1986-2012 SportsterÂ® & Buell - S&S Cycle

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S e ction 4: 1986-2012 Sportster® & Buell ®S&S ®Parts forTwin Cam 96 /103 2007-2012Parts forTwin Cam 88 ®1999-2006Parts forEvolution ®1984-1999Parts forSportster ® & Buell ®1986-2012Parts forVintage Engines1926-1984Parts forX-Wedge®2007-2012PERFORMANCEKITSSidewinder ® Big Bore KitsWhen the Harley-Davidson® Evolution® powered Sportster® was released in 1986 it wasobvious that the new engine had a lot of potential. Aside from the obvious benefit ofaluminum finned cylinders and a modern cylinder head and valve train, the crankcases werebeefed up enough to handle larger bore sizes with far fewer problems than previous engines.The crankcase cylinder deck height was raised to be the same as a big twin engine at 5.375"from the center of the crankshaft, and the cases were stronger in general so that materialdid not have to be welded on to the sides of the cylinder deck in order to accommodate 35/8"bore cylinders. The taller crankcase deck did result in cylinders that were too short to allow apractical stock bore stroker to be designed, so big bore was the only option!FITMENT• 1986-'03 Harley-Davidson® Sportster®• 1994-'02 Harley-Davidson® Buell®FEATURES AND BENEFITS• Available in three displacements, for four-speed (1986-’90) and five-speed (1991-’03)models, and in natural aluminum and black powdercoat finish.• Two displacements available : 79" and 89" big bore stroker kit• Requires that the crankcase cylinder spigot holes be bored to accept the larger cylinders• Complete instructions are provided for this machining operation, and S&S has specialtools available that simplify the crankcase boring procedure. See Section 9 in thiscatalog for more informationThis is a basic Sidewinder® Kit . The engine builder has chosen flattopped pistons to be used with the stock cylinder heads. In addition he/she has selected standard adjustable pushrods and a manifold to beused with an existing S&S carburetor.Parts forVictory®, Off-road& MetricRacingProductsTools & ShopSuppliesDealer Services& Promo ItemsWarranty &Company PolicyOEM Cross ReferenceAppendix & IndexS&S® SIDEWINDER® BIG BORE KITS for 1986-'03 Harley-Davidson® SPORTSTER® modelsDisplacement Stroke BoreCompressionRatioPiston Type Cylinder Length Engine Life Application Part No.79" Sportster** 313⁄16" 35⁄8" ‡ Forged Stock Stock-like 1986 to 2003 91-300289" Sportster* 45⁄16" 35⁄8" ‡ ForgedCTO+.437"1986 to 1990 91-3121Very good(5.087") 1991 to 2003 91-3123Specify Specify Specify Specify 1986-2003 106-5834All other Sportster & Buell® year groups must use the CTO part number.‡ Compression ratio depends on cylinder head type used.If stock heads are used extensive cylinder head modifications must be performed, making compression ratios completely dependent on final combustion chamber volume.† 1991 and later engines require conversion to 1986-’90 style pushrod tube assemblies when using adjustable pushrods. S&S kits for 1991 and later engines include a special pushrod tube adapter.Pushrod tube assemblies are not included and must be purchased separately.** This kit has stock height cylinders and will fit Buell® motorcycles. * Denotes kit supplied in S&S Hot Set Up Kit.Parts Included in S&S® SIDEWINDER® BIG BORE KITS for 1986-'03 Harley-Davidson® SPORTSTER® modelsKit Part FlywheelGaskets HeadHead MountDisplacement StrokePistons CylindersPushrods Pushrod ManifoldNo. AssemblyHead BaseBolt Center Front79" 313⁄16" 91-3002 Forged l l l91-3121 l Forged l l l l l l l l l89" * 45⁄16"91-3123 l Forged l l l l l l l l l* Denotes kit supplied in S&S Hot Set Up Kit.4-14Order toll free 866-244-2673
1986-2012 Sportster ® & Buell ®S&S ®SB100 EnginesFor Harley-Davidson ® Sportster ® and Buell ®S&S SB100 engines come assembled with a natural aluminum finish. Crankcases have1986-’90 (four-speed) style cam geometry and 1991-’03 (five-speed) style drive side.Primary and transmission components not included.FITMENT• 1986–’03 Harley-Davidson® Sportster®• 1994–’02 Buell®FEATURES AND BENEFITSBolt-in replacement for stock engines• "Square" motor configuration (equal bore and stroke) produces excellent torque,greatly increases engine life• S&S Super G carburetor with teardrop air cleaner• S&S high flow Super Stock® cylinder heads• High strength supreme rods, S&S cylinders, and forged pistons• Adjustable pushrods and pushrod cover assemblies• Hydraulic tappets and S&S forged roller rocker arms• S&S billet gear cover kit and billet aluminum rocker covers• Now includes oil pump and oil filter mountKIT CONTENTS• Assembled SB100 engine• Oil Filter• InstructionsPART NUMBERSS&S Complete SB100 Engines For Sportster and Buell ModelsSB100 for Sportster ........................................ 31-9891SB100 for Buell ........................................... 31-98931101009080706050Dyno Results1993 Harley-Davidson® Sportster® Hugger w/S&S® SB 100 EngineS&S SB100 Engine In 1993 HuggerPeak Rear Wheel HP 111.2Peak Rear Wheel Torque 107.7PERFORMANCEKITSParts forTwin Cam 96 /103 2007-2012Parts forTwin Cam 88 ®1999-2006Parts forEvolution ®1984-1999Parts forSportster ® & Buell ®1986-2012Parts forVintage Engines1926-1984Parts forX-Wedge®2007-2012Parts forVictory®, Off-road& MetricRacingProducts40302000 2500 3000 3500 4000 4500 5000 5500 6000 6500EngSpd RPMTools & ShopSuppliesS&S® SB100 ENGINE SPECIFICATIONSDisplacement Bore StrokeCylinderLengthCamshaft Piston Type Compression Ratio Fuel Delivery Warranty Period100" 4" 4" 4.420" 600 S&S forged 10.3:1 S&S Super G Carb 1 year parts onlyNOTES:Requires 1991-'03 style primary components and transmission.Primary components, starter charging system, ignition system, and transmission components are not included.Proper installation of S&S® SB100 engines into Buell® motorcycle frames may require exhaust modifications.Dealer Services& Promo ItemsWarranty &Company PolicyOEM Cross ReferenceAppendix & IndexVisit us at www.sscycle.com4-15
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1986-2012 SportsterÂ® & Buell - S&S Cycle

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