272RX 

Rear inner cam gear, oversized: 1999-‘06 (except 2006 Dyna) .......33-4272RZ 

Pinion Gears 1999-up: 

Standard size ...................................................33-4160 

Undersized ....................................................33-4160X 

Double under ................................................ 33-4160XX 

Oversized .....................................................33-4160Z 

Double over ................................................. 33-4160ZZ 

S&S heavy duty cam bearing plate 


Cam Needle Bearings Assemblies 

Inner cam bearing Harley-Davidson® Twin Cam 88® and 1999-'06 (H-D® # 9198) 

(except 2006 Dyna®) ..................................... 

USA TÜV 2 31-4080 

33-4276 

Outer cam drive gear kit for Twin Cam 88® engine 

31-4080 

33-5212 

Warranty & 




NOTE: 

All reference to H-D® part numbers is for identification purposes only. We in no way 

are implying that any of S&S Cycle’s products are original equipment parts or that 

they are equivalent to the corresponding H-D® part number shown. Use of brand 

names such as Harley-Davidson® Sportster® are also for reference only. 

2-42 



S&S ® 

BILLET Gearcover 

Looking through this catalog, you will probably have noticed that S&S is offering more 

and more billet components. Billet offers a lot of structural and engineering advantages 

over cast parts, but the thing that makes everyone sit up and take notice is the beauty 

of polished or chrome billet aluminum. If you are replacing a cam or tappets, consider 

installing an S&S polished or chrome billet gearcover at the same time. While you’re at it, 

a billet oil filter bracket would really look great too. 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



FITMENT 

• 1999-'12 Twin Cam 88®, 96 and 103* 

Parts for 

Evolution ® 


PART NUMBERs 

S&S Billet Gearcover 

Polished ........................................ 

USA 

31-6516 

Chrome ............................................. 106-3774 

* The S&S gearcover is not compatible with 1999-’01 engines with stock fuel injection 

or ignition systems which require a cam position sensor in the gearcover. May be used in 

1999-’01 engines if an aftermarket ignition or fuel injection system, that does not require 

a cam position sensor, is installed. 

S&S ® 

BILLET Oil Filter Bracket 

These billet oil filter brackets were originally created to complete our S&S T124 dual cam 

engines, but they are an excellent upgrade for stock Harley-Davidson® Twin Cam 88® 

engines as well. The bracket places the filter slightly farther from the crankcase to allow 

just that little bit of extra clearance that makes installation and removal of the filter a lot 

easier. However, what really makes this filter bracket useful is that it allows oil to be routed 

to an oil cooler right from the filter mounting bracket. 

31-6516 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

FITMENT 

• 1999-'06 big twin (except 2006 Dyna® models) 

PART NUMBERs 

S&S Billet Oil Filter Bracket 

Polished ................................... 

USA TÜV 2 31-6510 

Chrome ............................................. 106-3884 

31-6510 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-43

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

PARTS 

4-1/8" BORE CYLINDERS & PISTONS 


for S&S 124" Hot Set up kits, Stock Bolt Pattern 

These cylinders are made of superior materials and has a thicker casting than stock cylinders. 

Other than being machined with a stock stud pattern, these cylinders are identical to the ones 

used in S&S 124" engines. 

FITMENT 

• Big twins with S&S 124" Hot Set Up Kit 

• Compatible with stock or S&S Super Stock® heads 

106-4159 

Parts for 

Evolution ® 



• Forged, coated pistons and S&S cylinders provide consistent performance and reliability 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-44 

OPTIONS 


Special Order OPTIONS 

• Diamond cut, full polished, natural and polish 

• Individual cylinders 

Displacement 

S&S® 41/8" BORE CYLINDERS FOR 124" HOT SET UP KITS 

Cylinders Only (single) Cylinders Only (pair) Cylinders w/ Pistons (pair) 

Front Rear Front Rear 

Silver 

Silver 

Black 

Silver 

Black 

(for S&S 

(for (for S&S 89cc/91cc 

Silver 

Black 

89cc/91cc heads) stock heads) 

heads) 

NOTE: S&S 41/8" pistons are machined to such close tolerances that it is not necessary to 

measure the piston. Additionally, the low friction coating on the piston skirt makes taking 

measurements very difficult. Therefore, hone cylinders to nominal diameter +/- 0.0005" 

for correct clearance. 


Black 

(for 

stock heads) 

124" 106-4105 106-4106 91-7252F 91-7252R 106-4158 91-7252 106-4159 – 91-7257 – 

124" dish 106-4105 106-4106 91-7252F 91-7252R 106-4158 91-7252 – 106-4163 – 91-7253 

Special Order – – – – 91-7506* 

Cylinder w/ piston kits include cylinders, piston kit, head gaskets, base gaskets, and exhaust gaskets 


S&S® 41/8" BORE PISTONS FOR HOT SET UP KITS 

Forged Piston Kits 

Rings, chromoly faced 

Heads 

Deck 

Height 

Stroke Piston Type Standard +.010" +.020" +.030" Standard +.010" +.020" +.030" 

S&S 89cc/91cc 

Flat topped 92-1556 92-1557 92-1558 92-1559 

1.050" 45/8" 

Stock 10.9cc dished 92-1575 92-1576 92-1577 – 

94-1400X 94-1401X 94-1402X 94-1403X 

Piston kits include set of pistons, rings, wristpins, and clips 

Wristpin 

.927" x 2.825" long.......................... USA 3 TÜV 1,6,7 94-9277 

.927" x 2.250" long.................................... 106-1052 

Keeper 

Each .......................................... TÜV 7 94-9278-S 

2 pack. ........................................ TÜV 7 94-9278-2 

4 pack. ......................................... 

TÜV 7 106-2304 

S&S® 41/8" BORE CYLINDERS FOR 124" HOT SET UP KITS Specifications 

Displacement Stroke Cylinder Length 


Stock Heads 91cc S&S Heads 89cc S&S Heads 

124" 45/8" 5.013" 10.8:1 10.8:1 11:1 

124" dish 45/8" 5.013" 10.4:1 10.2:1 10.4:1 

GASKETS, DOWELS, AND HARDWARE 

Description S&S Part No. H-D® Part No. 

Head Gasket (each) 

93-1091-S 

Base Gasket (each) 

93-1092-S 

Base O-ring (each) 50-8049 

Exhaust Gasket (each) 106-5029 (H-D® #65324-83A, 65324-83B) 

Oil Return O-ring (each) 50-8008 (H-D® #11105, 11275) 

Cylinder Dowel (each) 50-8177 (H-D® #16595-99A) 

Center Case Bolt (waisted) (each) 50-0327 

Flat Washer (each) 50-7026 

Nut 5/16" - 24 (each) 50-5023 

Center Case Bolt Seal (each) 50-8063-S


S&S ® 

4-1/8" BORE CYLINDERS AND PISTONS 

Replacements for cylinders included in S&S T-Series 41/8" bore engines, these cylinders are 

made of superior materials and have a thicker casting than stock cylinders. 

FITMENT 

• S&S bolt pattern T124, T117 and T111 engines 


• Forged, coated pistons and S&S cylinders provide consistent performance and reliability 


PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


OPTIONS 

• Silver, wrinkle black powdercoat, or polished finish 


• Natural, diamond cut, and full polished 

• Individual cylinders 

91-7099 

41/8" BORE CYLINDERS FOR S&S® ENGINES Specifications 

Displacement Stroke Cylinder Length Compression Ratio 

124" 4 5/8" 5.013" 10.8:1 

117" 4 3/8" 4.888" 10.2:1 

111" 4 1/8" 4.763" 9.7:1 

Parts for 


1986-2012 

Parts for 


1926-1984 

41/8" BORE CYLINDERS FOR S&S® ENGINES 

Cylinder Only Cylinders Only (Set) Cylinders w/ Pistons (Set) 

Displacement Front Rear Front Rear Front Rear 

Silver Black Polished 

Silver Black Polished Silver Black Polished 

124" 106-4099 106-4100 91-7079F 91-7079R 91-7165F 91-7165R 106-4157 91-7079 91-7165 106-4161 91-7099 – 

117" 106-4089 106-4090 – – – – 106-4151 – – 106-4152 91-7098 – 

111" 106-4083 106-4084 – – – – 106-4150 – – 106-4149 – 91-7290 

Special Order 91-7506* 

Cylinder w/ piston kits include fitted pistons and cylinders, head gaskets, base, and exhaust gaskets 


41/8" BORE PISTONS FOR S&S® ENGINES 

Displacement 



Deck Height Stroke Standard +.010" +.020" +.030" Standard +.010" +.020" +.030" 

124" 

4 5/8" 92-1556 92-1557 92-1558 92-1559 

117" 1.050" 4 3/8" 92-1550 92-1551 92-1552 92-1553 94-1400X 94-1401X 94-1402X 94-1403X 

111" 4 1/8" 92-1560 92-1561 92-1562 92-1563 


Wristpin 

.927"...................................... USA TÜV 3 1,6,7 94-9277 

Keeper 

Each .......................................... TÜV 7 94-9278-S 

2 pack......................................... TÜV 7 94-9278-2 

4 pack.......................................... 

TÜV 7 106-2304 

GASKETS, DOWELS, AND HARDWARE 


Head Gasket (each) 

93-1047-S 

Base Gasket (each) 

93-1048-S 


Cylinder Dowel (each) 50-8177 (H-D® #16595-99A) 

NOTE: S&S 41/8" pistons are machined to such close tolerances that it is not necessary to measure the piston. Additionally, the low friction coating on the piston skirt makes taking 

measurements very difficult. Therefore, hone cylinders to nominal diameter +/- 0.0005" for correct clearance. 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-45

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

PARTS 


3-7/8" BORE REPLACEMENT CYLINDERS AND PISTONS 

These 3 7/8" bore cylinders are a good choice for installation and repair of 95" kits. Superior materials, 

thicker casting in critical areas and bigger cooling fins, combined with excellent wear resistance ensure 

excellent engine life. 

FITMENT 

• Cylinders can be used for stock replacement 

• 95" kit for 1999-’06 models – pistons have 5.3cc pop up dome 

• S&S 106" stroker kit for 1999-’06 models – pistons have flat tops 

91-7045 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 


• Installation of S&S cylinders instead of boring stock cylinder saves time and labor when 

installing 95" kits 

• S&S 37/8" bore cylinders require no crankcase machining to install 

• Piston weight for 95" kits are the same as stock – no flywheel rebalancing 

• Forged, coated pistons and S&S cylinders are compatible with stock or S&S Super Stock® heads 


OPTIONS 

• Silver or wrinkle black powdercoat finish 


• Natural, diamond cut, polished and full polished 

106-0432 Series Piston 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

S&S® 37/8" BORE CYLINDERS 

Displacement Stroke 

Cylinder 

Length 

Compression Ratio Cylinder Only (Single) Cylinders Only (Set) Cylinders w/Pistons (Set) 

Stock Heads 89cc S&S Heads 79cc S&S Heads Silver Black Silver Black Silver Black 

106" Stroker 4 1/2" 4.937" 10.1:1 9.8:1 10.8:1 106-4061 106-3128 106-4137 91-7045 106-4140 91-7061 

95" 4" 9.7:1 9.3:1 10.3:1 106-4138 91-7047 

Special Order – – 91-7506* 

Cylinder w/ piston kits include fitted pistons and cylinders, head gaskets, base, and exhaust gaskets 

*Special Order: Download the Special Order form at sscycle.com/soforms 

Displacement 

Deck 

Height 


S&S® 37/8" BORE PISTONS 


Stroke Standard +.005" +.010" +.020" Standard +.005" +.010" +.020" 

0.927" Wristpin 

106" Stroker 1.020" 4 1/2" 92-1210 92-1214 92-1211 92-1212 94-1295X 94-1299X 94-1296X 94-1297X 94-9277 USA TÜV 3 1,6,7 

95" 1.270" 4" 92-1200 92-1204 92-1201 92-1202 94-1290X 94-1294X 94-1291X 94-1292X 94-9277 USA TÜV 3 1,6,7 



& Promo Items 

Warranty & 




2-46 

Keeper .927” 

Each .......................................... TÜV 7 94-9278-S 

2 pack. ........................................ TÜV 7 94-9278-2 

4 pack. ......................................... 

TÜV 7 106-2304 

NOTES: 

• For 95" and 106" ‘cylinder only’ kits, pistons must be measured and cylinders bored/ 

honed accordingly. Recommended piston fitment: 

• Close: 0.0020" – 0.0025" Loose: 0.0032" – 0.0045" 

• S&S 3 7/8" pistons for 103" kits are machined to such close tolerances that it is not 

necessary to measure the piston. Additionally, the low friction coating on the piston 

skirt makes taking measurements very difficult. Therefore, hone cylinders to nominal 

diameter +/- 0.0005" for correct clearance. 


Gaskets & Dowels 


MLS Head Gasket, .045” (each) 106-2947 

MLS Head Gasket, .030” (2 pack) 900-0216 

Base O-ring (each) 50-8048 (H-D® #11256) 


Oil Return O-ring (each) 50-8008 (H-D® #11105, 11275) 

Cylinder Dowel (each) 50-8177 (H-D® #16595-99A)


S&S ® 

3.927" BORE REPLACEMENT CYLINDERS AND PISTONS 

Superior materials, thicker casting in critical areas and bigger cooling fins are what make S&S 

cylinders the best! Improved cooling and strength combined with excellent wear resistance will 

maintain horsepower and reliability for years to come. Replacement cylinders for S&S 97" and 

106" top end kits. 

FITMENT 

• S&S 97" top end kit for 1999-’06 models 

106-3765 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 




• Piston weight for 97" kits are the same as stock, requiring no flywheel rebalancing 

• S&S 3.927" bore cylinders require no crankcase machining to install 

• Forged, coated pistons and S&S cylinders are compatible with stock or 

S&S Super Stock® 89cc heads 


• Pistons compatible with tapered or standard rods 

OPTIONS 

• Silver or wrinkle black powdercoat finish 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 


• Natural, diamond cut, polished and full polished 

106-3688 

Parts for 

X-Wedge® 

2007-2012 

S&S® 3.927" BORE CYLINDERS for 97" & 106" Top end kits 


Cylinder Only (Front or Rear) 

Displacement Stroke Cylinder Length 

Stock Heads 89cc S&S Heads Silver Black 

97" 4" 4.937" 9.7 9.4 106-3765 106-3767 

Special Order – – – – 91-7506* 

Since front and rear cylinders are interchangeable they are not sold in pairs. 


Parts for 


& Metric 

Racing 

Products 

S&S® 3.927" BORE PISTONS 97" & 106" Top end kits 

Displacement 



Deck Height Stroke Standard +.010" Standard +.010" 

0.927" Wristpin 

97" 1.270" 4" 106-3688 106-4414 106-3709A 106-4422A 106-1052 


Keeper .927” 

Each .......................................... TÜV 7 94-9278-S 

2 pack......................................... TÜV 7 94-9278-2 

4 pack.......................................... 

TÜV 7 106-2304 

NOTE: 

• S&S 3.927" pistons are machined to such close tolerances that it is not necessary to 

measure the piston. Additionally, the low friction coating on the piston skirt makes 

taking measurements very difficult. Therefore, hone cylinders to nominal diameter 

+/- 0.0005" for correct clearance. 

GASKETS 


MLS Head Gasket, .045" (each) 106-3714 

MLS Head Gasket, .030" (2 pack) 900-0216 

Base O-ring 50-8048 (H-D® #11256) 

Gasket Kit 

(includes head, base, & exhaust gaskets and o-rings) 

106-3763 

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2-47

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

4" BORE REPLACEMENT PISTONS 




Parts for 


1926-1984 

Parts for 


1986-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

PERFORMANCE 

PARTS 

92-1436 

S&S® 4" BORE PISTONS 

Displacement 



Deck Height Stroke Standard +.010" +.020" +.030" Standard +.010" +.020" +.030" 

116" 

4 5/8" 92-1436 92-1437 92-1438 92-1439 

1.200" 

100" 4" 92-1430 92-1431 92-1432 92-1433 

94-1306X 94-1307X 94-1308X 94-1309X 


Wristpin 

.927". ..................................... USA TÜV 3 1,6,7 94-9277 

Keeper 

Each .......................................... TÜV 7 94-9278-S 

2 pack. ........................................ TÜV 7 94-9278-2 

4 pack. ......................................... 

TÜV 7 106-2304 


& Promo Items 

Warranty & 



• For 100" and 116" ‘cylinder only’ kits, pistons must be measured and cylinders bored/ 

honed accordingly. Recommended piston fitment: 

• Close: 0.0020" – 0.0025" Loose: 0.0032" – 0.0045" 

• Stock crankcases must be bored to accept the larger S&S 4" cylinders 

• Early S&S 4" bore kits used o-rings to seal the cylinder base. Later kits use a base 

gasket. Use the correct sealing method for your kit 

2-48 



S&S ® 

SUPER STOCK ® 91cc CYLINDER HEADS 

FOR 4-1/8" BORE ENGINES 

Cylinder heads shown on this page are replacements for S&S 41/8" bore engines and 124" 

Hot Set Up Kits. Heads for S&S engines are machined with the S&S head bolt pattern, for 

use with S&S crankcases. Heads for the 124" Hot Set Up Kit are machined with the stock 

head bolt pattern, for use with stock crankcases. 


• Heads can be decked up to .060" to increase compression 

• S&S .640" lift valve springs 

• Stock Harley-Davidson® rocker boxes can be retained if S&S manual 

compression release or S&S Easy Start cams are used. Must use S&S valve 

cover gasket kit part #90-4120 with stock rocker covers. Conversely, when electronic 

compression releases are used, S&S rocker covers must be used. 

90-1370 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

OPTIONS 

• Compression release machining or without compression release machining 

• S&S or stock head bolt pattern 

• Natural, silver powdercoat, black powdercoat, or polished finish 

Description 

1999-'05 bt** 

91cc 41/8" Bore 

Stock bolt pattern 

S&S Replacement cylinder head Kits for S&S 124" Hot Set Up Kit® for 1999-'05 big twins** 

Finish 

Silver 

Black 

Compression Release 

Machining 

Springs 

Part No. 

• .640" lift 106-4272 

.640" lift 900-4272 

• .640" lift 90-1163 

.640" lift 900-1163 

Special Order * Specify – – 90-1060 

* 


** 2006 model year cylinder heads can be found in Section 1. 

Description 

91cc 41/8" Bore 

S&S Bolt pattern 

S&S Replacement cylinder head kits 

for S&S bore T-Series engines for 1999-'06 big twins 

Finish 

Compression Release 

Machining 

Springs 

Part No. 

Natural • .640" lift 90-1370 

Silver • .640" lift 106-4275 

Black • .640" lift 90-1371 

Polished • .640" lift 90-1372 

Special Order * – – – 90-1060 

* 


NOTES: 

• 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 our TÜV 

certified engines and our EPA approved engines, but our performance engines as well! 

• Since April 1, 2007, these redesigned heads have been installed on all S&S 41/8" bore engines 

and Hot Set Up Kits. 

• Replacement heads of the old style are available by special order. 

S&S® Top End Gasket Kits for 1999-’12 Big twins 

S&S 41/8" Bore (Graphite) Stock 41/8" Bore (Layered Steel) 

90-1910 USA TÜV 3 6 90-1914 

Includes a set of .043” head and base gaskets, exhaust gaskets and o-rings. 


Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-49

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


PERFORMANCE 

PARTS 


SUPER STOCK ® 79cc & 89cc CYLINDER HEADS 

S&S 79cc cylinder heads are intended for stock engines and other small 

displacement applications. These heads are compatible with stock Harley- 

Davidson® rocker covers. Must use S&S valve cover gasket kit part #90-4124 

with stock rocker covers. They are a very economical performance upgrade 

designed for use with other performance enhancers and are machined to accept 

S&S® compression releases. 

Intended for larger displacement engines, S&S 89cc heads have a whopping 

264cfm flow rate (compared to 182cfm for stock H-D® heads), larger valves 

and .640" lift valve springs. S&S recommends S&S Easy Start cams or manual or 

electric compression release system in order to maintain reliable engine starting 

on high compression applications. 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 


FITMENT 

• 1999 – '05 big twins (2006 model year heads can be found in Section 1) 

• Stock rocker covers 


• Heads can be decked up to .060" to increase compression 

• 79cc heads 1.940" intake and 1.575" exhaust valves 

• 89cc heads have 2.000" intake and 1.605" exhaust valves 

• S&S .585" or .640" lift valve springs 

• Stock Harley-Davidson® rocker boxes can be retained if S&S manual 

compression release or S&S Easy Start cams are used. Must use S&S 

valve cover gasket kit part #90-4120 with stock rocker covers 

OPTIONS 

• Compression release machining or without compression release machining 


Compression Ratios for S&S® Super Stock® Cylinder Heads 

for 1999-'063 Big twins 

Engine Displacement and 

Configuration 

79cc 

Chamber Volume 

89cc 

88" 9.1 8.3 

95" 9.6/10.3* 8.7/9.3* 

97" Big Bore 10.3 9.4 

103" 10.2/11.1* 9.3/10.1* 

106" Stroker 10.7 9.8 

* S&S pop-up piston 

110" 10.8 9.8 

Fitment 

1999-'05 bt 

106-4277 

S&S heads for Harley-Davidson® engines are now available in silver powdercoat finish. This is 

a perfect match for the finish on stock cylinders and crankcases. 

S&S® Super Stock® Cylinder Head Kits 

Chamber 

Volume 

79cc 

89cc 

Finish 

Silver 

Wrinkle 

Black 

Silver 

Wrinkle 

Black 

Compression 

Release 

Machining 

Springs Part No. 

• .640" lift 106-4277 

.585" lift 900-0254 

• .640" lift 90-1293 

.585" lift 900-0251 

• .640" lift 106-4270 

.585" lift 900-0409 

• .640" lift 90-1106 

.585" lift 900-0410 

Special 

Order 1 – – – – 90-1060* 

1 

Use this Special Order part number to order assembled or unassembled cylinder heads with spring 

options, special finish or diamond cut 


S&S® Head Bolt Packages for Cylinder Heads 

For 1999-'12 Big twins 

Engine Displacement 

Part No. 

88", 95", 100", 106", 107", 110", 111" 93-3070 

116", 117" 93-3071 

124" 93-3072 



S&S® Top End Gasket Kits for 1999-'12 Big twins 

33/4" Bore 37/8" Bore 3.927" Bore 4" Bore 

90-1911 90-1912 106-3763 90-1913 

Includes a set of head and base gaskets, exhaust gaskets and o-rings. 

2-50 



Continued 

S&S® Super Stock® 79cc & 89cc Cylinder Heads 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

PARTS 

90-4120 

S&S valve cover gasket kit. 

Must be used with stock rocker covers. 

NOTES: 

• 79cc heads 

• When 79cc stock compatible heads are used with stock H-D® pistons, TDC lifts of up to .186" for intake and .179" for exhaust and can be used without additional valve pocket 

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, piston valve pocket machining will be 

required. 

• 79cc heads may be decked as much as .060" to increase compression. If heads are decked, piston valve pockets must be re-machined. 

• Moderate valve spring force in S&S Super Stock® cylinder heads allows the use of camshafts designed for the stock style chain cam drive system. However, for maximum reliability 

and performance we recommend the S&S gear drive cams. 

• Must use S&S valve cover gasket kit part #90-4120 with stock rocker covers. 

• 89cc heads 

• If 89cc heads are used with stock pistons, valve reliefs must be machined in the pistons due to larger valve size. 

• 89cc heads may be decked as much as .060" to increase compression. If heads are decked, valve-to-piston clearance must be checked. If stock pistons are used, valve pockets must 

be re-machined. 

• Moderate valve spring force in S&S® Super Stock® cylinder heads allows the use of camshafts designed for the stock style chain cam drive system. However, for maximum reliability 

and performance we recommend the S&S gear drive cams. 

• A larger intake manifold is recommended to supplement the heads in order to let them flow to their full potential. 

• Must use S&S valve cover gasket kit part #90-4120 with stock rocker covers. 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

MANIFOLD RECOMMENDATIONS 

• S&S® manifolds for 1999-’06 carbureted engines are available to fit stock CV carburetors 

and S&S Super E and G carbs. Note that 2006 models require a slightly shorter manifold. (See 

"Important Manifold Information") 

• S&S single bore throttle body and manifold are recommended for engines with Magneti 

Marelli® and Delphi® fuel injection. 

• S&S single bore throttle body and manifold are recommended for 2006-'12, except 2008-'12 

touring models. Due to the change in manifold flange mounting bolt pattern, stock flanges and 

S&S seal part #16-0235 must be used. The Screamin’ Eagle® 58mm throttle body/manifold 

may also be used on 2006-'09 engines. 

• We recommend the stock 50 mm throttle body or Screamin’ Eagle 58mm throttle body/ 

manifold for 2008-up touring models with Electronic Throttle Control (ETC). These engines 

can be tuned with the Harley-Davidson® Super Tuner package, Pro EFI Super Tuner, Power 

Commander® or an aftermarket EFI tuning module or software tuner. 

IMPORTANT MANIFOLD INFORMATION 

• In 2006, Harley-Davidson® changed the bolt pattern of the flanges that connect the manifold 

to the cylinder heads for all big twin engines. The pattern was changed from an offset bolt 

pattern to a symmetrical bolt pattern, so flanges can fit either the front or rear cylinder head. 

In addition, the intake port was moved slightly toward the drive side of the engine, making the 

port-to-port distance of the intake manifold slightly shorter. S&S® heads for 2006-up big twins 

are machined with the symmetrical bolt pattern and relocated port to allow for the fitment 

of stock manifolds. In 2008, Harley-Davidson touring models were equipped with electronic 

throttle control (ETC). The throttle body and manifold used on these engines is a one-piece 

unit that contains a servomechanism to control the position of the throttle plate. S&S does not 

offer a throttle body for this application, so the stock 50mm throttle body or a Screamin’ Eagle® 

58mm throttle body is recommended. This limits the cylinder length of engines using an ETC 

manifold/throttle body to stock length because the ETC manifold/throttle body units are only 

available in stock length. However, S&S does supply specially machined cylinder heads for our 

124" Hot Set Up Kit® for 2008 and later baggers, which allows the use of a stock length manifold 

on these longer-than-stock engines. 

Ordering Notes: 

• Select the cylinder head kit that is correct for your application. 

• Select a gasket kit for the bore size of your engine. (Refer to "S&S Top End Gasket Kits" chart on 

previous page) 

• Select an S&S manifold for your engine size or cylinder length and fuel system. (Optional) 

• Select head bolt package. (Refer to "S&S Head Bolt Packages" chart on previous page) 

Tools & Shop 

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2-51

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Head BOLTS WITH WASHERS 


Parts for 



PERFORMANCE 

PARTS 

head bolt washers 

Thickness 

Part No. 

.100" 50-7088 

.150" 50-0418-S 

.250" 50-7091 

Parts for 

Evolution ® 


Parts for 


1986-2012 

S&S® head bolt-information chart 

Length w/ Washer 1.690" 1.840" 1.920" 2.070" 2.220" 2.370" 3.134" 3.284" 3.501" 3.651" 

Washer Thickness .250" .100" .250" .100" .250" .100" .250" .100" .250" .100" 

Head Bolt w/Washer 93-3028 TÜV 4 93-3027 93-3036 93-3031 93-3038 93-3032 93-3029 TÜV 4 93-3030 93-3037* 93-3033* TÜV 2 

Washers Only 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088 

* Drilled & tapped deeper to allow shortening for custom lengths. 

Parts for 


1926-1984 

S&S® head bolts for Harley-Davidson® twin cam 88® and Twin Cam 96 engines 

Engine Displacement Stroke Cylinder Length Cylinder Head Type Short Bolt w/Washer Long Bolt w/Washer Head Bolt Kit 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

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88", 95" 4" 4.935" 

100" 4" 4.850" 

106" Stroker 41⁄2" 4.935" 

107" 41⁄4" 4.975" 

111" 41⁄8" 4.763" 

116" 45⁄8" 5.160" 

117" 43⁄8" 4.888" 

124" 45⁄8" 5.013" 

50-0333 

Stock H-D® 93-3031 93-3030 93-3014 USA 

S&S® – 93-3030 93-3070 

Stock H-D® 93-3036 93-3030 93-3014 USA 

S&S® – 93-3029 TÜV 4 

– 

Stock H-D® 93-3031 93-3030 93-3014 USA 

S&S® – 93-3030 93-3070 

Stock H-D® 93-3031 93-3037 93-3012 

S&S® – 93-3030 93-3070 

Stock H-D® 93-3027 93-3030 93-3010 USA 

S&S® – 93-3029 TÜV 4 

– 

Stock H-D® 93-3038 93-3037 93-3016 

S&S® – 93-3037 93-3071 

Stock H-D® 93-3031 93-3030 93-3014 USA 

S&S® – 93-3030 93-3070 

Stock H-D® 93-3038 93-3037 93-3016 

S&S® – 93-3037 93-3071 

CALCULATING CUSTOM HEAD BOLT LENGTHS 

See instructions on page 12-6 

S&S ® Chrome Head Bolt Covers 

Dress up your engine with these magnetic chrome head bolt covers. Easy installation, 

no tools, no messy adhesives. A powerful magnet holds cover in place, yet allows easy 

removal. Chrome plated steel looks great on any engine, but is a must for polished 

engines. For S&S head bolts only. 

(Set of 4) ............................................. 

USA 

50-0333 

2-52 



S&S ® 

High Performance Hydraulic Tappets 

Standard equipment in S&S T-Series engines and every Hot Set Up Kit® for Harley-Davidson® Twin Cam 88® and 

96, these tappets are a great choice for any stock or high performance application. Only the finest materials and 

precision machining techniques are used in the manufacture of these lifters, and strict quality control ensures that 

they will work flawlessly every time, no matter what the application. Whether you have a stock 88 incher or the 

most outrageous big inch engine with a radical cam and spring combination, S&S tappets are built to take it. 

FITMENT 

• 1999–'12 big twins 


OPTIONS 

Tappets are available with the HL 2 

T Limited Travel Kit for improved cold starts and high rpm valve timing accuracy. 

PART NUMBER 

Four hydraulic tappets without HL 2 

T Kit (H-D® #18538-99A, 18538-99B) ... 

USA 

33-5350 

Four hydraulic tappets with HL 2 

T Kit ..................................33-5351 

S&S ® 

NOTE: S&S tappets with HL 2 

T Kit require the use of adjustable pushrods. 

Hydraulic Lifter Limited Travel Spacer (HL 2 

T) 

Designed to limit the range of travel of the hydraulic tappet plunger, HL 2 

T spacers do not allow the tappets to collapse, 

meaning both high rpm performance and starting are improved. A great addition to stock applications, the S&S HL 2 

T 

kit is highly recommended for engines equipped with stronger valve springs and aggressive cam profiles. 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

FITMENT 

• Stock 2003 – ’12 big twin 

• Harley-Davidson® replacement tappets 1999-up bt 

• All S&S tappets 


• Low noise and positive valve train activation 

• More horsepower at higher RPM’s 

• Easier starting 

PART NUMBER 

Set of four spacers (fits tappets with .612" I.D.) (Fits H-D® #18526-89A, 18538-99B) ..33-5338 

S&S ® 

Tappet Covers 

The perfect finishing touch for any stock or custom engines, these S&S tappet 

covers are CNC machined from billet aluminum and polished to a show finish. 

FITMENT 

• 1999-’12 big twins 

• S&S crankcases 

33-5338 

Note: Will not fit factory tappets in 1999-'02 engines. 


• Adjustable pushrods must be used with HL 2 

T kit in order to obtain proper plunger position. 

• If replacing lifters in a 1999-'02 with H-D #18538-99B, order S&S part #33-5338. 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 


• CNC billet aluminum provides extra strength and dimensional stability 

over a wide temperature range 

• Simple to install upgrade that looks great 

KIT CONTENTS 

• Covers 

• Gaskets 

• Installation hardware 

33-5601 

PART NUMBERs 

USA 

Polished, Tappet Cover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5601 

Chrome, Tappet Cover Kit ............................... 106-3883 

Replacement Gasket (H-D® #18635-99B) each ..................33-5303-S 

2 pack ......................................33-5303-2 


Warranty & 




2-53

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

PARTS 

QUICKEE Adjustable PUSHRODS 

These pushrods can be both installed and removed easily. The S&S design permits a 

simple, trouble-free installation that does not require removal of the gas tank, rocker 

assemblies, tappet covers, or even the rocker box cover! OEM pushrods may be cut 

to permit removal without rocker disassembly. The threaded adjuster screws into the 

pushrod until the threads disengage and the adjuster simply slides into the pushrod, 

making installation or removal a snap. Once the pushrod is installed and adjusted, the 

locknut prevents the adjuster from moving. 1984-'99 style pushrod covers required. 


Parts for 

Evolution ® 


FITMENT 

• 1999-'12 Twin Cam 88® or 96 w/ stock engine height +/- .050" 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 


• Easy to install – removal of rocker box not needed 

• Adjustable to accommodate all tappets and cam base circle diameters and 

engine heights 

• Perfect for S&S HL 2 

T 

• No threads on wrench flats 

• Quickee Adjustable Pushrod Kit includes: 

• Pushrods 


• O-rings 


PART NUMBERS 

Quickee Adjustable Pushrod Kit .......................... 106-6051 

Quickee Adjustable Pushrods Only ..........................93-5122 

Special Order* (pushrods only) ..............................93-5135 


93-5122 

When a Quickee Adjustable pushrod is collapsed, it can easily be installed or removed from 

an assembled engine. 

Tools & Shop 

Supplies 



& Promo Items 



106-6051 

Quickee Adjustable Pushrod Kit 

Warranty & 





• 1984-'99 style pushrod covers are required for access to the Quickee Adjustable Pushrod 

adjusters in 1999-up big twins. We suggest pushrod & cover kits. 

• Longer keepers are required for taller than stock engines. 

2-54 



S&S ® 

Standard ADJUSTABLE PUSHRODS 

S&S Standard Adjustable Pushrods are an economical alternative to the S&S 

Quickee Adjustable pushrods, but require rocker cover removal to install or remove. To 

assure consistent valve train operation under all conditions, S&S adjustable pushrods are 

manufactured from rigid chromoly steel tubing. 

FITMENT 


• Lengths available for various displacements 


• Adjustable to accommodate all tappets & cam base circle diameters 

• Perfect for HL 2 

T kits 

• Standard Adjustable Pushrod Kit includes: 

• Pushrods 


• Tappet cover gaskets 

• O-rings 




PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

PART NUMBERS 

S&S Standard Adjustable Pushrod Kit .......................93-5095 


Parts for 

X-Wedge® 

2007-2012 

S&S® Standard adjustable Pushrods for Harley-Davidson® Twin Cam 88® and Twin Cam 96/103 

Displacement Engine Height Cylinder length Pushrods Only Pushrod Clip Pushrod Covers 

88", 95", 96", 103", 106" Stock 4.937" 93-5096 93-4100 106-1340 

USA 

100" -.070" 4.850" – 93-4100 

USA 

106-1340 

107" +.055" 4.975" 93-5100 93-4101 106-1340 

USA 

116" +.243" 5.160" 93-5098 93-4115 106-1340 

USA 

124" +.096" 5.013" 93-5098 93-4115 106-1340 

USA 

Special Order Specify Specify 93-5102** 93-4109* – 

*Custom, extra long stainless steel 4.250", customer to cut to required length 

**Special Order: Download the Special Order Form at sscycle.com/soforms 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


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Warranty & 


93-5095 

Standard Adjustable Pushrod Kit 




2-55

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

PARTS 


PUSHROD COVERS AND RELATED PARTS 

S&S pushrod cover kits include all of the parts required for four pushrods except keepers. 

Keepers are sold separately because of the different length requirements of some engines. 

These covers are a must when using adjustable pushrods. 

FITMENT 


Parts for 

Evolution ® 


PART NUMBERs 

Pushrod Cover Kit (includes top and bottom covers, cover cap, cover spring, and 

spring washer for four pushrods) .......................... 

USA 

106-1340 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

replacement parts 

Top cover (H-D® #17935-79B).............. USA USA 1,2,3 

TÜV 1,2,3,6,7 93-4016 

Bottom cover (H-D® #17938-83) ............ 

USA USA 1,2,3 

TÜV 1,2,6,7 93-4015 

Cover cap (H-D#17945-36B)............... USA USA 1,2,3 

TÜV 1,2,3,6,7 93-4017 

Cover spring (H-D#17947-36) ............. USA USA 1,2,3 

TÜV 1,2,3,6,7 93-4018 

Cover cap washer (H-D#6762B) each ......................... 

USA 

50-7131 

10 pack ............................................. 

USA 

50-7136 

Top o-ring (H-D® #11190, 11157, 11293) ..............................50-8039 

Middle o-ring (H-D#11132A) each ............................ 

USA 

50-8038 

10 pack ............................................. 

USA 

93-4111 

Bottom o-ring (H-D#11145A) each ........................... 

USA 

50-8037 

10 pack ............................................. 

USA 

93-4112 

Quad Seal 

Pushrod o-ring kits (includes top, middle, and bottom o-rings 

for four pushrods) ............................... 

USA TÜV 2,4,5 93-4022 

106-1340 

S&S® Pushrod Cover Keeper Sets For 1999-'12 BIG TWINS 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




93-4101 

All S&S pushrod keepers are chromed steel, except part #93-4109. Keeper part #93-4109 

is intended for unusually tall engines. It is manufactured of unchromed stainless steel to 

prevent rust or peeling after it is trimmed to the required length. 

Part No. Length S&S TUBES 

93-4070 2.400" All Stock Height TC88/96/103 

93-4100 2.500" 96", 103", 106”, 117” HSU 

93-4101 2.600" 124" 

93-4115 2.800" 116" 

93-4102 2.900" 

93-4103 3.000" 

93-4104 3.100" 

93-4105 3.200" 

93-4106 3.330" 

93-4107 3.500" 

93-4108 3.625" 

93-4109 4.250" 

Keepers are sold in sets of four. 

Stainless steel may be cut to 

length. 

NOTE: All reference to H-D® part numbers is for identification purposes only. We in no way are implying that any of S&S Cycle’s products are original equipment parts or that they are 

equivalent to the corresponding H-D® part number shown. 

2-56 



S&S ® 

FORGED ROLLER ROCKER ARMS 

Forged from 8620 steel, heat-treated, and then shot-peened for additional strength and 

protection from fatigue, our roller rocker arms were designed to eliminate failure-prone stress 

areas found in some other rockers. Most rockers come equipped with ½" long bushings or 

needle bearings, however ours utilize ¾" long bronze bushings. The end result is what we 

believe to be the finest rocker arm available anywhere, for any price. 

FITMENT 


900-4065A 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 




• Extremely durable rollers reduce valve stem side thrusting with high lift cams 

• Superior wear and fatigue resistance even in the most demanding applications 

• ¾" long bushings provide 50% more bushing support area than ½" long bushings 

KIT CONTENTS 

• 2 front and 2 rear rocker arms 

PART NUMBERS 

Set of 4 rocker arms ....................................900-4065A 

Replacement parts: 

Front exhaust or rear intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-4065FA 

Rear exhaust or front intake ...........................900-4065RA 

Rebuild kits (rebuilds 4 rocker arms) .........................90-4104 

Rocker arm bushing (¾" long) ........... 

USA 1,2,3 

TÜV 1,2,3,4,5,6,7 90-4014 

Rocker arm shafts: 

Set (includes 4) (H-D® #17611-83) ....................... 

USA 

90-4036 

Individual ......................... 

USA USA 1,2,3 

TÜV 1,2,4,5,6,7 90-4006 

S&S ® 

STANDARD FORGED ROCKER ARMS 

S&S now offers an economical solution for stock rebuilds and mild performance upgrades. S&S standard rocker arms 

are forged from 8620 steel for greater strength than stock forged or cast steel rocker arms. In addition, they feature 

the same ¾" long rocker shaft bushings that our S&S roller rocker arms do. Thousands of hours of engine testing 

have proved them to be superior to other non-roller rocker arms. 

90-4036 

S&S rocker arm shaft set 

NOTE: 

• Adjustable pushrods must be used with S&S roller rocker arms to obtain proper valve 

clearance. 

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

• All reference to H-D® part numbers is for identification purposes only. We in no way are 

implying that any of S&S Cycle’s products are original equipment parts or that they are 


Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

FITMENT 



• ¾" long bronze bushings provide 50% more load bearing area than 

the ½" long bushings used in stock and other aftermarket rocker arms 

KIT CONTENTS 

• 2 front and 2 rear rocker arms 

PART NUMBERS 

Standard forged rocker arms ............................900-4119A 

Replacement parts: 

Front exhaust or rear intake (H-D® #17375-83A) ............900-4119FA 

Rear exhaust or front intake (H-D® #17360-83A) ............900-4119RA 

Rocker arm bushing (¾" long) ............ USA 1,2,3 TÜV 1,2,3,4,5,6,7 90-4014 

Rocker arm shafts: 

Set (includes 4) (H-D® #17611-83) ....................... 

USA 

90-4036 

Individual ......................... 

USA USA 1,2,3 

TÜV 1,2,4,5,6,7 90-4006 

900-4119A 

NOTE: 

• S&S roller rocker arms are recommended for use with cams having more than 0.585" of lift. 

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

• All reference to H-D® part numbers is for identification purposes only. We in no way are 




Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-57

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

PERFORMANCE 

PARTS 

.585" Lift Dual VALVE SPRINGS 

FITMENT 

• Twin Cam 88® big twins w/ stock heads (both 7mm and 5/16” valve stems) 

• All S&S Super Stock® heads (5/16” valve stems) 


• Dual springs reduce the risk of valve float 

• Suitable for high performance applications 

• Accommodates camshaft lift to 0.585” 

KIT CONTENTS 

• Valve Guide Seals 

• Inner & Outer Springs 

• Top Collars 

• Bottom Collars 

• Keepers 

• Shims 


90-2277 

Parts for 


& Metric 

PART NUMBER 

S&S .585” Lift Dual Valve Spring Kit for 1999-’04 (5/16” valve stems) ....90-2277 

S&S .585" Lift Dual Valve Spring Kit for 2005-’12 (7mm valve stems) ..900-0420 

Racing 

Products 

S&S® Dual Valve Springs Specifications 

Lift Installed Height Seat Force Force @ Max Lift 

.585" 1.800" 130 lb. 325 lb. 

Tools & Shop 

Supplies 




Warranty & 



& Promo Items 

2-58 



S&S ® 

HIGH PERFORMANCE .640" LIFT TRIPLE VALVE SPRINGs 

Not only designed to increase spring force and reduce the risk of valve float, S&S valve 

springs also eliminate most of the complicated procedures and specialized tools required 

to prepare cylinder heads for high lift cams up to .640" lift. 

FITMENT 

• 1999–’04 Twin Cam 88®/88B with stock heads (5/16” valve stems) 



• Patented steel top collars are drilled for lightness and to increase 

cooling oil flow over valve springs 

• For very high performance applications, kits with low mass titanium 

top collars are also available 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

KIT CONTENTS 

• Valve keepers 

• Top collars 

• Bottom collars 

• Outer springs 

• Middle springs 

• Inner springs 

• Shims 

PART NUMBERS 

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

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

S&S® Sidewinder® Valve Springs Specifications 

Lift Installed Height Seat Force Force @ Max Lift 

.640" 1.800" 170 lb. 390 lb. 

Not recommended for cams with over 0.640" lift 

90-2078 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

Application Notes: 

• Use with shoulderless-style valve guides. 

• Special keepers included fit valves with stock 5⁄16" stems and S&S collars only. 

• Spring seat force is typically 170 lbs. at stock 1.800" installed height. 

• Open force is 390 lbs. at .560" lift, 415 lbs. at .630" lift. 

• May also be used in any other heads that require stock O.D. outer spring. 

• S&S springs will not fit 2005 - later stock heads because of the change in valve spring 

and valve stem diameter. 



& Promo Items 

Warranty & 


Installation NOTE: 

• High lift cams may require the engine builder to obtain additional clearance between the piston and valves, the intake and exhaust valves and the upper spring collar and rocker cover. 

Clearance should also be checked between the rocker arm and valve spring collar as well as between the rocker arm and rocker cover. It is imperative that the engine builder confirm these 

clearances and check for spring coil bind, even when using parts specifically designed for high performance. Most valve train failures can be traced to over-revving or failure to confirm 

correct clearances during assembly. 




2-59

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

PERFORMANCE 

PARTS 


SIDEWINDER ® .650" Lift Valve Springs 

FITMENT 

• Twin Cam 88® big twins w/ stock heads (both 7mm and 5/16” valve stems) 



• Works well with cams up to .650" lift 

• Manufactured from ultra clean high silicon Kobe alloy wire 

then micro shot peened and nitrided 

• CNC machined 9˚ locks 

• High performance conical single wire spring 

• Chromoly forged retainers 

106-5909 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

KIT CONTENTS 

• Valve keepers 

• Top collars 

• Bottom collars 

• Springs 

• Shims 

Parts for 


& Metric 

PART NUMBERS 

S&S Sidewinder® Valve Spring Kit for 1999-'04 (5/16” valve stems) ......... 900-0050 

S&S Sidewinder® Valve Spring Kit for 2005-'12 (7mm valve stems) .......106-5909* 

*Kit includes valve guide seals. See page 2-84 for additional seals. 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




Racing 

Products 

NOTE: 

S&S® Sidewinder® Valve Springs Specifications 

Lift Installed Height Seat Force 

• S&S recommends roller rocker arms be used with lifts over .585" 

Force @ Max 

Lift 

Max RPM 

.650" 1.860" 178 lb. 376 lb. 6500 


2-60 



S&S ® 

Die Cast ROCKER COVERS 

Produced using the die-casting manufacturing process and then machined with computer 

controlled equipment. Includes Viton® o-ring style cover seals for leak-free operation. 

FITMENT 

• All Twin Cam 88® big twins 

• Sold as stock on 41/8" bore S&S engines 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 




• Special rocker arm supports are included 

• S&S rocker covers are finished with show-quality chrome 

• Installation on stock and most comparable sized engines can be performed without 

removing the engine from the frame 

• Clearanced to permit valve lifts up to .640" using S&S valve spring packages and 

stock rocker arms or S&S roller rocker arms 

• S&S rocker covers accept valve springs up to 1.660" O.D. without modification 

• Exclusive one way valve built into the rocker cover gasket to control oil carry over 

KIT CONTENTS 

• Front and rear covers 

• All necessary gaskets and o-rings 

• Mounting hardware 

PART NUMBER 

S&S Rocker Cover ................................... 

TÜV 2 90-4110 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

90-4110 


Notes: 

• If using valve spring packages with taller than stock installed height, some minor 

clearancing may be required. 

• Cylinder heads must be set up correctly for high lift cams, and it remains the builder’s 

responsibility to confirm all clearances. 

• In most instances, only minor clearancing is required to use S&S rocker covers with 

valve springs larger than 1.660" O.D. 


• S&S® rocker covers are required if S&S cylinder heads are used with S&S electric 

compression releases. 


S&S Rocker Cover Wrench Set, see page 8-7. 


& Promo Items 

Warranty & 





2-61

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

PERFORMANCE 

PARTS 


Super Stock ® Stealth Air Cleaner Kits 

The Power Of Style! 

High performance intake systems have been an important part of the S&S product 

line since the early 1960’s. These new S&S Super Stock Stealth air cleaner kits make a 

powerful statement about style and performance. 


• For the rider who likes to go fast, but doesn’t like to advertise 

• Air directional stinger cone in the filter 

• Use with your stock Harley-Davidson® Twin Cam 88®, 96 or 103 air cleaner 

cover – the word "sleeper" comes to mind 

• Can also be used with any of several S&S designed covers 

• High flow (1" taller) filter kit available 


Cut-away showing a stock Twin Cam 88® /96/103 cover on S&S Stealth air cleaner kit. 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

S&S Super Stock® Air Cleaner KitS 

Application Fuel System STEALTH* 

AIR STREAM BOBBER-DISHED BOBBER-DOMED MUSCLE 

Chrome Finish 

1999-’12 bt Stock CV/EFI, except 1999 Softail® carb 170-0060 170-0056 170-0104 170-0105 170-0106 

1999-’06 bt S&S Super E & G Carbs 170-0058 170-0063 170-0110 170-0111 170-0112 

*These kits do not contain covers – use your stock Twin Cam 88®, 96 or 103 cover or choose an S&S cover Not legal for sale or use on CA pollution controlled vehicles. 

Parts for 


& Metric 


2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ Airstream Cover vs Stock Air Cleaner 

100 

90 

S&S Super Stock Stealth w/ Airstream Cover 






100 

90 


2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ Bobber Cover vs Stock Air Cleaner 

S&S Super Stock Stealth w/ Bobber Cover 






80 

80 

Racing 

Products 

70 

60 

70 

60 

50 

40 

50 

40 

Tools & Shop 

Supplies 

30 

20 

10 

30 

20 

10 


& Promo Items 

1000 2000 

3000 

4000 5000 6000 

EngSpd RPM 

1000 2000 

3000 

4000 5000 6000 

EngSpd RPM 

These dyno charts compare the performance of a totally stock 2012 FLHX to the same bike with an S&S Stealth air cleaner, fitted with the S&S Airstream and S&S Bobber air cleaner covers. In both 

cases, the S&S Stealth air cleaner out-performs the stock air cleaner. With more filter exposure, the S&S Bobber cover delivers the largest increase in torque of 1.5 ft/lb over stock! For even more 

power add S&S performance mufflers. Both were tuned with Dynojet® Power Vision® Tuner. 

Warranty & 




High Flow replacement Air filters 

Standard (Filter only) ................ 170-0126 

1" Taller Kit* (includes 2 spacers)...... 170-0127 

(Filter only).................... 170-0154 

*1” taller filter kit does not fit Muscle air cleaner kit. 

170-0126 

Standard high flow air flilter 

170-0127 

1" taller high flow air filter kit 

This built-in stinger cone is featured in all 

Super Stock air cleaner kits except the tuned 

induction systems. 

• Directs air smoothly into the bore of the 

carburetor or EFI throttle body 

• Reduced turbulence and increased flow 

• Featured in S&S teardrop air cleaners 

since the early 1970’s 

2-62 



S&S ® 

Super Stock ® Stealth Air Cleaner Covers 

S&S Air Stream Air Cleaner Cover 


• An updated version of the speed inspired S&S teardrop shape 

• Screened vent for more air without sucking in rain/road debris 

• Steel construction with your choice of chrome or Black Jack (wrinkle black powdercoat) 

Air Stream 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Part numbers 

Air Stream Air Cleaner Cover 

Parts for 

Evolution ® 


Chrome ............................................. 170-0118 

Black Jack ........................................... 170-0122 

S&S Bobber Billet Air Cleaner Covers 


• Minimalist air cleaner cover that really delivers the goods! 

• Fits over the end of the air filter and leaves the filter element exposed 

• Choose from the Dished Bobber or the Domed Bobber covers 

• CNC machined from billet aluminum in chrome or Black Jack 

(wrinkle black powdercoat) 

170-0118 

Bobber Dished 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Part numbers 

Bobber Dished Air Cleaner Cover 

Chrome ............................................. 170-0119 

Black Jack ........................................... 170-0123 

170-0119 

170-0123 

Bobber Domed 

Parts for 


& Metric 

Bobber Domed Air Cleaner Cover 

Chrome ............................................. 170-0120 

Black Jack ........................................... 170-0124 

Racing 

Products 

S&S muscle Billet Air Cleaner Covers 


• Similar to the Bobber covers 

• Leaves the entire air filter exposed for a raw hot rod look 

• Cover is held on with muscle car style hood pins 

• CNC machined from billet aluminum in chrome or Black Jack (wrinkle black powdercoat) 

Part numbers 

Muscle Air Cleaner Cover 

170-0120 

170-0124 

Muscle 

Tools & Shop 

Supplies 


& Promo Items 

Chrome ............................................. 170-0121 

Black Jack ........................................... 170-0125 

Warranty & 



170-0121 



170-0125 


2-63

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


PERFORMANCE 

PARTS 


SINGLE BORE TUNED INDUCTION SYSTEM 

FITMENT 

• Twin Cam 88®/96/103 big twins 


• Bolt-on performance – over twice the filtering area over stock intake system 

• Increases horsepower and torque across the rpm range using air column inertia 

and carefully timed gas dynamic pressure waves 

• Smooth intake tract of carefully selected tuned lengths increases performance 

• High flow washable and reusable cotton media provides performance, protection, 

and economy 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

S&S SINGLE BORE TUNED INDUCTION SYSTEM KITS 

Fitment Fuel Delivery Finish Part No. 

4 1/8" Bore S&S T-Series S&S Single Bore EFI 

170-0083 

4 1/8" Bore S&S T-Series S&S Super E/G 

Chrome 

170-0084 

1999-up big twins S&S Single Bore EFI Runner 170-0085 

and 

1999-'06 big twins S&S Super E/G 

Red Filters 170-0086 

1999-'12 big twins 

(except 2008-up Touring) 

Stock CV & EFI Delphi® 170-0087 

CTO 

Specify Specify 106-5337* 

*Use the Configure to Order (CTO) part number to order different finish and filter color. 


Replacement Filters (each sold with clamp) 

Red ..............................................................17-1020 

Blue .............................................................17-1023 

Billet adaptor brackets make single 

bore tuned induction compatible 

with many engines and motorcycles. 

Tools & Shop 

Supplies 

Renew the color of your air filter with an 8 oz. bottle of S&S Air 

Filter Oil. Choice of red or blue oil. 

S&S Air Filter Oil, Red .........................106-1163 

S&S Air Filter Oil, Blue ........................106-1164 


& Promo Items 

Warranty & 




2-64 

Washable nylon air filter covers are water resistant and filter 

out large debris, allowing the filter media to stop small dirt 

particles from getting into your engine 

S&S Nylon Air Filter Cover 

each ..................................... 106-0247 

2 pack ................................... 106-0248 


• Does not fit Screamin' Eagle 58mm throttle bodies on 2008-up touring models. 

• Tuned induction will not fit on motorcycles equipped with fairing lower glove boxes. 



S&S ® 

Teardrop AIR Cleaner Kit 

FITMENT 

• Twin Cam 88®/96/103 big twins 



• Efficient and free flowing intake that can add two to five horsepower 

• Uniquely designed back plate has air horn style radiused entryway to reduce turbulence 

• Dimpled cover with directional air cone on inside creates smooth path for air 

• Great addition to performance exhaust or cams 

KIT CONTENTS 

• Filter 

• Backing plate 

• All mounting hardware 


Teardrop Air Cleaner Kits 

Model/Engine Stock Carb/EFI: S&S® Super E or G: 

S&S 41/8" bore engines – 17-0416 

2001-'12 Softail EFI, All 2002-Up EFI (Delphi®) 17-0450 – 

1999-'01 EFI big twin (Magneti Marelli®) 106-4589 – 

1999-'06 Carbureted 17-0450 17-0403 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 


Optimize your stock carBuretor 

Jet,Kit,CV Carb,1999-2006 bt ........................11-5203 

Jet,Kit,CV Carb,1995-2006 bt .........................11-5202 

A respectable gain in both horsepower and torque can be seen in this graph comparing a stock 

big twin to one equipped with an S&S® air cleaner and SPO® touring mufflers. 

Parts for 


& Metric 

Racing 

Products 

S&S ® 

TearDrop AIR CLEANER COVERS 

FITMENT 

• S&S teardrop air cleaners for Super E & G carbs and S&S EFI throttle bodies 

• S&S air cleaner kits for stock fuel systems 

PART NUMBER 

Slasher Air Cleaner Cover . ...................................17-0004 

Polished Nostalgic S&S Cycle Air Cleaner Cover 

E & G carbs ............................................... 17-0071 

Super B carbs ..............................................17-0070 

Wrinkle Black Powerdercoat .................................17-0384 

New! Stealth Air Cleaner Covers. See page 2-3 

17-0004 

Slasher Air Cleaner Cover has slots strategically cut around the perimeter 

of the cover to allow a more direct path to the air filter, increasing power 

output by 1–2 hp! 

17-0071 or 17-0070 

Nostalgic Air Cleaner Cover has raised 

letters that say "S&S Cycle" and a mirror like 

polished finish. 

17-0384 

Wrinkle Black Powdercoat Air Cleaner Cover. 


Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-65

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

HIGH FLOW AIR FILTER KITs 

FITMENT 

• S&S teardrop air cleaners for Super E & G carbs and S&S EFI throttle bodies 


17-0045 

High flow air filter kit for 

S&S Teardrop Air Cleaners 

Parts for 



Parts for 

Evolution ® 


PERFORMANCE 

PARTS 


• Low restriction filter element comes pre-oiled for true plug and play installation 

• 1" wider filtration area provides up to 37% more airflow over standard S&S filters 

• Resulting band of exposed filter material imparts a high performance look 

KIT CONTENTS 

• Wide filter 

• Filter spacers 

170-0127 

1" Taller High flow air filter kit for 

New Super Stock® Air Cleaners 

Parts for 


1986-2012 

Parts for 


1926-1984 

PART NUMBERS 

High Flow Air Cleaner Kit 

Classic S&S® Teardrop (includes spacers) ....................17-0045 

Super Stock® Stealth, 1" Taller (includes spacers) ........... 170-0127 

Replacement Filter only 

Teardrop, Standard .................................... 106-4724 

Super Stock® Stealth, Standard .......................... 170-0126 

Super Stock® Stealth, 1" Taller ........................... 170-0154 

Replacement Filter Spacers ..............................50-5009-S 

100 

90 

80 

70 

60 


2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ 1" Taller Filter vs Standard Filter 

S&S High Performance 1" Taller Filter 



S&S High Performance Standard Filter 



Parts for 

X-Wedge® 

2007-2012 

This dyno chart compares the performance of S&S High Flow filters when used with 

an S&S Stealth air cleaner kit. With added area for drawing in more air, the optional 1" 

taller filter can increase torque by 1.7 ft/lb over the standard sized filter! This test was 

conducted on a stock 96" engine with stock mufflers. More impressive performance 

gains can be expected on large displacement engines with performance exhaust, 

performance camshaft, and high flow cylinder heads. 

50 

40 

30 

20 

10 

Parts for 


& Metric 

Racing 

Products 

S&S ® 

HIGH PERFORMANCE FILTERS 

FOR STOCK Air Cleaners 

1000 2000 

3000 

4000 5000 6000 

EngSpd RPM 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-66 

FITMENT 

• 1999 - ‘12 carbureted and EFI big twins 


• Direct replacement for stock Harley-Davidson® filter assemblies 

• Washable and reusable – cost effective upgrade that pays for itself over time 

• Great by itself or complement to performance exhaust or cams 

Application 

1999 - '06 Carbureted Twin Cam 88®, 

2001-'12 Softail® EFI (except Cross Bones), 

2002-'07 FL EFI, 2004-'07 EFI Dyna® 

1999-2001 EFI big twin 


Part No. 

106-4630 

(H-D® #29461-99) 

106-4631 

(H-D® #29462-99) 

106-4630– Twin Cam 88® (carb), 

2001-‘09 Softail® EFI (except Cross Bones), 

2002-'07 FL EFI and 2004-‘07 EFI Dyna® 

– Replaces H-D® #29461-99 

NOTE: All reference to H-D® part numbers is for identification purposes only. We in no 

way are implying that any of S&S® Cycle's products are original equipment parts or that 

they are equivalent to the corresponding H-D part number shown. 106-4631– 

Twin Cam 88® FL EFI 1999-‘01 – Replaces H-D #29462-99


S&S ® 

SUPER E & G COMPLETE Carburetor KITS 

Built to last, these high flow butterfly type carburetors are easily tuned for maximum 

performance and drivability. The Super E’s 17/8" bore is more than adequate for street engines 

up to about 100" displacement. The huge 21/16" bore on the Super G is recommended for 

engines 100" and larger. 

FITMENT 

• 1999–’06 Twin Cam 88® engines 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 




• Increased air flow for more power 

• Adjustable accelerator pump for quick throttle response and easy starting 

• Utilization of the factory dual cable system ensures safe operation 

• Direct replacement and high quality fit and finish – less down time and better performance 

• Variable position enrichment starting system 

KIT CONTENTS 

• Super E or G carburetor 

• S&S intake manifold 


• Mounting hardware 

• Gaskets, seals and hoses 


WATCH THE KICK START SUPER E CARB VIDEO AT 


Models Super E Complete Kit Super G Complete Kit 

1999-'05 big twin 11-0450 11-0451 

2006 big twin 106-0874 106-0875 

Models Super E (Carb only) Super G (Carb only) 

All Years & Models 11-0420 11-0421 

11-0450 

Super E Carburetor complete kit for 1999-'05 big twin 

OPTION 

Optional cruise control adapter kits allows riders to keep 

factory cruise feature on 1999-’06 models 

Cruise Control Adapter Kit ................11-2927 

NOTES: 

• S&S® does not recommend polishing or chrome plating Super E & G carbs. Our repair department has seen many carbs with plugged passages due to polishing compounds, and some 

carbs that have been destroyed because the polishing or chrome plating had altered critical machined surfaces. 

• Recommended for closed circuit use only—S&S Super E & G carbs shown are not approved for use on motor vehicles operated on California public highways, or in other states where 

similar pollution laws may apply. The user shall determine the suitability of the product for his or her use and shall assume all risk and liability in connection therewith. 

• Replacement parts for S&S Super E & G carburetors can be found on page 2-96. 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

S&S ® 

TÜV APPROVED SUPER E CARBURETOR KIT 

Riders in the European Union can replace their stock Harley-Davidson® carb with a reliable 

S&S Super E. Before being shipped, carburetors are jetted for the year of bike specified. 

FITMENT 

• 1999–’06 carbureted Twin Cam 88® 

Tools & Shop 

Supplies 


& Promo Items 

KIT CONTENTS 

• Documentation proving TÜV approval 

• 17/8" bore Super E carburetor 

• Polished intake manifold 


• All mounting hardware and gaskets 

• Complete instructions 

Part Number 

TÜV Approved S&S Super E Carburetor Kit .................... 106-2482 


Warranty & 




2-67

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



PERFORMANCE 

PARTS 


Manifolds for Carbureted big twin Engines 

These manifolds have provisions for mounting the stock MAP sensor directly to the manifold, 

and are primarily designed for Harley-Davidson® Twin Cam 88® engines. These manifolds 

may also be used on engines for 1984-'99 big twins which require a MAP sensor, such 

as S&S engines equipped with the S&S Intelligent Spark Technology® (IST®) ignition. 

Available in 17⁄8" and 21/16" bore sizes and for 40–48mm CV carburetors. 

FITMENT 

• 1999–’06 big twins 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-68 


• Fits stock or S&S heads 

• Fits stock or engines with taller cylinders 

S&S® Manifolds for Harley-Davidson® Twin Cam 88® Engines 

(requiring MAP Sensor* machining) 

Engine Style 

Cylinder Manifold Super E Super G 

and Displacement 

Length Size 

Part No. 

88", 95", 106" Twin Cam 88 4.937" 410 16-1718 16-2588 

100" Twin Cam 88 & Stock 

2006 Models 

4.850" 405 16-1717 16-2587 

107" Twin Cam 88 4.975" 414 16-1716 16-2586 

111" Twin Cam 88 4.763" 398 106-4487 16-2604 

116" Twin Cam 88 5.160" 428 16-1719 16-2589 

117" Twin Cam 88 4.888" 408 – 16-2603 

124" Twin Cam 88 5.013" 417 – 16-2598 

Special Order Specify – 16-1639 16-2539** 

* All S&S engines for 1984-'06 and 1999-up big twins equipped with S&S IST ignition system. 

**Special Order: Download the Special Order Form at sscycle.com/soforms 

NOTES: 

• S&S manifolds require S&S style manifold seals. 

• S&S style o-rings must be used with these manifolds. S&S o-rings are slightly thinner to 

accommodate the larger S&S port diameter. Use of stock o-rings may cause damage. 

S&S ® 

50-8372 

MANIFOLDS FOR SINGLE BORE EFI BIG TWIN ENGINES 

Specifically designed for S&S Single Bore EFI applications, these S&S manifolds 

include fuel injector mounting ports and provisions for installation of a stock style 

MAP sensor. 

FITMENT 

• Stock height or taller than stock 1999-’12 bt 

(except 2008-up touring models) 

• S&S 52mm or 58mm throttle bodies 

• Stock or S&S heads 


16-0136-S 

NOTE: S&S style o-rings must be used with these manifolds. S&S o-rings are 

slightly thinner to accommodate the larger S&S port diameter. Use of stock 

o-rings may cause damage. 


Manifold for CV carburetor 

Manifold for S&S carburetors 

S&S CV Manifolds – 1999-2005 big twin 

Style/Displacement (mm) Manifold Size Part No. 

88", 95", 106" Twin Cam 88 40-45mm 410 16-1722 

(H-D® #27613-99) 

100" Twin Cam 88 40-45mm 405 16-1721 

107" Twin Cam 88 40-45mm 414 16-1723 

116" Twin Cam 88 40-45mm 428 16-1724 

96 stock 48mm 410 160-0001 

S&S CV Manifolds – 2006 & up big twin 

Style/Displacement (mm) Manifold Size Part No. 

96 stock 40-45mm 405 16-1721 

96 stock 48mm 405 160-0002 

Special order Specify – 16-1725A* 


U-Rings for Constant Velocity Carbs 

U-ring, 40-42mm (H-D® #27002-89) ....................16-0242 

U-ring, 44-48mm .................................16-0241 

Replacement Parts For Manifolds 

Manifold Fitting VOES Rubber Cap 

3⁄16" I.D. x 5⁄16" O.D. x ½" ....................................... 50-8372 TÜV 2 

Manifold Vacuum Fitting ..................................... 16-0136-S 

Engine Displacement Cylinder Length Manifold Size Part No. 

2006-Up Big twins with STock or S&S Heads 

88", 95", 96" 103" & 106" 4.937" 405 16-5134 

124" Hot Set Up Kit® (except 2008-up 

touring models w/stock or S&S heads) 

5.013" 417 16-5139 

124" Hot Set Up Kit® (except 2008- 

up touring models w/S&S heads only) 

5.013" 405 16-5134 

1999-’05 Big twins With Stock or S&S Heads 

88", 95", 103" & 106" 4.937" 410 16-5141 

124" Hot Set Up Kit (w/stock or S&S heads) 5.013" 417 16-5139 

S&S 41/8" Bore T-Series Engines 

111" 4.763" 398 16-5136 

117" 4.888" 408 16-5138 

124" 5.013" 417 16-5139 

Special Order (All Styles) Specify 389-428 16-5142* 

* Special Order: Download the Special Order Form at sscycle.com/soforms


S&S ® 

Early EFI Upgrade Package 

Is your fuel injection system getting tired Lots of mileage on your motorcycle S&S has 

assembled a package that includes everything you need to refresh and upgrade your fuel 

delivery system! 

Fitment 

• 1995 ½ – 2001 EFI touring models 

Features & benefits 

• Complete package to upgrade early fuel injection systems 

• Replacement ECU can be programmed with various calibrations 

• New injectors 

• 52mm throttle body/fuel rail 

• Intake manifold with vacuum fittings 

• Teardrop air cleaner 

• Typical increase of 4 horsepower over stock 

Part Numbers 

1995 ½ – 2001 EFI touring models .......................550-0068 

S&S ® 

SINGLE BORE EFI THROTTLE BODIES 

52mm: Offering a 30% larger cross sectional area than stock throttle bodies, the S&S 

52mm bore throttle body flows more than enough air for all but the most demanding street 

engines. 

58mm: In response to constant requests for something bigger, S&S also offers a huge 

58mm bore throttle body! Strictly for large displacement competition engines, this throttle 

body allows your engine to breathe easily and make more power! 

FITMENT 

• 1999-’12 big twins 

(except 2008-up touring models with electronic throttle control) 


• Excellent performance 

• Recommended tuning products: 

• S&S VFI 

• Dynojet® Power Vision Tuner 

• Cruise control compatible with no extra bracket 

OPTIONS 

• 52mm or 58mm 

KIT CONTENTS 

• Throttle body assembly 

• Fuel injectors 

• Fuel rail 

• Harness adaptors 

• All necessary hardware, gaskets, and hoses 

PART NUMBERS AND SPECIFICATIONS 

S&S® 52mm Single Bore EFI Throttle Body/Fuel Rail Kits 

1995-’01 EFI big twin (except Softail® models) ..................17-5068 

2002-’05 EFI big twin & 2001 Softail models ...................17-5067 

2006–'12 EFI big twin* .................................... 17-5070 

S&S® 58mm Single Bore EFI Throttle Body/Fuel Rail Kits 

1995-’01 EFI big twin (except Softail® models) ................ 106-4406 

2002-’05 EFI big twin & 2001 Softail models ................. 106-4407 

2006–'12 EFI big twin* ................................... 106-4408 

* except 2008–up touring models with electronic throttle control. 

NOTES: 

• If you plan to use another programmable fuel injection module, it is 

best to consult the manufacturer to be certain that it is compatible 

with the S&S single bore system and has enough tuning capability for 

your engine configuration. 

• Installation of S&S throttle body on 1995-'01 bikes requires S&S ECU. 

Single bore throttle bodies are not compatible with stock Magneti 

Marelli® ECU 

106-4408 

Stock 

Seeing is believing. It’s pretty easy to see 

the differences in the bore sizes of a stock 

Harley-Davidson® throttle body and the 

S&S® 52mm or 58mm throttle bodies. 

How big do you want to go 

S&S 58mm 

S&S 52mm 


PERFORMANCE 

PARTS 

SuperFlow® SF1020 Super 

Bench flow bench shows the 

difference in flow between the 

S&S 52mm (21/16") EFI throttle 

body and the new S&S 58mm 

throttle body. The peak numbers 

at WOT are pretty impressive, 

but what may not be as apparent 

is that the percentage of increase 

in air flow is greatest right off 

idle, between 5° and 25°. The 

increase in this area is as high 

as 23%, which translates into 

better off-idle response. 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-69

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

PERFORMANCE 

PARTS 

Two Cable Throttle Assemblies 

The S&S two cable throttle assemblies are high quality "pull open – pull close" type 

throttles designed for use on any two cable carburetor installations on bikes with 1" O.D. 

handlebars. A special soft plastic material used to mold the grips makes them look and feel 

exactly like stock grips. There are four different assemblies available to make installation 

on most chassis easy. 

Two Cable Throttle Required 

S&S Super E and G carburetors require the use of a two cable, pull open–pull closed 

throttle assembly. Any chassis including 1980 and earlier stock models equipped with a 

single cable throttle mechanism requires conversion to a two cable, pull open–pull closed 

type. S&S offers high quality two cable throttle assemblies for this purpose. Stock big twin 

models from 1981 to present have a two cable throttle and should not require changing. 

Super E and G Carb kits for 1990 and later models come with the new longer throttle cable 

guide bracket which allows the use of the stock CV style throttle cables. 


S&S® THROTTLE CABLE APPLICATION CHART 

NOTE: The chart on this page is used only when using throttle cable bracket part #11- 

2339. This bracket is standard on all S&S Super E & G carburetor kits for big twins 1989 

and earlier and all kits for Harley-Davidson ® Sportster ® models with the exception of 

the kit for 2004-’05 models. Carburetor kits for 1990 and later big twin models come 

with the longer cable bracket part #11-2338 for use with stock CV throttle cables. 

Super E and G carburetors ordered for big twin models 1981 and later are being 

shipped with the correct throttle cable bracket to fit the stock cables. Big twin carbs 

that are not year specific will be shipped with both cable brackets. All Sportster models 

1988-’03 will still require conversion to butterfly style cables. 

Parts for 


& Metric 

Racing 

Products 

Application 

Fastening 

Method 

Length 

Total Housing 

Length 

Vinyl Housing 

Open Side 

Close Side 

1996-Up Softail (FXSTS, FXSTC, FLSTC, FLSTF) 

Snap-in 39" 35" 

USA USA 

1996-Up Dyna® 

19-0438 19-0439 

1996-Up All FLT models Snap-in 48" 44" 19-0464 19-0465 

1996-Up custom application Snap-in 42" 38" USA USA 

19-0440 19-0441 

* 1998 and later required Harley-Davidson® throttle assembly #71831-96 ** 1980 and earlier must be converted to dual cable throttle assembly. 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




Replacement Parts 

S&S Universal Throttle Cable ................................... 106-3520 

Throttle Grip Clamp Set 1985-’95 .......................... 

USA 

106-3519 

USA 

Top Throttle Grip Clamp only ........................... 19-0222 

Bottom Throttle Grip Clamp only . . . . . . . . . . . . . . . . . . . . . . . . . 

USA 

19-0220 

Throttle Grip Clamp Screw 

(Fits S&S throttle assemblies: Part #19-0448, #19-0449, #19-0482, #19-0450, and #19-0229) 

each...................................................50-0043 

10 pack .......................................... 

USA 

50-0129 

Throttle Grip Set. ...................................... 

USA 

106-3521 

USA 

Right Hand Grip only. ................................. 19-0225 

Left Hand Grip only .................................... 

USA 

19-0226 

Cable Adjuster 

Fits S&S throttle assembly part #19-0229. ........................ 

USA 

19-0223 

Cable Adjuster Jam Nut 

Fits S&S throttle assembly part #19-0229 ..............................19-0227 

Handlebar Spacing Sleeve 

4" x 1" O.D. – converts 7⁄8" handlebars to 1" O.D. .................. 

USA 

19-0235 

106-3521 

106-3520 

50-0043 

19-0223 

19-0227 

106-3519 

19-0235 

2-70 



S&S ® 

COMPRESSION RELEASES 

With the S&S compression release kit, a stock starter is able to start almost any engine. 

The S&S compression release system consists of a small valve that opens during starting 

and allows a portion of the cylinder pressure to escape into the exhaust port. The reduced 

cylinder pressure makes it easier for the starter to turn the engine. When the engine starts, 

the valve closes and the engine runs normally, with full compression. These compression 

releases are a good solution for engines using other manufacturer’s cams, which do not 

have built-in compression releases. 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



FITMENT 

• S&S cylinder heads for big twin 

Parts for 

Evolution ® 


OPTIONS 

• Manual release: 

Activated by a cable similar to a choke control, this slick system can be used with any 

style rocker cover. 

• Electric release: 

Solenoid operated, this system automatically opens and closes when the starter button is 

pressed and released. Convenient and simple, this is the best setup for big displacement 

high compression bikes. Requires S&S die cast rocker covers, see page 2-61. 

PART NUMBERs 

S&S Electric Compression Release Kit . ........................... 90-4915 

S&S Manual Compression Release Kit ........................... 90-4925 

S&S Cable Knob: Special billet accessory knob for manual compression release 

(see picture) .................................................... 50-8701 

S&S Two-Piece Socket Kit: 

Allows in-frame installation of S&S compression releases and protects wiring from 

damage during installation. ...................................... 53-0045 

S&S Compression Release Hole Plug ............................ 90-4916 


Silicone Solenoid Caps ......................................... 55-1009 

Wiring Harness ................................... 

USA 2,3 

TÜV 2,5,6 55-1010 

Compression Release Assembly . ................................ 90-4914 

champion ® spark plugs 

Replace Your Spark Plugs For Maximum Performance and Fuel Economy. 

S&S® now offers the same high quality Champion® spark plugs that we include with our 

engines for replacement in S&S and stock engines alike. These long reach resistor spark plugs 

are available in 12mm and 14mm sizes. They are the correct heat range for all S&S engines 

and also fit 1977 and later Harley-Davidson® engines. Compatible with any ignition system. 

Champion® Spark Plugs 

90-4915– Electric Compression Release Kit 

90-4916 

Application Size 2 Pack Each 

NOTES: 

• S&S rocker covers must be used with electric compression releases due to clearance 

requirements for the solenoids. 

• Rocker covers must be removed when installing S&S® compression releases. If lack 

of frame clearance prevents removal of rocker covers, engine must be removed from 

frame for compression release installation. 

• In most cases, S&S compression releases can be installed while the engine is in the 

frame with the special S&S two-piece socket kit, part #53-0045 . 

• If cylinder heads are machined for S&S compression releases, but compression releases 

are not used, special plug part #90-4916 (two required) must be installed to seal the 

machined hole. 

• Stock cylinder heads cannot be machined for S&S compression releases because there 

is not enough material in critical areas. 

55-1322 

50-8701 

53-0045 

55-1009 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 


Twin Cam 88®/96/103, Sportster®, 

X-Wedge® & S&S 41/8" bore engines 

Evolution®, Vintage Models (SH-Series, Iron XL, 

KN-Series, P-Series) & S&S 35/8" & 4" bore engines 

12mm 

Long Reach 

14mm 

Long Reach 

55-1322 USA 

(H-D® #32362-04) 

Champion® #RN12YC 

55-1323 USA 

(H-D® #32311-83, 32342-04) 

Champion® #RA84C 

55-1320 USA 

(H-D® #32362-04) 

Champion® #RN12YC 

55-1321 USA 

(H-D® #32311-83, 32342-04) 

Champion® #RA84C 


55-1323 



2-71

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

PERFORMANCE 

PARTS 


VARIABLE FUEL INJECTION MODULES (VFI) 


• Directly replaces stock Harley-Davidson® fuel injection modules – plugs directly into 

stock wiring harness 

• Includes ProTune II software and can be updated at sscycle.com/software/protune 

• Three stage engine overheat protection helps prevent possible engine damage 

caused by improper modifications to fuel maps 

• Altitude compensation automatically adjusts for altitude variations 

• Live tuning allows manual changes to maps while the engine is running 

• Self diagnostics and actuator test functions help tuning and verify proper installation/ 

operation 

• Engine light can be programmed to function as a shift light 

• Closed loop capable 

• Knock sensing ignition control (USB Delphi® style unit only) 

• Optional closed loop sensor kit and knock sensor kit extend module capabilities 

• Speedometer calibration function for 2004-up Harley-Davidson® models (does not 

require installation of separate speedometer calibrator) 

CLOSED LOOP CAPABILITY 

When equipped with a dual closed loop sensor kit and running in closed loop mode, 

VFI tuning becomes a breeze! S&S supplies base maps for several displacement groups, 

creating a starting point to get bikes up and running. Utilizing dual oxygen sensors (sold 

separately) placed in the exhaust, the S&S closed loop system modifies the base fuel map 

to meet the specific requirements of your engine! 

• Automatic tuning on the street or on the dyno 

• Each cylinder is tuned individually 

• Fuel map changes are saved in the module and can be merged with the preloaded 

base map 

• Works with stock oxygen sensors used on late model Harley-Davidson® 

motorcycles 

Closed loop VFI can also automatically compensate fuel delivery for modifications creating 

up to a 20 hp gain, such as changes in: 

• Displacement 

• Cams 

• Exhaust 

• Head porting or installation of aftermarket heads 

Magneti Marelli® style S&S VFI module 

FITMENT 

• 1999–‘01 big twins (except 2001 Softail®) 

KIT CONTENTS 

• Magneti Marelli® style S&S VFI module 

• USB port cover kit 

• ProTune II software 


PART NUMBERS 

Magneti Marelli Style VFI Module ....................... 559-0001* 

Magneti Marelli Style VFI Closed Loop Sensor Kit .......... 106-2067 

Barometric pressure sensor relocation kit (required for T-Series EFI engines 

using S&S oil pump)...................................... 55-1599 

*Special Order: Download the special order form at sscycle.com/soforms 

106-2067 

559-0001 

Warranty & 




2-72 

NOTE: Due to the extreme range of control offered by the S&S VFI modules, we recommend that they be installed and tuned by S&S Certified VFI Tuning Centers. Check www.sscycle.com 

to find a tuning center near you. 



Continued 

S&S® VARIABLE FUEL INJECTION MODULES 

Delphi® style S&S VFI module 

FITMENT 

• Delphi® ECU equipped big twins 

KIT CONTENTS 

• Delphi® style S&S VFI module 

• ProTune II software 

• USB port cover kit (part #55-5090 only) 

• Serial port cover, cable and bank angle adapter harness (part #55-5034 only) 


PART NUMBERS 

Delphi Style VFI Module for 2001-'03 bt .................. 55-5034* 

• Will only work on custom bikes, 2001-'03 Softail, and 2002-'03 touring models 

• Not compatible with Knock Sensor Kit 

• Requires a 9-Pin serial COM port or USB to serial adapter 

Delphi Style VFI Module for 2001-'11 bt 

(except 2008-up touring and 2011 Softail®) ...................55-5090* 

S&S Delphi Style VFI Closed Loop Sensor Kit ............... 106-2066 

Knock Sensor Kit (55-5090 module only) ................... 106-0810 

*Special Order: Download the special order form at sscycle.com/soforms 

S&S Sensor Kits and Replacement Parts 

S&S VFI Closed Loop Sensor Kit 

Magneti Marelli® Style ............................... 106-2067 

Delphi® Style ........................................ 106-2066 

Knock Sensor Kit (Delphi style only) ........................ 106-0810 

Service Kit, O 2 

Sensor .................................... 106-2061 

Service Kit, Connector, DTM, 4-Position Receptacle ..........55-1592 

Service Kit, DTM Pin .......................................55-1521 

Service Kit, Oxygen Sensor Boss ..........................55-6071-S 

Service Kit, Subharness (Magneti Marelli Style) ................55-1588 

Service Kit, Subharness (Delphi Style) ........................55-1595 

Service Kit, Electrical Tap (10 Pack) ...........................55-1596 

Barometric Sensor Relocation Kit ...........................55-1599 

Hardware Kit (USB Cover) 

(for 550-0001 and 55-5090 modules) .........................55-5091 

Serial Communications Cable 

(for 55-5034 and 55-5006 modules only) ................... 55-5009 

Serial Port Cover Kit (for 55-5034 module only) ...........55-5034P 

55-5090 

Installation of the oxygen sensors on the back or underside of the pipes makes them 

unobtrusive in nearly all applications. The wiring sub-harness installation requires minor 

wiring harness modifications. Complete installation instructions are included. 

NOTES: 

• 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 S&S website at www.sscycle.com/software/protune. 

• Please note that maps created for older versions of the VFI software are not 

compatible with the new closed loop software, however they can be converted to 

closed loop if desired. 

• Optional Delphi® style knock sensor adjusts timing to eliminate spark knock, 

prolonging engine life (55-5090 module only). 

• S&S VFI systems installed on 2004–up Harley-Davidson® models incorporate a 

speedometer calibration feature. 

PERFORMANCE 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-73

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

PERFORMANCE 

PARTS 


VFI Closed Loop Fuel Injection Kit 

S&S Variable Fuel Injection (VFI) modules for 2001-’03 Harley-Davidson® big twins 

with Delphi® style fuel injection are now available. Comes packaged with a dual 

oxygen sensor kit so they can be run in closed loop mode for automatic fine-tuning 

of fuel delivery – that brings older bikes up to 2007 and later technology. The 

S&S VFI module offers almost unlimited tuning capacity and can handle just about 

any performance upgrade possible. Once a base map for a particular configuration is 

installed, the oxygen sensor kit continuously fine-tunes the engine. To save time 

getting started, the module is pre-loaded with a fuel map for a touring bike with a 

95" engine and the CD includes easily changed calibrations for other models. With the 

oxygen sensor kit included with the module, this map can be used as a starting point for 

this very popular engine configuration. Maps for several other engine configurations are 

on the software CD that is included with this VFI closed loop fuel injection kit. Maps are 

also available for download at www.sscycle.com/software/protune. 

The S&S VFI modules are easy to install. They directly replace the stock Harley- 

Davidson fuel injection module and plug into the stock wiring harness. Minor wiring 

modifications are required for the oxygen sensor kit and to retain the "tip over" safety 

feature of the stock system. Also, oxygen sensor bungs must be welded into the existing 

exhaust pipes. Full instructions are included. 

Fitment 

• 2001-’03 big twins with Delphi® style fuel injection 


• Easy installation – module plugs into the stock wiring harness 

• Altitude compensation – automatically adjusts for altitude variations 

• Live Tuning – make manual changes to maps while the engine is running 

• Self diagnostics and actuator test functions 

• Engine light can be programmed to function as a shift light 

• ProTune II software included with each module – updates can be downloaded 

from sscycle.com/software/protune 

• Engine overheat protection 

• Oxygen sensor kit continuously fine-tunes the engine 

• Module is pre-loaded with a fuel map for a touring bike with a 95" engine 

Part Number 

S&S VFI Closed Loop Fuel Injection Kit* .................... 550-0010 

*A Serial to USB adaptor is required for this module when using computers that do 

not have a serial port. 

Save a bundle on this S&S VFI closed loop fuel injection kit. You get an S&S 

VFI module and closed loop dual oxygen sensor kit for a great price. It’s 

almost like getting the sensor kit for free! 



Warranty & 


2-74 



S&S ® 

EZFI MODULE 

S&S EZFI Module for 2001-’10 Softail® and 2002-’11 big twins 

(excludes 2008-up touring models) 

Great for modifying fuel delivery to stock engines equipped with power enhancers 

like high flow air cleaners, exhaust systems or performance cams, and the EZFI 

plugs directly into the stock ECM. With simple adjustments, you can add fuel 

where your bike needs it and remove fuel where it does not. 


• Provides economical tuning for stock or mildly modified engines 

• Plugs into stock ECM 

• Does not adjust timing, only modifies fuel delivery 

• Stock TSSM functions such as turn signals, safety functions, and instruments 

are not affected 

KIT CONTENTS 

• EZFI module 

• Tuning software 

• Install Instructions 

• Velcro® 

PART NUMBERS 

S&S® EZFI Module Kit ................................... 106-0890 

Diagnostic Cable ..........................................55-1271 

OPTIONS 

An optional wiring harness allows for quick and easy bypass of the EZFI module 

in order to return the fuel system to stock for diagnostic or comparison reasons. 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-0891 

S&S ® 

EFI WIRING HARNESS 

The S&S custom EFI wiring harness was designed specifically for the installation of fuel 

injected S&S engines into stock or custom frames with up to 4" of backbone stretch. 

FITMENT 

• S&S T-Series engines with Delphi® style VFI modules 

• Harley-Davidson® engines with factory Delphi modules 

• Does not support J1850 devices 

FEATURES AND Benefits 

• Plugs directly into Delphi® style S&S VFI modules and stock Delphi modules used in 

late model Harley-Davidson® motorcycles 

• Compatible with most stock and aftermarket components for Harley-Davidson 

Softail® models including: 

• Tip-over sensor 

• Oxygen sensors 

• Includes provisions for a knock sensor, which is utilized in the newest S&S VFI modules 

106-0891 

NOTEs: 

• Since the S&S EZFI module does not control ignition timing, it is not recommended for 

engines with higher than stock compression ratios. 

• Not for sale or use on CA or EPA pollution controlled vehicles. 

PERFORMANCE 

PARTS 

OPTIONS 

S&S is also offering an optional matching connector set specifically for the S&S EFI wiring 

harness. The set contains the correct connectors to allow custom builders to make tight, 

waterproof connections from electrical components to the S&S harness. Set includes 

connectors for: 

• Speedometer 

• Headlights 

• Fuel gauge 

• Left and right handlebar controls 

• Indicator lights 

• Front turn signals 

• Extra DT and DTM replacement terminals and sealing plugs 

PART Numbers 

Custom wiring harness kit .................................106-0478 

Connector set ............................................106-2857 

When connecting S&S T-Series engines to this EFI harness, 

a K-to-B style fuel injector adaptor must be used. 

Injector adaptor ........................................... 55-5074 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 


106-0478 

55-5074 




2-75

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

PERFORMANCE 

PARTS 

SPEEDOMETER CALIBRATOR 

The easiest way to adjust stock Harley-Davidson® electronic speedometers. No more 

worrying about the effects of changing gear ratios, tire size, or wheel size. Installation is as 

simple as unplugging the connection between the transmission sensor and speedometer 

and connecting it to the S&S calibration module. 

FITMENT 

• 2006 and earlier Harley-Davidson® big twin models equipped with OEM electronic 

speedometer (except 2006 Dyna®) 


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

• Compact size (2.25" x 1.50" x 1.10") permits neat, unobtrusive installation 

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

PART NUMBER 

S&S Speedometer Calibrator .................................55-1007 


NOTES: 

• Not compatible with Rev Tech® transmissions. 

• Calculating the difference between actual and indicated speeds/mileage requires only 

that the rider compare odometer readings to a known distance. Highway mile markers 

are usually accurate enough to use for calibration, although the test should be repeated 

between several different markers for confirmation. The S&S speedometer calibrator 

can then be adjusted to increase or decrease the speed and mileage indicated by the 

speedometer. In most cases it is possible to achieve accuracy within 0.5%. 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-76 

S&S ® 

IST ® Guardian Diagnostic System 

In addition to a 3-step break-in rev-limiter function, the Guardian Diagnostic System offers 

engine builders and tuners some powerful tools to use with the S&S IST ignition module. 

FITMENT 

• 1999-'06 carbureted big twins 

• Vehicles equipped with the IST ignition module (will not work with stock Harley- 

Davidson® or other aftermarket systems) 


• Adjustable rev-limiter. Modules are initially set to a 6,250 rpm rev limit, but this can be 

set to any value up to 7,200 rpm 

• Scan tool function allows you to view diagnostic test codes (DTCs) or clear history DTCs 

• Calibrate the speedometer in 2004-'06 H-D® models 

• Look at live data: rpm, manifold absolute pressure, engine temperature, battery voltage, 

spark timing, dwell, and coil current for both cylinders while the engine is running, to 

aid in service work or performance tuning 

• Look at history information: number of starts, number of rev-limiter hits after the 

break-in rev-limit has expired, amount of time spent in various operating conditions, 

maximum temperature reached, current rev-limit, total engine cycles and running time 

KIT CONTENTS 

• PC software CD 

• Translator unit 

• Adaptor cables 

System Requirements 

• Microsoft® Windows® 2000 or higher operating system 

(not compatible with 64-bit operating systems) 

• Pentium II 350 MHz processor or faster/equivalent, Pentium III 500 MHz processor or 

faster/equivalent preferred 

• Minimum 64 MB RAM, 128 MB or more recommended 

• At least 300 MB of free hard drive space 

• CD-ROM or DVD-ROM drive required for installation 

• Keyboard and mouse (or equivalent pointing device) 

• 9-pin serial port or serial to USB adapter 

PART Numbers 

S&S IST Guardian Diagnostic System .........................55-5075 

Replacement Cables: 

Harness, translator to data link ...............................55-5062 

Cable, RS-232, PC to translator ...............................55-5063 


Hours of Operation 

break-in rev-limits schedule 

Rev-Limit 

0 to 8 4,250 

8 to 16 5,125 

16 to 24 6,025 

24+ 6,250* 

* The final rev-limit can be set to any value up to 7200 rpm using S&S IST Guardian 

Diagnostic software. Available for modules sold separately only. 

Note: 

• PC must have 9-pin serial port for communication with ignition module. 

Otherwise, a serial to USB adapter must be used. 

• Not compatible with S&S IST ignition modules manufactured before 

10/01/2003. Software can be by sending the IST module to S&S Cycle.


S&S ® 

IST ® IGNITION SYSTEM 

Truly revolutionary, the Intelligent Spark Technology (IST) system monitors stock crank 

position, cam position (if equipped), MAP, and cylinder head temperature sensors, in addition 

to the exclusive S&S Knock Sensor. If knock or detonation occurs, the IST system adjusts timing 

until it stops. It then stores information about conditions that cause the engine to knock. In 

effect, the system "learns" the ignition requirements of a particular engine and creates a fully 

custom ignition map for it. Requires two coils or single fire coil pack. 

FITMENT 

• 1999–’06 carbureted big twins – requires installation kit (see below) 


• Protects your engine from damaging detonation or knock 

• Automatically adjusts to lower grade fuel 

• Installation kits plug into stock wiring harnesses 

• 6250 rpm preset rev-limiter 

• High output automatically maximizes coil output 

• Automatic dwell adjust will optimize current for any 0.5Ω to 3.0Ω coil 

• Short circuit and reverse polarity protected 

• With the Guardian diagnostic system (55-5075), you can calibrate the speedometer 

on 2004 - 2006 H-D® models 

IST will automatically adjust ignition timing for modifications such as: 

• Increased displacement from stroker or big bore kits 

• Bigger cams 

• Performance exhaust 

• Head porting or installation of aftermarket heads 

• Gear ratios 

S&S High Output 3.0Ω Single Fire Coil: 

The perfect complement for S&S IST® or Super Stock® ignition systems. This single fire 

coil is actually two separate coils in a single package. Coil impedance is 3Ω per coil. Not 

compatible with the S&S Variable Fuel Injection (VFI) System. ............55-1571 

S&S High Output 0.5Ω Single Fire Coil: 

High output 0.5Ω single fire coil for S&S IST ignition, Delphi® style VFI modules (fits 

carbureted Harley-Davidson® big twins 1999-'06, except 1999-'01 touring models), and 

custom applications requiring a 0.5Ω coil. Not compatible with S&S Super Stock ignition. 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USA 55-1576 

PART NUMBER 

S&S Intelligent Spark Technology Ignition Module . .................55-1221 

Installation kit (required): 

1999–’03 carbureted big twins . .....................................55-1012 

2004–’06 carbureted big twins . .....................................55-1220 

KIT CONTENTS 

• Wiring harness adapter 

• Knock sensor 

• Temperature sensor 

55-1012 

Installation Kit 


PERFORMANCE 

PARTS 

Exclusive S&S knock sensor installed 

on cylinder head top motor mount. 

No other ignition system for v-twin 

motorcycles uses knock sensing to 

control ignition timing. 

NOTE: 

• Do not use a dual fire coil with the S&S ignition module. 

• This kit will NOT work with vehicles equipped with flat slide carbs, open primaries, and dry clutches. If you want to use IST with these configurations, contact S&S – we can help set up IST. 

• The S&S IST Ignition System is not recommended for kick start applications unless a cam position sensor is used. Engines using a crankshaft position sensor only will be difficult to kick start. 

We recommend our Super Stock® ignition system for kick start applications. 

55-1576 

55-1221 

55-1571 


Cylinder Head Temperature Sensor (H-D® #32446-99) .......... TÜV 2 55-1014 

MAP Sensor Only (H-D® #32316-99) .............................. 55-5057 

Knock Sensor Kit with Mounting Brackets and Hardware ........ 55-1015 

Knock Sensor Motor Mount Bracket .......................... 55-1054 

Knock Sensor Head Mount Spacer (S&S Heads Only) .......... 50-7140-S 

Knock Sensor Only ........................................ 106-2942 

Wiring Harness Adapter (2004-2006 Twin Cam 88®) ............ 55-1499 

Wiring Harness Adapter (1999-2003 Twin Cam 88®) ...... TÜV 1,2 55-1017 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-77

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 


Chrome plated Billet Transmission Side Covers 

For Mechanical and Hydraulic Clutches 

Parts for 



Parts for 

Evolution ® 


PERFORMANCE 

PARTS 

S&S offers two chrome plated billet transmission side covers that fit our six-speed transmissions, 

as well as stock and aftermarket left side drive transmissions for 1987-‘06 big twins (except 

2006 Harley-Davidson® Dyna® and all FXR models). The first version is cable actuated and is 

compatible with all stock and aftermarket cables. The second is a hydraulic version designed 

to convert a cable actuated clutch to hydraulic actuation without changing the clutch pressure 

plate, throw-out bearing or pushrod. The hydraulic side cover has a piston diameter of 1.550" 

and is compatible with stock and aftermarket master cylinders with 11⁄16" diameter pistons. 

Parts for 


1986-2012 

Billet Transmission Side Covers 

Cable Actuated, Chrome .......................................... 106-4035 

Hydraulic, Chrome ............................................... 106-3885 

S&S chrome billet side covers fit 1987-'06 big twins except 2006 Dyna® and all FXR 

models. Available for cable and hydraulically actuated clutches. 

Parts for 


1926-1984 


Parts for 

X-Wedge® 

2007-2012 

Note: If replacing a Harley-Davidson® Screamin’ Eagle® hydraulic side cover, a three piece pushrod with the thrust bearing on the right hand side must be used. (Oil slinger removal 

required on stock H-D® right-side pushrods.) 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

S&S ® 

Transmission Top Covers 

The S&S transmission top covers are made of chrome plated die-cast or polished billet 

aluminum, so naturally, they look great. The two versions are for different applications. 

S&S Chrome Die Cast Transmission Top Cover 

For 1991-’99 Softail® and 1991-'00 FLT Models 

This cover may be used as stock replacement for 1991-’99 Harley-Davidson® Softail® and 

1991-'00 FLT Models......................................... 

USA 

56-5115 

S&S Chrome Billet Transmission Top Cover 

For 1999-‘05 Dyna® Models 

This cover is required for proper oil line connection in 1999-’05 Dyna models when installing an 

S&S T124 engine or when installing S&S replacement crankcases. This top cover may also be 

used as stock replacement for 1999-'05 Dyna models. ................... 106-3886 

56-5115 



Warranty & 


All reference to H-D® part numbers is for identification purposes only. We in no way are 



106-3886 

This cover is included in oil line kit, part #31-0424. 

2-78 



S&S ® 

High Performance Clutch 

The S&S high performance clutch offers more gripping power with more friction surfaces 

and a larger friction centerline diameter. This clutch is able to handle over 150 horsepower. 

For competition applications, stronger pressure plate springs are available that increase the 

power handling capacity to nearly 200 horsepower. Fits in stock primary cases with only 

minor clearancing operations, which are not visible when the primary is assembled. 

Fitment 

• Available for 1991-'06 big twin models (except 2006 Dyna®) 


• Updated clutch to simplify installation – no need for retention epoxy 

• Superior to competitively priced high performance clutches 

• Fits in stock primary with minor modification 

• With supplied springs, lever effort is slightly less than a stock Harley-Davidson® clutch, 

but handles engines up to 150 hp 

• Optional high pressure clutch springs, available for competition applications, increases 

power handling capacity to nearly 200 hp 

• Light duty springs for light clutch pull in less demanding stock street applications 

• 11 friction plate, 10 steel plate design – narrow friction rings increase contact diameter 

for increased torque capacity 

• Supplied with early style 66-tooth ring gear for increased strength and reduced tooth 

breakage 

• Perfect for use with the S&S six-speed transmission 

Options 

• Mechanical or hydraulic actuation 

• 36 or 37-tooth sprocket 

• Early style starter pinion gear required for 1994-'99 models to match 66-tooth ring 

gear supplied 

Kit Contents 

• Clutch assembly 

• Special inner transmission mainshaft bearing race 

• Installation hardware 


Lever Effort Comparison Chart 

56-5152 

Stock Clutch S&S Standard Clutch S&S Touring Springs S&S Race Springs 

Max. HP Up to 90 HP Up to 150 HP Up to 85 HP Up to 200 HP 

Lever Pull 26.0 lbs 27.4 lbs 20.3 lbs 45.0 lbs 

The S&S high performance hydraulically actuated clutch is compatible with 

Harley-Davidson® hydraulic clutch, pushrod, and bearing. 

PERFORMANCE 

PARTS 

S&S High Performance Clutch 

Mechanical Actuation 

With 36-Tooth Sprocket ..................................... 

USA 

56-5150A 


USA 

56-5151A 

Hydraulic Actuation 


USA 

56-5152A 


USA 

56-5153A 

Optional Parts 

Starter Pinion Gear – 9-Tooth ....................................... 56-1037 

High Pressure "Race" Clutch Springs ............................. 

USA 

56-5106 

Low Pressure "Touring" Clutch Springs. .......................... 

USA 

56-5109 


56-5150A 

S&S high performance cable actuated 

clutch is compatible with stock 

and aftermarket cable style 

transmission side covers. See 

page 2-78 for S&S chrome billet 

transmission side covers. 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

S&S ® 

Inner Primary Bearing Race 

The tendency of the stock inner primary bearing race on late model big twins to shift on the transmission 

mainshaft under high torque loads, also known as "walking" of the race, can cause destruction of the 

transmission mainshaft seal, and ultimately the mainshaft seal, output gear and output gear bearing. 

The S&S inner primary bearing race features an extra step on the inside diameter that acts as a stop 

on the transmission mainshaft. When the race is pressed on to the shaft, the step will not allow the 

race to move inward toward the mainshaft seal. The improved S&S bearing race is a must for any high 

performance application. 

Fitment 

• All 1991-'06 big twins (except '06 Dyna®) 


• Will not "walk" on transmission mainshaft 

• Prevents costly damage to mainshaft seal, output gear & output gear bearing 

• Simple to install 

56-5089 

Part number 

S&S Inner Primary Bearing Race ........................... 

USA 

56-5089 


S&S Inner Bearing Race Puller, see page 9-10 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-79

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

PERFORMANCE 

PARTS 

How many final drive belts have S&S engines broken Yes, a lot of power can break things, 

so what’s the solution The solution is that we are offering stronger belts! S&S has teamed 

up with the Gates® Corporation, a leading manufacturer of power transmission belts, to 

offer a series of secondary drive belts for many popular v-twin models. These belts feature 

Gates’ super strong X3N carbon cord material which is significantly stronger than the 

Aramid material used in many OEM final drive belts. 

S&S final drive belts by Gates are available with 14mm pitch in 1½" and 11/8" widths. See 

the chart below and match the width and number of teeth required for your vehicle. You 

can find this information in the vehicle service manual. 


Gates ® High Strength Final Drive Belts 

Secondary Drive Belts (14mm pitch) 

Teeth 11/8" Wide 11/2" Wide 

125 106-0357 USA – 

126 – 106-0348 USA 

127 – 106-0349 

128 106-0358 USA 106-0350 

130 106-0359 USA 106-0351 

132 106-0360 USA 106-0352 

133 106-0361 USA 106-0353 

135 106-0362 106-0354 

136 – 106-0355 

139 106-0363 106-0356 

149 106-1338 – 

156 – 106-2827 

Parts for 

X-Wedge® 

2007-2012 

106-0361 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




Attention Custom Bike Manufacturers! 

Special Order Belts From S&S® and Gates® 

Special belt sizes, private brand labeling, and assistance with belt drive design, are available 

to custom performance OEM's and aftermarket bike builders, through S&S. These products 

and services are available for licensed motorcycle manufacturers only, and a minimum 

order quantity may be required. 

Drive belts with your company name imprinted on them are a perfect way to show off your 

brand. Any belt size currently available in the S&S catalog, as well as the special ordered 

sizes, can be specially branded. Minimum order quantities would apply. 

Whether you’re designing a completely new chassis, or simply need a replacement belt, 

S&S can help you find the belt you’re looking for. Through the combined efforts of Gates 

and S&S, S&S can now provide customers with the technical assistance they need for 

designing new secondary belt drive systems. In addition, S&S can help you determine 

required tooth count for your existing chassis design, based on the pulley center-to-center 

distances and pulley tooth counts. 

All belts have a 14mm tooth pitch, and are made of the super strong Gates Carbon X3N 

material. Belts are available in three standard widths of 1.125", 1.5"and 1.181" (30mm), 

but can be special ordered in nearly any width for a nominal charge. If you want a belt with 

a special tooth count, they are also available (see the special order chart for availability). 

Contact your S&S Customer Support Representative for more information. 

Belts Available By Special Order (14mm Pitch) 

Tooth Count 1.181" (30mm) Width* 1.25" Width* 

125 • 

126 • • 

127 • • 

128 • 

130 • 

131 • • 

132 • 

133 • 

135 • 

136 • • 

137 • • 

139 • 

140 • • 

149 • 

150 • • 

151 • • 

152 • • 

156 • 

*Minimum order required: 1.181" (30mm) – 16 belts; 1.25" – 17 belts. 

2-80 



S&S ® 

Crankcase Replacement Parts 

38 

for Harley-Davidson ® Twin Cam 88 ® Engines 

1. Bolt, stator 10-24 x1" SHC - 4 required (H-D® #2720) 

each ........................................50-0044 

10 pack ......................................50-0194 

USA 

2. Seal, sprocket shaft (H-D® #12068) .. 31-4035 

3. Bearing, Timken® sprocket shaft 

(H-D ®#9028)......... USA TÜV 1,2,3 1,3,4,5,6,7 31-4013 

4. Timken Main Bearing Spacers 

Fits 11/4" stock diameter shaft. 

.0995" - .1005" (H-D® #9124. ............ .31-4071 

.1015" - .1025" (H-D® #9125). ............ 31-4072 

.1035" - .1045" (H-D® #9126) . ............ 31-4073 

.1055" - .1065" (H-D® #9127) ............. 31-4074 

.1075" - .1085" (H-D® #9128) ............ . 31-4075 

.1195" - .1205" (H-D® #9134) . ............ 31-4076 

5. Hardware Kit, 4" Bore, S&S 41/8" Bore,1999-'12 bt 

Chrome.............................106-4905 

Zinc. ...............................106-4904 

6. Bolt, case 5⁄16" -18 x 31/2" HHC - 8 required 

Chrome (each)....................... 50-0254-S 

6 pack .......................................106-3452 

Zinc (each) ..............................50-0117 

7. Washer, flat 5⁄16" x 11⁄16" x 1⁄16" - 8 required. 50-7034 

8. Bolt center case 1⁄4" -28 x 6" HHC Grade 8 

each ........................................50-0020 

5 pack .......................................50-0221 

9. Washer, flat, 1⁄4" x .474" x .050" (each) .... 50-7020 

10 pack ......................................50-7076 

10. Nut 1⁄4"-28 Grade 8 - 1 required ......... 50-5011 

11. Cylinder stud - 8 required (H-D® #16834-99A) 

USA 

each .............................. 31-2325-S 

USA 

8 pack ................................ 31-2340 

1 

4 

6 

37 

2 

38 

8 

3 

36 

7 

12 

11 

36 

40 

21 

37 

9 

35 

34 

41 

32 

12. Dowel, cylinder deck - 2 required (H-D® #16595-99A) 

each ........................................50-8177 

4 pack ....................................50-8177-4 

10 pack ......................................50-8179 

13. Bolt, cam plate 1⁄4" -20 x 1" SHC - 4 required (H-D® #4741A) 

each ........................................50-0084 

10 pack ......................................50-0244 

14. Bolt, cam plate 1⁄4" -20 x 11⁄4" SHC - 2 required 

each ........................................50-0008 

10 pack ......................................50-0153 

15. O-ring, cam plate - 9 required (H-D® #11301 ) 

each ..................................... 50-8066-S 

10 pack ......................................50-8066 

16. Dowel, cam plate - 2 required 

(H-D® #16589-99A). ................... 50-8148-S 

USA 

17. Bearing, inner cam (H-D® # 9198).. TÜV 231-4080 

18. Bearing, pinion shaft – Fits all S&S and OEM 2000-’02 

(Balanced models only) & all OEM 2003-up 

(H-D® #24604-00D).................. 

TÜV 2 31-4085 

19. Retaining ring, internal, spiraloc - 2 required 

(H-D® #35114-02). ..................... 50-8160-S 

20. O-ring, oil pump 11⁄16" I.D. x 15⁄16" O.D. x 1⁄8" CS 

USA 

(H-D® #11190, 11157, 11293) ......... 50-8039 

USA 

10 pack ............................... 93-4110 

21. Plug, magnetic drain . USA TÜV 1,2,3 1,2,3,4,5,6,7 50-8335 

22. Baffle plate ........................ 31-0119-S 

23. Screw 10-24 x 3⁄8" pan head - 2 required 

each ........................................50-0050 

10 pack ......................................50-0139 

24. Dowel, case alignment - 2 required (H-D® #16573-83) 

each ........................................50-8023 

10 Pack ......................................50-8109 

11 

12 

22 

27 

26 

26c 

23 

39 

26b 

26a 

24 

11 

25 

15 

31 

28 30 

29 

20 

21 

11 

33 

19 

25. O-ring, case alignment,- 2 required (H-D® #26432-76A) 

9⁄16" I.D. x 11⁄16" O.D. x 1⁄6" CS . .......... 50-8034-S 

26. Piston Oiler Jet Kit (H-D® #22371-99) (each)... 31-2025B 

2 pack ............................................31-2026 

Piston Oiler Jet Kit includes: 

a. O-ring,(-014),.500" ID x .625" OD (H-D® #11140, 11273) 

each ..............................................50-8032 

10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8130 

b. Jet, Assembly, Piston Cooling (H-D® #22307-99) 

each ............................................31-2025B 

C. Screw,Torx Panhead,8-32 x 3/8",Zinc,Steel (H-D® #68042-99) 

each ...........................................50-0054-S 

27. Hardware kit, oil line plugs. ................. N/A 

28. Fitting, crankcase vent 

1999-'00. ............................ 50-0454 

2001-'06 (each). ....................... 50-0449 

2 pack .....................................106-1171 

29. Plate, oil line cover. ..................106-1184 

30. BHSH CS 5/16" -18 x 3/4" (10 Pack) .........106-1178 

31. O-ring (H-D® #11105, 11275) (each) .............50-8008 

10 pack ......................................50-8078 

32. O-ring, 

9⁄16" I.D. x 11⁄16" O.D. x 1⁄6" CS. .......... 50-8034-S 

33. Pin, dowel (H-D® #18535-99)(each) ........ 50-8195-S 

2 pack .......................................50-8195 

These parts are for crankcases manufactured before 8-1-06: 

34. Washer, flat 1⁄4" chrome (each) ........... 50-7017 

12 pack ......................................50-7013 

35. Bolt, 1⁄4" -20 x 3⁄4" SHCS (each) ............. 50-0067 

12 pack ......................................50-0144 

36. Hose, oil, inlet/outlet. ................. 50-8157 

37. Spring clips ........................ 50-8156-S 

38. Oil line fittings, inlet/outlet - 2 required. ...... N/A 

39 . Oil line fitting- vent. ........................ N/A 

40. Plug, sump (H-D® #765). .... 

USA 1,2,3 

TÜV 4,5 50-8330 

41. Oil conduit block. ..................... 31-2076 

NOT SHOWN: 

42. Sensor,Kit,Crank Position,1984-2007 bt 

(H-D® #32707-01B) ............ USA 2,3 TÜV 4,5,7 55-1051 

16 

9 

14 

10 15 

17 

16 

18 

13 

14 

19 


REPLACEMENT 

PARTS 

NOTE: All reference to H-D® part numbers is for identification 

purposes only. We in no way are implying that any of S&S 

Cycle’s products are original equipment parts or that they are 


Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-81

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

REPLACEMENT 

PARTS 

CRANKCASE Breather REED VALVE 


Replacement Parts 2 

1. Valve,Assembly,Breather Reed 

Engines with Stock Oil Pumps 

1999-'02 bt with stock or S&S Super Stock® crankcases ......... 31-2070 

2003-up bt with stock or S&S Super Stock® crankcases.......... 31-2071 

S&S SA Crankcases ........................................ 31-2086 

Engines with S&S Oil Pumps 

1999-'02 bt with stock crankcases ........................... 31-2093 

3 

2003-up bt with stock crankcases and all S&S crankcases........ 31-2094 

2. O-ring, 

1999-'02 bt (-038),2.614" ID x 2.750" OD,Viton®..............50-8154-S 

2003-up bt (-036),2.364" ID x 2.500" OD,Viton® ..............50-8155-S 

3. Seal,Breather Reed Valve,1999-up bt .................... TÜV 2 31-4086 

4. Stop,Breather Reed Valve,Packaged,1984-up bt................ 31-2075 

7 

5. Reed,Breather Valve,bt (each)..............................31-2072-S 

4 pack ..................................................31-2072 

6. Screw,Torx BH,4-40 x 1/4",Black,Alloy Steel (each) .............50-0305-S 

10 pack .................................................50-0305 

7. Wave Spring ,2"OD X 1.6"ID X .375".......................... 50-8404 

8. Spring Adaptor (for S&S SA Crankcases) N/S................... 31-2103* 

* Required to accommodate the extra .375" case width of S&S Special Application big bore crankcases. 

N/S = Not Shown 

1 

4 

5 

6 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-82 

S&S ® 

Flywheel Replacement Parts 

1. Sprocket Shaft, 1999-2006 bt (includes key #5)..... TÜV 2 33-2009 

2. Sprocket Shaft, 2006 Dyna®, 2007-2012 bt ........ 33-2011 

3. Pinion Shaft, 1999-2012 bt (includes key #5) ...... TÜV 2 33-2030 

4. Pinion Shaft, 2000-2012 w/ balancer (includes key #5) ..33-2042 

5. Key (each) ........................................50-8227 

5 pack ............................................50-1013 

6. Front Rod Race, 1999-2012 ............ USA TÜV 3 1,6,7 34-4008 

7. Rear Rod Race ....................... USA TÜV 3 1,2,6,7 34-4013 

8. Crankpin (std.) ................................. 106-6239 

+.001...................................... 34-2176 

+.002..................................... 340-0018 

9. Crankpin Plug (each) ............................ 106-5256 

2 pack ..........................................50-8329-2 

12 

10. Race/Bearing Set .................................34-4011 

11. Wristpin Bushing, 

1999-2012* bt , straight bushing ..... USA TÜV 3 1,2,6,7 34-4012 

12. Connecting Rod Set, 7.668" length 

1999-2006 bt, straight wristpin ends ...............34-7405 

2007-2012 bt, tapered wristpin ends............. 106-3373 

* 2007-2012 engines with stock pistons require trimming of the bushing to fit tapered 1 rod end 


2 

5 


S&S Sprocket Shaft Bearing and Seal Installation Tool, see page 9-5. 

7 

11 

7 

10 9 

8 

6 

11 

9 

5 4 

NOTES: 

• Due to different crankpin diameters, S&S® connecting rod assemblies cannot be used with stock Harley-Davidson® flywheels. 

• S&S flywheels for Harley-Davidson® Twin Cam 88® and Twin Cam 96 engines are pressed together as opposed to using the traditional tapered shafts and crankpin. Assembly 

and truing requires special equipment. If you do not have the capability of servicing pressed together flywheel assemblies, S&S will remanufacture your S&S flywheel assembly 

to like new specifications. See Section 10: Dealer Services or call your S&S customer support representative for more information. 

3


S&S ® 

Oil Pump Replacement Parts 

For Harley-Davidson ® Twin Cam 88 ® Engines 

1. Cover, assembly, camchest 

Polished........................ TÜV 2 31-6506 

Chrome ............................ 106-3890 

2. Cover plate ...........................31-6507 

3. Bushing, cam support (each). .... TÜV 2 31-4087-S 

2 pack .......................... 

TÜV 2 31-4087 

4. Nut, gear retainer, rear cam .............31-6511 

5. O-ring, Viton (-220) (each). ............50-8245-S 

5 pack ................................50-8245 

6. Screw, SHC - 10-24 x 1" (each) ...........50-0044 

10 pack ...............................50-0194 

7. Alignment dowel (each). ..............50-8182-S 

2 pack ................................50-8182 

8. Idler gear shaft (each). ................31-2079-S 

2 pack ................................31-2079 

9. Divider plate.................. TÜV 1,2,7 31-6508 

10. Screw FHSC 10-24 x 1⁄2" (5 pack) ..........50-0312 

11. Gear, cam chest return. .................33-4291 

12. Gear assembly, pinion shaft. ............33-4170 

13. Gear, idler - Includes item PN 33-4214 bushing. ..33-4172 

14. Gear, cam drive........................33-4292 

15. Gear, spacer...........................33-4171 

16. Thread adapter......................31-2089-S 

17. Cam drive gear........................33-4293 

(For reference only, not included in pump kit.) 

18. Body assembly.................. TÜV 2 31-6505 

19. Spring, pressure control (each). ..... TÜV 2 31-6018 

10 pack .......................... TÜV 231-6084 

20. Plunger, pressure control valve. .... TÜV 2 31-6082 

21. Pressure control plug w/o-ring. ... TÜV 1,7 50-8326 

22. Fitting, flywheel cavity return ...........50-8183 

28 

1 

29 

40 

5 

3 4 

39 

23. Screw, SHC 8-32 x 5⁄8" ,(5 pack) ...........50-0293 

24. O-ring, Viton (H-D® #11301 )(each) ........50-8066-S 

10 pack ...............................50-8066 

25. Bushing, pinion shaft. ............ TÜV 2 31-4088 

26. Screw FHSC 10-24 x 3⁄4" (5 pack) .... TÜV 2 50-8328 

27. Screw FHSC 1⁄4"-20 x 2" (5 pack) ..........50-8163 

28. Kit, cover screw. .......................50-1035 

USA 

29. Gasket (H-D® #25244-99A) (each). ... 31-2032-S 

USA 

10 pack ......................... 31-2063 

30. Dowel pin, 3⁄32" diameter x 1" (each). ....50-8193-S 

5 pack ................................50-8193 

31. Retaining ring (5 pack). .................50-8241 

32. Bushing. .............................33-4214 

33. O-ring 5⁄16" O.D. x 1⁄16" Viton (-011). TÜV 2 50-8138-S 

34. O-ring (-209) Viton (H-D® #11190, 11157, 11293) 

USA 

each ................................. 50-8039 

USA 

10 pack ......................... 93-4110 

35. Washer, pinion gear. .................50-0331-S 

36. Screw, FHHC - 5⁄16"-18 x 3⁄4" G8 

(H-D® #25566-06) ........................50-0100 

37. Steel ball, 1/8" (each). .................50-8092-S 

10 pack ...............................50-1031 

38. Pin dowel - .275" I.D. x .3745" O.D. x .397" 

(H-D® #16589-99A) .....................50-8148-S 

NOTE: All reference to H-D® part numbers is for identification purposes only. We in no way 

are implying that any of S&S Cycle’s products are original equipment parts or that they are 


27 

26 

2 

36 

8 

35 

31 

50 

13 

32 

8 

37 

14 

32 

11 

39. Viton o-ring (-207) (5 pack) ..............50-8244 

40. Viton o-ring (-225) (5 pack) ..............50-8243 

41. Viton o-ring (-16) (5 pack) ...............50-8242 

42. Screw, FLC 1⁄4"-20 x 13⁄4" (each). .......50-0334-S 

5 pack ................................50-0334 

43. Pipe plug 1⁄8"-27 (H-D® #45830-48) (each) ....50-8331 

10 pack ...............................50-1015 

44. Key kit - cams. ........................50-1038 

45. Camshafts 

See Cam Selection Chart below. 

46. Ball, pressure relief valve 3⁄8" diameter 

.................. USA 1,2,3 TÜV 1,3,4,5,6,7 50-8091 

47. Spring, pressure relief valve .............50-8408 

48. Gear rebuild kit (N/S) (Includes #11, 12, 13, 14) 

....................................33-4290 

49. Seal rebuild kit (N/S) (Includes #5, 24, 29, 34, 39, 40, 41) 

....................................31-2097 

50. Breather Valves (see page 2-82) 

N/S = Not Shown 

43 24 

16 47 46 7 

6 

17 

9 

15 

38 

41 6 7 16 

23 18 30 

26 

12 10 

25 

24 

19 

20 

33 21 

S&S® GEAR DRIVE CAMS FOR USE With S&S OIL PUMPS 

FOR 1999-'06 Big twin (EXCEPT 2006 DYNA® MODELS) 

Cam* Easy Start Cams with Drive Gears Cams with Drive Gears 

510GP – 33-5220 

570GP 106-4751 – 

585GP 106-4771 33-5222 

625GP 106-5212 – 

640GP 106-4781 – 

675GP 106-5215 33-5225 

* See Cam listings in Section 1 of this catalog for further information on cam recommendations for 

different applications. 

44 

22 

REPLACEMENT 

PARTS 

34 

45 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-83

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-84 

REPLACEMENT 

PARTS 



Cylinder Heads Replacement Parts 

for 1999-up Big Twin Engines 

1. Cylinder head (See page 2-49) 

2. Valve 

All S&S heads with 89cc chamber 

Intake 

2.000" diameter...................... 90-2000 

2.000" diameter + .085" ..................90-2004 

Exhaust 

1.605" diameter...................... 90-2001 


Intake – 1.940" diameter ................90-2025 

Exhaust – 1.575" diameter ...............90-2026 

3. Valve seat 


Intake - 2.000" diameter. USA 1,2,3 TÜV 1,4,5,6,790-2002 

Exhaust - 1.605" diameter. USA 1,2,3 TÜV 1,2,4,5,6,790-2003 


Intake - 1.940" diameter ..................90-2027 

Exhaust - 1.575" diameter .................90-2028 

4. Valve guide - Intake or Exhaust 

Standard 

(H-D® #18112-92). 

+.001" (H-D® #18130-83C) ............ 

USA USA 1,2,3 

TÜV 1,2,4,5,6,7 90-2210 

USA 

90-2211 

+.002" (H-D® #18133-83A)............ 

USA 

90-2212 

+.003" (H-D® #18131-83C)............ 

USA 

90-2213 

+.030" .............................. 

USA 

90-2219 

5. Valve spring shim 

.015" (each) .............................90-2086 

5 pack .......................................50-7161 

.030" (each) .............................90-2087 

5 pack .......................................90-2198 

6. Bottom Collar (each) .... USA TÜV 1,2,3 4,5,6 90-2052 

4 pack .......................................90-2488 

7. Valve guide seal - intake or exhaust (H-D® #18001-83B) 

(Not included in valve spring kit) 

each ........................... 

USA 

90-2008 

USA 

8 pack ................................ 90-2158 

8. Outer Spring ........ USA TÜV 1,2,3 1,2,4,5,6,7 90-2050 

9. Middle Spring....... USA TÜV 1,2,3 1,2,4,5,6,7 90-2049 

10. Inner Spring.......... USA TÜV 1,2,3 4,5,6 90-2048 

11. Top Collar 

Steel (each)......................... 90-2051-S 

4 pack .......................................90-2486 

Titanium (each) ....................... 90-2046 

4 pack .......................................90-2487 

12. Keeper, valve spring, intake/exhaust 

each .............................. 90-2094-S 

8 pack .......................................50-7166 

13. Valve spring kit 

.640" lift - steel top collar .................90-2077 

.640" lift - titanium top collars ............90-2078 

14. Head bolt assembly – (8 Required) 

(Includes head bolt washer) 

88", 95", 96", 100", 107" & 111" ...........93-3030 

116", 117" .................................93-3037 

15. Head bolt washer 

.100" (each).................................50-7088 

5 pack .......................................50-7096 

.250" (H-D® #6016) (each) ....................50-7091 

10 pack ......................................50-7095 

16. Exhaust port stud (H-D® #16715-83) (each). . 50-0493 

5 pack .......................................50-1028 

17. Lock washer - 5⁄16" (H-D® #7041) ............50-7032 

18. Nut, flanged - 5⁄16" -24 (H-D® #7593) 

Zinc (each) ................................50-5025-S 

2 pack .................................... 50-5025-2 

5 pack .......................................50-1001 

Chrome (each) ............................50-5030-S 

2 pack .................................... 50-5030-2 

19. Exhaust pipe gasket, tapered (H-D® #65324-83A) 

each ........................................106-5029 

10 pack ......................................93-1072 

20. Intake manifold (See page 2-68) 

21. Manifold mounting screw 

SH - 5⁄16"-18 x 3⁄4" (H-D® #3275) (each) .... 50-0302-S 

10 pack ...................................50-0302 

SH - 5⁄16"-18 x 1". ..................... 50-0101 

HH - 5⁄16"-18 x 1" (H-D® #3987) (each). ...... 50-0108 

20 pack ...................................50-0155 

22. Flat washer - 5⁄16" (H-D® #6016). .......... 50-7034 

23. Manifold mounting flange 

USA 

Front (H-D® #27009-86A) (each). ....... 16-0232 

USA 

5 pack ............................... 16-0600 

USA 

Rear (H-D®#27010-86A) (each). ....... 16-0233 

USA 

5 pack ............................. 16-0601 

Set (Front & Rear) .................. 106-3516 

24. Manifold o-ring 

For S&S heads (each). .................. 16-0235 

10 pack ...................................16-0243 

For Stock heads (H-D®#26992-99, 26995-86A) 

each. .............................. 16-0236 

10 pack ...................................16-0244 

25. Head gasket 

For Stock Bolt Pattern 

33⁄4" x .043" Graphite (each). ........ 93-1045-S 

10 pack ...................................93-1060 

37/8"/3.927" x .030" Layered Steel (2 pack).900-0216 

37/8"/3.927" x .045" Layered Steel (each).106-3714 

10 pack ..................................900-0218 

4" x .043" Graphite (each) .......... 93-1043-S 

10 pack ...................................93-1058 

41/8" x .043" Layered Steel (each)..... 93-1091-S 

41/8" x .030" Layered Steel (2 pack) .... 900-0217 

For S&S Bores 

41/8" x .043" Graphite (each). ........ 93-1047-S 

10 pack ...................................93-1073 

41/8" x .045" Copper (each). ......... 93-1079-S 

10 pack ...................................93-1080 

43/8" x .045" Copper (Set of Two) ........ 93-1081 

26. Alignment dowel, base and head (H-D® #16595-99A) 

each ......................................... 50-8177 

4 pack .................................... 50-8177-4 

10 pack ......................................50-8179 

27. Alignment dowel o-ring – Base (all bore sizes) 

S&S heads 33⁄4" bore only (H-D® #11105, 11275) 

each .........................................50-8008 

10 pack ......................................50-8078 

28. Plug, HH - 14mm (each). ............... 90-4916 

2 pack .................................... 90-4916-2 

29. Washer, compression - 14mm 

507" x .705" x .047" (each). ............. 50-7094 

10 pack ......................................50-7102 

30. Head mount bolt - 3⁄8"-16 x 11⁄4" (H-D® #4716W) 

each ...................... USA TÜV 1,2,3 1,4,5,6 50-0168 

10 Pack .....................................106-3063 

31. Flat washer - 3⁄8" (H-D® #6019) 

each ...................... USA 1,2,3 TÜV 1,3,5,6 50-7051 

10 pack .....................................106-3064 

32. Vent hose fitting, (For 41/8" Bore Only) 

Front, 1⁄16"-27 pipe ....... 

USA 3 

TÜV 1,2,6,7 50-8117 

Rear, 1⁄8"-27 pipe. ... USA 1,2,3 TÜV 1,2,3,4,5,6,7 50-8115 

33. Check Valve (For 41/8" Bore Only).... 

TÜV 2 50-8122 

34. Base Gaskets 

For S&S Bores 

43/8" x .018" Graphite (2 pack) ............93-1082 

41/8" x .018" Graphite (each) ...........93-1048-S 

4" x .018" Graphite (each) .............93-1050-S 

For Stock Bolt Pattern 

41/8" x .018" Graphite (each) ...........93-1092-S 

35. Base O-ring (Used for early S&S bores) 

4" x .103" (each) ............................50-8049 

35/8" or 31/2" x.103" (each) ..................50-8048 

.585" Lift Dual VAlve Springs 

36. Valve spring shim 

For 1999-’04 bt 

.015" (each). ..................... 90-2086 

5 pack ........................50-7161 

.030" (each). ..................... 90-2087 

5 pack ........................90-2198 

For 2005-’12 bt 

.015” (each) .................... 500-0013 

.030” (each) .................... 500-0014 

37. Collar, bottom, steel ............ 900-0414 

38. Seal, valve guide 

1999-’04 bt. ..................... 90-2008 

2005-’12 bt. ................... 106-5688 

39. Spring, outer ...................... 90-2050 

40. Spring, middle ....................90-2049 

41. Collar, top, steel. ...............90-2065-S 

42. Valve keeper 

1999-'04 bt (each). ..............90-2094-S 

8 pack ........................50-7166 

2005-’12 bt (each). .............. 106-5692 

43. Valve spring kit, .585" lift Dual 

1999-'04 bt ..................... 90-2277 

2005-’12 bt. ................... 900-0420 

.650" Lift Sidewinder® VAlve Springs 

44. Valve Spring Shim 

.015" (each). ................... 500-0013 

.030" (each). ................... 500-0014 

45. Collar, Bottom, Steel (each). ...... 106-5691 

46. Seal,Valve Guide 

1999-'04, 5/16. ...................90-2008* 

2005-'12, 7mm ................ 106-5688 

47. Spring, Valve .650" ............. 106-5689 

48. Collar, Top, Steel. ............... 106-5690 

49. Valve Keeper 

1999-'04 (each). ................90-2094-S 

8 pack ........................... 50-7166 

2005-'12 (each). ................ 106-5692 

50. Valve spring kit 

.650" lift Sidewinder® 

1999-'04. ..................... 900-0050 

2005-'12. ..................... 106-5909 

*Not included in valve spring kit.


Continued – 

S&S® Cylinder Heads Replacement Parts for 1999-up Big Twin Engines 

Top End Rebuild Gasket Kits For S&S® Engines For Big Twins 

S&S Engine Family Year Group Bore Size Part No. 

T-Series 1999-up S&S 43/8" 90-9511* 

T-Series 1999-up S&S 41/8" 90-9506 USA TÜV 3 6 

T-Series 1999-up 41/8" Stock Cases 90-9510 

T-Series 1999-up 4" 90-9505 

T-Series 1999-up 37/8" 90-9504 

Kits include: Intake and exhaust seals, head & base gaskets, o-rings, pushrod o-rings, and valve guide seals. 

* Does not include intake seals. 

REPLACEMENT 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


33 

21 

32 

19 

18 

28 

29 

17 

16 

30 

31 

13 

4 

7 

6 

5 

15 

8 

9 

10 

12 

11 

14 

.585" Lift Dual VAlve Springs 

42 

41 

43 

40 

39 

38 

37 

36 

.650" Lift Sidewinder® VAlve Springs 

49 

48 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

1 

50 

47 

Racing 

Products 

24 

46 

20 

21 

22 

23 

3 

27 

26 

45 

44 

Tools & Shop 

Supplies 

2 

25 


& Promo Items 

Warranty & 




NOTE: All reference to H-D® part numbers is for 

identification purposes only. We in no way are 

implying that any of S&S Cycle’s products are original 

equipment parts or that they are equivalent to the 

corresponding H-D® part number shown. 

35 

34 


2-85

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

REPLACEMENT 

PARTS 


Die-Cast Rocker Cover Replacement Parts 

For 1999-Up Big Twin Engines 

1. Screw, socket head 1⁄4"-20 x 3⁄4" (each). ...................... 50-0067 

12 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0144 

2. Washer, flat 1⁄4" (each) .................................. 50-7017 

12 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7013 

3. Washer, silicone coated 1⁄4" (each) ......................... 50-7015 

8 pack ...........................................................50-7015-8 

12 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7015-12 

4. Seal, o-ring 

(Included in gasket kit see #16 below.) 

5. Screw, socket head, 1⁄4"-20 x 1" (H-D® #4741A) 

each. ............................................................50-0092-S 

4 pack ............................................................50-0092P 

10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0154 

6. Screw, socket head, 1⁄4"-20 x 2" .......................... 50-0013 

7. Screw, hex flange head, 5⁄16"-18 x 21⁄2" . .................... 50-0123 

8. Support, rocker arm. .................................... 90-4140 

9. Gasket, rocker cover, 4 1/8" 

Graphite (each) ..................................... 

USA 

90-4071-S 

2 pack ...................................................... 

10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

USA 

90-4071 

USA 

90-4099 

For S&S 79cc heads ......................................90-4124 

10. Housing, rocker, Chrome .................... USA 3 TÜV 1,7 90-4107 

11. Screw, socket head, 5⁄16"-18 x 1" ........................ 50-0125-S 

12. Seal, rocker cover 

(Included in gasket kit see #16 below.) 

13. Washer, flat 5⁄16" (each). .................................. 50-7056 

10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7082 

14. Screw, socket head 5⁄16"-18 x 21⁄4" 

each. ............................................................50-0115-S 

10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0156 

15. Cover, rocker, chrome. ................. 

USA 1,2,3 

TÜV 1,2,4,5,6,7 90-4089 

16. Gasket set - rocker cover, cast (Not Shown) . . . . . . . . . . . . . . . . . . 90-4111 

11 

14 

13 

4 

15 

5 

6 

2 

7 

8 

1 

2 

3 

10 

4 

12 

9 

Warranty & 






2-86 



S&S ® 

Billet rocker cover Replacement Parts 

for 1999-Up Big Twin Engines (Obsolete) 

1. Base assembly, rocker ................................N/A 

2. Top, rocker cover .....................................N/A 

3. SHCS, 1⁄4"-20 x 3⁄4" (H-D® #4069A) (each) ...............50-0067 

12 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-0144 

REPLACEMENT 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



4. Washer, flat, chrome, 260" x .425" x .060" (H-D® #6099) 

each ........................................50-7017 

12 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-7013 

5. Washer, flat, rubber coated, 1⁄4" x 7⁄16" x .020" 

each ........................................50-7015 

8 pack ..................................... 50-7015-8 

S&S Cover 

5 

3 

4 

Stock Cover 

Parts for 

Evolution ® 


Parts for 


1986-2012 

12 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7015-12 

6. SHCS, 5⁄16"-18 x 1" with flatwasher . ..............50-0125-S 

7. O-ring, rocker cover seal, Viton® 

(Included in gasket kit #90-4073. See below) 

2 

7 

11 

Parts for 


1926-1984 

8. O-ring, (-114), .625" ID x .937" OD (H-D® #11270) 

each ..................................50-8033 

9. Gasket, Breather Baffle, Stock Pattern, Paper, 1999-’10 bt (H-D® #17592-99) 

each .........................................90-4078 

10. Gasket, Breather Cover, Stock Pattern, Paper, 1999-’10 bt (H-D® #17591-99) 

each .........................................90-4077 

11. Gasket, Rocker Cover, Steel, 1999-up bt (H-D® #17386-99A) 

6 

1 

8 

10 

9 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

each ................................ 90-4096-S 

12. Gasket, bottom rocker cover (H-D® #16719-99B) 

USA 

each ....................................... 90-4071-S 

Racing 

Products 

2 pack .................................. 

USA 

90-4071 

10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

USA 

90-4099 

9. Gasket kit, rocker cover (includes gaskets for 2 rocker covers) 

12 

Tools & Shop 

Supplies 

For S&S billet rocker covers 

(includes #5,7,8,9,10,12). ...........................90-4073 

For 1999-'10 bt 

(includes #8,9,10,11,12). ........................ 90-4097 


& Promo Items 

Warranty & 







2-87

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 


Super Stock ® STEALTH replacement parts 

Parts for 



REPLACEMENT 

PARTS 

11 

12 

6 

13 14 

Parts for 

Evolution ® 


9 

10 

Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 


15 

1 

5 

2 

5 

3 

5 

4 

18 

16 17 

19 



6 

7 

7 

8 

1. Cover, Air Cleaner Air Stream 

Chrome ................................................170-0118 

Black Jack ..............................................170-0122 

2. Cover, Air Cleaner, Domed Bobber 

Chrome ................................................170-0120 

Black Jack ..............................................170-0124 

3. Cover, Air Cleaner, Dished Bobber 

Chrome ................................................170-0119 

Black Jack ..............................................170-0123 

4. Cover Air Cleaner, Muscle 

Chrome ................................................170-0121 

Black Jack ..............................................170-0125 

5. Air Cleaner Cover Screw, SHCB, 5/16"-18 UNC X .500"...............500-0051 

6. Screw, SHC, Flanged Button, 1/4-20 UNC x .750" ..................500-0060 

7. Top Plate, Air Filter, Molded, Plastic ............................170-0026 

8. Filter, Air, Tapered, 

Standard Pleated, Cotton, Stealth Air Cleaner Kit.............170-0126 

1" Taller Pleated, Cotton, Stealth Air Cleaner Kit .............170-0127 

1" Taller Pleated, Cotton Filter Only.........................170-0154 

9. Screw, SHCB, 1/4-20 UNC X .825"................................500-0059 

10. Backplate 

1993-up Stock CV Carb; 2001-up Delphi® EFI (except Throttle by Wire).170-0021 

Super E/G, Black, Die Cast, 1993-up bt ......................170-0049 

11. Screw, Backplate Vent, SHCB, 1/2-13 x 1-1/2", Chrome Plated.........170-0044 

12. Screw, Backplate Vent, SHCB, 3/8-16 x 1-1/2", Chrome Plated.........170-0045 

13. Washer,Flat, ,Nitrile Rubber Coated 

.520" x .880" x .024" BT 1993-’99 & xl 1991-'06,...............50-7055 

.380" x .880" x .024" BT 1999-'06 ...........................50-7054 

14. Gasket,Backplate 

Stock CV Carb & EFI Throttle Body,1991-up xl/bt (except Throttle by Wire) .. 106-6022 

Super E/G,CV Adapter,....................................106-1724 

15. Lanyard, 6" Stainless Steel....................................500-0095 

16. Lynch Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-0083 

17. Washer, Fender, Chrome Plated................................500-0094 

18. Spring, Wave Washer, Stainless Steel ...........................500-0093 

19. Screw, Hex, Hood-pin, 1/4-20, UNC..............................500-0082 

2-88 



S&S ® 

Single Bore Tuned Induction System 

replacement parts 

Parts for 

Twin Cam 96 /103 

2007-2012 

1. Tuned Intake Kit, 2.19" Single Bore 

8. O-Ring, Adapter Plate Bracket 

Natural............................ 106-4968 

35/8" O.D. x 31/2" I.D. 1/16 CS, Viton ....... 50-0446 

Wrinkle Black ...................... 106-4969 

5 pack ........................ 50-1083 

Chrome Plated ..................... 106-4970 

9. Bracket Kit, 2.19" Single Bore Tuned Intake, Chrome 

2. Tuned Intake Assembly, 2.19" Single Bore 

Super E/G, S&S T124 ................ 106-4973 

Natural............................ 106-4965 

Super E/G, 1984-up BT .............. 106-4974 

Wrinkle Black ...................... 106-4966 

Single VFI, S&S T124 ................ 106-4976 

Chrome Plated ..................... 106-4967 

Single VFI, 1984-up BT .............. 106-4977 

3. Air Filter, w/clamp, .Stainless Cap – Conical – 27/16" I.D. x 4" 

Stock carb, Delphi® EFI, 1984-up BT ... 106-4978 

Red (1 Each)......................... 17-1020 

10. Backplate Screw 

Blue (1 Each)........................ 17-1023 

Screw, SHC, w/Threadlock, 1/4-20 x 1/2". 106-2084 

4. Gasket, Intake – Adapter Plate ........ 17-1022 

11. Screw, 5/16 -18 x 11/4, BHC, Chrome .... 50-0309-S 

5. Plate, Adapter, 2.19" Single Bore Tuned Intake 

2 pack ........................ 50-1078 

Chrome Steel........................ 17-1014 

12. Flat Washer 5/16" x 1/16" ................ 50-7034 

6. FHSC 1/4-20 x 5/8"..................... 50-0433 

13. Hose, Breather, 1/4" I.D., 90°. ........... 19-0178 

3 pack ........................ 50-1071 

14. Screw, Breather Fitting, 3/8 -16 x 11/4". ... 50-0436 

7. FHSC 5/16-18 x 5/8" .................... 50-0432 

15. Washer, Flat, 3/8" x 13/16" x 1/16", Chrome. 50-7106-S 

2 pack ........................ 50-1070 

16. Screw, Breather Fitting, 1/2 -13 x 1.25 ... 50-0435 

17. Shim Kit 

(a) 5/16" I.D. S&S 41/8" engines ......... 17-0314 

(b) 1/2" I.D. 1993-up BT. .............. 17-0464 

18. Enrichment Device, S&S Super E & G carbs 

(Use in place of enrichment device on air cleaner backplate) 

..............................11-2084 

19. Gasket, Backplate - E/G/SBEFI ....... 106-1724 

10 pack ......................106-2328 

20. Gasket, S&S SBEFI 58mm ............ 106-4662 

21. Gasket, Stock carb/Throttle Body. ..... 106-6022 

REPLACEMENT 

PARTS 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

17 

12 

15 

16 

3 

Racing 

Products 

21 

19, 20 

9 

10 

13 

14 

11 

8 6 

6 

5 

7 

7 

18 

4 

1 

3 

Tools & Shop 

Supplies 


& Promo Items 

2 

Warranty & 





2-89

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-90 

REPLACEMENT 

PARTS 

Air Cleaner Replacement Parts 

for stock fuel systems 

1. Air cleaner cover 

Chrome ........................................ 17-0078 

Chrome (Notched) 2006 Dyna® and all 2007 models. ......... 17-0073 

Black .......................................... 17-0075 

Slasher ......................................... 17-0004 

2. Element ........................................ 17-0079 

3. Backplate, BT 1993-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-0003 

4. Cover screw (each) ................................ 50-0072 

10 pack .....................................50-0094 

Black (each) .................................... 50-0310-S 

3 pack ......................................50-0310 

5. Screw 

a. BT 1999-up, EFI Softail® 2001, All 2002 EFI BT, and 2006 Dyna® 

HHCS 1⁄4"-28 x 11⁄4" (each) ......................... 50-0077 

10 pack .....................................50-0265 

b. All others – HHCS 1⁄4"-28 x 7⁄8" .................. 50-0074 

6. Backplate screw, BT 1999-up, All 2002-up EFI BT 

Zinc Plated (each) ................................ 106-2084 

10 pack ....................................106-2105 

7. Replacement shims, BT 1993-up 

Shim Kit, 12 pack (includes 4 each of .018", .030", .048"):. ..17-0464 

1⁄2" x .018" (each) ................................. 50-7085 

1⁄2" x .030" (each) ................................. 50-7086 

1⁄2" x .048" (each) ................................. 50-7087 

10 pack .....................................50-7098 

1⁄2" x .105" (each) ................................. 50-7089 

10 pack .....................................50-7097 

1⁄2" x .125" (each) ................................. 50-7090 

5pack ......................................50-7101 

BT 1999-up, All 2002-up EFI BT 

a. 5⁄8" x .025" (each) ............................... 50-7113 

10 pack .....................................50-7110 

b. 5⁄8" x .050" (each) ............................... 50-7114 

10 pack .....................................50-7111 

c. 5⁄8" x .075" (each). ............................... 50-7115 

10 pack .....................................50-7112 

8. Breather screw seal 

a. BT 1993-’99, All 2002 EFI BT – Washer, .520 (each) .. 50-7055 

10 pack .....................................50-7057 

b. BT 1999-up, All 2002 EFI BT – Washer, .380 (each) ... 50-7054 

10 pack .....................................50-7059 

c. All others – O-ring, 1⁄2" O.D. (each) .......... 

USA 

50-8006 

10 pack ............................... 

USA 

50-8077 

9. Breather fitting (each) ............................. 17-0350 

2 pack ......................................17-0355 

10. Crankcase breather vent hose, BT 1999-up .... USA 1,2 17-0339 

11. Vent hose, with angle cut ......................... 17-0365 

12. Hose fitting ..................................... 50-8121 

13. Flatwasher, 1⁄4" (each) ............................. 50-7021 

10 pack .....................................50-7074 

14. Plug, press-in clear plastic . . . . . . . . . . . . . . . . . . . . . . . . . .50-8313 

15. Support bracket locknut - 1⁄4"-28 x 7⁄8" (each) .......... 50-5010 

10 pack .....................................50-5015 

16. Support bracket screw - 5⁄16"-18 x 11⁄4" .............. 50-0110 

17. Lockwasher, 5⁄16" ................................. 50-7032 

18. Rubber tubing - 1⁄4" x 5⁄8" x 3'. ................ 

USA 

19-0169 

19. Wire tie (NS)..................................... 50-8003 

20. Hardware kit, air cleaner mounting (NS) 

BT 1984-'99 ..................................... 17-0244 


1 

1 

4 

1 


21. Washer, flat - 3⁄8" x 7⁄8" x .146" (each). ................ 50-7053 

10 pack .....................................50-7075 

22. Carb support bracket, BT 1999-up & EFI Softail® 2001. . 17-0308 

23. Shim - 1⁄4" x 3⁄4" x .200". ........................... 50-7024 

24. Screw vent fitting, BT 1999-up ..................... 17-0345 

25. Screw air cleaner backplate ........................ 17-0346 

26. Spring clamps (NS) .............................. 50-8001 

4 

4 

5b 

5a 

13 

21 

21 

5a 

2 

2 

2 

25 

25 

25 

22 

22 

6 

6 

23 

6 

22 

7a-c 

23 

7c 

23 

13 

7 

NOTE: FI = fuel injected 

(NS) = Not Shown 

9 

24 

8a 

8b 

21 

11 

3 

24 

12 

8a 

9 

10 

2006-Up Dyna® Models & 

All 2007 Big Twin Models 

(with Stock EFI) 

(Obsolete) 17-0444 

8b 

13 17 12 

11 

10b 

1999-Up Big Twin with 

3 

CV Carburetor, 2001 

Harley-Davidson® EFI 

18 

Softail®, & All 2001-'06 

EFI Models except Dyna® 

(Obsolete) 17-0101 

24 

9 

8 

13 15 11 

3 

18 

12 

8 

10b 

1993-’06 Carbureted Big 

Twin Models, 2001 EFI 

Softail® Models, and 

2002-Up All EFI Models 

(except 2006-Up Dyna®) 

(Obsolete) 17-0117


Continued – 

Replacement Parts For S&S® Air Cleaners For Stock Fuel Systems 

1. Air cleaner cover 

Chrome ....................................... 

TÜV 1,7 17-0378 

Wrinkle Black.........................................17-0384 

Slasher...............................................17-0004 

2. Element, pleated ....................................106-4722 

3. Backplate 

1993-2007 BT & 2007-up non-touring models .........106-0907 

2008 Touring ........................................106-2092 

4. Cover screw, 

Chrome (each).........................................50-0072 

10 pack ...............................................50-0094 

Black (each) .........................................50-0310-S 

3 pack .................................................50-0310 

5. Backplate screw, Zinc Plated (each) ....................106-2084 

10 pack ...............................................106-2105 

6. Backplate plug 1⁄8"-27 (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8331 

10 pack ................................................50-1015 

7. Gasket, backplate (each) ..............................106-1724 

10 pack ...............................................106-2328 

8. Adaptor assembly 

1993-up bt (except 2008 & up touring models) ................106-0881 

2008-up touring models .............................106-1716 

9. Hose, vent, breather, formed, 

.250" x .375" x 1.825", 1993-2007 BT. ..................17-0364 

2 pack ................................................106-0880 

10. Clamp, spring, 9/16" ...................................50-8001 

11. Banjo fitting (each) ....................................17-0350 

2 pack .................................................17-0355 

12. Washer, silicone coated steel 

1999-up BT, 3/8" (each). ................................50-7054 

10 pack ................................................50-7059 

13. Breather screw, 1999-up BT ...........................17-0348 

14. Replacement shims 

5⁄8" x .025" (each). .....................................50-7113 

10 pack ................................................50-7110 

5⁄8" x .050" (each) .....................................50-7114 

10 pack ................................................50-7111 

5⁄8" x .075" (each) ..................................... 50-7115 

10 pack ................................................50-7112 

15. Screw, LSHC, 1/4-20 x 1/2", zinc plated (each). ............106-2037 

10 pack ....................................................106-2125 

16. Gasket, throttle body, throttle by wire, 2008-up BT (each) 106-2643 

10 pack ....................................................106-2664 

17. Hose, vent, breather ........................... 

USA 1,2 17-0339 

18. Washer, flat, .375" x .813" x .063", zinc, steel 

each ......................................... USA 1,2,3 TÜV 1,3,5,650-7051 

10 pack ....................................................106-3064 

19. Washer, silicone coated steel 3/8" (each). ................50-7055 

10 pack ..................................................... 50-7057 

20. Banjo fitting (each) ....................................17-0350 

2 pack ...................................................... 17-0355 

21. Washer, silicone coated steel 1/2" (each). ................50-7054 

10 pack ..................................................... 50-7059 

22. Screw, breather, 3/8-16 UNC, +.250, 2008 Touring (each) 106-2667 

2 pack .....................................................106-2668 

23. Cover, breather screw, chrome, aluminum .............106-2022 

24. Screw, LSHC, 5/16-24 x 1/2", stainless steel ...............106-2023 

4 

1993-up bt stock CV and delphi® Single bore efi 

(except 2008-up touring models) 17-0450 

4 

1 

6 

1 

2 

2 

5 

8 

Replacement Parts for S&S® Teardrop Air Cleaner 

For 2008-up Baggers with stock EFI throttle body 106-2091 

7 

15 

16 

15 

3 

5 

3 

14 

7 

13 

8 

10 

17 

9 

7 

24 23 

10 

12 

11 

10 

18 

20 

19 

22 21 

REPLACEMENT 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-91

S e ction 2: 

Continued – 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



REPLACEMENT 

PARTS 

Replacement Parts For S&S® Air Cleaners For Stock Fuel Systems 


14 

19 

12 

13 

17 

16 

22 

Parts for 

Evolution ® 


2 

5 

18 

15 

17 

20 21 23 9 10 

Parts for 


1986-2012 

1 

5 

8 

7 

7 

6 

11 14 

Parts for 


1926-1984 

4 

5 

3 

106-4589 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 

Parts for 

X-Wedge® 

2007-2012 


& Promo Items 

Warranty & 




S&S Teardrop Air Cleaner replacement parts 

for Magneti Marelli® EFI 

1. Cover ................................................ 

TÜV 1,7 17-0378 

2. Filter ...................................................... 106-4722 

3. Backplate, Assembly, Air Cleaner, Stock EFI, 

Magneti Marelli®, 1995-2001 ............................... 106-4615 

4. Screw, PHIL/OH 1/4-20x1" (each) ...............................50-0072 

10 pack .................................................50-0094 

5. Spacer, 1/2" Hex, Threaded .........................................N/A 

6. Stud, Fully Threaded 

1999-’01 5/16-18 x 1.25", Zinc Plated ......................... 106-4676 

7. SHCS, 1/4-20 x 3/4 SEMS .......................................50-0066 

8. Screw, SHCS, 

1995-’98, 1/4-20 x 3/4", SEMS ...................................50-0066 

1999-’01, 5/16-18 x 3/4" (each) .................................50-0302-S 

10 pack .................................................50-0302 

9. Screw, LSHC 5/16-24, x 1/2" Stainless SteelFront Head ........... 106-2023 

10. Cover, Breather Screw, Chrome, Aluminum, Front Head ....... 106-2022 

11. Screw, Backplate Vent (Front Head) 

1999-’01, 5/16-18 .............................................17-0345 

12. Screw, Backplate (Rear Head), Socket Panhead 

5/16-24 x .360", Zinc, Alloy Steel ................................17-0346 

13. Screw, Breather, +.250" (Rear Head) 

1999-’01 ....................................................17-0348 

14. Washer, glat, Nitrile Rubber Coated, Cold Rolled Steel 

1999-’01, .380" x .880" x .024" (each) ..........................50-7054 

10 pack .................................................50-7059 

15. Clamp Spring, 9/16" ...........................................50-8001 

16. Hose, vent Breather, Epichlorohydrin Polymer ........... 

USA 1,2 17-0339 

17. Fitting, Vent, Aluminum Alloy (each) ...........................17-0350 

2 pack ..................................................17-0355 

18. Washer, Flat, .375" x .875" x .146", Zinc, Steel (each) ............50-7053 

10 pack .................................................50-7075 

19. Bracket, Support, Air Cleaner To Head, Nickel Plated 

1991-Up xl ................................................ 106-1285 

20. Washer, Flat, .281" x .625" x .080", Zinc, Steel (each) ............50-7021 

10 pack .................................................50-7074 

21. Washer, Lock, .250" ...........................................50-7019 

22. Screw, SHCS, 1/4-20 x 11/4" (each) .................................50-0008 

10 pack .................................................50-0153 

23. Clamp, Spring, .660" (each) ....................................50-8076-S 

10 pack ............................................... 106-1174 

2-92 



S&S ® 

Super E & G Air Cleaner Replacement Parts 

For 1999-'06 Big Twins 

1. Air cleaner assembly 

Includes: Chrome cover, backplate, filter element, & hardware 

BT 1999-'06 .......................... 17-0403 

41/8" Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-0416 

2. Air cleaner cover – 

Chrome ....................... TÜV 1,7 17-0378 

Black ................................ 17-0384 

Slasher .............................. 17-0004 

3. Element, pleated..................... 106-4722 

Element, pleated carbon ....... TÜV 1,2,3,7 17-0375 

4. Backplate 

BT 1999-'06 .............. 

USA 1,2 

TÜV 4,5 17-0336 

41/8" Bore 

Manufactured after 1-1-03 ... 

USA 3 

TÜV 1,6,7 17-0387 

5. Cover screw (each). .......................... 50-0072 

10 pack ............................. 50-0094 

Black (each). ...............................50-0310-S 

3 pack. .............................. 50-0310 

TÜV style (each) .................... TÜV 5 50-0347-S 

10 pack ....................... TÜV 5 50-0347 

6. Backplate screw 

Zinc Plated (each). ..........................106-2084 

10 pack ............................106-2105 

7. Backplate plug 1⁄8"-27 (each) ............... 50-8331 

10 pack ............................. 50-1015 

8. Screw, air cleaner to head .............. 17-0346 

9. Fast idle friction washer (each) .............. 50-7035 

10 pack ............................. 50-7058 

10. Fast idle steel washer (each) ................ 50-7037 

10 pack ............................. 50-7061 

11. Fast idle nylon washer (each)................ 50-7036 

10 pack ............................. 50-7060 

12. Fast idle lever ...... USA TÜV 1,2,3 1,3,4,5,6,7 17-0329 

13. Fast idle brass washer (each) ................ 50-7007 

10 pack ............................. 50-7010 

14. Fast idle lever screw (one required for current 

backplate) (each) ........................... 50-0041 

10 Pack ............................. 50-0062 

15. Shim, .850" x .325" x .400" 

S&S 41/8" Bore. ............. USA 3 TÜV 1,7 50-7027 

16. Shims 

a. BT 1984-’92, S&S 41/8" Bore 

5⁄16" x .018" (each) ........................ 50-7038 

10 pack ............................. 50-7107 

12 pack .............................106-2087 

5⁄16" x .030" (each) . . . . . . . . . . . . . . . . . . . . . . . 50-7039 

10 pack ............................. 50-7070 

5⁄16" x .048" (each) ...................... 50-7040 

10 pack ............................. 50-7028 

12 pack ............................. 17-0314 

b. BT 1993-'06 

5⁄8" x .025" (each)......................... 50-7113 

10 pack ............................. 50-7110 

5⁄8" x .050" (each) ........................ 50-7114 

10 pack ............................. 50-7111 

5⁄8" x .075" (each) ........................ 50-7115 

10 pack ............................. 50-7112 

17. Screw vent fitting 

b. BT 1999-up ........................ 17-0345 

1 

3 

8 

16b 

6 

17 

18 

12 

9 10 11 

18. Washer, silicone coated steel 

BT 1999-up, .520" (each) .................50-7055 

10 pack ..................................50-7057 

BT 1999-up, .380" (each) ..................50-7054 

10 pack ..................................50-7059 

19. Breather fitting (each) .....................17-0350 

2 pack ..................................17-0355 

20. Crankcase breather hose 

b. BT 1993-’99. .............. USA 1,2 17-0339 

21. Flatwasher – 5⁄16" x 1⁄16" .............. 50-7034 

22. Mounting bracket bolt – big twin 

S&S 41/8" Bore – 5⁄16"-18 x 11⁄4" ....... 50-0110 

23. Hose clamp (NS) .................... 50-8002 

24. Mounting hardware package (NS) 

Includes all parts needed to install following style air cleaners: 

BT 1999-'06 ........................ 17-0437 

41/8" Bore . . . . . . . . . . . . . . . . . . . . . . . . . . .17-0460 

38. Spring clamps (NS) ................. 50-8001 

4 

(NS) = Not Shown 

19 

13 

11 

7 

7 

14 

20b 

REPLACEMENT 

PARTS 

1999-'06 Carbureted Harley-Davidson® 

Twin Cam 88® 

17-0403 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

5 

2 

1 

22 

21 

4 

16a 

15 

9 

13 

11 

10 11 

9 

7 

14 

Tools & Shop 

Supplies 


& Promo Items 

6 

7 

Warranty & 


NOTE: The line drawing is used for illustration purposes only. Not all of the parts shown 

are included and used in every carb installation. Parts followed by an N/A are no longer 

available. Those followed by an (NS) means parts are not shown. 

5 

3 

1984-'05 Big Twin 41/8" Bore 

2 

17-0416 




2-93

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




REPLACEMENT 

PARTS 


Teardrop Air Cleaner replacement parts 

for S&S ® Single Bore EFI 

1. Air Cleaner Cover 

Slasher (slotted chrome).................. 17-0004 

Chrome........................... 

TÜV 1,7 17-0378 

2. Element, pleated. ....................106-4722 

3. Backplate SBFFI 

BT 1999-up........................... 17-0120 

S&S 41/8" bore engines.................. 17-0380 

4. Screw, Cover, oval 1/4-20 x 1 

Chrome (each) .............................50-0072 

10 pack .................................50-0094 

Black (each) ..............................50-0310-S 

3 pack ...............................50-0310 

5. Backplate screw 

Zinc Plated (each) .........................106-2084 

10 pack .............................106-2105 

6. Pipe plug, 1/8, air cleaner backplate (each) . 50-8331 

10 pack .................................50-1015 

7. Mounting bracket bolt, hex 5/16-18 x 11/4 .. 50-0110 

8. Flat washer, 5/16" x 1/16" ................ 50-7034 

9. Shim, .850" x .325" x .400"... 

USA 3 

TÜV 1,7 50-7027 

10. Shim kit for 41/8" bore.................. 17-0314 

Individual shims: 

5/16" x .018" (each) ..........................50-7038 

10 pack .................................50-7107 

12 pack ................................106-2087 

5/16" x .030" (each) ..........................50-7039 

10 pack .................................50-7070 

5/16" x .048" (each) ..........................50-7040 

10 pack .................................50-7028 

12 pack .................................17-0314 

5/16" x .105" (each) .........................50-7041 

5 pack ...................................50-7062 

11. Screw, cable guide & air cleaner backplate 

10-24 x 1/4 (each) ...........................50-7042 

2 pack ..................................50-7042P 

5 pack ...................................50-7066 

12. Breather hardware for 41/8" bore.... 

USA 

31-2104 

(Not included in air cleaner kit) 

13. Shims, individual 

5/8 x 7/8 x .025 (each) ........................50-7113 

10 pack .................................50-7110 

5/8 x 7/8 x .050 (each) ........................50-7114 

10 pack .................................50-7111 

5/8 x 7/8 x .075 (each) ........................50-7115 

10 pack .................................50-7112 

14. Silicone washer, 1/2" ID (each) ..............50-7055 

10 pack .................................50-7057 

15. Silicone washer, 3/8" ID (each) ..............50-7054 

10 pack .................................50-7059 

16. Breather hardware for 

1999-up BT .......................... 17-0455 

(Not included in air cleaner kit) 

4 

4 

1 

1 

1995 1 /2-'06 Big Twin 

Except Harley-Davidson ® 2006 Dyna ® Models 

Chrome Air Cleaner Cover ............17-0498 

Slasher Air Cleaner Cover .............17-0497 

17. Screw, wide head, 5/16-24 x .36. .......... 17-0346 

18. Air cleaner hardware kit (N/S) 

BT 1999-up .......................... 17-0482 

S&S 41/8" bore......................... 17-0481 

19. Breather vent fitting 

BT 1993-'99 .......................... 17-0347 

BT 1999-up........................... 17-0345 

20. Breather fitting (each) .....................17-0350 

2 pack ...................................17-0355 

21. Check Valve .......................... 50-8122 

22. Seal, backplate, neoprene, ............106-1667 

23. Screw, SHC, 5/16-18 x 11/4" .......... USA 50-0121 

2 

2 

7 

5 

17 

8 

5 

5 

6 

6 

3 

5 

15 

20 

14 

5 

6 

9 

19 

11 

10 

11 

21 

S&S 4 1 /8" Bore Engines 

3 

12 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0496 

(N/S) = Not shown 

NOTE: Breather hardware not included in 

these air cleaner kits. 

16 

13 

2-94 



S&S ® 

single bore EFI Throttle Body 

and Related Replacement parts 

1. Throttle body 

52mm 1995-'05................... 16-5101. 

52mm 2006-Up................... 16-5153. 

58mm 1995-'05.................. 106-3954. 

58mm 2006-Up.................. 106-3957. 

2. Cap, canister purge ...............50-8266-S 

5 pack ..........................50-1062 

3. Manifold (See page 2-68) 

4. Cap, rubber, manifold, fitting ....... 50-8372 

5. Throttle cable guide packet with hardware 

................................. 55-5084 

6. Screw, cable guide & air cleaner backplate 

each ...........................50-0041 

10 pack .........................50-0062 

7. O-ring, throttle body to manifold .. 50-7967-S 

8. Intake air temperature sensor with hardware 

(H-D® #27270-95).................... 55-5041 

9. Gasket, IAT ......................16-5009-S 

10. Screw, M3, IAT ...................50-0357-S 

11. Idle air control motor SS EFI with hardware 

1995-'05 (H-D® #27628-01). ........... 55-5085 

12. O-ring, IAC ......................50-8149-S 

13. Screw, 10-24, IAC 

1995-'05 (each) ....................50-0356-S 

10 pack .........................50-1060 

2006-Up (each) ....................50-0358-S 

10 pack .........................50-1056 

14. Fuel rail kit 

2001-'05 (Fuel inlet tube not included.) 

................................. 16-5202. 

1995-'01 (Fuel inlet tube included) (Not Shown). 

................................. 16-5207 

15. Tube clip, fuel rail inlet 2001-'07 

each .........................50-0391-S 

5 pack ..........................50-1054 

16. O-ring, fuel rail inlet, 2001-'07 

each ........................50-8137-S 

10 pack .........................50-1055 

17. Backing washer, fuel rail inlet 

2001-'07 ..................... 50-0349-S 

18. Screw, rail, 1995-Up 

each ...........................50-0039 

10 pack .........................50-0146 

19. Fuel injector 

each .........................55-5052A 

2 pack .........................55-5052 

20. O-ring, injector top, black. ...... 50-8264-S 

21. O-ring, injector bottom, orange 

............................. 50-8265-S 

22. Throttle position sensor VFI with hardware 

1995-'05 (H-D® #27271-95). .......... 55-5058 

23. Screw, TP sensor & fuel rail 

each ........................50-0358-S 

10 pack .........................50-1056 

24. Washer, TP sensor (each)......... 50-7145-S 

10 pack ........................50-1057 

25. MAP sensor (H-D® #32316-99)........ 55-5057 

26. Screw, throttle body to manifold 

each ........................50-0359-S 

10 pack ........................50-1063 

27. Washer, lock , #10, 

throttle body to manifold ........ 50-7000 

28. Gasket, backplate 

52mm (each) ......................106-1724 

10 pack .......................106-2328 

58mm (each)....................106-4662 

29. Harness, injector adapter kit 

1995-'05. ........................ 55-5074. 

2006-Up .................... 

TÜV 7 55-5209 

30. Fuel inlet tube 45°, 2002-up . ....... 50-0485 

29 

23 

15 

26 

27 

23 

14 

30 

24 

17 

3 

16 

19 

8 

18 

Fuel Rail Parts For 1995-’01 (Not Shown) 

31. Spacer, throttle position – 2002-up .. 55-5200 

32. Pressure regulator, 1995-'01 ........ 16-5297 

33. Screw, pressure regulator, 6-32 x 3/16", 1995-'01 

................................50-0279-S 

34. Clamps, Hose, 1/2" diameter, smooth, 1995-'01 

each ...........................50-8352 

2 pack ........................ 106-1299 

35. Plug, assembly, MAP sensor hole, 1995-'01 

................................. 50-8350 

35. O-ring, MAP plug, 1995-'01 

each .........................50-8133-S 

10 pack .........................50-1101 

4 

22 

10 

9 

29 

20 

7 

2 

25 

13 

1 

19 

12 

11 

6 

28 

21 

5 

6a 

REPLACEMENT 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 





2-95

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




REPLACEMENT 

PARTS 

1. Carb body assembly 

17⁄8" Super E ...........................11-2381 

21⁄16" Super G ...........................11-2390 

2. Throttle shaft 

17⁄8" Super E – Includes two plate screws .......11-2383 

21⁄16" Super G – Includes two plate screws ......11-2483 

3. Throttle plate screw - (two required) 

each .......................................50-0055-S 

10 pack ......................................50-0064 

4. Throttle plate 

17⁄8" Super E .............................11-2055 

21⁄16" Super G ............................11-2355 

5. Throttle return spring (each) ................11-2382 

5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3502 

6. Throttle spool ..............................11-2385 

7. Throttle shaft lock washer (two required). ... 50-7031 

10 pack ......................................50-7073 

8. Throttle shaft nut (two required) (each). ...... 11-2350 

5 pack .......................................11-2363 

9. Throttle shaft nylon washer (each) .........50-7050 

10 pack ......................................50-7072 

10. Pump actuator lever .......................11-2376 

11. Actuator spring (each) ....................11-2375-S 

5 pack .......................................11-3501 

12. Pump actuator arm ........................11-2377 

13. Idle mixture screw (each) ...................11-2354 

5 pack .......................................11-2378 

14. Idle mixture screw spring (each) ............11-2052 

10 Pack ......................................11-2060 

15. Idle speed screw (each) .....................50-0038 

10 Pack ......................................50-0150 

16. Pump adjustment screw (each) .............50-0039 

10 Pack ......................................50-0146 

17. Idle speed/pump adjuster spring (each) ....11-2048 

10 pack ......................................11-2053 

18. Plunger nut (each) ..........................11-2344 

5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2372 

19. Plunger spring (each) .......................11-2340 

10 Pack ......................................11-2359 

20. Fast idle plunger . ..........................11-2343 

21. Cable guide assembly 

Use with butterfly style cables .............11-2339 

Use with constant velocity style cables .......11-2338. 

2004 - 06 XL ................................11-2337 

22. Cable clamp/float pin screw (each) .........50-0041 

10 Pack ......................................50-0062 

23. O-ring 

17⁄8" Super E (each) ..........................50-8016 

10 Pack ......................................50-8094 

21⁄16" Super G (each) .........................50-8015 

10 pack ......................................50-8093 

24. Bellows seal (each) ..........................11-2266 

5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2279 

25. Bowl vent plug (each) .......................50-0105 

10 pack ......................................50-0151 

26. Main discharge tube .......................11-2085 

27. Main jet – See Chart 


Super E & G Carburetor Replacement Parts 

28. Intermediate Jets – See Chart 

Series #94 fits all Super 17⁄8", 21/16", 21⁄4" gas 

carburetors. Sizes available: .025", .0265", .028", 

.0295", .031", .032", .033", .036", .040". 

29. Bowl gasket (each) ..........................11-2386 

10 pack ......................................11-2387 

30. Float ........................................11-2187 

31. Float pin (each). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2369 

5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2370 

32. Bowl screw 

10-24 x 3⁄4" - Three required. (each) .........50-0034 

10 Pack ......................................50-0063 

10-24 x 23⁄8" - One required (each) ..........50-0040 

10 Pack ......................................50-0061 

33. Carb bowl (only) .............................11-2388 

Carb bowl complete assembly ........... 11-2388P 

34. Bowl plug (each) ............................11-2090 

5 pack .......................................11-2092 

35. Seat o-ring* – (required with part #11-2465 & #11-2466 

only when replaces 360°style fuel inlet.) (each) .....50-8009 

10 pack ......................................50-8095 

36. Needle 

17⁄8" Super E & 21⁄16" Super G ...............11-2195 

Racing only .................................11-2197 

37. Seat 

17⁄8" E & 21⁄16" G (Replaces part #11-2347) 

Uses part #11-2195 needle. ................11-2465 

Racing only (Replaces part #11-2348) 


Racing only -threaded fuel inlet (6AN .157" ID for Super E or G) 


Racing only -threaded fuel inlet – (6AN .235" ID for Super E or G) 


Permeation Compliant fuel inlet seat Super E or G. 

Uses part #11-2195 needle. ...............106-2011 

38. Ejector nozzle o-ring (each) .................50-8011 

10 Pack ......................................50-8096 

39. Pump pushrod (each) .......................11-2373 

5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2393 

40. Ball check - (two required) (each) ............50-8090 

10 pack ......................................50-8125 

41. Ball check spring (each) .....................11-2374 

5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2392 

42. Pump cap o-ring - (two required) (each) .....50-8012 

10 Pack ......................................50-8100 

43. Pump cap assembly ........................11-2389 

44. Overflow hose per 24" (each) .............19-0262-S 

10 Pack ......................................19-0263 

45. Pump cap screw 8-32 - (two required) (each).50-0042 

10 Pack ......................................50-0098 

46. Diaphram spring (each) .....................11-2275 

10 pack ......................................11-2278 

47. Diaphragm .................................11-2282 

48. Gasket, backplate (each) ...................106-1724 

10 pack .....................................106-2328 

49. Enrichment device (Use with air horn only).. 11-2084 

50. Fuel line With 90° bend* 19" 

Use with part #11-2465 or #11-2466 

USA 

........................... 19-0475A 

Permeation Compliant straight, 311" x .563" x 17.5" 

Use with part #106-2011 , 90° seat .......190-0001 

51. Fuel line insulator – 12" 

USA 

............... 

USA 1,2,3 

TÜV 1,2,3,6,719-0172 

52. Spacer,Kit, with o-ring 

17/8" x 1". ............................ 16-0057* 

21/16" x 1". ........................... 16-0357* 

21/4" x 1". ............................ 16-0157* 

* Use with 1" Spacer Block. ............. 16-0058 

53. Insulator Block,Manifold,Super E,w/ O-ring 

17/8" x 1/4". ............................ 16-0491 

17/8" x 3/8". ............................ 16-0497 

21/16" x 1/4" ............................ 16-0492 

21/16" x 3/8" ............................ 16-0498 

21/4" x 1/4". ............................ 16-0499 

54. Screw, 

1" x 3⁄8"-16 ........................... 50-0161 

11⁄4" x 3⁄8"-16 ......................... 50-0162 

13⁄8" x 3⁄8"-16 ......................... 50-0163 

2" x 3⁄8"-16. ........................... 50-0164 

21⁄4" x 3⁄8"-16. ......................... 50-0165 

21⁄2" x 3⁄8"-16. ......................... 50-0166 

11⁄4" x 1⁄4"-20. ......................... 50-0008 

11⁄2" x 1⁄4"-20. ......................... 50-0079 

21⁄4" x 1⁄4"-20 ......................... 50-0078 

55. Tube,Fast Idle Pick-Up, .125" x 2.350",Brass ..0381F 

56. Tube,Ejector Nozzle,Flared,Brass .......106-6124 

CARBURETOR REBUILD KITS 

Body Rebuild Kit 

Super E (includes: #4, 5, 7, 8, 9, 11, 24, 29, 38).11-2906 

Super G(includes: #3, 5, 7, 9, 11, 23, 29, 38) . 11-2907 

Accelerator Pump Rebuild Kit 

Super E & G (includes: #39,40,41,42,46,47) . 11-2918 

Master Rebuild Kit 

Super E 

(includes Body Rebuild Kit #11-2906 & Accelerator Pump 

Rebuild Kit #11-2918 & #3, 13,14,15,16,17,19,22,23,31,32, 

35,36,37,39,40,41,42,44,45,46) ...........11-2923 

Super G 

(includes Body Rebuild Kit #11-2907 & Accelerator Pump 

Rebuild Kit #11-2918 & #3, 13,14,15,16,17,19,22,23,31,32, 

35,36,37,39,40,41,42,44,45,46) ...........11-2924 

RADIUSED INLETS (NOT SHOWN) 

Radiused Inlet;Kit;Carb;Super E/G. . . . . . . . . . . . 11-2163 

Kit Includes: 

(3) Screw;SLTD FH;w/ Lock Washer ....... 50-0073 

(3) Screw,SHC,w/ Thread Lock ..........106-2084 

(1) Cap,VOES Fitting. ................... 50-8372 

(1) Radiused Inlet. ......................... N/A 

(1) Fitting, Hose, Straight ................... N/A 

2-96 



6 

5 

2 

13 

3 

14 

18 

19 

20 

22 

21 

16 

17 

4 

23 

53 

54 

REPLACEMENT 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



49 

15 

17 

48 

1 

25 

55 

26 

27 

28 

9 

24 

10 

11 

12 

7 

8 

52 

Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

*Early Super E & G Carburetors equipped with a 360° fuel inlet that require service must be converted to the 

bottom feed style fuel inlet. To update production Super E and G carburetors equipped with an early 360° 

style inlet use part #50-8095 o-ring (1 each) #11-2465 seat (1 each) and #19-0475A fuel line (1 each). To 

update an early Super E or G carb equipped with a 360° style racing size inlet, use parts #50-8095 o-ring (1 

each) #11-2466 seat (1 each) and #19-0475A fuel line (1 each) . 

MAIN JETS - SERIES #72 INDIVIDUAL SIZE SELECTION CHART 

Size Each 5 Pack Size Each 5 Pack Size Each 5 Pack 

.040 11-4040 11-7220 .068 11-4068 11-7234 .096 11-4096 11-7248 

.042 11-4042 11-7221 .070 11-4070 11-7235 .098 11-4098 11-7249 

.044 11-4044 11-7222 .072 11-4072 11-7236 .100 11-4100 11-7250 

.046 11-4046 11-7223 .074 11-4074 11-7237 .102 11-4102 11-7251 

.048 11-4048 11-7224 .076 11-4076 11-7238 .104 11-4104 11-7252 

.050 11-4050 11-7225 .078 11-4078 11-7239 .106 11-4106 11-7253 

.052 11-4052 11-7226 .080 11-4080 11-7240 .108 11-4108-S 11-7254 

.054 11-4054 11-7227 .082 11-4082 11-7241 .110 11-4110 11-7255 

.056 11-4056 11-7228 .084 11-4084 11-7242 .115 11-4115 11-7256 

.058 11-4058 11-7229 .086 11-4086 11-7243 .120 11-4120 11-7257 

.060 11-4060 11-7230 .088 11-4088 11-7244 Blank 11-4040 11-7258 

.062 11-4062 11-7231 .090 11-4090 11-7245 

.064 11-4064 11-7232 .092 11-4092 11-7246 

.066 11-4066 11-7233 .094 11-4094 11-7247 

Intermediate JETS - SERIES #94 INDIVIDUAL SIZE SELECTION CHART 

Size Each 3 Pack Size Each 3 Pack 

.025 11-0250 11-7107 .033 11-0330 11-7113 

.0265 11-0265 11-7108 .036 11-0360 11-7114 

.028 11-0280 11-7109 .040 11-0400 11-7115 

.0295 11-0295 11-7110 Blank 11-0000 11-7116 

.031 11-0310 11-7111 

.032 11-0320 11-7112 

37 

35 

36 

31 

32 

33 

22 

35 

34 

50 50 

37 

NOTE: Early Series #94 gas jets were stamped with single 

digit numbers. Conversions for these numbers are: 

1 ............................................ .025" 

2 ............................................ .028" 

3 ............................................ .031" 

4 ............................................ .033" 

5 ............................................ .036" 

6 ............................................ .040" 


30 

38 

56 

29 

40 

42 

41 

45 

44 

51 

39 

47 

32 

46 

43 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-97

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

REPLACEMENT 

PARTS 


6-Speed Transmission And Cassette 


1. Trap door, S&S 6-speed transmission 

2000-'06 Harley-Davidson® Softail® and 1991-'06 FLT models ....... 56-1221 

1991-'05 Dyna®, 1991-'99 Softail, and 1991-up FXR models ........ 56-1253 

2. Kit, gaskets and seals - 1991-'06 Softail (S&S complete transmission) . . . 56-1226 

3. Hardware kit, 6-speed transmission ............................. 56-1227 

4. Kit, ball and ramp, 6-speed transmission 18° ..................... 56-1228 

5. Kit, throwout bearing ......................................... 56-1229 

6. Kit, speed sensor hole cover .................................... 56-1230 

7. Kit, bearings, thrust washers, and retaining clips .................. 56-1231 

8. Mainshaft nut, jam hex nylon, 3⁄4-16, UNF-2B ................... 56-1278-S 

9. Kit, shift pawl, 6-speed transmission ............................ 56-1225 

9a. Sleeve, Shaft .................................................. 56-0001-S 

10. Shift fork, 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-1275 

11. Shift fork, 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-1276 

12. Shift fork, 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-1277 

13. Shaft, shift rail ............................................... 56-1274 

14. Drum, shift .................................................. 56-1273 

15. Nut, hex 11⁄2-24 UNS-2B LH .................................... 56-3003 

16. Sprocket, 34 tooth ................................................. N/A 

17. Hardware, kit sprocket. ........................................ 56-1272 

18. Spacer, sprocket .............................................. 56-1293 

19. Ring, retaining beveled internal 3.346 ........................... 50-8469 

20. Cover, top - S&S complete transmission and cassette applications 

Die cast – 1991-’99 Softail® and 1991-'00 FLT models 

S&S or stock transmission case. ............................ 

USA 

56-5115 

Billet chrome – 1999-'05 Dyna® models ........................ 106-3886 

21. Switch, neutral ............................................... 56-5113 

22. Shaft, counter, S&S 6-speed, with integral main gear .............. 56-5114 

23. Gear, fifth, countershaft, S&S 6-speed ........................... 56-5116 

24. Assembly, carrier, drum, LH .................................... 56-1294 

25. Gear, second, countershaft, S&S 6-speed ......................... 56-5117 

26. Gear, first, countershaft, S&S 6-speed. ........................... 56-5118 

27. Gear, third/fourth, countershaft, S&S 6-speed. .................... 56-5119 

28. Nut, bearing retainer, trap door, 115⁄16 - 20 UN-2B .................. 50-8477 

29. Collar, shift .................................................. 56-5149 

30. Assembly, carrier, drum, RH .................................... 56-1295 

31. Sleeve, shift collar .......................................... 56-0010-S 

Parts for 


& Metric 

48 

3 

Racing 

Products 

21 

20 

Tools & Shop 

Supplies 

42 

17 

15 

49 

16 

2 & 43 

3 

3 


& Promo Items 

3 

18 2 

7 

9 2 24 

14 

30 

Warranty & 


19 

7 & 46 



39 

2-98 



38 

Continued – 

Replacement Parts For S&S® 6-Speed Transmissions And Cassettes 

32. Spacer, thrust, mainshaft, S&S 6-speed .......................... 56-1302 

33. Gear, fourth, main, S&S 6-speed ................................ 56-5126 

34. Gear, third, mainshaft, S&S 6-speed ............................. 56-5127 

35. Mainshaft with first gear S&S 6-speed ........................... 56-5128 

36. Gear, second, mainshaft, S&S 6-speed ........................... 56-5129 

37. Gear, fifth, mainshaft, S&S 6-speed. ............................. 56-5131 

38. Gear, main drive (with bearings and seal) S&S 6-speed ............. 56-5123 

39. Case, transmission, S&S 6-speed – 1991-'99 Harley-Davidson® Softail® 

Natural ..................................................... 56-1125 

Black ............................................................ N/A 

Polished..................................................... 56-1127 

2 & 44 

10 

1 

9a 

11 

12 

22 

3 

9 

13 

23 

40. Cover, side, S&S 6-speed transmission 

Mechanically actuated ....................................... 106-4035 

Hydraulically actuated. ....................................... 106-3885 

41. Assembly, dipstick ........................................... 56-5132 

42. S&S inner primary bearing race- optional (Not shown) ........ 

USA 

56-5089 

43. Gasket, top cover 

Softail, FLT. ................................................ 56-5107-S 

1999-'05 Dyna® .............................................. 56-1256 

44. Gasket, trap door .........................................56-5108-S 

10 pack .................................................56-5108 

45. Gasket, side cover .........................................56-5111-S 

10 pack .................................................56-5111 

46. Bearing, main drive gear .....................................56-1281 

47. Spacer kit, oil filter – Optional for FLT only (Not shown) .............56-1292 

48. Hardware kit, 1991-'98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106-0850 

49. Gasket kit, 1991-'98 Dyna ...................................106-0882 

50. Bearing, Ball, S&S 6 speed, 20mm x 47mm x 14mm. .............. 56-1282-S 

25 

7 

31 

29 

26 

27 

REPLACEMENT 

PARTS 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

2 

Racing 

Products 

29 

6 

31 

37 

3 

7 & 50 28 

8 

5 

4 2 & 45 

41 

Tools & Shop 

Supplies 

36 

35 

40 

3 


& Promo Items 

7 

34 

31 

29 

33 

32 

Warranty & 





2-99

S e ction 2: 

S&S ® 

Parts for 

Twin Cam 96 /103 

2007-2012 

Parts for 



Parts for 

Evolution ® 


Parts for 


1986-2012 

Parts for 


1926-1984 

Parts for 

X-Wedge® 

2007-2012 

Parts for 


& Metric 

Racing 

Products 

Tools & Shop 

Supplies 


& Promo Items 

Warranty & 




2-100 

REPLACEMENT 

PARTS 



CHROME PLATED BILLET TRANSMISSION SIDE COVER 


1. Hydraulic Clutch Side Cover (Chrome Billet). .........106-3885 

Cable Actuated (Chrome Billet) ....................106-4035 

2. Gasket Side Cover (each) ........................ 56-5111-S 

10 pack ....................................56-5111 

3. Dipstick Assembly (H-D® #37071-87, 37075-87) .......... 56-5132 

4. Piston, Hydraulic Clutch (Billet). .................... 56-1303 

5. O-ring, 1 1/4 ID x 1/8 CS, Buna-N 70 (each). .......... 50-8283-S 

10 pack ....................................50-1099 

6. O-ring, 1 1/4 ID x 1/8 CS, Viton ..................... 50-8282-S 

7. Banjo Bolt 3/8-24 x 3/4 ........................... 50-0426-S 

8. Adapter, Hydraulic Clutch Line. .................... 56-5198 

9. Crush Washer, Copper .400 ID x .590 OD x .050 . .... 50-0423-S 

10. Valve, Bleed Fitting, 1/4-28 .........................50-0498 

11. Washer, Flat .260 x .420 x .06 Chrome ........... 50-8451-S 

12. Screw, Cap Hex SH 1/4-20 UNC x 1.75 Zinc ........ 50-0010-S 

13. Screw, Cap Hex SH 1/4-20 UNC x 2.75 Zinc .......... 50-0459 

13 

10 1 

12 11 9 

S&S ® 

High performance Clutch Replacement Parts 

. 

1. Race, inner primary bearing, 5/6 speed main shaft 

All 1991-'05 BT and 2006 Harley-Davidson® Softail® models 

.......................... 

USA 

56-5089 

2. Basket, 

Clutch, 36-tooth............................ 

USA 

56-5081 

Clutch, 37-tooth............................ 

USA 

56-5082 

3. Bearing, clutch (basket to hub). .............. 

USA 

56-5102 

4. Hub, clutch ............................... 

USA 

56-5075 

5. Washer, thrust, 19.5 mm I.D. x 35.6 mm O.D. .............N/A 

6. Nut, mainshaft, clutch hub, 3⁄4-18 UNS-2B.................N/A 

(Recommended early style mainshaft nut H-D® #37496-84) 

(Recommended late style mainshaft nut H-D® #37496-90) 

7. Plate, pressure - clutch 

Mechanical (3-piece pushrod actuated). ....... 

USA 

56-5076 

Hydraulic (1-piece pushrod actuated). ............. 106-3147 

8. Spring, pressure plate, clutch 

Light duty, 334 lbs. (6 pack) .................. USA 

56-5109 

Standard, 370 lbs. ....................... 

USA 

56-5105-S 

Heavy duty, 408 lbs. (each). ................ 

USA 

56-5106-S 

6 pack ......................... 

USA 

56-5106 

9. Nut, flange, M10 x 1.25". .................... 

USA 

50-8411 

10. Screw, clutch adjuster, M10 x 1.25". ........... 

USA 

50-8414 

11. Bolt, special, M6 x 30, w/washer. ........... 

USA 

50-8413-S 

12. Jutter spring with seat ...................... 

USA 

56-5110 

13. Clutch pack, 11 frictions, 10 steels. .......... 

USA 

56-5085-S 

14. Kit, shim, clutch inner race. .................. 

USA 

56-5090 

Shim, 5/6 speed main shaft 

1.300" O.D. x .960" I.D. x .0075" (36 gauge) thick. ... 

USA 

56-5092-S 


USA 

56-5093-S 


USA 

56-5094-S 

1.300" O.D. x .960" I.D. x .0470" (18 gauge) thick .... 

USA 

56-5095-S 

1 

OPTIONAL: 

15. Pinion Gear ............................... 

USA 

56-1037 

16. Loctite®, fast cure epoxy .12 ounce (Not Shown). .....51-9007-S 

14 

12 

15 

2 

13 

3 

6 

1 

4 

5 

7 

5 

8 

4 

6 

3 

7 

10 

9 

8 

2 

11

SECTION 2: 1999-2006 BIG TWINS - S&S Cycle

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