SECTION 2: 1999-2006 BIG TWINS - S&S Cycle
SECTION 2: 1999-2006 BIG TWINS - S&S Cycle
SECTION 2: 1999-2006 BIG TWINS - S&S Cycle
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When the Harley-Davidson® Twin Cam 88® and Twin Cam 88B engines were first introduced in<br />
<strong>1999</strong> and 2000, it was apparent that they had a lot of potential for performance improvement. S&S set<br />
about tackling the job of creating products that made them go a lot faster and made them even more<br />
dependable too.<br />
Owners of <strong>1999</strong> - ‘06 Twin Cam 88 equipped big twins should be aware that even though 2007 and later<br />
models have bigger engines from the factory, your 88" motor has the same potential for upgrade. S&S<br />
has been making performance kits for these bikes for over 12 years and we have a lot to offer. Some of<br />
these performance solutions are much less expensive than you might think!<br />
S&S 4 Step Performance Upgrade Program<br />
The S&S 4-Step program is the easiest way to get immediate gratification, and even more performance<br />
as your budget allows.<br />
Step 1 S&S slip-on muffler, Power Tune Duals header, and an S&S Air Cleaner. Now even more<br />
options are available with the new S&S Super Stock® air cleaners (See Page 2-2)<br />
Step 2 S&S bolt-in performance cams and pushrods<br />
Step 3 S&S 95" and 97" bolt-in big bore kit<br />
Step 4 Let S&S CNC port your stock heads!<br />
S&S 95" or 97" Hot Set Up Kit®<br />
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<br />
solution. Hot Set Up Kits contain everything you need in one easy-to-install package of components that<br />
have been tested and proven to work together…every time. A typical Hot Set Up Kit contains S&S Easy<br />
Start gear drive cams and pushrods for outstanding performance. Kits are even available that include CNC<br />
ported stock heads. (See Page 2-18)<br />
124" Hot Set Up Kit<br />
This proven big bore/stroker Hot Set Up Kit is for the rider who wants to go for the gusto! It features 41/8"<br />
bore pistons and cylinders, an S&S 45/8" stroke flywheel assembly, and S&S heads. Also includes S&S<br />
Easy Start .640 gear drive cams, pushrods, and required gaskets and hardware. Cases must be bored to<br />
accommodate bigger cylinders, but it’s worth it! (See Page 2-30)<br />
S&S Complete Engines – The Ultimate Upgrade!<br />
There is no doubt that a complete S&S engine is the best way to get the power and reliability you want.<br />
Replace your entire stock engine with a new S&S power plant. Available in 111 and 124 cubic inch<br />
displacements…S&S quality all the way! (See engines starting on page 2-32)<br />
Note: Not available for <strong>2006</strong> Dyna® models<br />
Performance Guide<br />
STEP 1: INTAKE & EXHAUST 2-2<br />
Air Cleaners 2-2<br />
Headers 2-6<br />
Mufflers 2-7<br />
STEP 2: CAMS & PUSHRODS 2-11<br />
Cams 2-11<br />
Pushrods 2-14<br />
Tuners 2-15<br />
STEP 3: <strong>BIG</strong> BORE KIT 2-16<br />
97" Big Bore Kit 2-16<br />
STEP 4: CNC PORTED HEADS 2-19<br />
Performance Kits<br />
PERFORMANCE KIT OVERVIEW 2-20<br />
<strong>BIG</strong> BORE KITS 2-22<br />
HOT SET UP KITS® 2-24<br />
STROKER KITS 2-27<br />
PERFORMANCE ENGINES 2-32<br />
Performance Parts<br />
CRANKCASES 2-35<br />
FLYWHEELS 2-37<br />
OIL PUMPS 2-38<br />
CAMS 2-39<br />
GEARCOVERS 2-43<br />
CYLINDERS & PISTONS 2-45<br />
CYLINDER HEADS 2-49<br />
TAPPETS 2-53<br />
PUSHRODS 2-54<br />
ROCKER ARMS 2-57<br />
VALVE SPRINGS 2-58<br />
ROCKER COVERS 2-61<br />
FUEL SYSTEMS 2-62<br />
ELECTRONICS 2-72<br />
TRANSMISSION 2-78<br />
CLUTCH 2-79<br />
BELTS 2-80<br />
Replacement Parts 2-81<br />
<strong>SECTION</strong> 2: <strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong>
S e ction 2:<br />
S&S ® Step 1: Intake and Exhaust<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Super Stock ® Stealth Air Cleaner Kits<br />
The Power Of Style!<br />
High performance intake systems have been an important part of the S&S product<br />
line since the early 1960’s. These new S&S Super Stock Stealth air cleaner kits make a<br />
powerful statement about style and performance.<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Features and Benefits<br />
• For the rider who likes to go fast, but doesn’t like to advertise<br />
• Air directional stinger cone in the filter<br />
• Use with your stock Harley-Davidson® Twin Cam 88®, 96, 103 air cleaner cover<br />
– the word "sleeper" comes to mind<br />
• Can also be used with any of several S&S designed covers<br />
• High flow (1" taller) filter kit available<br />
Cut-away showing a stock Twin Cam 88®, 96 or 103 cover on S&S Stealth air cleaner kit.<br />
S&S Super Stock® Air Cleaner KitS<br />
AIR STREAM BOBBER-DISHED BOBBER-DOMED MUSCLE<br />
Application Fuel System STEALTH*<br />
Chrome Finish<br />
Stock CV/EFI, except <strong>1999</strong> Softail® carb 170-0060 170-0056 170-0104 170-0105 170-0106<br />
<strong>1999</strong>-’06 bt<br />
S&S Super E & G Carbs 170-0058 170-0063 170-0110 170-0111 170-0112<br />
*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.<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Dyno Comparison<br />
2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ Airstream Cover vs Stock Air Cleaner<br />
100<br />
90<br />
S&S Super Stock Stealth w/ Airstream Cover<br />
Peak Corrected HP 71.4<br />
Peak Corrected Torque 87.5<br />
Stock Air Cleaner<br />
Peak Corrected HP 68.0<br />
Peak Corrected Torque 86.6<br />
100<br />
90<br />
Dyno Comparison<br />
2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ Bobber Cover vs Stock Air Cleaner<br />
S&S Super Stock Stealth w/ Bobber Cover<br />
Peak Corrected HP 71.7<br />
Peak Corrected Torque 88.1<br />
Stock Air Cleaner<br />
Peak Corrected HP 68.0<br />
Peak Corrected Torque 86.6<br />
80<br />
80<br />
Racing<br />
Products<br />
70<br />
60<br />
70<br />
60<br />
50<br />
40<br />
50<br />
40<br />
Tools & Shop<br />
Supplies<br />
30<br />
20<br />
10<br />
30<br />
20<br />
10<br />
Dealer Services<br />
& Promo Items<br />
1000 2000<br />
3000<br />
4000 5000 6000<br />
EngSpd RPM<br />
1000 2000<br />
3000<br />
4000 5000 6000<br />
EngSpd RPM<br />
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<br />
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<br />
more power add S&S performance mufflers. Both were tuned with Dynojet® Power Vision® Tuner.<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-2<br />
High Flow replacement Air filters<br />
Standard (Filter only) ............... 170-0126<br />
1" Taller Kit* (includes 2 spacers) .... 170-0127<br />
(Filter only). .................. 170-0154<br />
* 1” taller filter kit does not fit Muscle air cleaner kit<br />
Order toll free 866-244-2673<br />
170-0126<br />
Standard high flow air flilter<br />
170-0127<br />
1" taller high flow air filter kit<br />
This built-in stinger cone is featured in all<br />
Super Stock air cleaner kits except the tuned<br />
induction systems.<br />
• Directs air smoothly into the bore of the<br />
carburetor or EFI throttle body<br />
• Reduced turbulence and increased flow<br />
• Featured in S&S teardrop air cleaners<br />
since the early 1970’s
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ® Step 1: Intake and Exhaust<br />
Super Stock ® Stealth Air Cleaner Covers<br />
S&S Air Stream Air Cleaner Cover<br />
• Fits the new S&S Stealth air cleaner kits<br />
• An updated version of the speed inspired S&S teardrop shape<br />
• Screened vent for more air without sucking in rain/road debris<br />
• Steel construction with your choice of chrome or Black Jack (wrinkle black powdercoat)<br />
Air Stream<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Part numbers<br />
Air Stream Air Cleaner Cover<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Chrome ............................................. 170-0118<br />
Black Jack ........................................... 170-0122<br />
S&S Bobber Billet Air Cleaner Covers<br />
170-0118<br />
Bobber Dished<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
• Fits the new S&S Stealth air cleaner kits<br />
• Minimalist air cleaner cover that really delivers the goods!<br />
• Fits over the end of the air filter and leaves the filter element exposed<br />
• Choose from the Dished Bobber or the Domed Bobber covers<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
• CNC machined from billet aluminum in chrome or Black Jack<br />
(wrinkle black powdercoat)<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Part numbers<br />
Bobber Dished Air Cleaner Cover<br />
Chrome ............................................. 170-0119<br />
Black Jack ........................................... 170-0123<br />
170-0119<br />
170-0123<br />
Bobber Domed<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Bobber Domed Air Cleaner Cover<br />
Chrome ............................................. 170-0120<br />
Black Jack ........................................... 170-0124<br />
Racing<br />
Products<br />
S&S muscle Billet Air Cleaner Covers<br />
• Fits the new S&S Stealth air cleaner kits<br />
• Similar to the Bobber covers<br />
• Leaves the entire air filter exposed for a raw hot rod look<br />
• Cover is held on with muscle car style hood pins<br />
• CNC machined from billet aluminum in chrome or Black Jack (wrinkle black powdercoat)<br />
Part numbers<br />
170-0120<br />
170-0124<br />
Muscle<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Muscle Air Cleaner Cover<br />
Chrome ............................................. 170-0121<br />
Black Jack ........................................... 170-0125<br />
Warranty &<br />
Company Policy<br />
170-0121<br />
OEM Cross Reference<br />
Appendix & Index<br />
170-0125<br />
Visit us at www.sscycle.com<br />
2-3
S e ction 2:<br />
S&S ® Step 1: Intake and Exhaust<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
SINGLE BORE TUNED INDUCTION SYSTEM<br />
FEATURES AND BENEFITS<br />
• Bolt-on performance – over twice the filtering area over stock intake system<br />
• Increases horsepower and torque across the rpm range using air column inertia<br />
and carefully timed gas dynamic pressure waves<br />
• Smooth intake tract of carefully selected tuned lengths increases performance<br />
• High flow washable and reusable cotton media provides performance,<br />
protection, and economy<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
S&S SINGLE BORE TUNED INDUCTION SYSTEM KITS<br />
Fitment Fuel Delivery Finish Part No.<br />
S&S Super E/G<br />
Chrome 170-0086<br />
<strong>1999</strong>-'06 big twins<br />
Runner<br />
and<br />
Stock CV & EFI Delphi® Red Filters 170-0087<br />
CTO<br />
Specify Specify 106-5337*<br />
*Use the Configure to Order (CTO) part number to order different finish and filter color.<br />
Not legal for sale or use on CA pollution controlled vehicles.<br />
Billet adaptor brackets make single<br />
bore tuned induction compatible<br />
with many engines and motorcycles.<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Replacement Filters (each sold with clamp)<br />
Red ............................................................17-1020<br />
Blue ...........................................................17-1023<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Renew the color of your air filter with an 8 oz. bottle of S&S Air<br />
Filter Oil. Choice of red or blue oil.<br />
S&S Air Filter Oil, Red .........................106-1163<br />
S&S Air Filter Oil, Blue ........................106-1164<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
Washable nylon air filter covers are water resistant and filter out<br />
large debris, allowing the filter media to stop small dirt particles<br />
from getting into your engine<br />
S&S Nylon Air Filter Cover<br />
each ..................................... 106-0247<br />
2 pack ................................... 106-0248<br />
OEM Cross Reference<br />
Appendix & Index<br />
NOTE: Tuned induction will not fit on motorcycles equipped with fairing lower glove boxes.<br />
2-4<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ® Step 1: Intake and Exhaust<br />
Teardrop AIR Cleaner Kit<br />
FEATURES AND BENEFITS<br />
• Efficient and free flowing intake that can add two to five horsepower<br />
• Uniquely designed back plate has air horn style radiused entryway to<br />
reduce turbulence<br />
• Dimpled cover with directional air cone on inside creates smooth path for air<br />
• Great addition to performance exhaust or cams<br />
KIT CONTENTS<br />
• Filter<br />
• Backing plate<br />
• All mounting hardware<br />
• Instructions<br />
Teardrop Air Cleaner Kits<br />
Model/Engine Stock Carb/EFI: S&S® Super E or G:<br />
2001-'12 Softail EFI, All 2002-Up EFI (Delphi®) 17-0450 –<br />
<strong>1999</strong>-'01 EFI big twin (Magneti Marelli®) 106-4589 –<br />
<strong>1999</strong>-'06 Carbureted 17-0450 17-0403<br />
Not legal for sale or use on CA pollution controlled vehicles.<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Optimize your stock carBuretor<br />
Jet,Kit,CV Carb,<strong>1999</strong>-<strong>2006</strong> bt ......11-5203<br />
Jet,Kit,CV Carb,1995-<strong>2006</strong> bt .......11-5202<br />
11-5203<br />
A respectable gain in both horsepower and<br />
torque can be seen in this graph comparing<br />
a stock big twin to one equipped with an<br />
S&S® air cleaner and SPO® touring mufflers.<br />
S&S ®<br />
SUPER E & G COMPLETE Carburetor KITS<br />
FEATURES AND BENEFITS<br />
• Increased air flow for more power<br />
• Adjustable accelerator pump for quick throttle response and easy starting<br />
• Utilization of the factory dual cable system ensures safe operation<br />
• Direct replacement and high quality fit and finish – less down time and better performance<br />
• Variable position enrichment starting system<br />
KIT CONTENTS<br />
• Super E or G carburetor<br />
• S&S intake manifold<br />
• Teardrop air cleaner kit<br />
• Mounting hardware, gaskets, seals and hoses<br />
• Instructions<br />
Models<br />
S&S Carburetor Kits<br />
Super E<br />
Complete Kit<br />
Super G<br />
Complete Kit<br />
<strong>1999</strong>-'05 big twin 11-0450 11-0451<br />
<strong>2006</strong> big twin 106-0874 106-0875<br />
Models<br />
Super E<br />
(Carb only)<br />
Super G<br />
(Carb only)<br />
All Years & Models 11-0420 11-0421<br />
Optional cruise control adapter kits allows<br />
riders to keep factory cruise feature.<br />
Cruise Control Adapter Kit ..11-2927<br />
NOTES:<br />
S&S® does not recommend polishing or chrome plating Super E & G carbs. Our repair department has seen many<br />
carbs with plugged passages due to polishing compounds, and some carbs that have been destroyed because the<br />
polishing or chrome plating had altered critical machined surfaces.<br />
Recommended for closed circuit use only—S&S Super E & G carbs shown are not approved for use on motor<br />
vehicles operated on California public highways, or in other states where similar pollution laws may apply.<br />
The user shall determine the suitability of the product for his or her use and shall assume all risk and liability in<br />
connection therewith.<br />
Replacement parts for S&S Super E & G carburetors can be found on page 2-96.<br />
Visit us at www.sscycle.com<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-5
S e ction 2:<br />
S&S ® Step 1: Intake and Exhaust<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Power Tune Duals<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Fitment<br />
• Harley-Davidson® touring models<br />
Features and benefits<br />
• Adds 8 horsepower over stock header pipes<br />
• Independent dual look with hidden crossover<br />
• Exclusive design moves the rear cylinder header away from the passenger<br />
to reduce radiated heat<br />
• Full chrome heat shielding with 220º coverage<br />
• Updated styling to give the bike a modern look<br />
• Oxygen sensor bungs*<br />
• Durable16 gauge construction<br />
• Spherical inlet design for improved sealing and exhaust gasket durability<br />
• Hardware included to mount crossover pipe<br />
• Compatible with all slip-on mufflers<br />
• Exhaust port gaskets included<br />
• Made in the U.S.A.<br />
Part numberS<br />
S&S Power Tune Duals, 1995-’08 bt.....................................550-0003<br />
* Has 18mm sensor fittings in the stock locations for 2007-’08 bikes. If not equipped with<br />
oxygen sensors, the ports can be used for tuning. Plugs are included if ports are not used.<br />
WATCH THE S&S POWER TUNE DUAL & SPO MUFFLER<br />
VIDEO AT SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
OEM Cross Reference<br />
Appendix & Index<br />
Warranty &<br />
Company Policy<br />
Dealer Services<br />
& Promo Items<br />
Tools & Shop<br />
Supplies<br />
Racing<br />
Products<br />
2-6<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ® Step 1: Intake and Exhaust<br />
SPO ® touring MUFFLERS<br />
SPO Touring Mufflers have exhaust sound levels that are compliant with<br />
the SAE J2825 exhaust sound test when installed on a stock motorcycle.<br />
Touring mufflers restyled. With their unique oval shape, the restyled S&S SPO<br />
mufflers give your dresser a distinctive custom look, enhanced midrange torque, and a<br />
sound reminiscent of the low rumble of a late 1960’s muscle car. These mufflers feature<br />
sculpted alloy end-caps in your choice of show chrome finish or coated with high-temp<br />
black Xylan®. Double walled construction and show quality chrome virtually eliminate<br />
bluing.<br />
NEW! End caps are now available separately, so you can change up the look of your<br />
SPO mufflers.<br />
Fitment<br />
• Harley-Davidson® touring models with non-catalyst mufflers<br />
(except 2010 Road Glide® Custom and Street Glide® and all Tri Glide® models)<br />
Features and benefits<br />
• Modern styling<br />
• Double walled construction<br />
• Sculpted alloy end-caps with machined-in S&S logo<br />
• Great looking show chrome finish<br />
• Increased performance – works best with S&S air cleaner and/or<br />
camshaft upgrade<br />
• Utilizes factory mounting locations and hardware<br />
• Made in the U.S.A.<br />
•<br />
Options<br />
• Xylan® black alloy end-cap<br />
• Chrome alloy end-cap<br />
550-0001<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Interactive Flipbook<br />
See mufflers installed on a variety of models.<br />
www.sscycle.com/exhaust<br />
Tools & Shop<br />
Supplies<br />
S&S® SPO® Touring Mufflers<br />
Fitment End-cap Style Part Number<br />
1995-’12 H-D® touring<br />
(except 2010 Road Glide & Street Glide<br />
and all Tri Glide models)<br />
WATCH THE S&S POWER TUNE DUAL & SPO MUFFLER<br />
VIDEO AT SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
Xylan® Black 550-0002<br />
Chrome 550-0001<br />
Replacement End Caps<br />
Chrome End Cap (set) ............................... 550-0106<br />
Black End Cap (set) ................................. 550-0107<br />
SEE SPECIAL NOTES: ON PAGE 2-9 FOR DISCLAIMERS<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-7
S e ction 2:<br />
S&S ® Step 1: Intake and Exhaust<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
3-1/2" touring MUFFLERS<br />
Fitment<br />
• 1995-'12 Harley-Davidson® touring models with non-catalyst mufflers<br />
(except 2010 Road Glide® Custom and Street Glide®)<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
106-5979<br />
Black Xylan® Billet End Cap Style<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Features and benefits<br />
• Great looking show chrome finish<br />
• Great sounding rumble<br />
• Increased performance – works best with an S&S air cleaner and/or cam upgrade<br />
• Double layered packing – basalt wool over stainless steel wool<br />
• Fits on stock header pipes – utilizes factory mounting locations and hardware<br />
• Made in the U.S.A.<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Options<br />
LISTEN & COMPARE AT<br />
• Slash-back end<br />
SSCYCLE.COM/AUDIO<br />
• Slash-down end<br />
• Tapered end<br />
• End cap – available chrome plated or black Xylan® coated<br />
• Quiet-Tour or Power-Tour versions available:<br />
• Quiet-Tour – increases performance with a mellow rumble<br />
• Power-Tour –gives you maximum performance with a louder rumble<br />
S&S 31/2"Touring Mufflers<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Style Quiet-Tour Power-Tour<br />
Slash-back 106-5977 106-5982<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Slash-down 106-5976 106-5981<br />
Tapered 106-5978 –<br />
Billet End-cap Black Xylan® 106-5979 106-5983<br />
Billet End-cap Chrome 106-5980 106-5984<br />
Chrome Tapered<br />
Chrome Slash-down<br />
Chrome Slash-back<br />
Racing<br />
Products<br />
Interactive Flipbook<br />
See mufflers installed on a variety of models.<br />
www.sscycle.com/exhaust<br />
Chrome Billet End Cap<br />
Xylan® Billet End Cap<br />
SEE SPECIAL NOTES: ON PAGE 2-9 FOR DISCLAIMERS<br />
OEM Cross Reference<br />
Appendix & Index<br />
Warranty &<br />
Company Policy<br />
Dealer Services<br />
& Promo Items<br />
Tools & Shop<br />
Supplies<br />
2-8<br />
To really wake up this stock 96" 2009 FLHT (bottom curves) we added a set of S&S 551 cams<br />
to the S&S slash-back mufflers and air cleaner kit. S&S performance mufflers will enhance the<br />
results of any performance modifications made to the engine.<br />
Order toll free 866-244-2673<br />
This dyno chart shows the improvement a set of S&S 31/2" slash-back Power-Tour mufflers and<br />
an S&S air cleaner kit (middle curves) and an S&S tuned induction kit (top curves) made on a<br />
stock 96" 2009 FLHT (bottom curves).
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ® Step 1: Intake and Exhaust<br />
80db SPO ® MUFFLERS<br />
EPA and SAE J2825 compliant when used on a stock motorcycle<br />
S&S 80db SPO mufflers are designed to look and sound great, and are EPA compliant!<br />
Great for touring models, these mufflers are sure to leave your hearing intact after a long<br />
day of riding.<br />
FITMENT<br />
• 1995-'12 Harley-Davidson® touring models with non-catalyst mufflers<br />
(except 2010 Road Glide® Custom, Street Glide® and all Tri Glide® models)<br />
FEATURES AND BENEFITS<br />
• More power than stock Harley-Davidson® mufflers throughout the midrange<br />
• Made from stainless steel so they’ll never rust, pit, or corrode<br />
• Highly polished finish looks great on any bike<br />
• Legal replacement for models without catalyst in mufflers (no recalibration required)<br />
KIT CONTENTS<br />
• Installation instructions<br />
• Two mufflers<br />
• Utilizes factory mounting hardware and locations<br />
PART NUMBER<br />
S&S 80db SPO Mufflers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-6634<br />
LISTEN & COMPARE AT<br />
SSCYCLE.COM/AUDIO<br />
55-6634<br />
NOTES:<br />
• Baffles are riveted in place to meet EPA tamper proof requirements.<br />
• Use on any other engine configurations are not covered by this certification.<br />
• Does not meet California or TÜV standards.<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
This EPA compliance statement is a quick way to tell the difference between our 80db<br />
SPO® mufflers and our standard performance SPO mufflers. The other difference is that the<br />
standard version has a replaceable baffle, while the 80db version’s baffle is permanently<br />
riveted in place.<br />
Notice the increase in midrange torque after installing the S&S® 80db SPO® mufflers. This<br />
means more power for passing, climbing hills, and accelerating to highway speed.<br />
SPECIAL NOTES:<br />
• 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.<br />
• Dyno results are from tests performed at the S&S® Research and Development facility in Viola, Wisconsin.<br />
• Emissions Notice: S&S <strong>Cycle</strong>, Inc. exhaust systems and slip-on mufflers are legal for sale and use on U.S. EPA and California pollution controlled motorcycles not originally equipped with<br />
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<br />
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.<br />
Unless otherwise noted additional S&S components shown are restricted to closed course competition use only.<br />
• 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<br />
ordinances before use.<br />
• All reference to Harley-Davidson® part numbers is for identification purposes only. We are in no way implying that any of S&S <strong>Cycle</strong>'s products are original equipment parts or that they<br />
are equivalent to the corresponding H-D part number shown.<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-9
S e ction 2:<br />
S&S ® Step 1: Intake and Exhaust<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
SLIP-ON PERFORMANCE MUFFLERS<br />
FITMENT<br />
• Harley-Davidson® Softail® and Dyna® big twins with non-catalyst mufflers<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
FEATURES AND BENEFITS<br />
• Low restriction, high performance<br />
• Cost effective performance upgrade – best horsepower/dollar ratio<br />
• Maintains a smooth power curve while delivering excellent low and midrange torque<br />
– makes adjustments to the fuel delivery system minimal and straightforward<br />
• Show chrome finish<br />
OPTIONS<br />
• Slash-cut<br />
• Tapered<br />
LISTEN & COMPARE AT<br />
SSCYCLE.COM/AUDIO<br />
Chrome Slash-cut<br />
106-6016 Slash-cut Style<br />
Chrome Tapered<br />
Dyno Comparison<br />
Stock H-D® Twin Cam 88® Engine vs w/S&S Slip-On vs w/S&S Slip-On, 510 Cam, & Super E<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
90<br />
80<br />
Twin Cam 88 w/S&S Exh, 510 Cam, E Carb<br />
Peak Corrected HP 83.7<br />
Peak Corrected Torque 87.8<br />
Twin Cam 88 w/S&S Exhaust<br />
Peak Corrected HP 68.7<br />
Peak Corrected Torque 79.3<br />
Twin Cam 88 Stock<br />
Peak Corrected HP 60.9<br />
Peak Corrected Torque 68.7<br />
70<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
60<br />
50<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
40<br />
30<br />
20<br />
2000 2500 3000 3500 4000 4500 5000 5500 6000<br />
EngSpd RPM<br />
Racing<br />
Products<br />
This dyno chart shows the difference between stock mufflers and S&S® mufflers, and the<br />
difference between S&S slash-cut and S&S tapered mufflers.<br />
Bottom curves: Stock 88" Harley-Davidson® Twin Cam 88® engine with stock exhaust. Middle<br />
curves: Stock 88" Twin Cam 88 engine with S&S® slip-on mufflers on stock header pipes. Top<br />
curves: Stock Twin Cam 88 engine with S&S slip-on mufflers on stock header pipes, S&S Super<br />
E carburetor, and S&S 510 bolt-in cams.<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
S&S Slip-on Performance Mufflers<br />
Application Slash-cut Tapered<br />
1995-'12 Harley-Davidson® Dyna® Models<br />
(except 2008-'12 FatBob® and 2010-'12 Wide Glide®)<br />
106-5769 106-5770<br />
2000-'06 Softail®, Softail Standard, and Heritage Softail® Models - Shorty* 106-5757 106-5763<br />
2000-'06 Softail, Fatboy® and Deuce Models - Shotgun* 106-5762 106-5761<br />
*Not intended for motorcycles originally equipped with a catalyst.<br />
SPECIAL NOTES:<br />
• See page 2-9 for disclaimers.<br />
• All reference to Harley-Davidson® part numbers is for identification purposes only. We are in no way implying that any of S&S <strong>Cycle</strong>'s products are original equipment parts or that they<br />
are equivalent to the corresponding H-D part number shown.<br />
2-10<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ® Step 2: Camshafts and Pushrods<br />
CAMSHAFT OVERVIEW<br />
S&S offers a variety of cam grinds for <strong>1999</strong>-up big twin engines in both chain drive and<br />
gear drive versions. Cams that exceed the limits of the stock valve springs require the use<br />
of special high lift springs. Most S&S cams have higher lift than stock and are designed to<br />
take advantage of the extra flow of ported stock heads or S&S Super Stock® heads. Due<br />
to the high lift of these cams, S&S adjustable pushrods are recommended. Not all grinds<br />
are available in the chain drive version. To get the best performance from a performance<br />
cam installation, a high flow intake and exhaust system is also recommended.<br />
EASY START CAMS<br />
The most innovative S&S product since the electric compression release system, these<br />
cams will revolutionize the starting of late model big twins. Regardless of displacement<br />
or compression ratio, a stock starter and battery will now easily turn over any engine.<br />
These cams also install just as easily as non compression release versions and require no<br />
extra parts or machining! Available in both chain drive and gear drive.<br />
HOW Do Easy Start Cams WORK<br />
The heart of our Easy Start cams is a centrifugally retracted, spring loaded, compression<br />
release lobe milled into the heel of each exhaust lobe. At cranking speeds, the lobe<br />
bumps the exhaust valve open slightly during the compression stroke, making the<br />
engine much easier to turn over. Once the engine fires and reaches 800 RPM, the lobe<br />
swings out of the tappet roller path, allowing the engine to run normally and with full<br />
compression.<br />
Compare S&S Cams To Other Popular Cams<br />
If you have been using cams from another manufacturer and would like to know what<br />
S&S has to offer that is similar, the chart below lists a number of popular cams along<br />
with the S&S cams that work well in similar applications.<br />
Cam Name<br />
Application CROSS REFERENCE CHART<br />
S&S Cam<br />
Name<br />
H-D® Screamin'<br />
Eagle® Cam<br />
Andrews® Cam Most Fitting Application<br />
551 SE-203/255 21H/26H Touring Models<br />
570 – 54H All Big Twin Models<br />
583 SE-203/255 21H/26H Softail®/Dyna® Models<br />
585 SE-211/251/257 31H/32H/50H/55H/67H All Big Twin Models<br />
625 SE-258/260 60H All Big Twin Models<br />
640 SE-264 59H All Big Twin Models<br />
675 – 64H All Big Twin Models<br />
Recommended applications for S&S Cams<br />
475: A bolt-in replacement cam with stock cam timing is designed for riders<br />
with stock engines that want to eliminate the factory chain drive system, but are<br />
not necessarily looking for more power. Does not require tuning. Bolt-in stock.<br />
509: Designed as a bolt-in, high torque cam for <strong>1999</strong>-'06 models. 180 psi cranking<br />
compression, no need for compression releases. For 88 CID engines with stock<br />
compression ratio. Idle-4500 rpm. Bolt-in torque.<br />
510: Designed as a bolt-in cam for 88, 95, and 96 CID engines with compression<br />
ratios below 9.7:1, it is primarily intended for use with stock, un-ported heads. 3000-<br />
5500 rpm. Bolt-in overall.<br />
546: Intended as a replacement part for S&S emissions certified engines, this is a<br />
short duration emissions cam with very little overlap to reduce emissions of unburned<br />
hydrocarbons. Requires high lift springs and normal clearance checks. 1000-4000 rpm<br />
551: Designed for engines with 96 to 106 CID and 9:1 to 9:9 compression this is a<br />
bolt-in cam set designed for stock or mildly modified touring bikes. 551 cams are not<br />
recommended for compression ratios of 10:1 or greater. Greatly improves low-end<br />
and midrange torque, strongest from idle-4000rpm.<br />
570: Designed for 88 to 103 CID engines with compression ratios between 9:1 and<br />
10:1 this cam will provide a nice power increase across the entire power band. 3200-<br />
5700 rpm. Excellent bolt-in for overall power on 103".<br />
583: Optimized for use in the Softail®/Dyna® lines, this cam makes horsepower<br />
and torque that you can feel all the way through the rpm range, making the most<br />
power right where you need it:1500–5000rpm<br />
585: Designed for 88 to 95 CID engines with compression ratios from 9.7:1 to<br />
10.5:1 and 100 to 124 CID engines from 9:1 to 10:1 compression. Provides massive<br />
horsepower and torque increases starting at 3000rpm and holds steady all the way<br />
to redline. 3500-6000 rpm for 88" - 103" engines and 2500-5500 for larger engines.<br />
625: Cam set designed for 95" or larger engines with compression ratios between<br />
10.0 and 10.75:1. 3000-6000 rpm.<br />
640: Used in S&S T124 engines, this cam makes horsepower! Intended for engines<br />
of 95 CID or more w/ compression ratios between 10.5:1 and 11.5:1. 3000-6000 rpm.<br />
675: A high lift monster, this cam set is designed for 120" or larger engines with at<br />
least 11:1 compression ratio. 4500-6500 rpm.<br />
Note: Stock valve springs in <strong>1999</strong>-’04 big twin models can handle cams with valve lifts as high<br />
as .515". Stock valve springs in 2005-up engines can accommodate valve lifts up to .590".<br />
Specifications of S&S® Chain Drive and Gear Drive Camshafts for <strong>1999</strong>-UP Big twin<br />
Valve Timing (open/close)<br />
Intake<br />
Exhaust<br />
Open BTDC/Close ABDC<br />
Open BBDC/Close ATDC<br />
Valve Duration<br />
Centerline<br />
Lift @ TDC<br />
Valve Lift<br />
Intake Exhaust Intake Exhaust Intake Exhaust<br />
475 2˚/34˚ 36˚/4˚ 216˚ 220˚ .475" 106˚ 106˚ .060" .060"<br />
509 18˚/18˚ 46˚/11˚ 216˚ 237˚ .509" 90˚ 107.5˚ .174" .140"<br />
510 20˚/38˚ 52˚/20˚ 238˚ 252˚ .510" 99˚ 106˚ .187" .178"<br />
546 5˚/55˚ 52˚/5˚ 240˚ 237˚ .546" 115˚ 113.5˚ .126" .106"<br />
551** 17°/19° 41°/17° 216° 238° .550" 91˚ 102˚ .178" .170"<br />
570 20˚/40˚ 55 ˚/20˚ 240˚ 255˚ .570" 100˚ 107.5˚ .187" .179"<br />
583 5˚/18˚ 58˚/24˚ 203˚ 262˚ .583" 96.5˚ 107˚ .113" .206"<br />
585 20˚/45˚ 60˚/20˚ 245˚ 260˚ .585" 102.5˚ 110˚ .186" .179"<br />
625 20˚/55˚ 60˚/20˚ 255˚ 260˚ .625" 107.5˚ 110˚ .189" .184"<br />
640 25˚/60˚ 65˚/25˚ 265˚ 270˚ .640" 107.5˚ 110˚ .228" .214"<br />
675 25˚/64˚ 70˚/25˚ 269˚ 275˚ .675" 109.5˚ 112.5˚ .235" .205"<br />
*Note: Although several cam grinds were used in stock engines from <strong>1999</strong>-’06, the timing specs of the 475G cams is most similar to cams used in <strong>1999</strong>-’03 EFI engines.<br />
**551 cams are not recommended with compression ratio of 10:1 or higher.<br />
Visit us at www.sscycle.com<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-11
S e ction 2:<br />
S&S ® Step 2: Camshafts and Pushrods<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
CHAIN DRIVE CAM KITS<br />
FEATURES AND BENEFITS<br />
• Increase performance at an affordable price<br />
• Quick installation – reuse many stock components<br />
• Easy Start Cams allow stock starter<br />
to start any engine<br />
KIT CONTENTS<br />
• Cams<br />
• Gearcover gasket<br />
• Cam bearings<br />
• Thread lock<br />
• Instructions<br />
WATCH THE S&S EASY START CAMS CRANK TEST<br />
VIDEO AT SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
33-5182A<br />
S&S CHAIN DRIVE CAM KITS FOR <strong>1999</strong>-'06 MODELS (except <strong>2006</strong> Dyna®)<br />
Cam Name Standard Cam Kit Easy Start Cam Kit<br />
509 330-0016 –<br />
510 33-5182A –<br />
551 330-0002 106-5293<br />
570 330-0003 106-5296<br />
583 330-0004 106-5289<br />
585 330-0005 106-5299<br />
625 330-0006 106-5302<br />
640 330-0007 106-5305<br />
INSTALLATION KITs for S&S CHAIN DRIVE CAM (recommended)<br />
Models<br />
Standard Cam Kit<br />
<strong>1999</strong>-'06 (except <strong>2006</strong> Dyna® models)* 33-5175<br />
Includes a gearcover gasket, cam bearings and instructions. *<strong>2006</strong> Dyna® cams are in Section 1.<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
583 Cam<br />
Peak Corrected HP 86.6<br />
Peak Corrected Torque 98.5<br />
1500<br />
2000 2500 3000<br />
Dyno Comparison<br />
2009 FLHT with S&S® 551 Touring Cam vs Stock Cam<br />
S&S 551 Touring Cam<br />
Peak Corrected HP 83.7<br />
Peak Corrected Torque 100.4<br />
Dyno Comparison<br />
Fatboy® 583 Cam vs Stock Cam<br />
96 Stock Cam<br />
Peak Corrected HP 74.5<br />
Peak Corrected Torque 88.2<br />
3500 4000 4500 5000 5500 6000<br />
EngSpd RPM<br />
96 Stock Cam<br />
Peak Corrected HP 74.3<br />
Peak Corrected Torque 86.3<br />
Tools & Shop<br />
Supplies<br />
10<br />
1500<br />
2000 2500 3000<br />
3500 4000 4500 5000 5500 6000<br />
EngSpd RPM<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
33-5175<br />
Installation kits are included<br />
with cam kits.<br />
NOTE:<br />
• If 475, 509 or 510C cams are used with the stock chain drive system in Twin Cam 88®<br />
engines, it is recommended to use cylinder heads with stock valve springs or performance<br />
valve springs with no more than 160 lb. of seat force. For more demanding applications,<br />
we recommend the S&S gear drive cams.<br />
• When using <strong>1999</strong>-'06 chain drive cams for lifts over .510", S&S strongly recommends<br />
that the stock chain drive be upgraded to the S&S gear drive or to the H-D® #25284-08 or<br />
#25284-11 hybrid plate. This kit updates the problematic spring loaded chain tensioners<br />
to reliable hydraulic tensioners and also upgrades the oil pump.<br />
• 551 cams are not recommended with compression ratio of 10:1 or higher.<br />
• S&S can do a special order cam. Contact your S&S Customer Service Representative for<br />
more information.<br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
1500<br />
Dyno Comparison<br />
2009 FLHT with S&S® 585 Performance Cam vs Stock Cam<br />
S&S 585 Touring Cam<br />
Peak Corrected HP 91.9<br />
Peak Corrected Torque 94.2<br />
2000 2500 3000<br />
96 Stock Cam<br />
Peak Corrected HP 74.3<br />
Peak Corrected Torque 86.3<br />
3500 4000 4500 5000 5500 6000<br />
EngSpd RPM<br />
2-12<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ® Step 2: Camshafts and Pushrods<br />
GEAR DRIVE CAM KITS<br />
FEATURES AND BENEFITS<br />
• Improves valve timing accuracy by eliminating timing chain lash<br />
• Easy Start Cams allow stock starter to start any engine<br />
• No tensioner shoes to wear out or fail<br />
OPTIONS<br />
Which S&S Gear Drive Cam Kit to Order<br />
• If updating a stock chain drive system, it's easiest to order a complete kit. Includes:<br />
• Camshafts with inner gears<br />
• Outer cam drive gear kit<br />
• Camshaft installation kit<br />
• If replacing cams in an engine already equipped with S&S gear drive cams, order cams<br />
with inner gears and reuse the existing outer gears. Camshaft installation kit for the<br />
appropriate model year is recommended.<br />
• If installing a set of gear drive cams from another manufacturer, order S&S cam gear kits<br />
for the appropriate model year. Each kit provides the inner cam gear as well as an outer<br />
cam gear. Camshaft installation kit for the appropriate model year is recommended.<br />
Cam Name<br />
Complete Kit<br />
S&S GEAR DRIVE CAMS FOR <strong>1999</strong>-'06 MODELS*<br />
Easy Start<br />
Cams w/ Inner Gears<br />
Stock Oil Pump<br />
Complete Kit<br />
Standard<br />
Cams w/ Inner Gears<br />
Stock Oil Pump<br />
475 – – 106-4033 106-4385<br />
509 – – 330-0017 330-0018<br />
510 – – 33-5177 33-5174<br />
546 – – 33-5230 –<br />
551 106-5442 106-5441 330-0100 330-0099<br />
570 106-5243 106-5242 33-5178 33-5166<br />
583 106-5859 106-5858 330-0107 330-0108<br />
585 106-5247 106-5246 33-5179 33-5168<br />
625 106-5251 106-5250 33-5180 33-5170<br />
640 106-4840 106-4839 33-5181 33-5172<br />
675 106-5255 106-5254 33-5231 33-5237<br />
*<strong>2006</strong> Dyna® cams are in Section 1.<br />
INSTALLATION KITS for S&S Gear DRIVE CAM (recommended)<br />
Models<br />
Standard Cam Kit<br />
<strong>1999</strong>-'06 (except <strong>2006</strong> Dyna® models)* 106-5896<br />
Includes a gearcover gasket, cam bearings and instructions. *<strong>2006</strong> Dyna® install kit is in Section 1.<br />
106-5896<br />
Camshaft installation kit for <strong>1999</strong>-'06 models<br />
provides parts needed to install S&S® gear drive<br />
cam sets. Included with complete cam kits.<br />
Gear Drive Easy Start Cams<br />
for early models<br />
WATCH THE S&S EASY START CAMS CRANK TEST<br />
VIDEO AT SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
NOTES:<br />
• Pinion shaft run-out must be checked before installing S&S® gear drive cams.<br />
• A hydraulic press and other professional tools are required to install S&S gear drive<br />
cams. Additionally, material must be removed from the inner surface of the stock<br />
gearcover. The stock crankcase will require clearancing for S&S .625", .640", and<br />
.675" lift cams. S&S recommends that gear drive cams be installed by a professional<br />
mechanic.<br />
• New cam bearings and a new gearcover gasket are required to complete cam<br />
installation. Gear drive cams for <strong>1999</strong>-' 06 models require the use of ball bearing style<br />
cam bearing rather than the stock roller bearing. Roller bearings have more internal<br />
clearance which can cause excessive gear lash and increased noise. The correct parts<br />
are provided in S&S Camshaft Installation Kit, part #106-5896.<br />
• Due to the inherent characteristics of gear drives, you may experience more valve<br />
train noise with gear driven cams. Oversized and undersized gears are available to<br />
help achieve correct gear lash. We have found that with 160 lb. of valve seat force, the<br />
S&S gear drive cams will perform well up to 6200 rpm. If higher rpm is anticipated,<br />
valve springs that provide higher seat force should be used.<br />
• S&S can do a special order cam. Contact your S&S Customer Service Representative<br />
for more information.<br />
Visit us at www.sscycle.com<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-13
S e ction 2:<br />
S&S ® Step 2: Camshafts and Pushrods<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Adjustable PUSHRODS<br />
S&S Quickee Adjustable Pushrods can be both installed and removed easily. The<br />
S&S design permits a simple, trouble-free installation that does not require removal<br />
of the gas tank, rocker assemblies, tappet covers or even the rocker box cover! OEM<br />
pushrods may be cut to permit removal without rocker disassembly. The threaded<br />
adjuster screws into the pushrod until the threads disengage and the adjuster simply<br />
slides into the pushrod, making installation or removal a snap. Once the pushrod is<br />
installed and adjusted, the locknut prevents the adjuster from moving. 1984-'99 style<br />
pushrod covers required.<br />
S&S Standard Adjustable Pushrods are an economical alternative to the S&S<br />
Quickee Adjustable pushrods, but require rocker cover removal to install or remove. To<br />
assure consistent valve train operation under all conditions, S&S adjustable pushrods<br />
are manufactured from rigid chromoly steel tubing.<br />
FITMENT<br />
• <strong>1999</strong>-'12 Twin Cam 88® or 96 w/ stock engine height +/- .050"<br />
FEATURES AND BENEFITS<br />
• Easy to install – removal of rocker box not needed<br />
• Adjustable to accommodate all tappets and<br />
cam base circle diameters and engine heights<br />
• Perfect for S&S HL 2<br />
T<br />
• No threads on wrench flats<br />
• Quickee Adjustable Pushrod Kit includes:<br />
• Pushrods<br />
• Chrome pushrod covers<br />
• O-rings<br />
• Cover keepers<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
When a Quickee Adjustable is collapsed, it can easily be installed or removed from an assembled<br />
engine.<br />
93-5095<br />
Standard Adjustable Pushrod Kit<br />
Tools & Shop<br />
Supplies<br />
PART NUMBERS<br />
Quickee Adjustable Pushrod Kit .......................... 106-6051<br />
S&S Standard Adjustable Pushrod Kit .......................93-5095<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
Replacement parts on page 2-56<br />
WATCH THE PUSHROD INSTALLATION VIDEO AT<br />
SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
106-6051<br />
Quickee Adjustable Pushrod Kit<br />
OEM Cross Reference<br />
Appendix & Index<br />
EXTRA PARTS NEEDED:<br />
• Longer keepers are required for taller than stock engines. See page 2-50.<br />
2-14<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ® Step 2: Camshafts and Pushrods<br />
Dynojet ® Power vision ® tuner<br />
Power Vision is a performance tuner and data monitor that offers the latest<br />
flash tuning technology, data logging, and other industry exclusive<br />
features. Developed to tune any Harley-Davidson® motorcycle<br />
with the Delphi ECM, the Power Vision Product Suite includes<br />
a full color touch screen flash device, vehicle interface cable, and<br />
WinPV (Windows PC based tuning application).<br />
Fitment<br />
• 2001-’12 Harley-Davidson® models equipped with Delphi® ECM<br />
Features and Benefits<br />
• Flash tune all H-D® models equipped with a Delphi ECM<br />
• Does NOT require the user to interface with a computer in order to flash a tune.<br />
Change rev limit, idle speed, and other parameters directly from the device<br />
• Display all H-D vehicle data as well as wide band AFR** and various calculated<br />
channels (such as Avg MPG)<br />
• Customizable virtual gauges allow data to be monitored live, and / or logged<br />
while riding<br />
• User defined visual alarms for any data channel<br />
• AutoTune Basic and Pro – calculates and stores fuel trims to help you optimize<br />
fuel curve utilizing the factory o2 sensors (Basic), or Dynojet’s Wide Band 2<br />
System (Pro)!<br />
• Check and clear diagnostic codes<br />
• Reset adaptive fuel trims and idle offset (with bike running)<br />
WinPV Software Features<br />
• Allows you to import Power Commander Maps<br />
• Tuning parameters laid out in a clear, concise manner utilizing a "tree view structure"<br />
• A viewing mode for every type of user, beginners or professionals<br />
• Individual tuning parameters are able to be saved as "value files". The value files can<br />
then be applied to other calibrations<br />
• Compare, restore, and undo features<br />
• Various math functions can be performed on any value<br />
• Synchronized editing of front and rear VE and / or Spark tables<br />
• Helpful tuning parameter descriptions<br />
• Automatic update client ensures you have the latest tuning application, firmware,<br />
and tune file database<br />
**when outfitted with a Dynojet Auto Tuner<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
The Power Vision Suite includes a highly flexible tuning / data logging device, as well<br />
as a productive tuning application (WinPV) that’s user friendly compared to other<br />
products on the market.<br />
Part Number<br />
Dynojet Power Vision Tuner<br />
2001-'12 H-D® models (except 2011 -'12 Softail® & 2012 Dyna®) MFR PIN PV-1 ..... 550-0087<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
S&S ® Step 2: Camshafts and Pushrods<br />
Dynojet ® Auto Tune<br />
for power Vision ®<br />
Want to get the most from your Power Vision Then upgrade with the Auto Tune Module<br />
kit. Exclusive to Power Vision, this exciting new accessory works in conjunction with your<br />
Power Vision to open the lines of communication simply not available through the narrow<br />
OEM band.<br />
FITMENT<br />
• 2001-’12 Harley-Davidson® models equipped with Delphi® ECM<br />
FEATURES & BENEFITS<br />
• Transmits wide band Air-Fuel Ratios (AFR) to Power Vision Data Recorder<br />
• Not an automatic tuning system. Requires Log Tuner software (free download) and<br />
user interaction. Process corrects fuel and spark requirements<br />
• Utilizes factory Ion Sense to precisely tune spark advance<br />
• Combine with Log Tuner software to tune like the pros<br />
• Kit includes Y-adapters for simultaneously interface with Power Vision and Auto Tuner<br />
module and oxygen sensors to provide more accurate tuning at all operating ranges<br />
PART NUMBERS<br />
Dynojet AutoTuner<br />
2001-'12 H-D® models (except 2011 -'12 Softail®, and 2012 Dyna®). ............550-0109<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-15
S e ction 2:<br />
S&S ® Step 3: Big Bore KIt<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
97" <strong>BIG</strong> BORE KITS<br />
FITMENT<br />
• <strong>1999</strong>-'06 big twins<br />
FEATURES AND BENEFITS<br />
• Largest bore that we feel can safely be used in a cylinder with a stock spigot O.D.<br />
• Bolt-on 9 to 10 cubic inches – cylinders do not require crankcase machining to install<br />
• Piston weight for 97" kits are the same as stock, requiring no flywheel rebalancing<br />
• Forged coated pistons are compatible with stock or S&S Super Stock® 79cc & 89cc heads<br />
• Valve pocket recessed in S&S pistons are enlarged for oversize valves and higher lift cams<br />
• Silver or wrinkle black powdercoat cylinder finish color matches stock Harley-Davidson® finish<br />
• Maintains stock engine height<br />
• Oversize pistons are available<br />
KIT CONTENTS<br />
• Piston set with rings<br />
• Top end gasket kit<br />
• S&S cylinders<br />
• Instructions<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
OEM Cross Reference<br />
Appendix & Index<br />
Warranty &<br />
Company Policy<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
S&S® 97" <strong>BIG</strong> BORE KITS<br />
Specifications Compression Ratio Part No.<br />
Year Displacement Stroke Bore Cylinder Length Piston Type<br />
<strong>1999</strong> - '06 97" 4" 3.927" 4.937"<br />
Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or honing.<br />
Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />
Forged<br />
3 cc Dome<br />
85cc Stock<br />
Heads<br />
79cc S&S Heads<br />
89cc S&S Heads<br />
Silver<br />
Powdercoat<br />
Wrinkle Black<br />
Powdercoat<br />
9.7:1 10.3:1 9.4:1 106-5974 106-5975<br />
2-16<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
This dyno chart shows performance of a <strong>2006</strong> FLHR using stock heads with the S&S 97” Big Bore Kit, S&S performance mufflers and either an S&S<br />
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!<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
NOTES:<br />
• S&S® highly recommends installing a performance cam for easier starting and better engine performance.<br />
• S&S high flow cylinder heads will provide further horsepower gains.<br />
• For an additional .2 bump in compression, order .030" thick head gaskets #900-0216 (2 pack). Remember to check your<br />
clearances.<br />
• These kits require tuning. When used on EFI models, S&S recommends Dynojet® Power Vision flash tuner, for more information,<br />
see page 2-15.<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-17
S e ction 2:<br />
S&S ® Step 4: CNC Ported heads<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
CNC Ported Cylinder Head sERVICES<br />
S&S® offers a CNC porting service for stock cylinder heads for <strong>1999</strong>-’12 Harley-Davidson®<br />
big twin engines. This is an economical way to get a substantial horsepower increase<br />
while maintaining a stock appearance.<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
S&S has developed high flowing intake port, exhaust port, and combustion chamber<br />
shapes for stock cylinder heads. S&S then digitally reproduces them in a stock head<br />
casting with our 5-axis CNC machining centers. After CNC porting, heads are assembled<br />
with new one-piece, forged racing grade stainless steel alloy, valves, valve guides and<br />
high performance conical valve springs.<br />
Fitment<br />
• Available for <strong>1999</strong>-’12 big twin engines<br />
• Ideal for 88" - 124" engines (must use Screamin’ Eagle® high flow injectors, HD<br />
#27796-08, with kits over 106")<br />
Features and benefits<br />
• CNC machined ports for a consistent performance increase from stock heads<br />
• Great throttle response, high velocity port without losing low RPM torque<br />
• Assembled with performance valves and springs ready to bolt-on<br />
• Choice of .585" or .650" lift valve springs<br />
• Combustion chambers are available in the following volumes:<br />
• 83cc-Generally used for stock 88" up to 106" engine displacements<br />
• 85cc- Same as stock Twin Cam 88" and 96" engine displacements<br />
• 89cc- Recommended for up to 117" engine displacements<br />
• 90cc- Generally used for 124" and up engine displacements<br />
• Available in factory black or silver<br />
Service options<br />
• Exchange Service<br />
• CNC ported heads are available for immediate delivery, core charge per set<br />
must be paid<br />
• Send your stock heads to S&S<br />
• Core charge credited if customer's returned heads pass inspection (see notes<br />
on next page)<br />
• No turn-around delay<br />
• Rework Service<br />
• Send your stock heads to S&S<br />
• Get the same set of heads back with CNC machined ports<br />
• The best option for heads with a special cosmetic treatment<br />
• Allow 2 week turn-around<br />
• Custom CNC Port Duplication<br />
• S&S can digitize your port design and machine it in your heads, ask an S&S<br />
customer service representative for details<br />
Part Number<br />
S&S CNC Porting Service for Stock Heads ............................. 106-5880<br />
WATCH THE S&S CNC PORTING VIDEOS AT<br />
SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
Shown is the S&S CNC machined intake port before the valve guide is installed. Notice the<br />
raised vane ahead of the valve guide hole. The purpose of this vane is to split the air stream<br />
ahead of the valve guide to reduce turbulence and increase flow.<br />
Digitized port shapes are faithfully reproduced in any stock Harley-Davidson® cylinder<br />
head on our 5-axis CNC machining center. Intake port, exhaust port and combustion<br />
chamber are all modified. This head will be assembled with new forged stainless steel<br />
valves and high lift valve springs to complete the package.<br />
Stock<br />
Harley-Davidson®<br />
CNC Ported<br />
by S&S®<br />
Valve Size<br />
Intake 1.805" 1.900"<br />
Exhaust 1.575" 1.610"<br />
Max Valve Lift .585" .650"<br />
Max TDC Lift<br />
Intake – .230"<br />
Exhaust – .215"<br />
Port Flow*<br />
Intake 216.2 cfm 248.6 cfm<br />
Exhaust 191.8 cfm 209.7 cfm<br />
88" 9.0:1 9.2:1<br />
95" 9.2:1 9.4:1<br />
Compression<br />
97" 9.7:1 9.9:1<br />
Ratio<br />
103" 10.1:1 10.3:1<br />
106" Stroker 10.1:1 10.3:1<br />
124" DD Piston 10.7:1 10.9:1<br />
Chamber Volume 85cc 83cc**<br />
*Flow testing performed on a SuperFlow® 1020 flow bench at 28" of water test pressure at .600"<br />
lift. Heads tested are <strong>2006</strong>-up style.<br />
** As a general rule of thumb, for every 1cc decrease in chamber volume equals a .1 increase in<br />
compression ratio.<br />
2-18<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Continued<br />
CNC Ported Cylinder Heads from S&S®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
The CNC Difference: The dyno chart compares a stock 2009 FLHT (black curves) with the same<br />
bike after an S&S 106" Big Bore Top End Kit, 585 cams and S&S slip on mufflers, and an S&S<br />
teardrop AC were installed. The top curves show the same engine after the heads were CNC ported<br />
and a 58mm throttle body was installed. Both 106" engines perform much better than stock, and<br />
are pretty comparable to each other until about 3500 rpm. At that point, the engine with CNC<br />
heads continues to increase in torque and horsepower because it can still get enough air.<br />
Dyno Comparison<br />
Stock 2009 FLHT vs S&S 106” Kit, Slip-On’s, Intake, CNC Porting. With 551 & 585 Cams<br />
S&S 106”, Slip-On’s, 585 Cams, CNC, & SE 58<br />
Peak Rear Wheel HP 115.2<br />
Peak Rear Wheel Torque 112.0<br />
130<br />
120<br />
110<br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
1000 2000 3000<br />
S&S 106”, Slip-On’s,551 Cams CNC, S&S AC<br />
Peak Rear Wheel HP 96.9<br />
Peak Rear Wheel Torque 113.4<br />
Stock 2009 FLHT<br />
Peak Rear Wheel HP 68.6<br />
Peak Rear Wheel Torque 84.7<br />
4000 5000 6000<br />
7000<br />
EngSpd RPM<br />
Choose The Right Cam For You: This dyno chart compares a stock 96" 2009 FLHT on the<br />
same bike with an S&S 106" Big Bore Top End Kit with CNC ported heads, S&S slip-on mufflers,<br />
performance intake, and two different cams. The blue curves represent the 106 with S&S 551<br />
touring cams and S&S teardrop air cleaner on the stock 50mm throttle body. Great torque for<br />
performance touring applications. The top curves show the S&S 585 cams with a 58mm throttle<br />
body. The increased duration of the 585 reduces low and midrange torque, but the combination of<br />
more aggressive valve timing, higher lift and a larger throttle body significantly increases usable<br />
rpm and top end horsepower. A good choice for lighter bikes and racing applications. Both engines<br />
were tuned with Screamin' Eagle® Race Tuner.<br />
Notes:<br />
• Only cylinder heads that are in good condition and have "like new" appearance may<br />
be exchanged. Heads with non-OEM compression release machining, superficial<br />
damage, peeling or discolored paint, or other cosmetic alterations are not acceptable<br />
for exchange, but may be reworked. Rework will take slightly longer than exchange<br />
service. Customer will be contacted to review options if heads do not pass inspection.<br />
• CNC porting is not available for previously ported heads, heads that have been<br />
structurally damaged, or heads that are determined to be unserviceable during initial<br />
inspection. These heads will be returned to the customer without modification. In<br />
these cases, the customer will be notified and options will be reviewed. New, CNC<br />
ported stock heads or S&S heads are available for purchase.<br />
• Due to variations in stock cylinder head castings, all inside surfaces of the ports may<br />
not "clean up" during machining. As a result, the inside of one or more ports may<br />
not appear to be completely machined. This does not effect performance and is not<br />
considered a defect.<br />
• CNC porting is not currently available for Harley-Davidson® CVO engines or Screamin'<br />
Eagle® cylinder heads.<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-19
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PERFORMANCE<br />
KITS<br />
Performance Kit overview<br />
For harley-Davidson ® Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
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.<br />
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<br />
and specifications are listed to help you understand the performance package that is best for your journey.<br />
97" Big Bore Kit<br />
Up the displacement of your Twin Cam® 88 to a whopping 97". This bolt-on cylinder kit adds significant displacement<br />
without any machining required to your engine. Stroke stays the same at 4.00". Bore increases from 3.750 to 3.927". This kit<br />
contains pistons, cylinders and all related parts, gaskets and instructions. See page 2-22<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
106-5974<br />
95"/97" Hot Set Up Kit<br />
Looking to go further Consider the Hot Set Up Kits. Available in 95" or 97" displacements, these kits will put some stride in<br />
your glide. Your stock cylinders can be bored for 95" pistons or select 97" pistons and cylinders already sized. Pushrods, covers<br />
and hydraulic lifters are all included. Select from a variety of cylinder heads to achieve the compression ratio you desire or keep<br />
your stock heads. Kits include S&S Easy Start 570 or 585 chain drive camshafts. See page 2-24<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
106-0214<br />
106" Stroker Kit<br />
Stroke it! This performance package gives big displacement. The kit’s flywheel assembly increases your stroke from 4 3/8"<br />
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<br />
needed. Maintains stock engine height for easy installation. See page 2-27<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
32-2490<br />
106" Stroker Hot Set Up Kit<br />
Move beyond the Stroker Kit to the Stroker Hot Set Up Kit! Select the compression ratio you desire from a choice of cylinder<br />
heads. Kits come with S&S Easy Start chain drive cams or select the camshaft the best fits your riding style. Pushrods, covers,<br />
hydraulic lifters and gaskets are included. Realize up to a 50% horsepower increase! See page 2-28<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-20<br />
320-0015<br />
900-0220<br />
Order toll free 866-244-2673<br />
124" Hot Set- Up Kit<br />
Move to the ultimate in performance packages! Increase your bore to 41/8" and stroke to 45/8" to realize a massive 124<br />
cubic inches of pure performance. This kit includes flywheel assembly, cylinders and pistons, S&S Easy Start 640 lift chain<br />
drive camshafts, hydraulic lifters, pushrods, covers, valve springs and rocker arms. Comes complete with all gaskets and<br />
instructions. CTO options give you even more choices. Crankcases require boring to accept the larger cylinder spigots.<br />
See page 2-30
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Continued<br />
S&S Performance Kit Overview<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
KITS<br />
KIT DESCRIPTION BORE STROKE<br />
Performance kit specifications for Harley-Davidson® Twin Cam 88®<br />
Stock<br />
Heads<br />
79cc 89cc 91cc<br />
COMPRESSION RATIO<br />
CNC Heads<br />
83cc 85cc 87cc 90cc<br />
CAMSHAFT<br />
HORSEPOWER<br />
(CNC Heads)<br />
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<br />
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<br />
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<br />
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<br />
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<br />
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<br />
* Not Recommended<br />
KIT DESCRIPTION<br />
Performance kit contents, options and requirements for Harley-Davidson® twin Cam 88®<br />
Flywheels<br />
Cylinders<br />
Pistons<br />
w/ rings<br />
Rocker<br />
Arms<br />
PACKAGE CONTENTS<br />
Pushrods<br />
w/ covers<br />
Lifters<br />
Camshafts<br />
Valve<br />
Springs<br />
Heads w/<br />
springs<br />
MACHINING<br />
REQUIRED<br />
CTO<br />
OPTIONS<br />
97" Big Bore Kit • • • •<br />
95" Hot Set Up Kit • • • • •<br />
97" Hot Set Up Kit • • • • • • •<br />
106" Stroker Kit • •<br />
106" Stroker Hot Set Up Kit • • • • • •<br />
124" Hot Set Up Kit • • • • • • • • •<br />
= Optional<br />
= Order separately<br />
= Bore & hone cylinders<br />
= Crankcase machining for center stud<br />
= Crankcase machining for cylinder spigots<br />
= Camshaft selection<br />
Gaskets<br />
= CNC heads<br />
= Combustion chamber size selection<br />
= Cylinder & piston set available<br />
*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.<br />
TORQUE<br />
REJETTING OR<br />
CALIBRATION<br />
CHANGE<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-21
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
97" <strong>BIG</strong> BORE KITS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
PERFORMANCE<br />
KITS<br />
FITMENT<br />
• <strong>1999</strong>-'06 big twins<br />
FEATURES AND BENEFITS<br />
• Largest bore that we feel can safely be used in a cylinder with a stock spigot O.D.<br />
• Bolt-on 9 to 10 cubic inches – cylinders do not require crankcase machining to install<br />
• Piston weight for 97" & 106" kits are the same as stock, requiring no flywheel rebalancing<br />
• Forged coated pistons are compatible with stock or S&S Super Stock® 79cc & 89cc heads<br />
• Valve pocket recessed in S&S pistons are enlarged for oversize valves and higher lift cams<br />
• Silver or wrinkle black powdercoat cylinder finish color matches stock Harley-Davidson® finish<br />
• Maintains stock engine height<br />
• Oversize pistons are available<br />
KIT CONTENTS<br />
• Piston set with rings<br />
• Top end gasket kit<br />
• S&S cylinders<br />
• Instructions<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
S&S® 97" <strong>BIG</strong> BORE KITS<br />
Specifications Compression Ratio Part No.<br />
Year Displacement Stroke Bore Cylinder Length Piston Type<br />
<strong>1999</strong> - '06 97" 4" 3.927" 4.937"<br />
Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or honing.<br />
Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />
Forged<br />
3 cc Dome<br />
85cc Stock<br />
Heads<br />
79cc S&S Heads<br />
89cc S&S Heads<br />
Silver<br />
Powdercoat<br />
Wrinkle Black<br />
Powdercoat<br />
9.7:1 10.3:1 9.4:1 106-5974 106-5975<br />
OEM Cross Reference<br />
Appendix & Index<br />
Warranty &<br />
Company Policy<br />
Dealer Services<br />
& Promo Items<br />
2-22<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
KITS<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
This dyno chart shows performance of a <strong>2006</strong> FLHR using stock heads with the S&S 97” Big Bore Kit, S&S performance mufflers and<br />
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<br />
increased to 18.4 ft/lb!<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
NOTES:<br />
• S&S® highly recommends installing a performance cam for easier starting and better engine performance.<br />
• S&S high flow cylinder heads will provide further horsepower gains.<br />
• For an additional .2 bump in compression, order .030" thick head gaskets #900-0216 (2 pack). Remember to check your clearances.<br />
• These kits require tuning. When used on EFI models, S&S recommends Dynojet® Power Vision flash tuner, for more information, see page 2-15.<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-23
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
PERFORMANCE<br />
KITS<br />
95" & 97" HOT SET UP KIT ®<br />
FITMENT<br />
• <strong>1999</strong>-'06 big twins<br />
FEATURES AND BENEFITS<br />
• For 95" kits, stock cylinders can be bored to 3 7/8", honed and reused<br />
• .045" MLS head gaskets standard<br />
• Up to a 40 HP increase<br />
• True bolt on kit, no machining required<br />
• Maintains stock engine height<br />
• Wrinkle black or silver powdercoat match stock appearance<br />
• Kits include S&S 570 or 585 Easy Start chain drive cams – depending on resultant<br />
compression ratio<br />
• S&S pushrods are made of high strength chrome-moly tubing<br />
• Valve pocket recesses in S&S pistons are enlarged for oversize valves and high lift cams<br />
Dyno Comparison<br />
Stock Harley-Davidson® Twin Cam 88® vs S&S® 95” Super Stock® Hot Set Up Kit®<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Now with<br />
Easy Start<br />
Cams!<br />
900-0243<br />
This 97" Hot Set Up Kit includes chain drive easy start<br />
camshaft kit, cylinder kit, hydraulic tappet set, gasket kit,<br />
cylinder head kit with head bolts, and adjustable pushrod kit.<br />
Dyno Comparison<br />
Harley-Davidson® Twin Cam 88® with 97” Hot Set Up Kit® 79cc Heads vs 83cc CNC Heads<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
110<br />
100<br />
90<br />
S&S 95” Super Stock Hot Set Up Kit<br />
Peak Corrected HP 100.2<br />
Peak Corrected Torque 99.5<br />
Stock Twin Cam 88 Engine<br />
Peak Corrected HP 62.7<br />
Peak Corrected Torque 74.7<br />
120<br />
100<br />
90<br />
80<br />
S&S 97” Hot Set Up Kit w/ 83cc CNC Heads<br />
Peak Corrected HP 108.3<br />
Peak Corrected Torque 102.6<br />
S&S 97” Hot Set Up Kit w/ 79cc Heads<br />
Peak Corrected HP 108.9<br />
Peak Corrected Torque 102.7<br />
Racing<br />
Products<br />
80<br />
70<br />
70<br />
60<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
60<br />
50<br />
40<br />
30<br />
Lower curves show completely stock <strong>1999</strong> FXDL. Middle and upper curves represent <strong>1999</strong><br />
FXDL with Screamin’ Eagle® 6200 rpm ignition module, and S&S performance mufflers and<br />
95" Hot Set Up Kit® (Super E carburetor, 570G cams, high performance tappets, .640" triple<br />
valve springs, adjustable pushrods), stock heads (middle) or Super Stock® heads (upper).<br />
Year<br />
2500 3000 3500<br />
Displacement<br />
4000 4500 5000 5500 6000<br />
EngSpd RPM<br />
Stock<br />
Stroke<br />
Bore<br />
Cylinder<br />
Length<br />
S&S® 95" & 97" HOT SET UP KIT® SPECIFICATIONS<br />
Piston Type<br />
85cc Stock<br />
Heads<br />
89cc S&S Heads<br />
Compression Ratio<br />
79cc S&S Heads<br />
83cc CNC Ported Stock<br />
Heads<br />
<strong>1999</strong> - '06 95"<br />
37/8"<br />
Forged, 5.3cc pop-up dome 9.7:1 9.4:1 10.4:1 9.9:1<br />
<strong>1999</strong>-'06,<br />
4"<br />
4.937"<br />
97" 3.927" Forged, 3cc domed 9.7:1 9.3:1 10.3:1 9.8:1<br />
(except Dyna®)<br />
Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or honing.<br />
50<br />
40<br />
30<br />
20<br />
2000 2500 3000<br />
3500 4000 4500 5000 5500 6000 6500 7000<br />
EngSpd RPM<br />
2000 carbureted Dyna / S&S Teardrop / E series 2-1 exhaust / S&S IST ignition / 585 Easy<br />
Start cams<br />
2-24<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
CONTINUED -<br />
S&S® 95" & 97" Hot Set Up Kit®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
S&S® 95" Super Stock® Hot Set Up Kits® for 88" Engines<br />
Includes S&S 37⁄8" bore cylinders and pistons, 585 Easy Start chain drive cams and 79cc heads<br />
Application Silver Black<br />
PERFORMANCE<br />
KITS<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
S&S® 95" Hot Set Up Kits®<br />
900-0418<br />
106-0214<br />
These kits require special S&S pistons.<br />
Order the required piston oversize from these charts.<br />
92-1200<br />
Pistons work with 4" stroke flywheels in<br />
88" engines to produce 95 cubic inches<br />
<strong>1999</strong>-’06 (except <strong>2006</strong> Dyna® Models*) 900-0418 900-0419<br />
CTO<br />
*Kits for <strong>2006</strong> Harley-Davidson® Dyna models, use CTO part number.<br />
106-5744<br />
S&S® 95" Super Stock® Hot Set Up Kits® for 88" Engines<br />
Includes S&S 37⁄8" bore cylinders and pistons, 585 gear drive cams and 79cc heads<br />
Application Silver Black<br />
<strong>1999</strong>-’06 (except <strong>2006</strong> Dyna® Models*) 106-5744 106-0214<br />
CTO<br />
*Kits for <strong>2006</strong> Harley-Davidson® Dyna models, use CTO part number.<br />
106-5744<br />
92-1200 Series Pistons for S&S® 95" Hot Set Up Kit®<br />
Oversize<br />
Part No.<br />
Standard 92-1200<br />
+.005 92-1204<br />
+.010 92-1201<br />
+.020 92-1202<br />
Cylinder & Piston Kit - Silver 106-4138<br />
Cylinder & Piston Kit - Black 91-7047<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
NOTES:<br />
• 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<br />
the Dynojet Power Vision Flash Tuner, see page 2-15 for more information.<br />
• Stock cylinders must either be bored to 37/8" or replaced with S&S® 37/8" bore cylinders.<br />
• 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<br />
less power. S&S can CNC port your heads, for an economical increase in power.<br />
• For 95" kits ordered without cylinders, pistons must be measured and cylinders bored/honed accordingly. Recommended piston fitment:<br />
• Close: 0.0020" – 0.0025"<br />
• Loose: 0.0032" – 0.0045"<br />
• 92-1200 series pistons have a 1.270" deck height.<br />
• .030" MLS head gaskets optional: Part #900-0216<br />
• Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />
S&S can provide quality, professional machine shop and engine building service through our remanufacturing program. We can handle any job from fitting a set of pistons in your<br />
cylinders, to complete installation of any engine kit. Contact your S&S customer service representative for details.<br />
S&S® 97" Hot Set Up Kits® on next page<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-25
S e ction 2:<br />
CONTINUED -<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
S&S® 95" & 97" Hot Set Up Kit®<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
KITS<br />
S&S® 97" Hot Set Up Kits® With 79cc Super Stock® Heads, cylinders & Pistons<br />
Model Year Cam Compression<br />
Ratio<br />
Piston<br />
Type<br />
Valve<br />
Springs<br />
Wrinkle Black<br />
Part No.<br />
Silver<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
<strong>1999</strong>-<strong>2006</strong> bt<br />
(except <strong>2006</strong> Dyna®)*<br />
CTO<br />
585CE 10.3:1 106-3680 585” 900-0243 900-0244<br />
106-5744<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
S&S® 97" Hot Set Up Kits®<br />
900-0243<br />
900-0245<br />
*Kits for <strong>2006</strong> Harley-Davidson® Dyna models, use CTO part number.<br />
Model Year<br />
<strong>1999</strong>-<strong>2006</strong> bt<br />
(except <strong>2006</strong> Dyna®)*<br />
CTO<br />
S&S® 97" Hot Set Up Kits® With 83cc CNC Ported Heads, cylinders & Pistons<br />
Cam<br />
Compression<br />
Ratio<br />
Piston<br />
Type<br />
Valve<br />
Springs<br />
Wrinkle Black<br />
Part No.<br />
Silver<br />
570CE 9.8:1 106-3680 585” 900-0245 900-0246<br />
*Kits for <strong>2006</strong> Harley-Davidson® Dyna models, use CTO part number.<br />
106-5744<br />
S&S® 97" Hot Set Up Kits® With cylinders & Pistons Without Heads<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
900-0247<br />
Model Year<br />
<strong>1999</strong>-<strong>2006</strong> bt<br />
(except <strong>2006</strong> Dyna®)*<br />
CTO<br />
Cam<br />
Compression Ratio<br />
with 85cc Stock Heads<br />
Piston<br />
Type<br />
570CE 9.7:1 106-3680<br />
Valve<br />
Springs<br />
Purchase<br />
Seperately<br />
Wrinkle Black<br />
Part No.<br />
Silver<br />
900-0247 900-0248<br />
106-5744<br />
S&S .585" lift dual valve spring kit must be used with stock heads. See page 2-58.<br />
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<br />
to have S&S CNC port your heads. See page 2-18 for more details.<br />
*Kits for <strong>2006</strong> Harley-Davidson® Dyna models, use CTO part number.<br />
NOTES:<br />
• 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<br />
significantly less power.<br />
• S&S Easy Start Cams can save you money – no need to buy compression releases or S&S rocker covers. Note when using <strong>1999</strong>-'06 chain drive cams: For lifts over .510", S&S<br />
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<br />
loaded chain tensioners to more reliable hydraulic tensioners and also upgrades the oil pump.<br />
• S&S can CNC port your heads, for an economical increase in power.<br />
• .030" MLS head gaskets optional: Part #900-0216<br />
• Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />
• Fuel injection tuning required. S&S offers fuel injection tuning solutions starting on page2-15.<br />
2-26<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
106" Stroker Kits<br />
for use with stock cylinders<br />
This kit combines an S&S 4½" stroke flywheel assembly with S&S 37⁄8" bore pistons for a<br />
displacement of 106 cubic inches.<br />
FITMENT<br />
• <strong>1999</strong>-'06 big twins<br />
PERFORMANCE<br />
KITS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
FEATURES AND BENEFITS<br />
• Installation of the kit does not require any special machining, other than fitting the<br />
pistons<br />
• S&S stroker pistons, which are sold separately, are available in all standard oversizes<br />
• Stock 88" cylinders can be bored from 3¾" bore to 37⁄8" to accommodate the S&S<br />
pistons, or a pre-fit S&S cylinder and piston kit may be installed<br />
• Engines with factory 95" kits require piston fitting only – stock or S&S cylinder<br />
heads can be used<br />
• Fuel injected engines will require recalibration of the fuel injection system – the S&S<br />
VFI modules and closed loop sensor kits are highly recommended<br />
• Maintains stock engine height<br />
To achieve the full potential of this engine configuration, we suggest that you<br />
consider the 106" Hot Set Up Kit® found on page 2-28.<br />
32-2490<br />
S&S® Stock Bore Stroker Kit shown here is only available with assembled<br />
flywheels. Pistons must be purchased separately, see below. Kit includes<br />
special S&S piston oiling jets. For Dyno chart see page 2-28..<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Specification Chart<br />
S&S® 106" Stock Bore Stroker Kits For Harley-Davidson® Twin Cam 88® and Twin Cam 88B Engines<br />
Displacement Stroke Bore Compression Ratio* Piston Type Piston Deck Height Cylinder Length Application Engine Life<br />
106" 41⁄2" 37⁄8" 10.1:1 Flat Top 1.020" 4.937" Trips Very Good<br />
* 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<br />
Includes S&S piston oiling jets<br />
S&S® 106" Stroker Kits<br />
For Harley-Davidson® Twin Cam 88® Engines with stock cylinders<br />
Application<br />
Part No.<br />
<strong>1999</strong>-’06 Twin Cam 88 Except <strong>2006</strong> Dyna® 32-2490<br />
2000-’06 Twin Cam 88B 32-2491<br />
<strong>2006</strong> Dyna® 106-2189<br />
Custom Flywheels - Special Order* 32-2141*<br />
S&S piston oilers are supplied with this kit.<br />
Must be ordered separately with custom flywheels.<br />
* Special Order: Download the Special Order Form at sscycle.com/soforms<br />
92-1210 Series<br />
These kits require special S&S pistons.<br />
Order the required piston oversize from this chart.<br />
92-1210 Series Pistons for S&S® 106" Hot Set Up Kit®<br />
Oversize Piston Deck Height Part No.<br />
Standard<br />
92-1210<br />
+.005" 92-1214<br />
+.010" 92-1211<br />
1.020"<br />
+.020" 92-1212<br />
Cylinder & Piston Kit - Silver* 106-4140<br />
Cylinder & Piston Kit - Black* 91-7061<br />
*Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or<br />
honing.<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-27
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
KITS<br />
106" Stroker Hot Set Up ® KIT<br />
Delivering real performance gains at a reasonable price, the heart of this 106" stroker kit<br />
is an S&S 4½" stroke flywheel assembly. Installation requires no crankcase machining or<br />
modification, and stock cylinders can be reused to further reduce cost. Select S&S Super<br />
Stock® heads for the maximum power output. 106" stroker kit is recommended for <strong>1999</strong>-<br />
'06 engines.<br />
FITMENT<br />
• <strong>1999</strong>-'06 big twins<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
FEATURES AND BENEFITS<br />
• Up to 75% horsepower increase<br />
• Strong S&S 4½" stroke pressed together flywheel assembly<br />
• No crankcase modifications required!<br />
• S&S 585 Easy Start chain drive cams to maximize performance<br />
• High performance hydraulic tappets assure accurate valve timing<br />
• Stock cylinders can be bored to 37/8" and reused to reduce cost<br />
• 9.8:1 compression ratio means reliable performance<br />
• S&S pushrods are made from high strength chromoly tubing<br />
• Valve pocket recesses in S&S pistons are enlarged for oversize valves and higher lift cams<br />
• Installation instructions and all necessary hardware and gaskets are included<br />
• Maintains stock engine height<br />
• Available in wrinkle black powdercoat or silver powdercoat<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
320-0015 Now with<br />
Easy Start<br />
Cams!<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
After installing the pictured 106" S&S® stroker kit, hp output increased by 75% when<br />
combined with a high flow air cleaner and performance exhaust!<br />
Year Stroke Displacement Bore<br />
Cylinder<br />
Length<br />
S&S® 106" STROKER KIT SPECIFICATIONS<br />
Piston Type<br />
Flat Top<br />
<strong>1999</strong>-'06 41/2" 106" 37/8" 4.937"<br />
Forged<br />
Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or honing.<br />
Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />
89cc S&S Heads<br />
(included)<br />
Compression Ratio<br />
79cc S&S Heads<br />
85cc Stock Heads<br />
83cc CNC ported<br />
stock heads<br />
9.8:1 10.8:1 10.1:1 10.3:1<br />
S&S can provide quality, professional machine shop and engine building service through our remanufacturing program. We can handle any job from<br />
fitting a set of pistons in your cylinders, to complete installation of any engine kit. Contact your S&S customer service representative for details.<br />
2-28<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
CONTINUED -<br />
S&S® 106" Stroker Hot Set Up® Kit<br />
320-0015<br />
320-0021<br />
S&S® 106" Stroker Hot Set Up Kits® with 89cc Super Stock® Heads<br />
For Harley-Davidson® Twin Cam 88® Engines<br />
Engine Style Silver Powdercoat Black Powdercoat<br />
<strong>1999</strong>-<strong>2006</strong> Twin Cam 88 Touring and Dyna® (except <strong>2006</strong> Dyna® models)* 320-0015 320-0018<br />
2001-<strong>2006</strong> Twin Cam 88B Softail® w/Balancer 320-0016 320-0019<br />
CTO<br />
All kits include pushrod kit and chain drive Easy Start cams.<br />
Order pistons separately. * For <strong>2006</strong> Dyna®, see Section 1.<br />
106-5745<br />
The heads included in these kits have 89cc combustion chambers.<br />
S&S® 106" Stroker Hot Set Up Kits® without heads<br />
For Harley-Davidson® Twin Cam 88® Engines<br />
Engine Style<br />
Part No.<br />
<strong>1999</strong>-<strong>2006</strong> Twin Cam 88 Touring and Dyna® (except <strong>2006</strong> Dyna® models)* 320-0021*<br />
2001-<strong>2006</strong> Twin Cam 88B Softail® w/Balancer 320-0022*<br />
106-5745<br />
CTO<br />
This kit requires special S&S pistons.<br />
Order the required piston oversize from this chart.<br />
92-1210 Series<br />
All kits include pushrod kit and chain drive Easy Start cams. Order pistons separately.<br />
*S&S Sidewinder® .585" lift valve spring kit must be used with stock heads. See page 2-58.<br />
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<br />
CNC port your heads. See page 2-18 for more details. * For <strong>2006</strong> Dyna®, see Section 1.<br />
92-1210 Series Pistons for S&S® 106" Hot Set Up Kit®<br />
Oversize Piston Deck Height Part No.<br />
Standard<br />
92-1210<br />
+.005" 92-1214<br />
+.010" 92-1211<br />
1.020"<br />
+.020" 92-1212<br />
Cylinder & Piston Kit - Silver* 106-4140<br />
Cylinder & Piston Kit - Black* 91-7061<br />
*Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or honing.<br />
NOTES:<br />
• For 106" stroker kits ordered without cylinders, pistons must be measured and cylinders bored/honed accordingly. Recommended piston fitment:<br />
• Close: 0.0020" – 0.0025"<br />
Loose: 0.0032" – 0.0045"<br />
• S&S Easy Start Cams can save you money – no need to buy compression releases or S&S rocker covers.<br />
• Unless professional headwork is done, kits using stock, un-ported cylinder heads will produce significantly less power compared to S&S heads.<br />
• S&S® recommends its 106" big bore kit for 2007-up bikes as it yields the same displacement as the 106" stroker kit, uses the stock flywheel assembly, and requires no<br />
engine disassembly below the base gasket. Turn to page 2-22 of this section for more details on 106" Big Bore Kits.<br />
• 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<br />
recommends the Dynojet Power Vision Flash Tuner, see page 2-15 for more information.<br />
• Main Bearing Note: S&S flywheel assemblies for <strong>1999</strong>-up big twin engines are designed for use with Timken® style sprocket shaft bearings. They will fit directly in stock<br />
Harley-Davidson® <strong>1999</strong>-’02 crankcases and in all S&S crankcases for Twin Cam 88® engines with no modifications. S&S does not produce a set of flywheels that is a direct<br />
replacement for the 2003 and later big twin engines. Stock 2003 and later engines use the same roller type bearing for the sprocket shaft that is used on the pinion shaft.<br />
However, S&S flywheels may be used in 2003 and later engines with the installation of the Harley-Davidson® bearing kit #24004-03A. These crankcases use a roller type<br />
bearing for the sprocket shaft. Verify that the bearing kit contains the 24604-00D or 24607-07 sprocket shaft bearing. Do not use a 24604-00, 24604-00A, 24604-00B<br />
or 24604-00C bearing.<br />
• .030" MLS head gaskets optional: Part #900-0216<br />
• 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<br />
can provide this service for you.<br />
PERFORMANCE<br />
KITS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-29
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
PERFORMANCE<br />
KITS<br />
124" HOT SET UP KIT ®<br />
Keep your stock crankcases and take the horsepower output of your late model big twin<br />
to the max with an S&S 124" Hot Set Up Kit! Configured specifically for your application,<br />
this kit is sure to exceed your performance expectations!<br />
FITMENT<br />
• All big twin models<br />
FEATURES AND BENEFITS<br />
• Huge displacement increase means huge power increase<br />
• Stock crankcases, cylinder heads, oil pump, and cam cover can be reused, saving<br />
hundreds of dollars<br />
• Original engine serial numbers are retained<br />
• Chain drive S&S 640 Easy Start Cams included!<br />
• Silver or wrinkle black powdercoat finish heads match factory finish, giving bike a<br />
"sleeper" advantage<br />
• .045" MLS head gaskets<br />
• Requires crankcase boring –S&S can provide quality, professional machine shop<br />
and engine building service through our remanufacturing program. Contact your<br />
S&S customer service representative for details.<br />
• Adds .096" to engine height<br />
OPTIONS<br />
The following three options are examples of the most commonly ordered kits.<br />
Option 1 (10.8:1 compression ratio) includes:<br />
• S&S 91cc high flow Super Stock® heads<br />
• Flat topped pistons<br />
Option 2 (without heads) Available only through CTO. Includes:<br />
• Flat topped pistons<br />
Option 3 (without heads, 10.4:1 compression ratio, works with stock cylinder heads)<br />
Includes:<br />
• 10.9cc Dished pistons<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
900-0220<br />
Now with<br />
Easy Start<br />
Cams!<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
S&S® 124" HOT SET UP KIT® SPECIFICATIONS<br />
Piston Type/Compression Ratio<br />
Year Stroke Displacement Bore Cylinder Length<br />
91cc S&S Heads 89cc S&S Heads 85cc Stock Heads<br />
<strong>1999</strong>-'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<br />
Cylinder w/ piston kits include fitted pistons and cylinders that require no boring or honing.<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
NOTES:<br />
• Requires recalibration.<br />
• Stock crankcases need to be machined to accept new cylinders. S&S can provide this service for you! See page 10-6.<br />
• S&S Easy Start Cams can save you money – no need to buy compression releases or S&S rocker covers. Note when using <strong>1999</strong>-'06 chain drive cams: For lifts over .510", S&S strongly<br />
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<br />
tensioners to more reliable hydraulic tensioners and also upgrades the oil pump.<br />
• Main Bearing Note: S&S flywheel assemblies for <strong>1999</strong>-'12 big twin engines are designed for use with Timken® style sprocket shaft bearings. They will fit directly in stock Harley-<br />
Davidson® <strong>1999</strong>-’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<br />
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<br />
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<br />
bearing kit contains the 24604-00D or 24607-07 sprocket shaft bearing. Do not use a 24604-00, 24604-00A, 24604-00B or 24604-00C bearing.<br />
• 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<br />
provide this service for you.<br />
2-30<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
CONTINUED -<br />
S&S® 124" Hot Set Up Kit®<br />
Dyno Comparison<br />
2009 FLHT with S&S® 124" Hot Set Up Kit vs Stock<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
S&S 124 Hot Set Up Kit w/ Performance Exhaust System<br />
Peak Corrected HP 125.7<br />
Peak Corrected Torque 125.3<br />
Stock 2009 FLHT<br />
Peak Corrected HP 68.6<br />
Peak Corrected Torque 84.7<br />
PERFORMANCE<br />
KITS<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
900-0220<br />
124" Hot Set Up kits® For Harley-Davidson® Twin Cam 88®/88B Engines<br />
(Kits include S&S® Super Stock® 91cc Cylinder Heads) (10.8:1 Compression)<br />
Model or Engine Type Finish Part No.<br />
<strong>1999</strong>-<strong>2006</strong> Twin Cam 88 Touring and Dyna® (except <strong>2006</strong> Dyna® models)*<br />
2001-<strong>2006</strong> Twin Cam 88B Softail® w/Balancer<br />
CTO<br />
This dyno chart compares a stock 96" 2009 FLHT with an S&S 124" Hot Set Up Kit<br />
with S&S® Stealth® air cleaner, Power Tune Duals and Power-Tour mufflers on the<br />
same bike. It is visibly clear that installing this performance kit dramatically increases<br />
power! The 124" Hot Set Up was tuned with a Dynojet® Power Vision Tuner.<br />
Not legal for sale or use on CA or EPA pollution controlled vehicles. *For <strong>2006</strong> Dyna® 124” Kits, see Section 1.<br />
Silver 900-0220<br />
Black 900-0221<br />
Silver 900-0222<br />
Black 900-0223<br />
Specify 106-5752<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
106-4294<br />
124" Hot Set Up kits® without Heads/Dished Pistons<br />
For Harley-Davidson® Twin Cam 88®/88B® Engines<br />
(10.4:1 Compression when used with 85cc stock heads)<br />
Model or Engine Type Finish Part No.<br />
<strong>1999</strong>-<strong>2006</strong> Twin Cam 88 Touring and Dyna® (except <strong>2006</strong> Dyna® models)*<br />
2001-<strong>2006</strong> Twin Cam 88B Softail® w/Balancer<br />
CTO<br />
Not legal for sale or use on CA or EPA pollution controlled vehicles. *For <strong>2006</strong> Dyna® 124” Kits, see Section 1.<br />
Silver 106-4294<br />
Black 106-0184<br />
Silver 106-4296<br />
Black 106-0188<br />
Specify 106-5752<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
900-0217 Gasket,Head,Stock Pattern,.030",4.125",2 Pack<br />
S&S now offers an MLS head gasket in .030" thickness for those engine builders who<br />
want tighter squish, higher compression, and who are willing to check their clearances.<br />
S&S can provide quality, professional machine shop and engine building service through our remanufacturing program. We can handle any job from<br />
fitting a set of pistons in your cylinders, to complete installation of any engine kit. Contact your S&S customer service representative for details.<br />
Visit us at www.sscycle.com<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-31
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
PERFORMANCE<br />
KITS<br />
T124 ENGINE<br />
FITMENT<br />
• The T124 can only be sold as a closed course competition engine for <strong>1999</strong>-’05 fuel<br />
injected engines and <strong>1999</strong>-’06 carbureted engines (except <strong>2006</strong> Dyna® models)<br />
For more 124" engine options on <strong>2006</strong>-up Dyna® and 2007-up big twin models, call our toll<br />
free number and ask about our CTO options. Also, see our Power Kits starting on page 2-20 for<br />
power-enhancing modification options.<br />
FEATURES AND BENEFITS<br />
• Bolt-in<br />
• Increased power & torque (see Dyno Chart)<br />
• Long piston stroke and high performance .640" lift gear driven cams<br />
• Chrome plated 2.00" stainless steel intake and 1.605" inconel exhaust valve<br />
• Chrome gearcover, tappet covers and rocker covers<br />
• Silver powdercoat, wrinkle black powdercoat, or polished finish. Diamond cut<br />
finish is available, but has a longer lead time<br />
• All engines have Easy Start camshafts for reliable starts and less starter motor wear<br />
FUEL INJECTED ENGINES (2002–’05)*<br />
• Delphi® style S&S Variable Fuel Injection (VFI) module with built-in three stage<br />
engine overheat protection<br />
• Closed loop fuel system, dual oxygen sensors provide air-fuel ratio feedback for<br />
correct fuel delivery under any condition<br />
• Included S&S ProTune II software CD provides base fuel maps for most<br />
aftermarket exhaust systems<br />
• Delphi style knock sensor module eliminates knock – prolonging engine life<br />
• Break-in rev-limiter prevents high RPM during break-in<br />
• Single bore throttle body with teardrop air cleaner<br />
• Two-year warranty<br />
*For <strong>2006</strong> touring models, use CTO part number for ordering<br />
FUEL INJECTED ENGINES (<strong>1999</strong>–’01)<br />
• Magneti Marelli® style S&S Variable Fuel Injection (VFI) module with built-in three<br />
stage engine overheat protection<br />
• Closed loop fuel system, dual oxygen sensors provide air-fuel ratio feedback for<br />
correct fuel delivery under any condition<br />
• Included S&S ProTune II software CD provides base fuel maps for most<br />
aftermarket exhaust systems<br />
• 52mm single bore throttle body with teardrop air cleaner<br />
• One-year warranty<br />
CARBURETED ENGINES (<strong>1999</strong>–’06)<br />
• S&S Super G carburetor with slotted "Slasher" air cleaner cover<br />
• Knock sensing ignition control prolongs engine life by automatically adjusting<br />
timing to eliminate knock by learning and storing ignition requirements of the<br />
engine<br />
• Guardian feature protects engine with a 3 step break-in rev-limiter<br />
• Two-year warranty<br />
CONTENTS<br />
• Complete S&S engine with fuel delivery/ignition system<br />
• Instructions<br />
• Mobil 1® 20W-50 and an S&S oil filter<br />
Complete Engine Rebuild Gasket Kits<br />
S&S Engine Family Year Group Bore Size Part No<br />
T-Series <strong>1999</strong>-’06 41/8" 106-0976<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S® T124 engine shown with<br />
optional chrome single bore tuned<br />
induction system. All engines come<br />
standard with a teardrop air cleaner.<br />
T124 engine specifications<br />
Displacement Bore Stroke Camshaft Piston Type Compression Ratio<br />
124" 4 1⁄8" 4 5/8" 640GP S&S forged 10.8:1<br />
140<br />
130<br />
120<br />
110<br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
Dyno Comparison<br />
S&S® T124 w/Single Bore Throttle Body - Tuned Induction vs Teardrop Air Cleaner<br />
S&S T124 w/Single Bore - Tuned Induction<br />
Peak Corrected HP 139.9<br />
Peak Corrected Torque 137.7<br />
2500 3000 3500<br />
S&S T124 w/Single Bore - Air Cleaner<br />
Peak Corrected HP 135.8<br />
Peak Corrected Torque 132.1<br />
4000 4500 5000 5500 6000 6500<br />
EngSpd RPM<br />
This dyno chart shows performance of a fuel injected T124 with a teardrop air cleaner and with a<br />
single bore tuned induction system. Although the results are not typical, we wanted to show what is<br />
possible with an S&S 124” motor. Typically you should see around 124 hp or 1 hp/cubic inch.<br />
NOTE:<br />
• A high performance clutch must be used. See page 2-79 for more information.<br />
• <strong>1999</strong>–’05 Dyna® requires oil line installation kit part #31-0424, includes special<br />
transmission top cover.<br />
• 2000–’06 FLT requires oil line installation kit part #31-0425.<br />
• If a different exhaust or intake system is used, the fuel maps must be modified. It is<br />
highly recommended that this tuning be done by a certified S&S® VFI tuning center.<br />
Visit our website at www.sscycle.com to locate your nearest certified S&S VFI tuning<br />
center or to download maps for the S&S VFI system.<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-32<br />
Chassis Style Fuel Delivery Ignition<br />
Warranty<br />
Period<br />
Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />
Order toll free 866-244-2673<br />
S&S® T124 Engines<br />
Diamond Cut<br />
Silver Black Polished Full Polished<br />
Black Full Polished<br />
106-4328 31-9895 31-9896 106-0830 106-0828 –<br />
<strong>1999</strong>-'03 Carb<br />
S&S® Super G Carburetor IST® 2 Years<br />
2004-'06 Carb 310-0200 310-0201 310-0202 310-0204 310-0203 310-0205<br />
2002-'03 FI<br />
106-4323 106-0402 106-0403 106-0800 – –<br />
Delphi® style VFI VFI 2 Years<br />
2004-'05 FI 310-0221 310-0216 310-0217 310-0219 – –<br />
<strong>1999</strong>-'01 FI Magneti Marelli® style VFI VFI 1 Year 106-4322 106-0399 106-0400 106-0831 106-0829 –<br />
CTO<br />
Specify Specify Varies 319-0010
S&S ®<br />
T111 ENGINE<br />
FITMENT<br />
• The T111 will only fit in place of <strong>1999</strong>-’05 fuel injected engines and<br />
<strong>1999</strong>-’06 carbureted engines (except <strong>2006</strong> Dyna® models)<br />
For more 111" engine options on <strong>2006</strong>-up Dyna® and 2007-up big twin models, call our toll free<br />
number and ask about our CTO options. Also, see our Power Kits starting on page 2-20 for powerenhancing<br />
modification options.<br />
FEATURES AND BENEFITS<br />
• Bolt-in – installs easily into stock frames<br />
• "Square" motor configuration (equal bore and stroke) produces excellent torque,<br />
greatly increases engine life, and reduces mechanical engine noise<br />
• S&S 585GP Easy Start gear driven cams and lightweight conical Sidewinder® valve<br />
springs further reduce valve train noise<br />
• Silver powdercoat or wrinkle black powdercoat finish<br />
• Chrome gearcover and tappet covers<br />
• Trademark S&S teardrop air cleaner<br />
FUEL INJECTED ENGINES (2002-’05)*<br />
• Delphi® style S&S Variable Fuel Injection (VFI) module with built-in three stage<br />
engine overheat protection<br />
• Closed loop fuel system, dual oxygen sensors provide air-fuel ratio feedback for<br />
correct fuel delivery under any condition<br />
• Included S&S ProTune II software CD provides base fuel maps for most aftermarket<br />
exhaust systems<br />
• Delphi style knock sensor module eliminates knock – prolonging engine life<br />
• Break-in rev-limiter prevents high RPM during break-in<br />
• 52mm single bore throttle body with teardrop air cleaner<br />
• Two-year warranty<br />
*For <strong>2006</strong> touring models, use CTO part number for ordering<br />
FUEL INJECTED ENGINES (<strong>1999</strong>-’01)<br />
• Single bore throttle body with teardrop air cleaner<br />
• Magneti Marelli® style S&S Variable Fuel Injection (VFI) module with built-in three<br />
stage engine overheat protection<br />
• Closed loop fuel system, dual oxygen sensors provide air-fuel ratio feedback for<br />
correct fuel delivery under any condition<br />
• Included S&S ProTune II software provides base fuel maps for most aftermarket<br />
exhaust systems<br />
• Two-year warranty<br />
CARBURETED ENGINES<br />
• S&S Super E carburetor with teardrop air cleaner cover<br />
• Knock sensing ignition control prolongs engine life by automatically adjusting timing<br />
to eliminate knock by learning and storing ignition requirements of the engine<br />
• Guardian feature protects engine with a 3 step break-in rev-limiter<br />
• Three-year warranty<br />
CONTENTS<br />
• Complete S&S engine with fuel delivery/ignition system<br />
• Instructions<br />
• Mobil 1® 20W-50 and an S&S oil filter<br />
Complete Engine Rebuild Gasket Kits<br />
S&S Engine Family Year Group Bore Size Part No<br />
T-Series <strong>1999</strong>-’06 41/8" 106-0976<br />
S&S® T111 Engines<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Those used to looking at dyno charts of high<br />
performance engines may wonder why the<br />
T111 does not make more horsepower on<br />
the top end. Thanks to the S&S® Super E carb,<br />
moderate compression ratio, and mild cams,<br />
it has a lot of torque and a broad power<br />
curve making passing vehicles, climbing<br />
hills, and accelerating up to speed as simple<br />
as twisting the throttle.<br />
T111 engine specifications<br />
Displacement Bore Stroke Camshaft Piston Type Compression Ratio<br />
111" 4 1⁄8" 4 1⁄8" 585GP S&S Forged 9.8:1<br />
Chassis Style Fuel Delivery Ignition Warranty Period Silver Black<br />
<strong>1999</strong>-'03 Carb<br />
106-4431 106-4430<br />
S&S® Super E Carburetor IST® 3 Years<br />
2004-'06 Carb 310-0198 310-0199<br />
2002-'03 FI<br />
106-4433 106-4432<br />
Delphi® style VFI<br />
2004-'05 FI VFI<br />
2 Years<br />
310-0214 310-0213<br />
<strong>1999</strong>-'01FI Magneti Marelli® style VFI 106-4435 106-4434<br />
Specify Specify Varies 319-0010<br />
CTO<br />
Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />
NOTE:<br />
• A high performance clutch must be used.<br />
• <strong>1999</strong>–’05 Dyna® requires oil line installation kit part #31-0424, which includes<br />
special transmission top cover.<br />
• 2000–’06 FLT requires oil line installation kit part #31-0425.<br />
• If a different exhaust or intake system is used, the fuel maps must be modified.<br />
It is highly recommended that this tuning be done by a certified S&S® VFI tuning<br />
center. Visit our website at www.sscycle.com to locate your nearest certified S&S<br />
VFI tuning center or to download maps for the S&S VFI system.<br />
Visit us at www.sscycle.com<br />
PERFORMANCE<br />
KITS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-33
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
KITS<br />
T124 TÜV APPROVED ENGINES<br />
FITMENT<br />
• The T124 TÜV can only be sold as a replacement engine for <strong>1999</strong>-’05 fuel<br />
injected engines and <strong>1999</strong>-’06 carbureted engines<br />
S&S does not offer full replacement TUV engines for <strong>2006</strong> Dyna® models.<br />
FEATURES AND BENEFITS<br />
• Similar to T124 but meets EU Chapter 9 standards 2002/51/EC for exhaust,<br />
97/24/EC for noise<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
FUEL INJECTED ENGINES (<strong>1999</strong>-’05)<br />
• 52mm single bore throttle body with teardrop air cleaner<br />
• Modified Delphi® style S&S Variable Fuel Injection (VFI) module with built-in<br />
three stage engine overheat protection<br />
• Closed loop fuel system, dual oxygen sensors provide air-fuel ratio feedback<br />
for correct fuel delivery under any condition<br />
• One-year warranty<br />
• Meets Euro III exhaust emissions limits<br />
CARBURETED ENGINES (<strong>1999</strong>-'06)<br />
• S&S® Super G, EC carburetor with chrome teardrop air cleaner<br />
• Knock sensing ignition control prolongs engine life by automatically adjusting<br />
timing to eliminate knock by learning and storing ignition requirements of<br />
the engine<br />
• Break-in rev limiter prevents high RPM during break-in<br />
• Two-year warranty<br />
• Meets Euro II exhaust emissions limits<br />
CONTENTS<br />
• Complete S&S engine<br />
• Fuel delivery/ignition system<br />
• Instructions<br />
• Certificates and documentation of TÜV approval<br />
• Mobil 1® 20W-50 and an S&S oil filter<br />
Complete Engine Rebuild Gasket Kits<br />
S&S Engine Family Year Group Bore Size Part No<br />
T-Series <strong>1999</strong>-’06 41/8" 106-0976<br />
T124 TUV APPROVED ENgine SPECIFICAtiONS<br />
Displacement Bore Stroke Camshaft Piston Type Compression Ratio<br />
124" 4 1⁄8" 4 5/8" 546GP S&S Forged 9.5:1<br />
NOTE:<br />
• <strong>1999</strong>-'01 EFI bikes will require conversion to Delphi® style single bore EFI fuel tank &<br />
wiring harness.<br />
• <strong>1999</strong>-’05 Dyna® requires oil line installation kit part #31-0424 ,which includes special<br />
transmission top cover.<br />
• 2000-’06 FLT, requires oil line installation kit part #31-0425.<br />
• In order to be compliant with EU Chapter 9 standards, all S&S® TÜV engines must be used with<br />
stock Harley-Davidson® exhaust, specified gearing, and the provided S&S ignition system.<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-34<br />
Chassis Style Fuel Delivery Ignition Warranty Period Silver Black Polished<br />
<strong>1999</strong>-'03 Carb<br />
106-4329 31-9965 –<br />
S&S® Super G Carb IST® 2 Years<br />
2004-'06 Carb 310-0209 310-0208 –<br />
<strong>1999</strong>-'05 FI Delphi® style VFI VFI 1 Year 106-4327 106-2356 106-2395<br />
Not legal for sale or use on CA or EPA pollution controlled vehicles.<br />
S&S ®<br />
T-Series Service Manual<br />
These manuals were created to help you maintain your S&S engine. They outline the<br />
procedures necessary for both the home mechanic and shop technician to ensure<br />
maximum performance and longevity.<br />
S&S T-Series engines .....................................61-1002<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
CRANKCASES<br />
For high performance applications or just the replacement of a worn out or broken engine,<br />
these cases are compatible with the stock primary, charging system and bolts directly to<br />
the stock transmission on all models.<br />
FITMENT<br />
• <strong>1999</strong>–'06 Harley-Davidson® Twin Cam 88® (except <strong>2006</strong> Dyna®)<br />
FEATURES AND BENEFITS<br />
• Much stronger than stock crankcases in every aspect, extra large front motor mount<br />
for increased strength<br />
• Large cam chest allows cam lift up to .675" without clearancing<br />
• Timken® style sprocket shaft bearings withstand the most demanding applications<br />
• Includes S&S crankcase breather reed valve to eliminate oil carry-over and oil<br />
scavenging problems<br />
• Clearanced for strokes up to 5"<br />
• All passages between the crankcase and the cam support plate are o-ring sealed<br />
• Includes pinion and Timken® bearing<br />
OPTIONS<br />
• Available in stock bore, 4" bore, and 41⁄8" bore versions<br />
• Silver powdercoat, wrinkle black powdercoat, or polished finish<br />
KIT CONTENTS<br />
• S&S crankcase<br />
• S&S breather reed valve<br />
• Bearings and hardware<br />
NOTES:<br />
• Oil line installation kit part #31-0424 is required for installation in <strong>1999</strong>-’05<br />
Dyna® models. This kit includes a special transmission top cover and oil lines.<br />
• Oil line installation kit part #31-0425 is required for installation in 2000-'06 FLT<br />
models. Stock transmission top cover may be used.<br />
S&S® Crankcase for <strong>1999</strong>-'06 Big twin Engines<br />
(except <strong>2006</strong> Dyna®)<br />
Crankcase Bore Size Silver Finish Black Finish Polished Finish<br />
Stock Bore<br />
(Stock Stud Pattern)<br />
106-4039 31-0172 –<br />
4" Bore<br />
(Stock Stud Pattern)<br />
106-4041 31-0175 –<br />
41/8" Bore<br />
(Stock Stud Pattern)<br />
106-4057 31-0181 31-0182<br />
41/8" Bore<br />
(S&S Stud Pattern)<br />
106-4043 31-0178 31-0179<br />
Special Order 31-0120*<br />
Use the special order part number to order crankcases with a special finish or motor mount style.<br />
*Special Order: Download the Special Order Form at sscycle.com/soforms<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
31-0425<br />
Oil line installation kit<br />
for <strong>1999</strong>-'06 FLT models<br />
Any Job is easy with the right tools<br />
S&S Degree Wheel Kit, page 9-13 and S&S Anti-Rotation Bracket, page 9-14<br />
Replacement parts on page 2-81<br />
31-0424<br />
Oil line installation kit<br />
<strong>1999</strong>-'05 Dyna® models<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-35
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
CRANKCASE BREATHER REED VALVES<br />
Besides offering improved oil scavenging and reduced oil carryover, S&S crankcase breather<br />
reed valves make your bike run better and provide a more enjoyable riding experience.<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PERFORMANCE<br />
PARTS<br />
How Do They Work<br />
The functional part of S&S crankcase breather reed valves consists of steel reeds that<br />
are normally in the closed position. When the pistons travel downward in the cylinders,<br />
pressure in the crankcase below the pistons causes the reeds to open, allowing the air and<br />
oil mist in the crankcase to escape into the cam chest. When the pistons change direction<br />
and begin traveling back upward in the cylinders, a vacuum is created in the crankcase.<br />
The vacuum causes the reeds to close, preventing air from entering the crankcase. The<br />
effect is that camchest pressure waves are reduced improving oil return from the heads to<br />
the camchest and also a slight vacuum is maintained in the crankcase, improving ring seal.<br />
31-2071<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
FITMENT<br />
• Twin Cam 88®/96 (except "B" engines)<br />
• S&S T-Series engines<br />
Replacement parts on page 2-82<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
PART NUMBERS<br />
For Engines with Stock Oil Pump<br />
<strong>1999</strong>-’02 .................................................31-2070<br />
2003-’10 .................................................31-2071<br />
S&S special application crankcases ............................31-2086<br />
Engines with S&S Oil Pump<br />
<strong>1999</strong>-’02 stock crankcases ...................................31-2093<br />
2003-’10 stock crankcases & all S&S crankcases .................31-2094<br />
Spring Adapter<br />
(For S&S SA crankcases)* ....................................31-2103<br />
*Required to accommodate the extra .375" case width of S&S Special Application big bore crankcases.<br />
** Does not fit with Screamin’ Eagle® oil pumps.<br />
NOTES:<br />
• The crankcases breather valve for Twin Cam 88® engines was designed and<br />
developed for use with stock Harley-Davidson® or S&S oil pumps and tappets,<br />
and may not be compatible with some aftermarket components.<br />
• Not available for Twin Cam 88B or Twin Cam 96B engines with internal<br />
balancers.<br />
OEM Cross Reference<br />
Appendix & Index<br />
Warranty &<br />
Company Policy<br />
Dealer Services<br />
& Promo Items<br />
Tools & Shop<br />
Supplies<br />
Racing<br />
Products<br />
2-36<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
FLYWHEEL ASSEMBLIES<br />
Recommended for performance applications, S&S flywheel assemblies are made of forged<br />
steel and have pressed-in shafts. A 1.5" diameter crankpin means that, unlike stock<br />
flywheel assemblies, lower connecting rod bearing races are replaceable.<br />
FITMENT<br />
• <strong>1999</strong>-'06 big twins<br />
KIT CONTENTS<br />
• Flywheel balanced and assembled with rods<br />
• Instructions<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Trying to identify an S&S® Flywheel<br />
See Flywheel I.D. Chart in the Replacement Parts section page 12-2<br />
Replacement parts on page 2-82<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Engine Displacement<br />
Stroke<br />
S&S® Flywheel Assemblies<br />
<strong>1999</strong>-'06 H-D® big twin models<br />
Twin Cam 88®<br />
Twin Cam 88B<br />
USA<br />
USA<br />
88", 95", 97", 100" 4" 32-2240 32-2241<br />
(H-D® #23971-03)<br />
<strong>2006</strong> H-D® Dyna® models<br />
32-2293<br />
(H-D® #23955-06)<br />
96", 103", 106" big bore, 110",117" 4 3/8" 32-2312 32-2314 32-2310<br />
Stock 96" 4 3/8" – – 106-3363<br />
106" stroker 4 ½" 32-2242 32-2243 32-2294<br />
107" 4 1/4" 32-2244 32-2245 –<br />
111" 4 1/8" 106-4712 106-6052 106-6053<br />
116", 124" 4 5/8" 32-2246 TÜV 2 32-2247 32-2295<br />
Special Order Specify 32-2141<br />
Use the special order part number to order flywheels assembled or unassembled, balanced or unbalanced, porkchop or with welded shafts.<br />
Special Order: Download the Special Order Form at sscycle.com/soforms<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
EXTRA PARTS NEEDED:<br />
• 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<br />
H-D# 24604–00, H-D#2460 –00A, H-D#24604–00B, or H-D#24604–00C bearing.<br />
• 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.<br />
Additional machining is required to install. S&S can provide this service.<br />
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.<br />
Visit us at www.sscycle.com<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-37
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
OIL PUMPS<br />
S&S oil pumps use the drive gears on special S&S gear drive cams to pump oil to the engine.<br />
Unlike stock pumps, S&S oil pumps regulate oil pressure after it gets filtered, providing<br />
more consistent oil pressure at all temperatures. Crankcase scavenging is increased while<br />
oil carryover and drag on the flywheels are reduced. Oil temperature can also drop by as<br />
much as 20° F.<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
FITMENT<br />
• 2002 - ’06 carbureted & EFI big twins (except <strong>2006</strong> Dyna®)<br />
• May be used in <strong>1999</strong>-'01 engines with aftermarket ignition or EFI (see note below)<br />
• Fits all engines built with S&S T-Series crankcases<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
FEATURES AND BENEFITS<br />
• Replaces stock oil pump, cams, cam support plate, bearing plate, bearings and<br />
decorative gearcover<br />
• Uses drive gears of special S&S gear drive cams to pump oil<br />
• Oil pressure is regulated after the oil filter – more consistent pressure to the engine<br />
• Increased scavenging capacity results in:<br />
• Less oil in the crankcase<br />
• Less power loss<br />
• Less heat build up<br />
• Less oil carryover<br />
• Excess oil from pressure control valve is filtered – longer pump life<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
PART NUMBERS<br />
S&S Oil Pump Kit without Cams<br />
Polished ..................................................31-6503<br />
Chrome ................................................. 106-3887<br />
S&S® GEAR DRIVE CAMS FOR USE With S&S OIL PUMPS<br />
FOR <strong>1999</strong>-'06 Big twin (EXCEPT <strong>2006</strong> DYNA® MODELS)<br />
Cam*<br />
Easy Start Cams<br />
with Drive Gears<br />
Cams with Drive Gears<br />
510GP – 33-5220<br />
570GP 106-4751 –<br />
585GP 106-4771 33-5222<br />
625GP 106-5212 –<br />
640GP 106-4781 –<br />
675GP 106-5215 33-5225<br />
* See Camshafts starting on page 2-39 of this catalog for further information on cam<br />
recommendations for different applications.<br />
Replacement parts on page 2-83<br />
31-6503<br />
OEM Cross Reference<br />
Appendix & Index<br />
SPECIAL NOTES:<br />
• Requires installation of gear drive cams, see chart.<br />
• The S&S oil pump is not compatible with <strong>1999</strong>-’01 engines with stock fuel injection or ignition systems which require a cam position sensor in the gearcover. May be used in <strong>1999</strong>-’01<br />
engines if an aftermarket ignition or fuel injection system, that does not require a cam position sensor, is installed.<br />
2-38<br />
Order toll free 866-244-2673
S&S ®<br />
CAMSHAFT OVERVIEW<br />
S&S offers a variety of cam grinds for <strong>1999</strong>-up big twin engines in both chain drive and<br />
gear drive versions. Cams that exceed the limits of the stock valve springs require the use<br />
of special high lift springs. Most S&S cams have higher lift than stock and are designed to<br />
take advantage of the extra flow of ported stock heads or S&S Super Stock® heads. Due<br />
to the high lift of these cams, S&S adjustable pushrods are recommended. Not all grinds<br />
are available in the chain drive version. To get the best performance from a performance<br />
cam installation, a high flow intake and exhaust system is also recommended.<br />
EASY START CAMS<br />
The most innovative S&S product since the electric compression release system, these<br />
cams will revolutionize the starting of late model big twins. Regardless of displacement<br />
or compression ratio, a stock starter and battery will now easily turn over any engine.<br />
These cams also install just as easily as non compression release versions and require no<br />
extra parts or machining! Available in both chain drive and gear drive.<br />
HOW Do Easy Start Cams WORK<br />
The heart of our Easy Start cams is a centrifugally retracted, spring loaded, compression<br />
release lobe milled into the heel of each exhaust lobe. At cranking speeds, the lobe<br />
bumps the exhaust valve open slightly during the compression stroke, making the<br />
engine much easier to turn over. Once the engine fires and reaches 800 RPM, the lobe<br />
swings out of the tappet roller path, allowing the engine to run normally and with full<br />
compression.<br />
Compare S&S Cams To Other Popular Cams<br />
If you have been using cams from another manufacturer and would like to know what<br />
S&S has to offer that is similar, the chart below lists a number of popular cams along<br />
with the S&S cams that work well in similar applications.<br />
Application CROSS REFERENCE CHART<br />
S&S Cam<br />
Name<br />
H-D® Screamin'<br />
Eagle® Cam<br />
Andrews® Cam Most Fitting Application<br />
551 SE-203/255 21H/26H Touring Models<br />
570 – 54H All Big Twin Models<br />
583 SE-203/255 21H/26H Softail®/Dyna® Models<br />
585 SE-211/251/257 31H/32H/50H/55H/67H All Big Twin Models<br />
625 SE-258/260 60H All Big Twin Models<br />
640 SE-264 59H All Big Twin Models<br />
675 – 64H All Big Twin Models<br />
Cam Name<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Recommended applications for S&S Cams<br />
475: A bolt-in replacement cam with stock cam timing is designed for riders<br />
with stock engines that want to eliminate the factory chain drive system, but are<br />
not necessarily looking for more power. Does not require tuning. Bolt-in stock.<br />
509: Designed as a bolt-in, high torque cam for <strong>1999</strong>-’06 models. 180 psi cranking<br />
compression, no need for compression releases. For 88 CID engines with stock<br />
compression ratio. Idle-4500 rpm. Bolt-in torque.<br />
510: Designed as a bolt-in cam for 88, 95, and 96 CID engines with compression<br />
ratios below 9.7:1, it is primarily intended for use with stock, un-ported heads. 3000-<br />
5500 rpm. Bolt-in overall.<br />
546: Intended as a replacement part for S&S emissions certified engines, this is a<br />
short duration emissions cam with very little overlap to reduce emissions of unburned<br />
hydrocarbons. Requires high lift springs and normal clearance checks. 1000-4000 rpm<br />
551: Designed for engines with 96 to 106 CID and 9:1 to 9:9 compression this is a<br />
bolt-in cam set designed for stock or mildly modified touring bikes. 551 cams are not<br />
recommended for compression ratios of 10:1 or greater. Greatly improves low-end<br />
and midrange torque, strongest from idle-4000rpm.<br />
570: Designed for 88 to 103 CID engines with compression ratios between 9:1 and<br />
10:1 this cam will provide a nice power increase across the entire power band. 3200-<br />
5700 rpm. Excellent bolt-in for overall power on 103”.<br />
583: Optimized for use in the Softail®/Dyna® lines, this cam makes horsepower<br />
and torque that you can feel all the way through the rpm range, making the most<br />
power right where you need it:1500–5000rpm<br />
585: Designed for 88 to 95 CID engines with compression ratios from 9.7:1 to<br />
10.5:1 and 100 to 124 CID engines from 9:1 to 10:1 compression. Provides massive<br />
horsepower and torque increases starting at 3000rpm and holds steady all the way<br />
to redline. 3500-6000 rpm for 88” - 103” engines and 2500-5500 for larger engines.<br />
625: Cam set designed for 95” or larger engines with compression ratios between<br />
10.0 and 10.75:1. 3000-6000 rpm.<br />
640: Used in S&S T124 engines, this cam makes horsepower! Intended for engines<br />
of 95 CID or more w/ compression ratios between 10.5:1 and 11.5:1. 3000-6000 rpm.<br />
675: A high lift monster, this cam set is designed for 120” or larger engines with at<br />
least 11:1 compression ratio. 4500-6500 rpm.<br />
Note: Stock valve springs in <strong>1999</strong>-’04 big twin models can handle cams with valve lifts as high as<br />
.515". Stock valve springs in 2005-up engines can accommodate valve lifts up to .590".<br />
Specifications of S&S® Chain Drive and Gear Drive Camshafts for <strong>1999</strong>-UP Big twin<br />
Valve Timing (open/close)<br />
Intake<br />
Exhaust<br />
Open BTDC/Close ABDC<br />
Open BBDC/Close ATDC<br />
Valve Duration<br />
Centerline<br />
Lift @ TDC<br />
Valve Lift<br />
Intake Exhaust Intake Exhaust Intake Exhaust<br />
475 2˚/34˚ 36˚/4˚ 216˚ 220˚ .475" 106˚ 106˚ .060" .060"<br />
509 18˚/18˚ 46˚/11˚ 216˚ 237˚ .509" 90˚ 107.5˚ .174" .140"<br />
510 20˚/38˚ 52˚/20˚ 238˚ 252˚ .510" 99˚ 106˚ .187" .178"<br />
546 5˚/55˚ 52˚/5˚ 240˚ 237˚ .546" 115˚ 113.5˚ .126" .106"<br />
551** 17°/19° 41°/17° 216° 238° .550" 91˚ 102˚ .178" .170"<br />
570 20˚/40˚ 55 ˚/20˚ 240˚ 255˚ .570" 100˚ 107.5˚ .187" .179"<br />
583 5˚/18˚ 58˚/24˚ 203˚ 262˚ .583" 96.5˚ 107˚ .113" .206"<br />
585 20˚/45˚ 60˚/20˚ 245˚ 260˚ .585" 102.5˚ 110˚ .186" .179"<br />
625 20˚/55˚ 60˚/20˚ 255˚ 260˚ .625" 107.5˚ 110˚ .189" .184"<br />
640 25˚/60˚ 65˚/25˚ 265˚ 270˚ .640" 107.5˚ 110˚ .228" .214"<br />
675 25˚/64˚ 70˚/25˚ 269˚ 275˚ .675" 109.5˚ 112.5˚ .235" .205"<br />
*Note: Although several cam grinds were used in stock engines from <strong>1999</strong>-’06, the timing specs of the 475G cams is most similar to cams used in <strong>1999</strong>-’03 EFI engines.<br />
**551 cams are not recommended with compression ratio of 10:1 or higher.<br />
Visit us at www.sscycle.com<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-39
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PERFORMANCE<br />
PARTS<br />
CHAIN DRIVE CAM KITS<br />
FEATURES AND BENEFITS<br />
• Increase performance at an affordable price<br />
• Quick installation – reuse many stock components<br />
• Easy Start Cams allow stock starter<br />
to start any engine<br />
KIT CONTENTS<br />
• Cams<br />
• Gearcover gasket<br />
• Cam bearings<br />
• Thread lock<br />
• Instructions<br />
33-5182A<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
100<br />
90<br />
80<br />
583 Cam<br />
Peak Corrected HP 86.6<br />
Peak Corrected Torque 98.5<br />
Dyno Comparison<br />
Fatboy® 583 Cam vs Stock Cam<br />
96 Stock Cam<br />
Peak Corrected HP 74.5<br />
Peak Corrected Torque 88.2<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
WATCH THE S&S EASY START CAMS CRANK TEST<br />
VIDEO AT SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
S&S CHAIN DRIVE CAM KITS FOR <strong>1999</strong>-'06 MODELS (except <strong>2006</strong> Dyna®)<br />
Cam Name Standard Cam Kit Easy Start Cam Kit<br />
70<br />
60<br />
50<br />
40<br />
30<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
509 330-0016 –<br />
510 33-5182A –<br />
551 330-0002 106-5293<br />
20<br />
1500<br />
2000 2500 3000<br />
3500 4000 4500 5000 5500 6000<br />
EngSpd RPM<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
570 330-0003 106-5296<br />
583 330-0004 106-5289<br />
585 330-0005 106-5299<br />
625 330-0006 106-5302<br />
640 330-0007 106-5305<br />
INSTALLATION KITs for S&S CHAIN DRIVE CAM (recommended)<br />
Models<br />
Standard Cam Kit<br />
<strong>1999</strong>-'06 (except <strong>2006</strong> Dyna® models)* 33-5175<br />
100<br />
90<br />
80<br />
70<br />
60<br />
Dyno Comparison<br />
2009 FLHT with S&S® 551 Touring Cam vs Stock Cam<br />
S&S 551 Touring Cam<br />
Peak Corrected HP 83.7<br />
Peak Corrected Torque 100.4<br />
96 Stock Cam<br />
Peak Corrected HP 74.3<br />
Peak Corrected Torque 86.3<br />
Includes a gearcover gasket, cam bearings and instructions. *<strong>2006</strong> Dyna® cams are in Section 1.<br />
50<br />
Racing<br />
Products<br />
40<br />
30<br />
20<br />
Tools & Shop<br />
Supplies<br />
10<br />
1500<br />
2000 2500 3000<br />
3500 4000 4500 5000 5500 6000<br />
EngSpd RPM<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
33-5175<br />
Installation kits are included<br />
with cam kits.<br />
NOTE:<br />
• If 475, 509 or 510C cams are used with the stock chain drive system in Twin Cam 88®<br />
engines, it is recommended to use cylinder heads with stock valve springs or performance<br />
valve springs with no more than 160 lb. of seat force. For more demanding applications,<br />
we recommend the S&S gear drive cams.<br />
• When using <strong>1999</strong>-'06 chain drive cams for lifts over .510", S&S strongly recommends<br />
that the stock chain drive be upgraded to the S&S gear drive or to the H-D® #25284-08 or<br />
#25284-11 hybrid plate. This kit updates the problematic spring loaded chain tensioners<br />
to reliable hydraulic tensioners and also upgrades the oil pump.<br />
• 551 cams are not recommended with compression ratio of 10:1 or higher.<br />
• S&S can do a special order cam. Contact your S&S Customer Service Representative for<br />
more information.<br />
100<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
1500<br />
Dyno Comparison<br />
2009 FLHT with S&S® 585 Performance Cam vs Stock Cam<br />
S&S 585 Touring Cam<br />
Peak Corrected HP 91.9<br />
Peak Corrected Torque 94.2<br />
2000 2500 3000<br />
96 Stock Cam<br />
Peak Corrected HP 74.3<br />
Peak Corrected Torque 86.3<br />
3500 4000 4500 5000 5500 6000<br />
EngSpd RPM<br />
2-40<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
GEAR DRIVE CAM KITS<br />
FEATURES AND BENEFITS<br />
• Improves valve timing accuracy by eliminating timing chain lash<br />
• Easy Start Cams allow stock starter to start any engine<br />
• No tensioner shoes to wear out or fail<br />
OPTIONS<br />
Which S&S Gear Drive Cam Kit to Order<br />
• If updating a stock chain drive system, it's easiest to order a complete kit. Includes:<br />
• Camshafts with inner gears<br />
• Outer cam drive gear kit<br />
• Camshaft installation kit<br />
• If replacing cams in an engine already equipped with S&S gear drive cams, order cams<br />
with inner gears and reuse the existing outer gears. Camshaft installation kit for the<br />
appropriate model year is recommended.<br />
• If installing a set of gear drive cams from another manufacturer, order S&S cam gear kits<br />
for the appropriate model year. Each kit provides the inner cam gear as well as an outer<br />
cam gear. Camshaft installation kit for the appropriate model year is recommended.<br />
Cam Name<br />
WATCH THE S&S EASY START CAMS CRANK TEST<br />
VIDEO AT SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
Complete Kit<br />
S&S GEAR DRIVE CAMS FOR <strong>1999</strong>-'06 MODELS<br />
Easy Start<br />
Standard<br />
Cams w/ Inner Gears<br />
Cams w/ Inner Gears<br />
Complete Kit<br />
Stock Oil Pump S&S Oil Pump Stock Oil Pump S&S Oil Pump<br />
475 – – – 106-4033 106-4385 –<br />
509 – – – 330-0017 330-0018 –<br />
510 – – – 33-5177 33-5174 33-5220<br />
546 – – – 33-5230 – –<br />
551 106-5442 106-5441 – 330-0100 330-0099 –<br />
570 106-5243 106-5242 106-4751 33-5178 33-5166 –<br />
583 106-5859 106-5858 – 330-0107 330-0108 –<br />
585 106-5247 106-5246 106-4771 33-5179 33-5168 –<br />
625 106-5251 106-5250 106-5212 33-5180 33-5170 –<br />
640 106-4840 106-4839 106-4781 33-5181 33-5172 –<br />
675 106-5255 106-5254 106-5215 33-5231 33-5237 –<br />
INSTALLATION KITS for S&S Gear DRIVE CAM (recommended)<br />
Models<br />
Standard Cam Kit<br />
<strong>1999</strong>-'06 (except <strong>2006</strong> Dyna® models)* 106-5896<br />
Includes a gearcover gasket, cam bearings and instructions. *<strong>2006</strong> Dyna® cams are in Section 1.<br />
106-5896<br />
Camshaft installation kit for <strong>1999</strong>-'06 models<br />
provides parts needed to install S&S® gear drive<br />
cam sets. Included with complete cam kits.<br />
106-4781<br />
Easy Start Cams for S&S Oil Pump<br />
Gear Drive Easy Start Cams<br />
for early models<br />
NOTES:<br />
• Pinion shaft run-out must be checked before installing S&S® gear drive cams.<br />
• A hydraulic press and other professional tools are required to install S&S gear drive cams.<br />
Additionally, material must be removed from the inner surface of the stock gearcover.<br />
The stock crankcase will require clearancing for S&S .625", .640", and .675" lift cams.<br />
S&S recommends that gear drive cams be installed by a professional mechanic.<br />
• New cam bearings and a new gearcover gasket are required to complete cam installation.<br />
Gear drive cams for <strong>1999</strong>-' 06 models require the use of ball bearing style cam bearing<br />
rather than the stock roller bearing. Roller bearings have more internal clearance which<br />
can cause excessive gear lash and increased noise. The correct parts are provided in S&S<br />
Camshaft Installation Kit, part #106-5896.<br />
• Due to the inherent characteristics of gear drives, you may experience more valve train<br />
noise with gear driven cams. Oversized and undersized gears are available to help<br />
achieve correct gear lash. We have found that with 160 lb. of valve seat force, the S&S<br />
gear drive cams will perform well up to 6200 rpm. If higher rpm is anticipated, valve<br />
springs that provide higher seat force should be used.<br />
• S&S can do a special order cam. Contact your S&S Customer Service Representative for<br />
more information.<br />
Visit us at www.sscycle.com<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-41
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
Cam Related Repair Parts<br />
Cam gear drive kits:<br />
(Includes front and rear inner cam gears, pinion gear, and outer cam gear)<br />
Fits <strong>1999</strong>-‘06 models ...............................................33-4275<br />
Outer cam drive gear kit:<br />
Fits <strong>1999</strong>-‘06 models ...............................................33-4276<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Replacement hardware pack for outer<br />
cam drive gear:<br />
Fits <strong>1999</strong>-up models ............................................. 33-4271P<br />
Replacement key ................................................. 106-1348<br />
Replacement gears, oversized & undersized<br />
Due to machining variations in the stock cam plate, oversized or undersized gears may be<br />
needed to achieve correct gear lash.<br />
Cam drive gear set: <strong>1999</strong>-up .......................................33-4293<br />
Outer rear cam drive gear only: <strong>1999</strong>-‘06 (except <strong>2006</strong> Dyna) ......... 106-4882<br />
Front inner cam gear: <strong>1999</strong>-‘06 (except <strong>2006</strong> Dyna) ..................33-4272F<br />
Rear inner cam gear, standard: <strong>1999</strong>-‘06 (except <strong>2006</strong> Dyna) ........ 33-4272R<br />
Rear inner cam gear, undersized: <strong>1999</strong>-‘06 (except <strong>2006</strong> Dyna) .....33-4272RX<br />
Rear inner cam gear, oversized: <strong>1999</strong>-‘06 (except <strong>2006</strong> Dyna) .......33-4272RZ<br />
Pinion Gears <strong>1999</strong>-up:<br />
Standard size ...................................................33-4160<br />
Undersized ....................................................33-4160X<br />
Double under ................................................ 33-4160XX<br />
Oversized .....................................................33-4160Z<br />
Double over ................................................. 33-4160ZZ<br />
S&S heavy duty cam bearing plate<br />
Fits <strong>1999</strong>-‘06 models ...............................................33-5212<br />
Cam Needle Bearings Assemblies<br />
Inner cam bearing Harley-Davidson® Twin Cam 88® and <strong>1999</strong>-'06 (H-D® # 9198)<br />
(except <strong>2006</strong> Dyna®) .....................................<br />
USA TÜV 2 31-4080<br />
33-4276<br />
Outer cam drive gear kit for Twin Cam 88® engine<br />
31-4080<br />
33-5212<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
NOTE:<br />
All reference to H-D® part numbers is for identification purposes only. We in no way<br />
are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that<br />
they are equivalent to the corresponding H-D® part number shown. Use of brand<br />
names such as Harley-Davidson® Sportster® are also for reference only.<br />
2-42<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
BILLET Gearcover<br />
Looking through this catalog, you will probably have noticed that S&S is offering more<br />
and more billet components. Billet offers a lot of structural and engineering advantages<br />
over cast parts, but the thing that makes everyone sit up and take notice is the beauty<br />
of polished or chrome billet aluminum. If you are replacing a cam or tappets, consider<br />
installing an S&S polished or chrome billet gearcover at the same time. While you’re at it,<br />
a billet oil filter bracket would really look great too.<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
FITMENT<br />
• <strong>1999</strong>-'12 Twin Cam 88®, 96 and 103*<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PART NUMBERs<br />
S&S Billet Gearcover<br />
Polished ........................................<br />
USA<br />
31-6516<br />
Chrome ............................................. 106-3774<br />
* The S&S gearcover is not compatible with <strong>1999</strong>-’01 engines with stock fuel injection<br />
or ignition systems which require a cam position sensor in the gearcover. May be used in<br />
<strong>1999</strong>-’01 engines if an aftermarket ignition or fuel injection system, that does not require<br />
a cam position sensor, is installed.<br />
S&S ®<br />
BILLET Oil Filter Bracket<br />
These billet oil filter brackets were originally created to complete our S&S T124 dual cam<br />
engines, but they are an excellent upgrade for stock Harley-Davidson® Twin Cam 88®<br />
engines as well. The bracket places the filter slightly farther from the crankcase to allow<br />
just that little bit of extra clearance that makes installation and removal of the filter a lot<br />
easier. However, what really makes this filter bracket useful is that it allows oil to be routed<br />
to an oil cooler right from the filter mounting bracket.<br />
31-6516<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
FITMENT<br />
• <strong>1999</strong>-'06 big twin (except <strong>2006</strong> Dyna® models)<br />
PART NUMBERs<br />
S&S Billet Oil Filter Bracket<br />
Polished ...................................<br />
USA TÜV 2 31-6510<br />
Chrome ............................................. 106-3884<br />
31-6510<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-43
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
4-1/8" BORE CYLINDERS & PISTONS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
for S&S 124" Hot Set up kits, Stock Bolt Pattern<br />
These cylinders are made of superior materials and has a thicker casting than stock cylinders.<br />
Other than being machined with a stock stud pattern, these cylinders are identical to the ones<br />
used in S&S 124" engines.<br />
FITMENT<br />
• Big twins with S&S 124" Hot Set Up Kit<br />
• Compatible with stock or S&S Super Stock® heads<br />
106-4159<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
FEATURES AND BENEFITS<br />
• Forged, coated pistons and S&S cylinders provide consistent performance and reliability<br />
• Valve pocket recesses in S&S pistons are enlarged for oversize valves and higher lift cams<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-44<br />
OPTIONS<br />
• Silver powdercoat or wrinkle black powdercoat finish<br />
Special Order OPTIONS<br />
• Diamond cut, full polished, natural and polish<br />
• Individual cylinders<br />
Displacement<br />
S&S® 41/8" BORE CYLINDERS FOR 124" HOT SET UP KITS<br />
Cylinders Only (single) Cylinders Only (pair) Cylinders w/ Pistons (pair)<br />
Front Rear Front Rear<br />
Silver<br />
Silver<br />
Black<br />
Silver<br />
Black<br />
(for S&S<br />
(for (for S&S 89cc/91cc<br />
Silver<br />
Black<br />
89cc/91cc heads) stock heads)<br />
heads)<br />
NOTE: S&S 41/8" pistons are machined to such close tolerances that it is not necessary to<br />
measure the piston. Additionally, the low friction coating on the piston skirt makes taking<br />
measurements very difficult. Therefore, hone cylinders to nominal diameter +/- 0.0005"<br />
for correct clearance.<br />
Order toll free 866-244-2673<br />
Black<br />
(for<br />
stock heads)<br />
124" 106-4105 106-4106 91-7252F 91-7252R 106-4158 91-7252 106-4159 – 91-7257 –<br />
124" dish 106-4105 106-4106 91-7252F 91-7252R 106-4158 91-7252 – 106-4163 – 91-7253<br />
Special Order – – – – 91-7506*<br />
Cylinder w/ piston kits include cylinders, piston kit, head gaskets, base gaskets, and exhaust gaskets<br />
* Special Order: Download the Special Order Form at sscycle.com/soforms<br />
S&S® 41/8" BORE PISTONS FOR HOT SET UP KITS<br />
Forged Piston Kits<br />
Rings, chromoly faced<br />
Heads<br />
Deck<br />
Height<br />
Stroke Piston Type Standard +.010" +.020" +.030" Standard +.010" +.020" +.030"<br />
S&S 89cc/91cc<br />
Flat topped 92-1556 92-1557 92-1558 92-1559<br />
1.050" 45/8"<br />
Stock 10.9cc dished 92-1575 92-1576 92-1577 –<br />
94-1400X 94-1401X 94-1402X 94-1403X<br />
Piston kits include set of pistons, rings, wristpins, and clips<br />
Wristpin<br />
.927" x 2.825" long.......................... USA 3 TÜV 1,6,7 94-9277<br />
.927" x 2.250" long.................................... 106-1052<br />
Keeper<br />
Each .......................................... TÜV 7 94-9278-S<br />
2 pack. ........................................ TÜV 7 94-9278-2<br />
4 pack. .........................................<br />
TÜV 7 106-2304<br />
S&S® 41/8" BORE CYLINDERS FOR 124" HOT SET UP KITS Specifications<br />
Displacement Stroke Cylinder Length<br />
Compression Ratio<br />
Stock Heads 91cc S&S Heads 89cc S&S Heads<br />
124" 45/8" 5.013" 10.8:1 10.8:1 11:1<br />
124" dish 45/8" 5.013" 10.4:1 10.2:1 10.4:1<br />
GASKETS, DOWELS, AND HARDWARE<br />
Description S&S Part No. H-D® Part No.<br />
Head Gasket (each)<br />
93-1091-S<br />
Base Gasket (each)<br />
93-1092-S<br />
Base O-ring (each) 50-8049<br />
Exhaust Gasket (each) 106-5029 (H-D® #65324-83A, 65324-83B)<br />
Oil Return O-ring (each) 50-8008 (H-D® #11105, 11275)<br />
Cylinder Dowel (each) 50-8177 (H-D® #16595-99A)<br />
Center Case Bolt (waisted) (each) 50-0327<br />
Flat Washer (each) 50-7026<br />
Nut 5/16" - 24 (each) 50-5023<br />
Center Case Bolt Seal (each) 50-8063-S
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
4-1/8" BORE CYLINDERS AND PISTONS<br />
Replacements for cylinders included in S&S T-Series 41/8" bore engines, these cylinders are<br />
made of superior materials and have a thicker casting than stock cylinders.<br />
FITMENT<br />
• S&S bolt pattern T124, T117 and T111 engines<br />
FEATURES AND BENEFITS<br />
• Forged, coated pistons and S&S cylinders provide consistent performance and reliability<br />
• Valve pocket recesses in S&S pistons are enlarged for oversize valves and higher lift cams<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
OPTIONS<br />
• Silver, wrinkle black powdercoat, or polished finish<br />
Special Order OPTIONS<br />
• Natural, diamond cut, and full polished<br />
• Individual cylinders<br />
91-7099<br />
41/8" BORE CYLINDERS FOR S&S® ENGINES Specifications<br />
Displacement Stroke Cylinder Length Compression Ratio<br />
124" 4 5/8" 5.013" 10.8:1<br />
117" 4 3/8" 4.888" 10.2:1<br />
111" 4 1/8" 4.763" 9.7:1<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
41/8" BORE CYLINDERS FOR S&S® ENGINES<br />
Cylinder Only Cylinders Only (Set) Cylinders w/ Pistons (Set)<br />
Displacement Front Rear Front Rear Front Rear<br />
Silver Black Polished<br />
Silver Black Polished Silver Black Polished<br />
124" 106-4099 106-4100 91-7079F 91-7079R 91-7165F 91-7165R 106-4157 91-7079 91-7165 106-4161 91-7099 –<br />
117" 106-4089 106-4090 – – – – 106-4151 – – 106-4152 91-7098 –<br />
111" 106-4083 106-4084 – – – – 106-4150 – – 106-4149 – 91-7290<br />
Special Order 91-7506*<br />
Cylinder w/ piston kits include fitted pistons and cylinders, head gaskets, base, and exhaust gaskets<br />
* Special Order: Download the Special Order Form at sscycle.com/soforms<br />
41/8" BORE PISTONS FOR S&S® ENGINES<br />
Displacement<br />
Forged Piston Kits<br />
Rings, chromoly faced<br />
Deck Height Stroke Standard +.010" +.020" +.030" Standard +.010" +.020" +.030"<br />
124"<br />
4 5/8" 92-1556 92-1557 92-1558 92-1559<br />
117" 1.050" 4 3/8" 92-1550 92-1551 92-1552 92-1553 94-1400X 94-1401X 94-1402X 94-1403X<br />
111" 4 1/8" 92-1560 92-1561 92-1562 92-1563<br />
Piston kits include set of pistons, rings, wristpins, and clips<br />
Wristpin<br />
.927"...................................... USA TÜV 3 1,6,7 94-9277<br />
Keeper<br />
Each .......................................... TÜV 7 94-9278-S<br />
2 pack......................................... TÜV 7 94-9278-2<br />
4 pack..........................................<br />
TÜV 7 106-2304<br />
GASKETS, DOWELS, AND HARDWARE<br />
Description S&S Part No. H-D® Part No.<br />
Head Gasket (each)<br />
93-1047-S<br />
Base Gasket (each)<br />
93-1048-S<br />
Exhaust Gasket (each) 106-5029 (H-D® #65324-83A, 65324-83B)<br />
Cylinder Dowel (each) 50-8177 (H-D® #16595-99A)<br />
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<br />
measurements very difficult. Therefore, hone cylinders to nominal diameter +/- 0.0005" for correct clearance.<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-45
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
3-7/8" BORE REPLACEMENT CYLINDERS AND PISTONS<br />
These 3 7/8" bore cylinders are a good choice for installation and repair of 95" kits. Superior materials,<br />
thicker casting in critical areas and bigger cooling fins, combined with excellent wear resistance ensure<br />
excellent engine life.<br />
FITMENT<br />
• Cylinders can be used for stock replacement<br />
• 95" kit for <strong>1999</strong>-’06 models – pistons have 5.3cc pop up dome<br />
• S&S 106" stroker kit for <strong>1999</strong>-’06 models – pistons have flat tops<br />
91-7045<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
FEATURES AND BENEFITS<br />
• Installation of S&S cylinders instead of boring stock cylinder saves time and labor when<br />
installing 95" kits<br />
• S&S 37/8" bore cylinders require no crankcase machining to install<br />
• Piston weight for 95" kits are the same as stock – no flywheel rebalancing<br />
• Forged, coated pistons and S&S cylinders are compatible with stock or S&S Super Stock® heads<br />
• Valve pocket recesses in S&S pistons are enlarged for oversize valves and higher lift cams<br />
OPTIONS<br />
• Silver or wrinkle black powdercoat finish<br />
Special Order OPTIONS<br />
• Natural, diamond cut, polished and full polished<br />
106-0432 Series Piston<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
S&S® 37/8" BORE CYLINDERS<br />
Displacement Stroke<br />
Cylinder<br />
Length<br />
Compression Ratio Cylinder Only (Single) Cylinders Only (Set) Cylinders w/Pistons (Set)<br />
Stock Heads 89cc S&S Heads 79cc S&S Heads Silver Black Silver Black Silver Black<br />
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<br />
95" 4" 9.7:1 9.3:1 10.3:1 106-4138 91-7047<br />
Special Order – – 91-7506*<br />
Cylinder w/ piston kits include fitted pistons and cylinders, head gaskets, base, and exhaust gaskets<br />
*Special Order: Download the Special Order form at sscycle.com/soforms<br />
Displacement<br />
Deck<br />
Height<br />
Forged Piston Kits<br />
S&S® 37/8" BORE PISTONS<br />
Rings, chromoly faced<br />
Stroke Standard +.005" +.010" +.020" Standard +.005" +.010" +.020"<br />
0.927" Wristpin<br />
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<br />
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<br />
Piston kits include set of pistons, rings, wristpins, and clips<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-46<br />
Keeper .927”<br />
Each .......................................... TÜV 7 94-9278-S<br />
2 pack. ........................................ TÜV 7 94-9278-2<br />
4 pack. .........................................<br />
TÜV 7 106-2304<br />
NOTES:<br />
• For 95" and 106" ‘cylinder only’ kits, pistons must be measured and cylinders bored/<br />
honed accordingly. Recommended piston fitment:<br />
• Close: 0.0020" – 0.0025" Loose: 0.0032" – 0.0045"<br />
• S&S 3 7/8" pistons for 103" kits are machined to such close tolerances that it is not<br />
necessary to measure the piston. Additionally, the low friction coating on the piston<br />
skirt makes taking measurements very difficult. Therefore, hone cylinders to nominal<br />
diameter +/- 0.0005" for correct clearance.<br />
Order toll free 866-244-2673<br />
Gaskets & Dowels<br />
Description S&S Part No. H-D® Part No.<br />
MLS Head Gasket, .045” (each) 106-2947<br />
MLS Head Gasket, .030” (2 pack) 900-0216<br />
Base O-ring (each) 50-8048 (H-D® #11256)<br />
Exhaust Gasket (each) 106-5029 (H-D® #65324-83A, 65324-83B)<br />
Oil Return O-ring (each) 50-8008 (H-D® #11105, 11275)<br />
Cylinder Dowel (each) 50-8177 (H-D® #16595-99A)
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
3.927" BORE REPLACEMENT CYLINDERS AND PISTONS<br />
Superior materials, thicker casting in critical areas and bigger cooling fins are what make S&S<br />
cylinders the best! Improved cooling and strength combined with excellent wear resistance will<br />
maintain horsepower and reliability for years to come. Replacement cylinders for S&S 97" and<br />
106" top end kits.<br />
FITMENT<br />
• S&S 97" top end kit for <strong>1999</strong>-’06 models<br />
106-3765<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
FEATURES AND BENEFITS<br />
• Piston weight for 97" kits are the same as stock, requiring no flywheel rebalancing<br />
• S&S 3.927" bore cylinders require no crankcase machining to install<br />
• Forged, coated pistons and S&S cylinders are compatible with stock or<br />
S&S Super Stock® 89cc heads<br />
• Valve pocket recesses in S&S pistons are enlarged for oversize valves and higher lift cams<br />
• Pistons compatible with tapered or standard rods<br />
OPTIONS<br />
• Silver or wrinkle black powdercoat finish<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Special Order OPTIONS<br />
• Natural, diamond cut, polished and full polished<br />
106-3688<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
S&S® 3.927" BORE CYLINDERS for 97" & 106" Top end kits<br />
Compression Ratio<br />
Cylinder Only (Front or Rear)<br />
Displacement Stroke Cylinder Length<br />
Stock Heads 89cc S&S Heads Silver Black<br />
97" 4" 4.937" 9.7 9.4 106-3765 106-3767<br />
Special Order – – – – 91-7506*<br />
Since front and rear cylinders are interchangeable they are not sold in pairs.<br />
* Special Order: Download the Special Order Form at sscycle.com/soforms<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
S&S® 3.927" BORE PISTONS 97" & 106" Top end kits<br />
Displacement<br />
Forged Piston Kits<br />
Rings, chromoly faced<br />
Deck Height Stroke Standard +.010" Standard +.010"<br />
0.927" Wristpin<br />
97" 1.270" 4" 106-3688 106-4414 106-3709A 106-4422A 106-1052<br />
Piston kits include set of pistons, rings, wristpins, and clips<br />
Keeper .927”<br />
Each .......................................... TÜV 7 94-9278-S<br />
2 pack......................................... TÜV 7 94-9278-2<br />
4 pack..........................................<br />
TÜV 7 106-2304<br />
NOTE:<br />
• S&S 3.927" pistons are machined to such close tolerances that it is not necessary to<br />
measure the piston. Additionally, the low friction coating on the piston skirt makes<br />
taking measurements very difficult. Therefore, hone cylinders to nominal diameter<br />
+/- 0.0005" for correct clearance.<br />
GASKETS<br />
Description S&S Part No. H-D® Part No.<br />
MLS Head Gasket, .045" (each) 106-3714<br />
MLS Head Gasket, .030" (2 pack) 900-0216<br />
Base O-ring 50-8048 (H-D® #11256)<br />
Gasket Kit<br />
(includes head, base, & exhaust gaskets and o-rings)<br />
106-3763<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-47
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
4" BORE REPLACEMENT PISTONS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
OEM Cross Reference<br />
Appendix & Index<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
PERFORMANCE<br />
PARTS<br />
92-1436<br />
S&S® 4" BORE PISTONS<br />
Displacement<br />
Forged Piston Kits<br />
Rings, chromoly faced<br />
Deck Height Stroke Standard +.010" +.020" +.030" Standard +.010" +.020" +.030"<br />
116"<br />
4 5/8" 92-1436 92-1437 92-1438 92-1439<br />
1.200"<br />
100" 4" 92-1430 92-1431 92-1432 92-1433<br />
94-1306X 94-1307X 94-1308X 94-1309X<br />
Piston kits include set of pistons, rings, wristpins, and clips<br />
Wristpin<br />
.927". ..................................... USA TÜV 3 1,6,7 94-9277<br />
Keeper<br />
Each .......................................... TÜV 7 94-9278-S<br />
2 pack. ........................................ TÜV 7 94-9278-2<br />
4 pack. .........................................<br />
TÜV 7 106-2304<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
SPECIAL NOTES:<br />
• For 100" and 116" ‘cylinder only’ kits, pistons must be measured and cylinders bored/<br />
honed accordingly. Recommended piston fitment:<br />
• Close: 0.0020" – 0.0025" Loose: 0.0032" – 0.0045"<br />
• Stock crankcases must be bored to accept the larger S&S 4" cylinders<br />
• Early S&S 4" bore kits used o-rings to seal the cylinder base. Later kits use a base<br />
gasket. Use the correct sealing method for your kit<br />
2-48<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
SUPER STOCK ® 91cc CYLINDER HEADS<br />
FOR 4-1/8" BORE ENGINES<br />
Cylinder heads shown on this page are replacements for S&S 41/8" bore engines and 124"<br />
Hot Set Up Kits. Heads for S&S engines are machined with the S&S head bolt pattern, for<br />
use with S&S crankcases. Heads for the 124" Hot Set Up Kit are machined with the stock<br />
head bolt pattern, for use with stock crankcases.<br />
FEATURES AND BENEFITS<br />
• Heads can be decked up to .060" to increase compression<br />
• S&S .640" lift valve springs<br />
• Stock Harley-Davidson® rocker boxes can be retained if S&S manual<br />
compression release or S&S Easy Start cams are used. Must use S&S valve<br />
cover gasket kit part #90-4120 with stock rocker covers. Conversely, when electronic<br />
compression releases are used, S&S rocker covers must be used.<br />
90-1370<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
OPTIONS<br />
• Compression release machining or without compression release machining<br />
• S&S or stock head bolt pattern<br />
• Natural, silver powdercoat, black powdercoat, or polished finish<br />
Description<br />
<strong>1999</strong>-'05 bt**<br />
91cc 41/8" Bore<br />
Stock bolt pattern<br />
S&S Replacement cylinder head Kits for S&S 124" Hot Set Up Kit® for <strong>1999</strong>-'05 big twins**<br />
Finish<br />
Silver<br />
Black<br />
Compression Release<br />
Machining<br />
Springs<br />
Part No.<br />
• .640" lift 106-4272<br />
.640" lift 900-4272<br />
• .640" lift 90-1163<br />
.640" lift 900-1163<br />
Special Order * Specify – – 90-1060<br />
*<br />
Special Order: Download the Special Order Form at sscycle.com/soforms<br />
** <strong>2006</strong> model year cylinder heads can be found in Section 1.<br />
Description<br />
91cc 41/8" Bore<br />
S&S Bolt pattern<br />
S&S Replacement cylinder head kits<br />
for S&S bore T-Series engines for <strong>1999</strong>-'06 big twins<br />
Finish<br />
Compression Release<br />
Machining<br />
Springs<br />
Part No.<br />
Natural • .640" lift 90-1370<br />
Silver • .640" lift 106-4275<br />
Black • .640" lift 90-1371<br />
Polished • .640" lift 90-1372<br />
Special Order * – – – 90-1060<br />
*<br />
Special Order: Download the Special Order Form at sscycle.com/soforms<br />
NOTES:<br />
• By changing the profile and shape of the cooling fins on our heads for 41/8" bore engines, a large<br />
reduction in the transmission of mechanical noise was found. This not only benefits our TÜV<br />
certified engines and our EPA approved engines, but our performance engines as well!<br />
• Since April 1, 2007, these redesigned heads have been installed on all S&S 41/8" bore engines<br />
and Hot Set Up Kits.<br />
• Replacement heads of the old style are available by special order.<br />
S&S® Top End Gasket Kits for <strong>1999</strong>-’12 Big twins<br />
S&S 41/8" Bore (Graphite) Stock 41/8" Bore (Layered Steel)<br />
90-1910 USA TÜV 3 6 90-1914<br />
Includes a set of .043” head and base gaskets, exhaust gaskets and o-rings.<br />
Visit us at www.sscycle.com<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-49
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
SUPER STOCK ® 79cc & 89cc CYLINDER HEADS<br />
S&S 79cc cylinder heads are intended for stock engines and other small<br />
displacement applications. These heads are compatible with stock Harley-<br />
Davidson® rocker covers. Must use S&S valve cover gasket kit part #90-4124<br />
with stock rocker covers. They are a very economical performance upgrade<br />
designed for use with other performance enhancers and are machined to accept<br />
S&S® compression releases.<br />
Intended for larger displacement engines, S&S 89cc heads have a whopping<br />
264cfm flow rate (compared to 182cfm for stock H-D® heads), larger valves<br />
and .640" lift valve springs. S&S recommends S&S Easy Start cams or manual or<br />
electric compression release system in order to maintain reliable engine starting<br />
on high compression applications.<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
FITMENT<br />
• <strong>1999</strong> – '05 big twins (<strong>2006</strong> model year heads can be found in Section 1)<br />
• Stock rocker covers<br />
FEATURES AND BENEFITS<br />
• Heads can be decked up to .060" to increase compression<br />
• 79cc heads 1.940" intake and 1.575" exhaust valves<br />
• 89cc heads have 2.000" intake and 1.605" exhaust valves<br />
• S&S .585" or .640" lift valve springs<br />
• Stock Harley-Davidson® rocker boxes can be retained if S&S manual<br />
compression release or S&S Easy Start cams are used. Must use S&S<br />
valve cover gasket kit part #90-4120 with stock rocker covers<br />
OPTIONS<br />
• Compression release machining or without compression release machining<br />
• Silver powdercoat or wrinkle black powdercoat finish<br />
Compression Ratios for S&S® Super Stock® Cylinder Heads<br />
for <strong>1999</strong>-'063 Big twins<br />
Engine Displacement and<br />
Configuration<br />
79cc<br />
Chamber Volume<br />
89cc<br />
88" 9.1 8.3<br />
95" 9.6/10.3* 8.7/9.3*<br />
97" Big Bore 10.3 9.4<br />
103" 10.2/11.1* 9.3/10.1*<br />
106" Stroker 10.7 9.8<br />
* S&S pop-up piston<br />
110" 10.8 9.8<br />
Fitment<br />
<strong>1999</strong>-'05 bt<br />
106-4277<br />
S&S heads for Harley-Davidson® engines are now available in silver powdercoat finish. This is<br />
a perfect match for the finish on stock cylinders and crankcases.<br />
S&S® Super Stock® Cylinder Head Kits<br />
Chamber<br />
Volume<br />
79cc<br />
89cc<br />
Finish<br />
Silver<br />
Wrinkle<br />
Black<br />
Silver<br />
Wrinkle<br />
Black<br />
Compression<br />
Release<br />
Machining<br />
Springs Part No.<br />
• .640" lift 106-4277<br />
.585" lift 900-0254<br />
• .640" lift 90-1293<br />
.585" lift 900-0251<br />
• .640" lift 106-4270<br />
.585" lift 900-0409<br />
• .640" lift 90-1106<br />
.585" lift 900-0410<br />
Special<br />
Order 1 – – – – 90-1060*<br />
1<br />
Use this Special Order part number to order assembled or unassembled cylinder heads with spring<br />
options, special finish or diamond cut<br />
*Special Order: Download the Special Order Form at sscycle.com/soforms<br />
S&S® Head Bolt Packages for Cylinder Heads<br />
For <strong>1999</strong>-'12 Big twins<br />
Engine Displacement<br />
Part No.<br />
88", 95", 100", 106", 107", 110", 111" 93-3070<br />
116", 117" 93-3071<br />
124" 93-3072<br />
OEM Cross Reference<br />
Appendix & Index<br />
S&S® Top End Gasket Kits for <strong>1999</strong>-'12 Big twins<br />
33/4" Bore 37/8" Bore 3.927" Bore 4" Bore<br />
90-1911 90-1912 106-3763 90-1913<br />
Includes a set of head and base gaskets, exhaust gaskets and o-rings.<br />
2-50<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Continued<br />
S&S® Super Stock® 79cc & 89cc Cylinder Heads<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
90-4120<br />
S&S valve cover gasket kit.<br />
Must be used with stock rocker covers.<br />
NOTES:<br />
• 79cc heads<br />
• 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<br />
clearancing. This allows the use of S&S® 510, 570, and 585 camshafts. If cams with higher TDC lifts are used, or if the heads are decked, piston valve pocket machining will be<br />
required.<br />
• 79cc heads may be decked as much as .060" to increase compression. If heads are decked, piston valve pockets must be re-machined.<br />
• 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<br />
and performance we recommend the S&S gear drive cams.<br />
• Must use S&S valve cover gasket kit part #90-4120 with stock rocker covers.<br />
• 89cc heads<br />
• If 89cc heads are used with stock pistons, valve reliefs must be machined in the pistons due to larger valve size.<br />
• 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<br />
be re-machined.<br />
• 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<br />
and performance we recommend the S&S gear drive cams.<br />
• A larger intake manifold is recommended to supplement the heads in order to let them flow to their full potential.<br />
• Must use S&S valve cover gasket kit part #90-4120 with stock rocker covers.<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
MANIFOLD RECOMMENDATIONS<br />
• S&S® manifolds for <strong>1999</strong>-’06 carbureted engines are available to fit stock CV carburetors<br />
and S&S Super E and G carbs. Note that <strong>2006</strong> models require a slightly shorter manifold. (See<br />
"Important Manifold Information")<br />
• S&S single bore throttle body and manifold are recommended for engines with Magneti<br />
Marelli® and Delphi® fuel injection.<br />
• S&S single bore throttle body and manifold are recommended for <strong>2006</strong>-'12, except 2008-'12<br />
touring models. Due to the change in manifold flange mounting bolt pattern, stock flanges and<br />
S&S seal part #16-0235 must be used. The Screamin’ Eagle® 58mm throttle body/manifold<br />
may also be used on <strong>2006</strong>-'09 engines.<br />
• We recommend the stock 50 mm throttle body or Screamin’ Eagle 58mm throttle body/<br />
manifold for 2008-up touring models with Electronic Throttle Control (ETC). These engines<br />
can be tuned with the Harley-Davidson® Super Tuner package, Pro EFI Super Tuner, Power<br />
Commander® or an aftermarket EFI tuning module or software tuner.<br />
IMPORTANT MANIFOLD INFORMATION<br />
• In <strong>2006</strong>, Harley-Davidson® changed the bolt pattern of the flanges that connect the manifold<br />
to the cylinder heads for all big twin engines. The pattern was changed from an offset bolt<br />
pattern to a symmetrical bolt pattern, so flanges can fit either the front or rear cylinder head.<br />
In addition, the intake port was moved slightly toward the drive side of the engine, making the<br />
port-to-port distance of the intake manifold slightly shorter. S&S® heads for <strong>2006</strong>-up big twins<br />
are machined with the symmetrical bolt pattern and relocated port to allow for the fitment<br />
of stock manifolds. In 2008, Harley-Davidson touring models were equipped with electronic<br />
throttle control (ETC). The throttle body and manifold used on these engines is a one-piece<br />
unit that contains a servomechanism to control the position of the throttle plate. S&S does not<br />
offer a throttle body for this application, so the stock 50mm throttle body or a Screamin’ Eagle®<br />
58mm throttle body is recommended. This limits the cylinder length of engines using an ETC<br />
manifold/throttle body to stock length because the ETC manifold/throttle body units are only<br />
available in stock length. However, S&S does supply specially machined cylinder heads for our<br />
124" Hot Set Up Kit® for 2008 and later baggers, which allows the use of a stock length manifold<br />
on these longer-than-stock engines.<br />
Ordering Notes:<br />
• Select the cylinder head kit that is correct for your application.<br />
• Select a gasket kit for the bore size of your engine. (Refer to "S&S Top End Gasket Kits" chart on<br />
previous page)<br />
• Select an S&S manifold for your engine size or cylinder length and fuel system. (Optional)<br />
• Select head bolt package. (Refer to "S&S Head Bolt Packages" chart on previous page)<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-51
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Head BOLTS WITH WASHERS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
head bolt washers<br />
Thickness<br />
Part No.<br />
.100" 50-7088<br />
.150" 50-0418-S<br />
.250" 50-7091<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
S&S® head bolt-information chart<br />
Length w/ Washer 1.690" 1.840" 1.920" 2.070" 2.220" 2.370" 3.134" 3.284" 3.501" 3.651"<br />
Washer Thickness .250" .100" .250" .100" .250" .100" .250" .100" .250" .100"<br />
Head Bolt w/Washer 93-3028 TÜV 4 93-3027 93-3036 93-3031 93-3038 93-3032 93-3029 TÜV 4 93-3030 93-3037* 93-3033* TÜV 2<br />
Washers Only 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088 50-7091 50-7088<br />
* Drilled & tapped deeper to allow shortening for custom lengths.<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
S&S® head bolts for Harley-Davidson® twin cam 88® and Twin Cam 96 engines<br />
Engine Displacement Stroke Cylinder Length Cylinder Head Type Short Bolt w/Washer Long Bolt w/Washer Head Bolt Kit<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
88", 95" 4" 4.935"<br />
100" 4" 4.850"<br />
106" Stroker 41⁄2" 4.935"<br />
107" 41⁄4" 4.975"<br />
111" 41⁄8" 4.763"<br />
116" 45⁄8" 5.160"<br />
117" 43⁄8" 4.888"<br />
124" 45⁄8" 5.013"<br />
50-0333<br />
Stock H-D® 93-3031 93-3030 93-3014 USA<br />
S&S® – 93-3030 93-3070<br />
Stock H-D® 93-3036 93-3030 93-3014 USA<br />
S&S® – 93-3029 TÜV 4<br />
–<br />
Stock H-D® 93-3031 93-3030 93-3014 USA<br />
S&S® – 93-3030 93-3070<br />
Stock H-D® 93-3031 93-3037 93-3012<br />
S&S® – 93-3030 93-3070<br />
Stock H-D® 93-3027 93-3030 93-3010 USA<br />
S&S® – 93-3029 TÜV 4<br />
–<br />
Stock H-D® 93-3038 93-3037 93-3016<br />
S&S® – 93-3037 93-3071<br />
Stock H-D® 93-3031 93-3030 93-3014 USA<br />
S&S® – 93-3030 93-3070<br />
Stock H-D® 93-3038 93-3037 93-3016<br />
S&S® – 93-3037 93-3071<br />
CALCULATING CUSTOM HEAD BOLT LENGTHS<br />
See instructions on page 12-6<br />
S&S ® Chrome Head Bolt Covers<br />
Dress up your engine with these magnetic chrome head bolt covers. Easy installation,<br />
no tools, no messy adhesives. A powerful magnet holds cover in place, yet allows easy<br />
removal. Chrome plated steel looks great on any engine, but is a must for polished<br />
engines. For S&S head bolts only.<br />
(Set of 4) .............................................<br />
USA<br />
50-0333<br />
2-52<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
High Performance Hydraulic Tappets<br />
Standard equipment in S&S T-Series engines and every Hot Set Up Kit® for Harley-Davidson® Twin Cam 88® and<br />
96, these tappets are a great choice for any stock or high performance application. Only the finest materials and<br />
precision machining techniques are used in the manufacture of these lifters, and strict quality control ensures that<br />
they will work flawlessly every time, no matter what the application. Whether you have a stock 88 incher or the<br />
most outrageous big inch engine with a radical cam and spring combination, S&S tappets are built to take it.<br />
FITMENT<br />
• <strong>1999</strong>–'12 big twins<br />
• S&S T-Series engines<br />
OPTIONS<br />
Tappets are available with the HL 2<br />
T Limited Travel Kit for improved cold starts and high rpm valve timing accuracy.<br />
PART NUMBER<br />
Four hydraulic tappets without HL 2<br />
T Kit (H-D® #18538-99A, 18538-99B) ...<br />
USA<br />
33-5350<br />
Four hydraulic tappets with HL 2<br />
T Kit ..................................33-5351<br />
S&S ®<br />
NOTE: S&S tappets with HL 2<br />
T Kit require the use of adjustable pushrods.<br />
Hydraulic Lifter Limited Travel Spacer (HL 2<br />
T)<br />
Designed to limit the range of travel of the hydraulic tappet plunger, HL 2<br />
T spacers do not allow the tappets to collapse,<br />
meaning both high rpm performance and starting are improved. A great addition to stock applications, the S&S HL 2<br />
T<br />
kit is highly recommended for engines equipped with stronger valve springs and aggressive cam profiles.<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
FITMENT<br />
• Stock 2003 – ’12 big twin<br />
• Harley-Davidson® replacement tappets <strong>1999</strong>-up bt<br />
• All S&S tappets<br />
FEATURES AND BENEFITS<br />
• Low noise and positive valve train activation<br />
• More horsepower at higher RPM’s<br />
• Easier starting<br />
PART NUMBER<br />
Set of four spacers (fits tappets with .612" I.D.) (Fits H-D® #18526-89A, 18538-99B) ..33-5338<br />
S&S ®<br />
Tappet Covers<br />
The perfect finishing touch for any stock or custom engines, these S&S tappet<br />
covers are CNC machined from billet aluminum and polished to a show finish.<br />
FITMENT<br />
• <strong>1999</strong>-’12 big twins<br />
• S&S crankcases<br />
33-5338<br />
Note: Will not fit factory tappets in <strong>1999</strong>-'02 engines.<br />
EXTRA PARTS NEEDED:<br />
• Adjustable pushrods must be used with HL 2<br />
T kit in order to obtain proper plunger position.<br />
• If replacing lifters in a <strong>1999</strong>-'02 with H-D #18538-99B, order S&S part #33-5338.<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
FEATURES AND BENEFITS<br />
• CNC billet aluminum provides extra strength and dimensional stability<br />
over a wide temperature range<br />
• Simple to install upgrade that looks great<br />
KIT CONTENTS<br />
• Covers<br />
• Gaskets<br />
• Installation hardware<br />
33-5601<br />
PART NUMBERs<br />
USA<br />
Polished, Tappet Cover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5601<br />
Chrome, Tappet Cover Kit ............................... 106-3883<br />
Replacement Gasket (H-D® #18635-99B) each ..................33-5303-S<br />
2 pack ......................................33-5303-2<br />
Visit us at www.sscycle.com<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-53
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
QUICKEE Adjustable PUSHRODS<br />
These pushrods can be both installed and removed easily. The S&S design permits a<br />
simple, trouble-free installation that does not require removal of the gas tank, rocker<br />
assemblies, tappet covers, or even the rocker box cover! OEM pushrods may be cut<br />
to permit removal without rocker disassembly. The threaded adjuster screws into the<br />
pushrod until the threads disengage and the adjuster simply slides into the pushrod,<br />
making installation or removal a snap. Once the pushrod is installed and adjusted, the<br />
locknut prevents the adjuster from moving. 1984-'99 style pushrod covers required.<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
FITMENT<br />
• <strong>1999</strong>-'12 Twin Cam 88® or 96 w/ stock engine height +/- .050"<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
FEATURES AND BENEFITS<br />
• Easy to install – removal of rocker box not needed<br />
• Adjustable to accommodate all tappets and cam base circle diameters and<br />
engine heights<br />
• Perfect for S&S HL 2<br />
T<br />
• No threads on wrench flats<br />
• Quickee Adjustable Pushrod Kit includes:<br />
• Pushrods<br />
• Chrome pushrod covers<br />
• O-rings<br />
• Cover keepers<br />
PART NUMBERS<br />
Quickee Adjustable Pushrod Kit .......................... 106-6051<br />
Quickee Adjustable Pushrods Only ..........................93-5122<br />
Special Order* (pushrods only) ..............................93-5135<br />
*Special Order: Download the Special Order Form at sscycle.com/soforms<br />
93-5122<br />
When a Quickee Adjustable pushrod is collapsed, it can easily be installed or removed from<br />
an assembled engine.<br />
Tools & Shop<br />
Supplies<br />
Replacement parts on page 2-56<br />
Dealer Services<br />
& Promo Items<br />
WATCH THE PUSHROD INSTALLATION VIDEO AT<br />
SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
106-6051<br />
Quickee Adjustable Pushrod Kit<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
EXTRA PARTS NEEDED:<br />
• 1984-'99 style pushrod covers are required for access to the Quickee Adjustable Pushrod<br />
adjusters in <strong>1999</strong>-up big twins. We suggest pushrod & cover kits.<br />
• Longer keepers are required for taller than stock engines.<br />
2-54<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Standard ADJUSTABLE PUSHRODS<br />
S&S Standard Adjustable Pushrods are an economical alternative to the S&S<br />
Quickee Adjustable pushrods, but require rocker cover removal to install or remove. To<br />
assure consistent valve train operation under all conditions, S&S adjustable pushrods are<br />
manufactured from rigid chromoly steel tubing.<br />
FITMENT<br />
• <strong>1999</strong>–'12 big twins<br />
• Lengths available for various displacements<br />
FEATURES AND BENEFITS<br />
• Adjustable to accommodate all tappets & cam base circle diameters<br />
• Perfect for HL 2<br />
T kits<br />
• Standard Adjustable Pushrod Kit includes:<br />
• Pushrods<br />
• Chrome pushrod covers<br />
• Tappet cover gaskets<br />
• O-rings<br />
• Cover keepers<br />
WATCH THE PUSHROD INSTALLATION VIDEO AT<br />
SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
PART NUMBERS<br />
S&S Standard Adjustable Pushrod Kit .......................93-5095<br />
Replacement parts on page 2-56<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
S&S® Standard adjustable Pushrods for Harley-Davidson® Twin Cam 88® and Twin Cam 96/103<br />
Displacement Engine Height Cylinder length Pushrods Only Pushrod Clip Pushrod Covers<br />
88", 95", 96", 103", 106" Stock 4.937" 93-5096 93-4100 106-1340<br />
USA<br />
100" -.070" 4.850" – 93-4100<br />
USA<br />
106-1340<br />
107" +.055" 4.975" 93-5100 93-4101 106-1340<br />
USA<br />
116" +.243" 5.160" 93-5098 93-4115 106-1340<br />
USA<br />
124" +.096" 5.013" 93-5098 93-4115 106-1340<br />
USA<br />
Special Order Specify Specify 93-5102** 93-4109* –<br />
*Custom, extra long stainless steel 4.250", customer to cut to required length<br />
**Special Order: Download the Special Order Form at sscycle.com/soforms<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
93-5095<br />
Standard Adjustable Pushrod Kit<br />
Visit us at www.sscycle.com<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-55
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
PUSHROD COVERS AND RELATED PARTS<br />
S&S pushrod cover kits include all of the parts required for four pushrods except keepers.<br />
Keepers are sold separately because of the different length requirements of some engines.<br />
These covers are a must when using adjustable pushrods.<br />
FITMENT<br />
• <strong>1999</strong>–'12 big twins<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PART NUMBERs<br />
Pushrod Cover Kit (includes top and bottom covers, cover cap, cover spring, and<br />
spring washer for four pushrods) ..........................<br />
USA<br />
106-1340<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
replacement parts<br />
Top cover (H-D® #17935-79B).............. USA USA 1,2,3<br />
TÜV 1,2,3,6,7 93-4016<br />
Bottom cover (H-D® #17938-83) ............<br />
USA USA 1,2,3<br />
TÜV 1,2,6,7 93-4015<br />
Cover cap (H-D#17945-36B)............... USA USA 1,2,3<br />
TÜV 1,2,3,6,7 93-4017<br />
Cover spring (H-D#17947-36) ............. USA USA 1,2,3<br />
TÜV 1,2,3,6,7 93-4018<br />
Cover cap washer (H-D#6762B) each .........................<br />
USA<br />
50-7131<br />
10 pack .............................................<br />
USA<br />
50-7136<br />
Top o-ring (H-D® #11190, 11157, 11293) ..............................50-8039<br />
Middle o-ring (H-D#11132A) each ............................<br />
USA<br />
50-8038<br />
10 pack .............................................<br />
USA<br />
93-4111<br />
Bottom o-ring (H-D#11145A) each ...........................<br />
USA<br />
50-8037<br />
10 pack .............................................<br />
USA<br />
93-4112<br />
Quad Seal<br />
Pushrod o-ring kits (includes top, middle, and bottom o-rings<br />
for four pushrods) ...............................<br />
USA TÜV 2,4,5 93-4022<br />
106-1340<br />
S&S® Pushrod Cover Keeper Sets For <strong>1999</strong>-'12 <strong>BIG</strong> <strong>TWINS</strong><br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
93-4101<br />
All S&S pushrod keepers are chromed steel, except part #93-4109. Keeper part #93-4109<br />
is intended for unusually tall engines. It is manufactured of unchromed stainless steel to<br />
prevent rust or peeling after it is trimmed to the required length.<br />
Part No. Length S&S TUBES<br />
93-4070 2.400" All Stock Height TC88/96/103<br />
93-4100 2.500" 96", 103", 106”, 117” HSU<br />
93-4101 2.600" 124"<br />
93-4115 2.800" 116"<br />
93-4102 2.900"<br />
93-4103 3.000"<br />
93-4104 3.100"<br />
93-4105 3.200"<br />
93-4106 3.330"<br />
93-4107 3.500"<br />
93-4108 3.625"<br />
93-4109 4.250"<br />
Keepers are sold in sets of four.<br />
Stainless steel may be cut to<br />
length.<br />
NOTE: All reference to H-D® part numbers is for identification purposes only. We in no way are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are<br />
equivalent to the corresponding H-D® part number shown.<br />
2-56<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
FORGED ROLLER ROCKER ARMS<br />
Forged from 8620 steel, heat-treated, and then shot-peened for additional strength and<br />
protection from fatigue, our roller rocker arms were designed to eliminate failure-prone stress<br />
areas found in some other rockers. Most rockers come equipped with ½" long bushings or<br />
needle bearings, however ours utilize ¾" long bronze bushings. The end result is what we<br />
believe to be the finest rocker arm available anywhere, for any price.<br />
FITMENT<br />
• <strong>1999</strong>-'12 big twins<br />
900-4065A<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
FEATURES AND BENEFITS<br />
• Extremely durable rollers reduce valve stem side thrusting with high lift cams<br />
• Superior wear and fatigue resistance even in the most demanding applications<br />
• ¾" long bushings provide 50% more bushing support area than ½" long bushings<br />
KIT CONTENTS<br />
• 2 front and 2 rear rocker arms<br />
PART NUMBERS<br />
Set of 4 rocker arms ....................................900-4065A<br />
Replacement parts:<br />
Front exhaust or rear intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-4065FA<br />
Rear exhaust or front intake ...........................900-4065RA<br />
Rebuild kits (rebuilds 4 rocker arms) .........................90-4104<br />
Rocker arm bushing (¾" long) ...........<br />
USA 1,2,3<br />
TÜV 1,2,3,4,5,6,7 90-4014<br />
Rocker arm shafts:<br />
Set (includes 4) (H-D® #17611-83) .......................<br />
USA<br />
90-4036<br />
Individual .........................<br />
USA USA 1,2,3<br />
TÜV 1,2,4,5,6,7 90-4006<br />
S&S ®<br />
STANDARD FORGED ROCKER ARMS<br />
S&S now offers an economical solution for stock rebuilds and mild performance upgrades. S&S standard rocker arms<br />
are forged from 8620 steel for greater strength than stock forged or cast steel rocker arms. In addition, they feature<br />
the same ¾" long rocker shaft bushings that our S&S roller rocker arms do. Thousands of hours of engine testing<br />
have proved them to be superior to other non-roller rocker arms.<br />
90-4036<br />
S&S rocker arm shaft set<br />
NOTE:<br />
• Adjustable pushrods must be used with S&S roller rocker arms to obtain proper valve<br />
clearance.<br />
• New rocker arm shafts are recommended for maximum performance and rocker life.<br />
• All reference to H-D® part numbers is for identification purposes only. We in no way are<br />
implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are<br />
equivalent to the corresponding H-D® part number shown.<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
FITMENT<br />
• <strong>1999</strong>-'12 big twins<br />
FEATURES AND BENEFITS<br />
• ¾" long bronze bushings provide 50% more load bearing area than<br />
the ½" long bushings used in stock and other aftermarket rocker arms<br />
KIT CONTENTS<br />
• 2 front and 2 rear rocker arms<br />
PART NUMBERS<br />
Standard forged rocker arms ............................900-4119A<br />
Replacement parts:<br />
Front exhaust or rear intake (H-D® #17375-83A) ............900-4119FA<br />
Rear exhaust or front intake (H-D® #17360-83A) ............900-4119RA<br />
Rocker arm bushing (¾" long) ............ USA 1,2,3 TÜV 1,2,3,4,5,6,7 90-4014<br />
Rocker arm shafts:<br />
Set (includes 4) (H-D® #17611-83) .......................<br />
USA<br />
90-4036<br />
Individual .........................<br />
USA USA 1,2,3<br />
TÜV 1,2,4,5,6,7 90-4006<br />
900-4119A<br />
NOTE:<br />
• S&S roller rocker arms are recommended for use with cams having more than 0.585" of lift.<br />
• New rocker arm shafts are recommended for maximum performance and rocker life.<br />
• All reference to H-D® part numbers is for identification purposes only. We in no way are<br />
implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are<br />
equivalent to the corresponding H-D® part number shown.<br />
Visit us at www.sscycle.com<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-57
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
PERFORMANCE<br />
PARTS<br />
.585" Lift Dual VALVE SPRINGS<br />
FITMENT<br />
• Twin Cam 88® big twins w/ stock heads (both 7mm and 5/16” valve stems)<br />
• All S&S Super Stock® heads (5/16” valve stems)<br />
FEATURES AND BENEFITS<br />
• Dual springs reduce the risk of valve float<br />
• Suitable for high performance applications<br />
• Accommodates camshaft lift to 0.585”<br />
KIT CONTENTS<br />
• Valve Guide Seals<br />
• Inner & Outer Springs<br />
• Top Collars<br />
• Bottom Collars<br />
• Keepers<br />
• Shims<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
90-2277<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
PART NUMBER<br />
S&S .585” Lift Dual Valve Spring Kit for <strong>1999</strong>-’04 (5/16” valve stems) ....90-2277<br />
S&S .585" Lift Dual Valve Spring Kit for 2005-’12 (7mm valve stems) ..900-0420<br />
Racing<br />
Products<br />
S&S® Dual Valve Springs Specifications<br />
Lift Installed Height Seat Force Force @ Max Lift<br />
.585" 1.800" 130 lb. 325 lb.<br />
Tools & Shop<br />
Supplies<br />
Replacement parts on page 2-84<br />
OEM Cross Reference<br />
Appendix & Index<br />
Warranty &<br />
Company Policy<br />
Dealer Services<br />
& Promo Items<br />
2-58<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
HIGH PERFORMANCE .640" LIFT TRIPLE VALVE SPRINGs<br />
Not only designed to increase spring force and reduce the risk of valve float, S&S valve<br />
springs also eliminate most of the complicated procedures and specialized tools required<br />
to prepare cylinder heads for high lift cams up to .640" lift.<br />
FITMENT<br />
• <strong>1999</strong>–’04 Twin Cam 88®/88B with stock heads (5/16” valve stems)<br />
• All S&S Super Stock® heads (5/16” valve stems)<br />
FEATURES AND BENEFITS<br />
• Patented steel top collars are drilled for lightness and to increase<br />
cooling oil flow over valve springs<br />
• For very high performance applications, kits with low mass titanium<br />
top collars are also available<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
KIT CONTENTS<br />
• Valve keepers<br />
• Top collars<br />
• Bottom collars<br />
• Outer springs<br />
• Middle springs<br />
• Inner springs<br />
• Shims<br />
PART NUMBERS<br />
Kit w/ steel top collars .................................... 90-2077<br />
Kit w/ titanium top collars .................................90-2078<br />
S&S® Sidewinder® Valve Springs Specifications<br />
Lift Installed Height Seat Force Force @ Max Lift<br />
.640" 1.800" 170 lb. 390 lb.<br />
Not recommended for cams with over 0.640" lift<br />
90-2078<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Application Notes:<br />
• Use with shoulderless-style valve guides.<br />
• Special keepers included fit valves with stock 5⁄16" stems and S&S collars only.<br />
• Spring seat force is typically 170 lbs. at stock 1.800" installed height.<br />
• Open force is 390 lbs. at .560" lift, 415 lbs. at .630" lift.<br />
• May also be used in any other heads that require stock O.D. outer spring.<br />
• S&S springs will not fit 2005 - later stock heads because of the change in valve spring<br />
and valve stem diameter.<br />
Replacement parts on page 2-84<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
Installation NOTE:<br />
• 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.<br />
Clearance should also be checked between the rocker arm and valve spring collar as well as between the rocker arm and rocker cover. It is imperative that the engine builder confirm these<br />
clearances and check for spring coil bind, even when using parts specifically designed for high performance. Most valve train failures can be traced to over-revving or failure to confirm<br />
correct clearances during assembly.<br />
Visit us at www.sscycle.com<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-59
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
SIDEWINDER ® .650" Lift Valve Springs<br />
FITMENT<br />
• Twin Cam 88® big twins w/ stock heads (both 7mm and 5/16” valve stems)<br />
• All S&S Super Stock® heads (5/16” valve stems)<br />
FEATURES AND BENEFITS<br />
• Works well with cams up to .650" lift<br />
• Manufactured from ultra clean high silicon Kobe alloy wire<br />
then micro shot peened and nitrided<br />
• CNC machined 9˚ locks<br />
• High performance conical single wire spring<br />
• Chromoly forged retainers<br />
106-5909<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
KIT CONTENTS<br />
• Valve keepers<br />
• Top collars<br />
• Bottom collars<br />
• Springs<br />
• Shims<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
PART NUMBERS<br />
S&S Sidewinder® Valve Spring Kit for <strong>1999</strong>-'04 (5/16” valve stems) ......... 900-0050<br />
S&S Sidewinder® Valve Spring Kit for 2005-'12 (7mm valve stems) .......106-5909*<br />
*Kit includes valve guide seals. See page 2-84 for additional seals.<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Racing<br />
Products<br />
NOTE:<br />
S&S® Sidewinder® Valve Springs Specifications<br />
Lift Installed Height Seat Force<br />
• S&S recommends roller rocker arms be used with lifts over .585"<br />
Force @ Max<br />
Lift<br />
Max RPM<br />
.650" 1.860" 178 lb. 376 lb. 6500<br />
Replacement parts on page 2-84<br />
2-60<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Die Cast ROCKER COVERS<br />
Produced using the die-casting manufacturing process and then machined with computer<br />
controlled equipment. Includes Viton® o-ring style cover seals for leak-free operation.<br />
FITMENT<br />
• All Twin Cam 88® big twins<br />
• Sold as stock on 41/8" bore S&S engines<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
FEATURES AND BENEFITS<br />
• Special rocker arm supports are included<br />
• S&S rocker covers are finished with show-quality chrome<br />
• Installation on stock and most comparable sized engines can be performed without<br />
removing the engine from the frame<br />
• Clearanced to permit valve lifts up to .640" using S&S valve spring packages and<br />
stock rocker arms or S&S roller rocker arms<br />
• S&S rocker covers accept valve springs up to 1.660" O.D. without modification<br />
• Exclusive one way valve built into the rocker cover gasket to control oil carry over<br />
KIT CONTENTS<br />
• Front and rear covers<br />
• All necessary gaskets and o-rings<br />
• Mounting hardware<br />
PART NUMBER<br />
S&S Rocker Cover ...................................<br />
TÜV 2 90-4110<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
90-4110<br />
Replacement parts on page 2-86<br />
Notes:<br />
• If using valve spring packages with taller than stock installed height, some minor<br />
clearancing may be required.<br />
• Cylinder heads must be set up correctly for high lift cams, and it remains the builder’s<br />
responsibility to confirm all clearances.<br />
• In most instances, only minor clearancing is required to use S&S rocker covers with<br />
valve springs larger than 1.660" O.D.<br />
EXTRA PARTS NEEDED:<br />
• S&S® rocker covers are required if S&S cylinder heads are used with S&S electric<br />
compression releases.<br />
Any Job is easy with the right tools<br />
S&S Rocker Cover Wrench Set, see page 8-7.<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-61
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Super Stock ® Stealth Air Cleaner Kits<br />
The Power Of Style!<br />
High performance intake systems have been an important part of the S&S product<br />
line since the early 1960’s. These new S&S Super Stock Stealth air cleaner kits make a<br />
powerful statement about style and performance.<br />
Features and Benefits<br />
• For the rider who likes to go fast, but doesn’t like to advertise<br />
• Air directional stinger cone in the filter<br />
• Use with your stock Harley-Davidson® Twin Cam 88®, 96 or 103 air cleaner<br />
cover – the word "sleeper" comes to mind<br />
• Can also be used with any of several S&S designed covers<br />
• High flow (1" taller) filter kit available<br />
Replacement parts on page 2-88<br />
Cut-away showing a stock Twin Cam 88® /96/103 cover on S&S Stealth air cleaner kit.<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
S&S Super Stock® Air Cleaner KitS<br />
Application Fuel System STEALTH*<br />
AIR STREAM BOBBER-DISHED BOBBER-DOMED MUSCLE<br />
Chrome Finish<br />
<strong>1999</strong>-’12 bt Stock CV/EFI, except <strong>1999</strong> Softail® carb 170-0060 170-0056 170-0104 170-0105 170-0106<br />
<strong>1999</strong>-’06 bt S&S Super E & G Carbs 170-0058 170-0063 170-0110 170-0111 170-0112<br />
*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.<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Dyno Comparison<br />
2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ Airstream Cover vs Stock Air Cleaner<br />
100<br />
90<br />
S&S Super Stock Stealth w/ Airstream Cover<br />
Peak Corrected HP 71.4<br />
Peak Corrected Torque 87.5<br />
Stock Air Cleaner<br />
Peak Corrected HP 68.0<br />
Peak Corrected Torque 86.6<br />
100<br />
90<br />
Dyno Comparison<br />
2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ Bobber Cover vs Stock Air Cleaner<br />
S&S Super Stock Stealth w/ Bobber Cover<br />
Peak Corrected HP 71.7<br />
Peak Corrected Torque 88.1<br />
Stock Air Cleaner<br />
Peak Corrected HP 68.0<br />
Peak Corrected Torque 86.6<br />
80<br />
80<br />
Racing<br />
Products<br />
70<br />
60<br />
70<br />
60<br />
50<br />
40<br />
50<br />
40<br />
Tools & Shop<br />
Supplies<br />
30<br />
20<br />
10<br />
30<br />
20<br />
10<br />
Dealer Services<br />
& Promo Items<br />
1000 2000<br />
3000<br />
4000 5000 6000<br />
EngSpd RPM<br />
1000 2000<br />
3000<br />
4000 5000 6000<br />
EngSpd RPM<br />
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<br />
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<br />
power add S&S performance mufflers. Both were tuned with Dynojet® Power Vision® Tuner.<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
High Flow replacement Air filters<br />
Standard (Filter only) ................ 170-0126<br />
1" Taller Kit* (includes 2 spacers)...... 170-0127<br />
(Filter only).................... 170-0154<br />
*1” taller filter kit does not fit Muscle air cleaner kit.<br />
170-0126<br />
Standard high flow air flilter<br />
170-0127<br />
1" taller high flow air filter kit<br />
This built-in stinger cone is featured in all<br />
Super Stock air cleaner kits except the tuned<br />
induction systems.<br />
• Directs air smoothly into the bore of the<br />
carburetor or EFI throttle body<br />
• Reduced turbulence and increased flow<br />
• Featured in S&S teardrop air cleaners<br />
since the early 1970’s<br />
2-62<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Super Stock ® Stealth Air Cleaner Covers<br />
S&S Air Stream Air Cleaner Cover<br />
• Fits the new S&S Stealth air cleaner kits<br />
• An updated version of the speed inspired S&S teardrop shape<br />
• Screened vent for more air without sucking in rain/road debris<br />
• Steel construction with your choice of chrome or Black Jack (wrinkle black powdercoat)<br />
Air Stream<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Part numbers<br />
Air Stream Air Cleaner Cover<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Chrome ............................................. 170-0118<br />
Black Jack ........................................... 170-0122<br />
S&S Bobber Billet Air Cleaner Covers<br />
• Fits the new S&S Stealth air cleaner kits<br />
• Minimalist air cleaner cover that really delivers the goods!<br />
• Fits over the end of the air filter and leaves the filter element exposed<br />
• Choose from the Dished Bobber or the Domed Bobber covers<br />
• CNC machined from billet aluminum in chrome or Black Jack<br />
(wrinkle black powdercoat)<br />
170-0118<br />
Bobber Dished<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Part numbers<br />
Bobber Dished Air Cleaner Cover<br />
Chrome ............................................. 170-0119<br />
Black Jack ........................................... 170-0123<br />
170-0119<br />
170-0123<br />
Bobber Domed<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Bobber Domed Air Cleaner Cover<br />
Chrome ............................................. 170-0120<br />
Black Jack ........................................... 170-0124<br />
Racing<br />
Products<br />
S&S muscle Billet Air Cleaner Covers<br />
• Fits the new S&S Stealth air cleaner kits<br />
• Similar to the Bobber covers<br />
• Leaves the entire air filter exposed for a raw hot rod look<br />
• Cover is held on with muscle car style hood pins<br />
• CNC machined from billet aluminum in chrome or Black Jack (wrinkle black powdercoat)<br />
Part numbers<br />
Muscle Air Cleaner Cover<br />
170-0120<br />
170-0124<br />
Muscle<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Chrome ............................................. 170-0121<br />
Black Jack ........................................... 170-0125<br />
Warranty &<br />
Company Policy<br />
Replacement parts on page 2-88<br />
170-0121<br />
OEM Cross Reference<br />
Appendix & Index<br />
170-0125<br />
Visit us at www.sscycle.com<br />
2-63
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
SINGLE BORE TUNED INDUCTION SYSTEM<br />
FITMENT<br />
• Twin Cam 88®/96/103 big twins<br />
FEATURES AND BENEFITS<br />
• Bolt-on performance – over twice the filtering area over stock intake system<br />
• Increases horsepower and torque across the rpm range using air column inertia<br />
and carefully timed gas dynamic pressure waves<br />
• Smooth intake tract of carefully selected tuned lengths increases performance<br />
• High flow washable and reusable cotton media provides performance, protection,<br />
and economy<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
S&S SINGLE BORE TUNED INDUCTION SYSTEM KITS<br />
Fitment Fuel Delivery Finish Part No.<br />
4 1/8" Bore S&S T-Series S&S Single Bore EFI<br />
170-0083<br />
4 1/8" Bore S&S T-Series S&S Super E/G<br />
Chrome<br />
170-0084<br />
<strong>1999</strong>-up big twins S&S Single Bore EFI Runner 170-0085<br />
and<br />
<strong>1999</strong>-'06 big twins S&S Super E/G<br />
Red Filters 170-0086<br />
<strong>1999</strong>-'12 big twins<br />
(except 2008-up Touring)<br />
Stock CV & EFI Delphi® 170-0087<br />
CTO<br />
Specify Specify 106-5337*<br />
*Use the Configure to Order (CTO) part number to order different finish and filter color.<br />
Not legal for sale or use on CA pollution controlled vehicles.<br />
Replacement Filters (each sold with clamp)<br />
Red ..............................................................17-1020<br />
Blue .............................................................17-1023<br />
Billet adaptor brackets make single<br />
bore tuned induction compatible<br />
with many engines and motorcycles.<br />
Tools & Shop<br />
Supplies<br />
Renew the color of your air filter with an 8 oz. bottle of S&S Air<br />
Filter Oil. Choice of red or blue oil.<br />
S&S Air Filter Oil, Red .........................106-1163<br />
S&S Air Filter Oil, Blue ........................106-1164<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-64<br />
Washable nylon air filter covers are water resistant and filter<br />
out large debris, allowing the filter media to stop small dirt<br />
particles from getting into your engine<br />
S&S Nylon Air Filter Cover<br />
each ..................................... 106-0247<br />
2 pack ................................... 106-0248<br />
SPECIAL NOTES:<br />
• Does not fit Screamin' Eagle 58mm throttle bodies on 2008-up touring models.<br />
• Tuned induction will not fit on motorcycles equipped with fairing lower glove boxes.<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Teardrop AIR Cleaner Kit<br />
FITMENT<br />
• Twin Cam 88®/96/103 big twins<br />
• S&S T-Series engines<br />
FEATURES AND BENEFITS<br />
• Efficient and free flowing intake that can add two to five horsepower<br />
• Uniquely designed back plate has air horn style radiused entryway to reduce turbulence<br />
• Dimpled cover with directional air cone on inside creates smooth path for air<br />
• Great addition to performance exhaust or cams<br />
KIT CONTENTS<br />
• Filter<br />
• Backing plate<br />
• All mounting hardware<br />
• Instructions<br />
Teardrop Air Cleaner Kits<br />
Model/Engine Stock Carb/EFI: S&S® Super E or G:<br />
S&S 41/8" bore engines – 17-0416<br />
2001-'12 Softail EFI, All 2002-Up EFI (Delphi®) 17-0450 –<br />
<strong>1999</strong>-'01 EFI big twin (Magneti Marelli®) 106-4589 –<br />
<strong>1999</strong>-'06 Carbureted 17-0450 17-0403<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Not legal for sale or use on CA pollution controlled vehicles.<br />
Optimize your stock carBuretor<br />
Jet,Kit,CV Carb,<strong>1999</strong>-<strong>2006</strong> bt ........................11-5203<br />
Jet,Kit,CV Carb,1995-<strong>2006</strong> bt .........................11-5202<br />
A respectable gain in both horsepower and torque can be seen in this graph comparing a stock<br />
big twin to one equipped with an S&S® air cleaner and SPO® touring mufflers.<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
S&S ®<br />
TearDrop AIR CLEANER COVERS<br />
FITMENT<br />
• S&S teardrop air cleaners for Super E & G carbs and S&S EFI throttle bodies<br />
• S&S air cleaner kits for stock fuel systems<br />
PART NUMBER<br />
Slasher Air Cleaner Cover . ...................................17-0004<br />
Polished Nostalgic S&S <strong>Cycle</strong> Air Cleaner Cover<br />
E & G carbs ............................................... 17-0071<br />
Super B carbs ..............................................17-0070<br />
Wrinkle Black Powerdercoat .................................17-0384<br />
New! Stealth Air Cleaner Covers. See page 2-3<br />
17-0004<br />
Slasher Air Cleaner Cover has slots strategically cut around the perimeter<br />
of the cover to allow a more direct path to the air filter, increasing power<br />
output by 1–2 hp!<br />
17-0071 or 17-0070<br />
Nostalgic Air Cleaner Cover has raised<br />
letters that say "S&S <strong>Cycle</strong>" and a mirror like<br />
polished finish.<br />
17-0384<br />
Wrinkle Black Powdercoat Air Cleaner Cover.<br />
Visit us at www.sscycle.com<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-65
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
HIGH FLOW AIR FILTER KITs<br />
FITMENT<br />
• S&S teardrop air cleaners for Super E & G carbs and S&S EFI throttle bodies<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
17-0045<br />
High flow air filter kit for<br />
S&S Teardrop Air Cleaners<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PERFORMANCE<br />
PARTS<br />
FEATURES AND BENEFITS<br />
• Low restriction filter element comes pre-oiled for true plug and play installation<br />
• 1" wider filtration area provides up to 37% more airflow over standard S&S filters<br />
• Resulting band of exposed filter material imparts a high performance look<br />
KIT CONTENTS<br />
• Wide filter<br />
• Filter spacers<br />
170-0127<br />
1" Taller High flow air filter kit for<br />
New Super Stock® Air Cleaners<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
PART NUMBERS<br />
High Flow Air Cleaner Kit<br />
Classic S&S® Teardrop (includes spacers) ....................17-0045<br />
Super Stock® Stealth, 1" Taller (includes spacers) ........... 170-0127<br />
Replacement Filter only<br />
Teardrop, Standard .................................... 106-4724<br />
Super Stock® Stealth, Standard .......................... 170-0126<br />
Super Stock® Stealth, 1" Taller ........................... 170-0154<br />
Replacement Filter Spacers ..............................50-5009-S<br />
100<br />
90<br />
80<br />
70<br />
60<br />
Dyno Comparison<br />
2012 FLHX w/ S&S® Super Stock® Stealth Air Cleaner w/ 1" Taller Filter vs Standard Filter<br />
S&S High Performance 1" Taller Filter<br />
Peak Corrected HP 75.2<br />
Peak Corrected Torque 90.4<br />
S&S High Performance Standard Filter<br />
Peak Corrected HP 74.1<br />
Peak Corrected Torque 88.7<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
This dyno chart compares the performance of S&S High Flow filters when used with<br />
an S&S Stealth air cleaner kit. With added area for drawing in more air, the optional 1"<br />
taller filter can increase torque by 1.7 ft/lb over the standard sized filter! This test was<br />
conducted on a stock 96" engine with stock mufflers. More impressive performance<br />
gains can be expected on large displacement engines with performance exhaust,<br />
performance camshaft, and high flow cylinder heads.<br />
50<br />
40<br />
30<br />
20<br />
10<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
S&S ®<br />
HIGH PERFORMANCE FILTERS<br />
FOR STOCK Air Cleaners<br />
1000 2000<br />
3000<br />
4000 5000 6000<br />
EngSpd RPM<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-66<br />
FITMENT<br />
• <strong>1999</strong> - ‘12 carbureted and EFI big twins<br />
FEATURES AND BENEFITS<br />
• Direct replacement for stock Harley-Davidson® filter assemblies<br />
• Washable and reusable – cost effective upgrade that pays for itself over time<br />
• Great by itself or complement to performance exhaust or cams<br />
Application<br />
<strong>1999</strong> - '06 Carbureted Twin Cam 88®,<br />
2001-'12 Softail® EFI (except Cross Bones),<br />
2002-'07 FL EFI, 2004-'07 EFI Dyna®<br />
<strong>1999</strong>-2001 EFI big twin<br />
Order toll free 866-244-2673<br />
Part No.<br />
106-4630<br />
(H-D® #29461-99)<br />
106-4631<br />
(H-D® #29462-99)<br />
106-4630– Twin Cam 88® (carb),<br />
2001-‘09 Softail® EFI (except Cross Bones),<br />
2002-'07 FL EFI and 2004-‘07 EFI Dyna®<br />
– Replaces H-D® #29461-99<br />
NOTE: All reference to H-D® part numbers is for identification purposes only. We in no<br />
way are implying that any of S&S® <strong>Cycle</strong>'s products are original equipment parts or that<br />
they are equivalent to the corresponding H-D part number shown. 106-4631–<br />
Twin Cam 88® FL EFI <strong>1999</strong>-‘01 – Replaces H-D #29462-99
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
SUPER E & G COMPLETE Carburetor KITS<br />
Built to last, these high flow butterfly type carburetors are easily tuned for maximum<br />
performance and drivability. The Super E’s 17/8" bore is more than adequate for street engines<br />
up to about 100" displacement. The huge 21/16" bore on the Super G is recommended for<br />
engines 100" and larger.<br />
FITMENT<br />
• <strong>1999</strong>–’06 Twin Cam 88® engines<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
FEATURES AND BENEFITS<br />
• Increased air flow for more power<br />
• Adjustable accelerator pump for quick throttle response and easy starting<br />
• Utilization of the factory dual cable system ensures safe operation<br />
• Direct replacement and high quality fit and finish – less down time and better performance<br />
• Variable position enrichment starting system<br />
KIT CONTENTS<br />
• Super E or G carburetor<br />
• S&S intake manifold<br />
• Teardrop air cleaner kit<br />
• Mounting hardware<br />
• Gaskets, seals and hoses<br />
• Instructions<br />
WATCH THE KICK START SUPER E CARB VIDEO AT<br />
SSCYCLE.COM/MEDIA/VIDEOS.PHP<br />
Models Super E Complete Kit Super G Complete Kit<br />
<strong>1999</strong>-'05 big twin 11-0450 11-0451<br />
<strong>2006</strong> big twin 106-0874 106-0875<br />
Models Super E (Carb only) Super G (Carb only)<br />
All Years & Models 11-0420 11-0421<br />
11-0450<br />
Super E Carburetor complete kit for <strong>1999</strong>-'05 big twin<br />
OPTION<br />
Optional cruise control adapter kits allows riders to keep<br />
factory cruise feature on <strong>1999</strong>-’06 models<br />
Cruise Control Adapter Kit ................11-2927<br />
NOTES:<br />
• 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<br />
carbs that have been destroyed because the polishing or chrome plating had altered critical machined surfaces.<br />
• Recommended for closed circuit use only—S&S Super E & G carbs shown are not approved for use on motor vehicles operated on California public highways, or in other states where<br />
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.<br />
• Replacement parts for S&S Super E & G carburetors can be found on page 2-96.<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
S&S ®<br />
TÜV APPROVED SUPER E CARBURETOR KIT<br />
Riders in the European Union can replace their stock Harley-Davidson® carb with a reliable<br />
S&S Super E. Before being shipped, carburetors are jetted for the year of bike specified.<br />
FITMENT<br />
• <strong>1999</strong>–’06 carbureted Twin Cam 88®<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
KIT CONTENTS<br />
• Documentation proving TÜV approval<br />
• 17/8" bore Super E carburetor<br />
• Polished intake manifold<br />
• Teardrop air cleaner kit<br />
• All mounting hardware and gaskets<br />
• Complete instructions<br />
Part Number<br />
TÜV Approved S&S Super E Carburetor Kit .................... 106-2482<br />
Visit us at www.sscycle.com<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-67
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Manifolds for Carbureted big twin Engines<br />
These manifolds have provisions for mounting the stock MAP sensor directly to the manifold,<br />
and are primarily designed for Harley-Davidson® Twin Cam 88® engines. These manifolds<br />
may also be used on engines for 1984-'99 big twins which require a MAP sensor, such<br />
as S&S engines equipped with the S&S Intelligent Spark Technology® (IST®) ignition.<br />
Available in 17⁄8" and 21/16" bore sizes and for 40–48mm CV carburetors.<br />
FITMENT<br />
• <strong>1999</strong>–’06 big twins<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-68<br />
FEATURES AND BENEFITS<br />
• Fits stock or S&S heads<br />
• Fits stock or engines with taller cylinders<br />
S&S® Manifolds for Harley-Davidson® Twin Cam 88® Engines<br />
(requiring MAP Sensor* machining)<br />
Engine Style<br />
Cylinder Manifold Super E Super G<br />
and Displacement<br />
Length Size<br />
Part No.<br />
88", 95", 106" Twin Cam 88 4.937" 410 16-1718 16-2588<br />
100" Twin Cam 88 & Stock<br />
<strong>2006</strong> Models<br />
4.850" 405 16-1717 16-2587<br />
107" Twin Cam 88 4.975" 414 16-1716 16-2586<br />
111" Twin Cam 88 4.763" 398 106-4487 16-2604<br />
116" Twin Cam 88 5.160" 428 16-1719 16-2589<br />
117" Twin Cam 88 4.888" 408 – 16-2603<br />
124" Twin Cam 88 5.013" 417 – 16-2598<br />
Special Order Specify – 16-1639 16-2539**<br />
* All S&S engines for 1984-'06 and <strong>1999</strong>-up big twins equipped with S&S IST ignition system.<br />
**Special Order: Download the Special Order Form at sscycle.com/soforms<br />
NOTES:<br />
• S&S manifolds require S&S style manifold seals.<br />
• S&S style o-rings must be used with these manifolds. S&S o-rings are slightly thinner to<br />
accommodate the larger S&S port diameter. Use of stock o-rings may cause damage.<br />
S&S ®<br />
50-8372<br />
MANIFOLDS FOR SINGLE BORE EFI <strong>BIG</strong> TWIN ENGINES<br />
Specifically designed for S&S Single Bore EFI applications, these S&S manifolds<br />
include fuel injector mounting ports and provisions for installation of a stock style<br />
MAP sensor.<br />
FITMENT<br />
• Stock height or taller than stock <strong>1999</strong>-’12 bt<br />
(except 2008-up touring models)<br />
• S&S 52mm or 58mm throttle bodies<br />
• Stock or S&S heads<br />
• S&S T-Series engines<br />
16-0136-S<br />
NOTE: S&S style o-rings must be used with these manifolds. S&S o-rings are<br />
slightly thinner to accommodate the larger S&S port diameter. Use of stock<br />
o-rings may cause damage.<br />
Order toll free 866-244-2673<br />
Manifold for CV carburetor<br />
Manifold for S&S carburetors<br />
S&S CV Manifolds – <strong>1999</strong>-2005 big twin<br />
Style/Displacement (mm) Manifold Size Part No.<br />
88", 95", 106" Twin Cam 88 40-45mm 410 16-1722<br />
(H-D® #27613-99)<br />
100" Twin Cam 88 40-45mm 405 16-1721<br />
107" Twin Cam 88 40-45mm 414 16-1723<br />
116" Twin Cam 88 40-45mm 428 16-1724<br />
96 stock 48mm 410 160-0001<br />
S&S CV Manifolds – <strong>2006</strong> & up big twin<br />
Style/Displacement (mm) Manifold Size Part No.<br />
96 stock 40-45mm 405 16-1721<br />
96 stock 48mm 405 160-0002<br />
Special order Specify – 16-1725A*<br />
*Special Order: Download the Special Order Form at sscycle.com/soforms<br />
U-Rings for Constant Velocity Carbs<br />
U-ring, 40-42mm (H-D® #27002-89) ....................16-0242<br />
U-ring, 44-48mm .................................16-0241<br />
Replacement Parts For Manifolds<br />
Manifold Fitting VOES Rubber Cap<br />
3⁄16" I.D. x 5⁄16" O.D. x ½" ....................................... 50-8372 TÜV 2<br />
Manifold Vacuum Fitting ..................................... 16-0136-S<br />
Engine Displacement Cylinder Length Manifold Size Part No.<br />
<strong>2006</strong>-Up Big twins with STock or S&S Heads<br />
88", 95", 96" 103" & 106" 4.937" 405 16-5134<br />
124" Hot Set Up Kit® (except 2008-up<br />
touring models w/stock or S&S heads)<br />
5.013" 417 16-5139<br />
124" Hot Set Up Kit® (except 2008-<br />
up touring models w/S&S heads only)<br />
5.013" 405 16-5134<br />
<strong>1999</strong>-’05 Big twins With Stock or S&S Heads<br />
88", 95", 103" & 106" 4.937" 410 16-5141<br />
124" Hot Set Up Kit (w/stock or S&S heads) 5.013" 417 16-5139<br />
S&S 41/8" Bore T-Series Engines<br />
111" 4.763" 398 16-5136<br />
117" 4.888" 408 16-5138<br />
124" 5.013" 417 16-5139<br />
Special Order (All Styles) Specify 389-428 16-5142*<br />
* Special Order: Download the Special Order Form at sscycle.com/soforms
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Early EFI Upgrade Package<br />
Is your fuel injection system getting tired Lots of mileage on your motorcycle S&S has<br />
assembled a package that includes everything you need to refresh and upgrade your fuel<br />
delivery system!<br />
Fitment<br />
• 1995 ½ – 2001 EFI touring models<br />
Features & benefits<br />
• Complete package to upgrade early fuel injection systems<br />
• Replacement ECU can be programmed with various calibrations<br />
• New injectors<br />
• 52mm throttle body/fuel rail<br />
• Intake manifold with vacuum fittings<br />
• Teardrop air cleaner<br />
• Typical increase of 4 horsepower over stock<br />
Part Numbers<br />
1995 ½ – 2001 EFI touring models .......................550-0068<br />
S&S ®<br />
SINGLE BORE EFI THROTTLE BODIES<br />
52mm: Offering a 30% larger cross sectional area than stock throttle bodies, the S&S<br />
52mm bore throttle body flows more than enough air for all but the most demanding street<br />
engines.<br />
58mm: In response to constant requests for something bigger, S&S also offers a huge<br />
58mm bore throttle body! Strictly for large displacement competition engines, this throttle<br />
body allows your engine to breathe easily and make more power!<br />
FITMENT<br />
• <strong>1999</strong>-’12 big twins<br />
(except 2008-up touring models with electronic throttle control)<br />
FEATURES AND BENEFITS<br />
• Excellent performance<br />
• Recommended tuning products:<br />
• S&S VFI<br />
• Dynojet® Power Vision Tuner<br />
• Cruise control compatible with no extra bracket<br />
OPTIONS<br />
• 52mm or 58mm<br />
KIT CONTENTS<br />
• Throttle body assembly<br />
• Fuel injectors<br />
• Fuel rail<br />
• Harness adaptors<br />
• All necessary hardware, gaskets, and hoses<br />
PART NUMBERS AND SPECIFICATIONS<br />
S&S® 52mm Single Bore EFI Throttle Body/Fuel Rail Kits<br />
1995-’01 EFI big twin (except Softail® models) ..................17-5068<br />
2002-’05 EFI big twin & 2001 Softail models ...................17-5067<br />
<strong>2006</strong>–'12 EFI big twin* .................................... 17-5070<br />
S&S® 58mm Single Bore EFI Throttle Body/Fuel Rail Kits<br />
1995-’01 EFI big twin (except Softail® models) ................ 106-4406<br />
2002-’05 EFI big twin & 2001 Softail models ................. 106-4407<br />
<strong>2006</strong>–'12 EFI big twin* ................................... 106-4408<br />
* except 2008–up touring models with electronic throttle control.<br />
NOTES:<br />
• If you plan to use another programmable fuel injection module, it is<br />
best to consult the manufacturer to be certain that it is compatible<br />
with the S&S single bore system and has enough tuning capability for<br />
your engine configuration.<br />
• Installation of S&S throttle body on 1995-'01 bikes requires S&S ECU.<br />
Single bore throttle bodies are not compatible with stock Magneti<br />
Marelli® ECU<br />
106-4408<br />
Stock<br />
Seeing is believing. It’s pretty easy to see<br />
the differences in the bore sizes of a stock<br />
Harley-Davidson® throttle body and the<br />
S&S® 52mm or 58mm throttle bodies.<br />
How big do you want to go<br />
S&S 58mm<br />
S&S 52mm<br />
Visit us at www.sscycle.com<br />
PERFORMANCE<br />
PARTS<br />
SuperFlow® SF1020 Super<br />
Bench flow bench shows the<br />
difference in flow between the<br />
S&S 52mm (21/16") EFI throttle<br />
body and the new S&S 58mm<br />
throttle body. The peak numbers<br />
at WOT are pretty impressive,<br />
but what may not be as apparent<br />
is that the percentage of increase<br />
in air flow is greatest right off<br />
idle, between 5° and 25°. The<br />
increase in this area is as high<br />
as 23%, which translates into<br />
better off-idle response.<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-69
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
PERFORMANCE<br />
PARTS<br />
Two Cable Throttle Assemblies<br />
The S&S two cable throttle assemblies are high quality "pull open – pull close" type<br />
throttles designed for use on any two cable carburetor installations on bikes with 1" O.D.<br />
handlebars. A special soft plastic material used to mold the grips makes them look and feel<br />
exactly like stock grips. There are four different assemblies available to make installation<br />
on most chassis easy.<br />
Two Cable Throttle Required<br />
S&S Super E and G carburetors require the use of a two cable, pull open–pull closed<br />
throttle assembly. Any chassis including 1980 and earlier stock models equipped with a<br />
single cable throttle mechanism requires conversion to a two cable, pull open–pull closed<br />
type. S&S offers high quality two cable throttle assemblies for this purpose. Stock big twin<br />
models from 1981 to present have a two cable throttle and should not require changing.<br />
Super E and G Carb kits for 1990 and later models come with the new longer throttle cable<br />
guide bracket which allows the use of the stock CV style throttle cables.<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S® THROTTLE CABLE APPLICATION CHART<br />
NOTE: The chart on this page is used only when using throttle cable bracket part #11-<br />
2339. This bracket is standard on all S&S Super E & G carburetor kits for big twins 1989<br />
and earlier and all kits for Harley-Davidson ® Sportster ® models with the exception of<br />
the kit for 2004-’05 models. Carburetor kits for 1990 and later big twin models come<br />
with the longer cable bracket part #11-2338 for use with stock CV throttle cables.<br />
Super E and G carburetors ordered for big twin models 1981 and later are being<br />
shipped with the correct throttle cable bracket to fit the stock cables. Big twin carbs<br />
that are not year specific will be shipped with both cable brackets. All Sportster models<br />
1988-’03 will still require conversion to butterfly style cables.<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Application<br />
Fastening<br />
Method<br />
Length<br />
Total Housing<br />
Length<br />
Vinyl Housing<br />
Open Side<br />
Close Side<br />
1996-Up Softail (FXSTS, FXSTC, FLSTC, FLSTF)<br />
Snap-in 39" 35"<br />
USA USA<br />
1996-Up Dyna®<br />
19-0438 19-0439<br />
1996-Up All FLT models Snap-in 48" 44" 19-0464 19-0465<br />
1996-Up custom application Snap-in 42" 38" USA USA<br />
19-0440 19-0441<br />
* 1998 and later required Harley-Davidson® throttle assembly #71831-96 ** 1980 and earlier must be converted to dual cable throttle assembly.<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Replacement Parts<br />
S&S Universal Throttle Cable ................................... 106-3520<br />
Throttle Grip Clamp Set 1985-’95 ..........................<br />
USA<br />
106-3519<br />
USA<br />
Top Throttle Grip Clamp only ........................... 19-0222<br />
Bottom Throttle Grip Clamp only . . . . . . . . . . . . . . . . . . . . . . . . .<br />
USA<br />
19-0220<br />
Throttle Grip Clamp Screw<br />
(Fits S&S throttle assemblies: Part #19-0448, #19-0449, #19-0482, #19-0450, and #19-0229)<br />
each...................................................50-0043<br />
10 pack ..........................................<br />
USA<br />
50-0129<br />
Throttle Grip Set. ......................................<br />
USA<br />
106-3521<br />
USA<br />
Right Hand Grip only. ................................. 19-0225<br />
Left Hand Grip only ....................................<br />
USA<br />
19-0226<br />
Cable Adjuster<br />
Fits S&S throttle assembly part #19-0229. ........................<br />
USA<br />
19-0223<br />
Cable Adjuster Jam Nut<br />
Fits S&S throttle assembly part #19-0229 ..............................19-0227<br />
Handlebar Spacing Sleeve<br />
4" x 1" O.D. – converts 7⁄8" handlebars to 1" O.D. ..................<br />
USA<br />
19-0235<br />
106-3521<br />
106-3520<br />
50-0043<br />
19-0223<br />
19-0227<br />
106-3519<br />
19-0235<br />
2-70<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
COMPRESSION RELEASES<br />
With the S&S compression release kit, a stock starter is able to start almost any engine.<br />
The S&S compression release system consists of a small valve that opens during starting<br />
and allows a portion of the cylinder pressure to escape into the exhaust port. The reduced<br />
cylinder pressure makes it easier for the starter to turn the engine. When the engine starts,<br />
the valve closes and the engine runs normally, with full compression. These compression<br />
releases are a good solution for engines using other manufacturer’s cams, which do not<br />
have built-in compression releases.<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
FITMENT<br />
• S&S cylinder heads for big twin<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
OPTIONS<br />
• Manual release:<br />
Activated by a cable similar to a choke control, this slick system can be used with any<br />
style rocker cover.<br />
• Electric release:<br />
Solenoid operated, this system automatically opens and closes when the starter button is<br />
pressed and released. Convenient and simple, this is the best setup for big displacement<br />
high compression bikes. Requires S&S die cast rocker covers, see page 2-61.<br />
PART NUMBERs<br />
S&S Electric Compression Release Kit . ........................... 90-4915<br />
S&S Manual Compression Release Kit ........................... 90-4925<br />
S&S Cable Knob: Special billet accessory knob for manual compression release<br />
(see picture) .................................................... 50-8701<br />
S&S Two-Piece Socket Kit:<br />
Allows in-frame installation of S&S compression releases and protects wiring from<br />
damage during installation. ...................................... 53-0045<br />
S&S Compression Release Hole Plug ............................ 90-4916<br />
Replacement Parts<br />
Silicone Solenoid Caps ......................................... 55-1009<br />
Wiring Harness ...................................<br />
USA 2,3<br />
TÜV 2,5,6 55-1010<br />
Compression Release Assembly . ................................ 90-4914<br />
champion ® spark plugs<br />
Replace Your Spark Plugs For Maximum Performance and Fuel Economy.<br />
S&S® now offers the same high quality Champion® spark plugs that we include with our<br />
engines for replacement in S&S and stock engines alike. These long reach resistor spark plugs<br />
are available in 12mm and 14mm sizes. They are the correct heat range for all S&S engines<br />
and also fit 1977 and later Harley-Davidson® engines. Compatible with any ignition system.<br />
Champion® Spark Plugs<br />
90-4915– Electric Compression Release Kit<br />
90-4916<br />
Application Size 2 Pack Each<br />
NOTES:<br />
• S&S rocker covers must be used with electric compression releases due to clearance<br />
requirements for the solenoids.<br />
• Rocker covers must be removed when installing S&S® compression releases. If lack<br />
of frame clearance prevents removal of rocker covers, engine must be removed from<br />
frame for compression release installation.<br />
• In most cases, S&S compression releases can be installed while the engine is in the<br />
frame with the special S&S two-piece socket kit, part #53-0045 .<br />
• If cylinder heads are machined for S&S compression releases, but compression releases<br />
are not used, special plug part #90-4916 (two required) must be installed to seal the<br />
machined hole.<br />
• Stock cylinder heads cannot be machined for S&S compression releases because there<br />
is not enough material in critical areas.<br />
55-1322<br />
50-8701<br />
53-0045<br />
55-1009<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
Twin Cam 88®/96/103, Sportster®,<br />
X-Wedge® & S&S 41/8" bore engines<br />
Evolution®, Vintage Models (SH-Series, Iron XL,<br />
KN-Series, P-Series) & S&S 35/8" & 4" bore engines<br />
12mm<br />
Long Reach<br />
14mm<br />
Long Reach<br />
55-1322 USA<br />
(H-D® #32362-04)<br />
Champion® #RN12YC<br />
55-1323 USA<br />
(H-D® #32311-83, 32342-04)<br />
Champion® #RA84C<br />
55-1320 USA<br />
(H-D® #32362-04)<br />
Champion® #RN12YC<br />
55-1321 USA<br />
(H-D® #32311-83, 32342-04)<br />
Champion® #RA84C<br />
Visit us at www.sscycle.com<br />
55-1323<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-71
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
VARIABLE FUEL INJECTION MODULES (VFI)<br />
FEATURES AND BENEFITS<br />
• Directly replaces stock Harley-Davidson® fuel injection modules – plugs directly into<br />
stock wiring harness<br />
• Includes ProTune II software and can be updated at sscycle.com/software/protune<br />
• Three stage engine overheat protection helps prevent possible engine damage<br />
caused by improper modifications to fuel maps<br />
• Altitude compensation automatically adjusts for altitude variations<br />
• Live tuning allows manual changes to maps while the engine is running<br />
• Self diagnostics and actuator test functions help tuning and verify proper installation/<br />
operation<br />
• Engine light can be programmed to function as a shift light<br />
• Closed loop capable<br />
• Knock sensing ignition control (USB Delphi® style unit only)<br />
• Optional closed loop sensor kit and knock sensor kit extend module capabilities<br />
• Speedometer calibration function for 2004-up Harley-Davidson® models (does not<br />
require installation of separate speedometer calibrator)<br />
CLOSED LOOP CAPABILITY<br />
When equipped with a dual closed loop sensor kit and running in closed loop mode,<br />
VFI tuning becomes a breeze! S&S supplies base maps for several displacement groups,<br />
creating a starting point to get bikes up and running. Utilizing dual oxygen sensors (sold<br />
separately) placed in the exhaust, the S&S closed loop system modifies the base fuel map<br />
to meet the specific requirements of your engine!<br />
• Automatic tuning on the street or on the dyno<br />
• Each cylinder is tuned individually<br />
• Fuel map changes are saved in the module and can be merged with the preloaded<br />
base map<br />
• Works with stock oxygen sensors used on late model Harley-Davidson®<br />
motorcycles<br />
Closed loop VFI can also automatically compensate fuel delivery for modifications creating<br />
up to a 20 hp gain, such as changes in:<br />
• Displacement<br />
• Cams<br />
• Exhaust<br />
• Head porting or installation of aftermarket heads<br />
Magneti Marelli® style S&S VFI module<br />
FITMENT<br />
• <strong>1999</strong>–‘01 big twins (except 2001 Softail®)<br />
KIT CONTENTS<br />
• Magneti Marelli® style S&S VFI module<br />
• USB port cover kit<br />
• ProTune II software<br />
• Installation instructions<br />
PART NUMBERS<br />
Magneti Marelli Style VFI Module ....................... 559-0001*<br />
Magneti Marelli Style VFI Closed Loop Sensor Kit .......... 106-2067<br />
Barometric pressure sensor relocation kit (required for T-Series EFI engines<br />
using S&S oil pump)...................................... 55-1599<br />
*Special Order: Download the special order form at sscycle.com/soforms<br />
106-2067<br />
559-0001<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-72<br />
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<br />
to find a tuning center near you.<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Continued<br />
S&S® VARIABLE FUEL INJECTION MODULES<br />
Delphi® style S&S VFI module<br />
FITMENT<br />
• Delphi® ECU equipped big twins<br />
KIT CONTENTS<br />
• Delphi® style S&S VFI module<br />
• ProTune II software<br />
• USB port cover kit (part #55-5090 only)<br />
• Serial port cover, cable and bank angle adapter harness (part #55-5034 only)<br />
• Installation instructions<br />
PART NUMBERS<br />
Delphi Style VFI Module for 2001-'03 bt .................. 55-5034*<br />
• Will only work on custom bikes, 2001-'03 Softail, and 2002-'03 touring models<br />
• Not compatible with Knock Sensor Kit<br />
• Requires a 9-Pin serial COM port or USB to serial adapter<br />
Delphi Style VFI Module for 2001-'11 bt<br />
(except 2008-up touring and 2011 Softail®) ...................55-5090*<br />
S&S Delphi Style VFI Closed Loop Sensor Kit ............... 106-2066<br />
Knock Sensor Kit (55-5090 module only) ................... 106-0810<br />
*Special Order: Download the special order form at sscycle.com/soforms<br />
S&S Sensor Kits and Replacement Parts<br />
S&S VFI Closed Loop Sensor Kit<br />
Magneti Marelli® Style ............................... 106-2067<br />
Delphi® Style ........................................ 106-2066<br />
Knock Sensor Kit (Delphi style only) ........................ 106-0810<br />
Service Kit, O 2<br />
Sensor .................................... 106-2061<br />
Service Kit, Connector, DTM, 4-Position Receptacle ..........55-1592<br />
Service Kit, DTM Pin .......................................55-1521<br />
Service Kit, Oxygen Sensor Boss ..........................55-6071-S<br />
Service Kit, Subharness (Magneti Marelli Style) ................55-1588<br />
Service Kit, Subharness (Delphi Style) ........................55-1595<br />
Service Kit, Electrical Tap (10 Pack) ...........................55-1596<br />
Barometric Sensor Relocation Kit ...........................55-1599<br />
Hardware Kit (USB Cover)<br />
(for 550-0001 and 55-5090 modules) .........................55-5091<br />
Serial Communications Cable<br />
(for 55-5034 and 55-5006 modules only) ................... 55-5009<br />
Serial Port Cover Kit (for 55-5034 module only) ...........55-5034P<br />
55-5090<br />
Installation of the oxygen sensors on the back or underside of the pipes makes them<br />
unobtrusive in nearly all applications. The wiring sub-harness installation requires minor<br />
wiring harness modifications. Complete installation instructions are included.<br />
NOTES:<br />
• All current production S&S modules are closed loop compatible, and all older S&S<br />
modules can be updated with current calibration by simply downloading software<br />
from the S&S website at www.sscycle.com/software/protune.<br />
• Please note that maps created for older versions of the VFI software are not<br />
compatible with the new closed loop software, however they can be converted to<br />
closed loop if desired.<br />
• Optional Delphi® style knock sensor adjusts timing to eliminate spark knock,<br />
prolonging engine life (55-5090 module only).<br />
• S&S VFI systems installed on 2004–up Harley-Davidson® models incorporate a<br />
speedometer calibration feature.<br />
PERFORMANCE<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-73
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
PERFORMANCE<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
VFI Closed Loop Fuel Injection Kit<br />
S&S Variable Fuel Injection (VFI) modules for 2001-’03 Harley-Davidson® big twins<br />
with Delphi® style fuel injection are now available. Comes packaged with a dual<br />
oxygen sensor kit so they can be run in closed loop mode for automatic fine-tuning<br />
of fuel delivery – that brings older bikes up to 2007 and later technology. The<br />
S&S VFI module offers almost unlimited tuning capacity and can handle just about<br />
any performance upgrade possible. Once a base map for a particular configuration is<br />
installed, the oxygen sensor kit continuously fine-tunes the engine. To save time<br />
getting started, the module is pre-loaded with a fuel map for a touring bike with a<br />
95" engine and the CD includes easily changed calibrations for other models. With the<br />
oxygen sensor kit included with the module, this map can be used as a starting point for<br />
this very popular engine configuration. Maps for several other engine configurations are<br />
on the software CD that is included with this VFI closed loop fuel injection kit. Maps are<br />
also available for download at www.sscycle.com/software/protune.<br />
The S&S VFI modules are easy to install. They directly replace the stock Harley-<br />
Davidson fuel injection module and plug into the stock wiring harness. Minor wiring<br />
modifications are required for the oxygen sensor kit and to retain the "tip over" safety<br />
feature of the stock system. Also, oxygen sensor bungs must be welded into the existing<br />
exhaust pipes. Full instructions are included.<br />
Fitment<br />
• 2001-’03 big twins with Delphi® style fuel injection<br />
Features and Benefits<br />
• Easy installation – module plugs into the stock wiring harness<br />
• Altitude compensation – automatically adjusts for altitude variations<br />
• Live Tuning – make manual changes to maps while the engine is running<br />
• Self diagnostics and actuator test functions<br />
• Engine light can be programmed to function as a shift light<br />
• ProTune II software included with each module – updates can be downloaded<br />
from sscycle.com/software/protune<br />
• Engine overheat protection<br />
• Oxygen sensor kit continuously fine-tunes the engine<br />
• Module is pre-loaded with a fuel map for a touring bike with a 95" engine<br />
Part Number<br />
S&S VFI Closed Loop Fuel Injection Kit* .................... 550-0010<br />
*A Serial to USB adaptor is required for this module when using computers that do<br />
not have a serial port.<br />
Save a bundle on this S&S VFI closed loop fuel injection kit. You get an S&S<br />
VFI module and closed loop dual oxygen sensor kit for a great price. It’s<br />
almost like getting the sensor kit for free!<br />
OEM Cross Reference<br />
Appendix & Index<br />
Warranty &<br />
Company Policy<br />
2-74<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
EZFI MODULE<br />
S&S EZFI Module for 2001-’10 Softail® and 2002-’11 big twins<br />
(excludes 2008-up touring models)<br />
Great for modifying fuel delivery to stock engines equipped with power enhancers<br />
like high flow air cleaners, exhaust systems or performance cams, and the EZFI<br />
plugs directly into the stock ECM. With simple adjustments, you can add fuel<br />
where your bike needs it and remove fuel where it does not.<br />
FEATURES AND BENEFITS<br />
• Provides economical tuning for stock or mildly modified engines<br />
• Plugs into stock ECM<br />
• Does not adjust timing, only modifies fuel delivery<br />
• Stock TSSM functions such as turn signals, safety functions, and instruments<br />
are not affected<br />
KIT CONTENTS<br />
• EZFI module<br />
• Tuning software<br />
• Install Instructions<br />
• Velcro®<br />
PART NUMBERS<br />
S&S® EZFI Module Kit ................................... 106-0890<br />
Diagnostic Cable ..........................................55-1271<br />
OPTIONS<br />
An optional wiring harness allows for quick and easy bypass of the EZFI module<br />
in order to return the fuel system to stock for diagnostic or comparison reasons.<br />
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-0891<br />
S&S ®<br />
EFI WIRING HARNESS<br />
The S&S custom EFI wiring harness was designed specifically for the installation of fuel<br />
injected S&S engines into stock or custom frames with up to 4" of backbone stretch.<br />
FITMENT<br />
• S&S T-Series engines with Delphi® style VFI modules<br />
• Harley-Davidson® engines with factory Delphi modules<br />
• Does not support J1850 devices<br />
FEATURES AND Benefits<br />
• Plugs directly into Delphi® style S&S VFI modules and stock Delphi modules used in<br />
late model Harley-Davidson® motorcycles<br />
• Compatible with most stock and aftermarket components for Harley-Davidson<br />
Softail® models including:<br />
• Tip-over sensor<br />
• Oxygen sensors<br />
• Includes provisions for a knock sensor, which is utilized in the newest S&S VFI modules<br />
106-0891<br />
NOTEs:<br />
• Since the S&S EZFI module does not control ignition timing, it is not recommended for<br />
engines with higher than stock compression ratios.<br />
• Not for sale or use on CA or EPA pollution controlled vehicles.<br />
PERFORMANCE<br />
PARTS<br />
OPTIONS<br />
S&S is also offering an optional matching connector set specifically for the S&S EFI wiring<br />
harness. The set contains the correct connectors to allow custom builders to make tight,<br />
waterproof connections from electrical components to the S&S harness. Set includes<br />
connectors for:<br />
• Speedometer<br />
• Headlights<br />
• Fuel gauge<br />
• Left and right handlebar controls<br />
• Indicator lights<br />
• Front turn signals<br />
• Extra DT and DTM replacement terminals and sealing plugs<br />
PART Numbers<br />
Custom wiring harness kit .................................106-0478<br />
Connector set ............................................106-2857<br />
When connecting S&S T-Series engines to this EFI harness,<br />
a K-to-B style fuel injector adaptor must be used.<br />
Injector adaptor ........................................... 55-5074<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
106-0478<br />
55-5074<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-75
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
PERFORMANCE<br />
PARTS<br />
SPEEDOMETER CALIBRATOR<br />
The easiest way to adjust stock Harley-Davidson® electronic speedometers. No more<br />
worrying about the effects of changing gear ratios, tire size, or wheel size. Installation is as<br />
simple as unplugging the connection between the transmission sensor and speedometer<br />
and connecting it to the S&S calibration module.<br />
FITMENT<br />
• <strong>2006</strong> and earlier Harley-Davidson® big twin models equipped with OEM electronic<br />
speedometer (except <strong>2006</strong> Dyna®)<br />
FEATURES AND BENEFITS<br />
• Allows precise adjustments in 1% increments between -29% and + 69%<br />
• Compact size (2.25" x 1.50" x 1.10") permits neat, unobtrusive installation<br />
• Sensitive components are sealed in epoxy for protection from vibration and weather<br />
PART NUMBER<br />
S&S Speedometer Calibrator .................................55-1007<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
NOTES:<br />
• Not compatible with Rev Tech® transmissions.<br />
• Calculating the difference between actual and indicated speeds/mileage requires only<br />
that the rider compare odometer readings to a known distance. Highway mile markers<br />
are usually accurate enough to use for calibration, although the test should be repeated<br />
between several different markers for confirmation. The S&S speedometer calibrator<br />
can then be adjusted to increase or decrease the speed and mileage indicated by the<br />
speedometer. In most cases it is possible to achieve accuracy within 0.5%.<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-76<br />
S&S ®<br />
IST ® Guardian Diagnostic System<br />
In addition to a 3-step break-in rev-limiter function, the Guardian Diagnostic System offers<br />
engine builders and tuners some powerful tools to use with the S&S IST ignition module.<br />
FITMENT<br />
• <strong>1999</strong>-'06 carbureted big twins<br />
• Vehicles equipped with the IST ignition module (will not work with stock Harley-<br />
Davidson® or other aftermarket systems)<br />
FEATURES AND BENEFITS<br />
• Adjustable rev-limiter. Modules are initially set to a 6,250 rpm rev limit, but this can be<br />
set to any value up to 7,200 rpm<br />
• Scan tool function allows you to view diagnostic test codes (DTCs) or clear history DTCs<br />
• Calibrate the speedometer in 2004-'06 H-D® models<br />
• Look at live data: rpm, manifold absolute pressure, engine temperature, battery voltage,<br />
spark timing, dwell, and coil current for both cylinders while the engine is running, to<br />
aid in service work or performance tuning<br />
• Look at history information: number of starts, number of rev-limiter hits after the<br />
break-in rev-limit has expired, amount of time spent in various operating conditions,<br />
maximum temperature reached, current rev-limit, total engine cycles and running time<br />
KIT CONTENTS<br />
• PC software CD<br />
• Translator unit<br />
• Adaptor cables<br />
System Requirements<br />
• Microsoft® Windows® 2000 or higher operating system<br />
(not compatible with 64-bit operating systems)<br />
• Pentium II 350 MHz processor or faster/equivalent, Pentium III 500 MHz processor or<br />
faster/equivalent preferred<br />
• Minimum 64 MB RAM, 128 MB or more recommended<br />
• At least 300 MB of free hard drive space<br />
• CD-ROM or DVD-ROM drive required for installation<br />
• Keyboard and mouse (or equivalent pointing device)<br />
• 9-pin serial port or serial to USB adapter<br />
PART Numbers<br />
S&S IST Guardian Diagnostic System .........................55-5075<br />
Replacement Cables:<br />
Harness, translator to data link ...............................55-5062<br />
Cable, RS-232, PC to translator ...............................55-5063<br />
Order toll free 866-244-2673<br />
Hours of Operation<br />
break-in rev-limits schedule<br />
Rev-Limit<br />
0 to 8 4,250<br />
8 to 16 5,125<br />
16 to 24 6,025<br />
24+ 6,250*<br />
* The final rev-limit can be set to any value up to 7200 rpm using S&S IST Guardian<br />
Diagnostic software. Available for modules sold separately only.<br />
Note:<br />
• PC must have 9-pin serial port for communication with ignition module.<br />
Otherwise, a serial to USB adapter must be used.<br />
• Not compatible with S&S IST ignition modules manufactured before<br />
10/01/2003. Software can be by sending the IST module to S&S <strong>Cycle</strong>.
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
IST ® IGNITION SYSTEM<br />
Truly revolutionary, the Intelligent Spark Technology (IST) system monitors stock crank<br />
position, cam position (if equipped), MAP, and cylinder head temperature sensors, in addition<br />
to the exclusive S&S Knock Sensor. If knock or detonation occurs, the IST system adjusts timing<br />
until it stops. It then stores information about conditions that cause the engine to knock. In<br />
effect, the system "learns" the ignition requirements of a particular engine and creates a fully<br />
custom ignition map for it. Requires two coils or single fire coil pack.<br />
FITMENT<br />
• <strong>1999</strong>–’06 carbureted big twins – requires installation kit (see below)<br />
FEATURES AND BENEFITS<br />
• Protects your engine from damaging detonation or knock<br />
• Automatically adjusts to lower grade fuel<br />
• Installation kits plug into stock wiring harnesses<br />
• 6250 rpm preset rev-limiter<br />
• High output automatically maximizes coil output<br />
• Automatic dwell adjust will optimize current for any 0.5Ω to 3.0Ω coil<br />
• Short circuit and reverse polarity protected<br />
• With the Guardian diagnostic system (55-5075), you can calibrate the speedometer<br />
on 2004 - <strong>2006</strong> H-D® models<br />
IST will automatically adjust ignition timing for modifications such as:<br />
• Increased displacement from stroker or big bore kits<br />
• Bigger cams<br />
• Performance exhaust<br />
• Head porting or installation of aftermarket heads<br />
• Gear ratios<br />
S&S High Output 3.0Ω Single Fire Coil:<br />
The perfect complement for S&S IST® or Super Stock® ignition systems. This single fire<br />
coil is actually two separate coils in a single package. Coil impedance is 3Ω per coil. Not<br />
compatible with the S&S Variable Fuel Injection (VFI) System. ............55-1571<br />
S&S High Output 0.5Ω Single Fire Coil:<br />
High output 0.5Ω single fire coil for S&S IST ignition, Delphi® style VFI modules (fits<br />
carbureted Harley-Davidson® big twins <strong>1999</strong>-'06, except <strong>1999</strong>-'01 touring models), and<br />
custom applications requiring a 0.5Ω coil. Not compatible with S&S Super Stock ignition.<br />
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USA 55-1576<br />
PART NUMBER<br />
S&S Intelligent Spark Technology Ignition Module . .................55-1221<br />
Installation kit (required):<br />
<strong>1999</strong>–’03 carbureted big twins . .....................................55-1012<br />
2004–’06 carbureted big twins . .....................................55-1220<br />
KIT CONTENTS<br />
• Wiring harness adapter<br />
• Knock sensor<br />
• Temperature sensor<br />
55-1012<br />
Installation Kit<br />
Visit us at www.sscycle.com<br />
PERFORMANCE<br />
PARTS<br />
Exclusive S&S knock sensor installed<br />
on cylinder head top motor mount.<br />
No other ignition system for v-twin<br />
motorcycles uses knock sensing to<br />
control ignition timing.<br />
NOTE:<br />
• Do not use a dual fire coil with the S&S ignition module.<br />
• This kit will NOT work with vehicles equipped with flat slide carbs, open primaries, and dry clutches. If you want to use IST with these configurations, contact S&S – we can help set up IST.<br />
• 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.<br />
We recommend our Super Stock® ignition system for kick start applications.<br />
55-1576<br />
55-1221<br />
55-1571<br />
Replacement Parts<br />
Cylinder Head Temperature Sensor (H-D® #32446-99) .......... TÜV 2 55-1014<br />
MAP Sensor Only (H-D® #32316-99) .............................. 55-5057<br />
Knock Sensor Kit with Mounting Brackets and Hardware ........ 55-1015<br />
Knock Sensor Motor Mount Bracket .......................... 55-1054<br />
Knock Sensor Head Mount Spacer (S&S Heads Only) .......... 50-7140-S<br />
Knock Sensor Only ........................................ 106-2942<br />
Wiring Harness Adapter (2004-<strong>2006</strong> Twin Cam 88®) ............ 55-1499<br />
Wiring Harness Adapter (<strong>1999</strong>-2003 Twin Cam 88®) ...... TÜV 1,2 55-1017<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-77
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Chrome plated Billet Transmission Side Covers<br />
For Mechanical and Hydraulic Clutches<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
PERFORMANCE<br />
PARTS<br />
S&S offers two chrome plated billet transmission side covers that fit our six-speed transmissions,<br />
as well as stock and aftermarket left side drive transmissions for 1987-‘06 big twins (except<br />
<strong>2006</strong> Harley-Davidson® Dyna® and all FXR models). The first version is cable actuated and is<br />
compatible with all stock and aftermarket cables. The second is a hydraulic version designed<br />
to convert a cable actuated clutch to hydraulic actuation without changing the clutch pressure<br />
plate, throw-out bearing or pushrod. The hydraulic side cover has a piston diameter of 1.550"<br />
and is compatible with stock and aftermarket master cylinders with 11⁄16" diameter pistons.<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Billet Transmission Side Covers<br />
Cable Actuated, Chrome .......................................... 106-4035<br />
Hydraulic, Chrome ............................................... 106-3885<br />
S&S chrome billet side covers fit 1987-'06 big twins except <strong>2006</strong> Dyna® and all FXR<br />
models. Available for cable and hydraulically actuated clutches.<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Replacement parts on page 2-100<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
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<br />
required on stock H-D® right-side pushrods.)<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
S&S ®<br />
Transmission Top Covers<br />
The S&S transmission top covers are made of chrome plated die-cast or polished billet<br />
aluminum, so naturally, they look great. The two versions are for different applications.<br />
S&S Chrome Die Cast Transmission Top Cover<br />
For 1991-’99 Softail® and 1991-'00 FLT Models<br />
This cover may be used as stock replacement for 1991-’99 Harley-Davidson® Softail® and<br />
1991-'00 FLT Models.........................................<br />
USA<br />
56-5115<br />
S&S Chrome Billet Transmission Top Cover<br />
For <strong>1999</strong>-‘05 Dyna® Models<br />
This cover is required for proper oil line connection in <strong>1999</strong>-’05 Dyna models when installing an<br />
S&S T124 engine or when installing S&S replacement crankcases. This top cover may also be<br />
used as stock replacement for <strong>1999</strong>-'05 Dyna models. ................... 106-3886<br />
56-5115<br />
OEM Cross Reference<br />
Appendix & Index<br />
Warranty &<br />
Company Policy<br />
All reference to H-D® part numbers is for identification purposes only. We in no way are<br />
implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are<br />
equivalent to the corresponding H-D® part number shown.<br />
106-3886<br />
This cover is included in oil line kit, part #31-0424.<br />
2-78<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
High Performance Clutch<br />
The S&S high performance clutch offers more gripping power with more friction surfaces<br />
and a larger friction centerline diameter. This clutch is able to handle over 150 horsepower.<br />
For competition applications, stronger pressure plate springs are available that increase the<br />
power handling capacity to nearly 200 horsepower. Fits in stock primary cases with only<br />
minor clearancing operations, which are not visible when the primary is assembled.<br />
Fitment<br />
• Available for 1991-'06 big twin models (except <strong>2006</strong> Dyna®)<br />
Features and benefits<br />
• Updated clutch to simplify installation – no need for retention epoxy<br />
• Superior to competitively priced high performance clutches<br />
• Fits in stock primary with minor modification<br />
• With supplied springs, lever effort is slightly less than a stock Harley-Davidson® clutch,<br />
but handles engines up to 150 hp<br />
• Optional high pressure clutch springs, available for competition applications, increases<br />
power handling capacity to nearly 200 hp<br />
• Light duty springs for light clutch pull in less demanding stock street applications<br />
• 11 friction plate, 10 steel plate design – narrow friction rings increase contact diameter<br />
for increased torque capacity<br />
• Supplied with early style 66-tooth ring gear for increased strength and reduced tooth<br />
breakage<br />
• Perfect for use with the S&S six-speed transmission<br />
Options<br />
• Mechanical or hydraulic actuation<br />
• 36 or 37-tooth sprocket<br />
• Early style starter pinion gear required for 1994-'99 models to match 66-tooth ring<br />
gear supplied<br />
Kit Contents<br />
• Clutch assembly<br />
• Special inner transmission mainshaft bearing race<br />
• Installation hardware<br />
• Instructions<br />
Lever Effort Comparison Chart<br />
56-5152<br />
Stock Clutch S&S Standard Clutch S&S Touring Springs S&S Race Springs<br />
Max. HP Up to 90 HP Up to 150 HP Up to 85 HP Up to 200 HP<br />
Lever Pull 26.0 lbs 27.4 lbs 20.3 lbs 45.0 lbs<br />
The S&S high performance hydraulically actuated clutch is compatible with<br />
Harley-Davidson® hydraulic clutch, pushrod, and bearing.<br />
PERFORMANCE<br />
PARTS<br />
S&S High Performance Clutch<br />
Mechanical Actuation<br />
With 36-Tooth Sprocket .....................................<br />
USA<br />
56-5150A<br />
With 37-Tooth Sprocket .....................................<br />
USA<br />
56-5151A<br />
Hydraulic Actuation<br />
With 36-Tooth Sprocket .....................................<br />
USA<br />
56-5152A<br />
With 37-Tooth Sprocket .....................................<br />
USA<br />
56-5153A<br />
Optional Parts<br />
Starter Pinion Gear – 9-Tooth ....................................... 56-1037<br />
High Pressure "Race" Clutch Springs .............................<br />
USA<br />
56-5106<br />
Low Pressure "Touring" Clutch Springs. ..........................<br />
USA<br />
56-5109<br />
Replacement parts on page 2-100<br />
56-5150A<br />
S&S high performance cable actuated<br />
clutch is compatible with stock<br />
and aftermarket cable style<br />
transmission side covers. See<br />
page 2-78 for S&S chrome billet<br />
transmission side covers.<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
S&S ®<br />
Inner Primary Bearing Race<br />
The tendency of the stock inner primary bearing race on late model big twins to shift on the transmission<br />
mainshaft under high torque loads, also known as "walking" of the race, can cause destruction of the<br />
transmission mainshaft seal, and ultimately the mainshaft seal, output gear and output gear bearing.<br />
The S&S inner primary bearing race features an extra step on the inside diameter that acts as a stop<br />
on the transmission mainshaft. When the race is pressed on to the shaft, the step will not allow the<br />
race to move inward toward the mainshaft seal. The improved S&S bearing race is a must for any high<br />
performance application.<br />
Fitment<br />
• All 1991-'06 big twins (except '06 Dyna®)<br />
Features and benefits<br />
• Will not "walk" on transmission mainshaft<br />
• Prevents costly damage to mainshaft seal, output gear & output gear bearing<br />
• Simple to install<br />
56-5089<br />
Part number<br />
S&S Inner Primary Bearing Race ...........................<br />
USA<br />
56-5089<br />
Any Job is easy with the right tools<br />
S&S Inner Bearing Race Puller, see page 9-10<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-79
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
PERFORMANCE<br />
PARTS<br />
How many final drive belts have S&S engines broken Yes, a lot of power can break things,<br />
so what’s the solution The solution is that we are offering stronger belts! S&S has teamed<br />
up with the Gates® Corporation, a leading manufacturer of power transmission belts, to<br />
offer a series of secondary drive belts for many popular v-twin models. These belts feature<br />
Gates’ super strong X3N carbon cord material which is significantly stronger than the<br />
Aramid material used in many OEM final drive belts.<br />
S&S final drive belts by Gates are available with 14mm pitch in 1½" and 11/8" widths. See<br />
the chart below and match the width and number of teeth required for your vehicle. You<br />
can find this information in the vehicle service manual.<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Gates ® High Strength Final Drive Belts<br />
Secondary Drive Belts (14mm pitch)<br />
Teeth 11/8" Wide 11/2" Wide<br />
125 106-0357 USA –<br />
126 – 106-0348 USA<br />
127 – 106-0349<br />
128 106-0358 USA 106-0350<br />
130 106-0359 USA 106-0351<br />
132 106-0360 USA 106-0352<br />
133 106-0361 USA 106-0353<br />
135 106-0362 106-0354<br />
136 – 106-0355<br />
139 106-0363 106-0356<br />
149 106-1338 –<br />
156 – 106-2827<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
106-0361<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Attention Custom Bike Manufacturers!<br />
Special Order Belts From S&S® and Gates®<br />
Special belt sizes, private brand labeling, and assistance with belt drive design, are available<br />
to custom performance OEM's and aftermarket bike builders, through S&S. These products<br />
and services are available for licensed motorcycle manufacturers only, and a minimum<br />
order quantity may be required.<br />
Drive belts with your company name imprinted on them are a perfect way to show off your<br />
brand. Any belt size currently available in the S&S catalog, as well as the special ordered<br />
sizes, can be specially branded. Minimum order quantities would apply.<br />
Whether you’re designing a completely new chassis, or simply need a replacement belt,<br />
S&S can help you find the belt you’re looking for. Through the combined efforts of Gates<br />
and S&S, S&S can now provide customers with the technical assistance they need for<br />
designing new secondary belt drive systems. In addition, S&S can help you determine<br />
required tooth count for your existing chassis design, based on the pulley center-to-center<br />
distances and pulley tooth counts.<br />
All belts have a 14mm tooth pitch, and are made of the super strong Gates Carbon X3N<br />
material. Belts are available in three standard widths of 1.125", 1.5"and 1.181" (30mm),<br />
but can be special ordered in nearly any width for a nominal charge. If you want a belt with<br />
a special tooth count, they are also available (see the special order chart for availability).<br />
Contact your S&S Customer Support Representative for more information.<br />
Belts Available By Special Order (14mm Pitch)<br />
Tooth Count 1.181" (30mm) Width* 1.25" Width*<br />
125 •<br />
126 • •<br />
127 • •<br />
128 •<br />
130 •<br />
131 • •<br />
132 •<br />
133 •<br />
135 •<br />
136 • •<br />
137 • •<br />
139 •<br />
140 • •<br />
149 •<br />
150 • •<br />
151 • •<br />
152 • •<br />
156 •<br />
*Minimum order required: 1.181" (30mm) – 16 belts; 1.25" – 17 belts.<br />
2-80<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Crankcase Replacement Parts<br />
38<br />
for Harley-Davidson ® Twin Cam 88 ® Engines<br />
1. Bolt, stator 10-24 x1" SHC - 4 required (H-D® #2720)<br />
each ........................................50-0044<br />
10 pack ......................................50-0194<br />
USA<br />
2. Seal, sprocket shaft (H-D® #12068) .. 31-4035<br />
3. Bearing, Timken® sprocket shaft<br />
(H-D ®#9028)......... USA TÜV 1,2,3 1,3,4,5,6,7 31-4013<br />
4. Timken Main Bearing Spacers<br />
Fits 11/4" stock diameter shaft.<br />
.0995" - .1005" (H-D® #9124. ............ .31-4071<br />
.1015" - .1025" (H-D® #9125). ............ 31-4072<br />
.1035" - .1045" (H-D® #9126) . ............ 31-4073<br />
.1055" - .1065" (H-D® #9127) ............. 31-4074<br />
.1075" - .1085" (H-D® #9128) ............ . 31-4075<br />
.1195" - .1205" (H-D® #9134) . ............ 31-4076<br />
5. Hardware Kit, 4" Bore, S&S 41/8" Bore,<strong>1999</strong>-'12 bt<br />
Chrome.............................106-4905<br />
Zinc. ...............................106-4904<br />
6. Bolt, case 5⁄16" -18 x 31/2" HHC - 8 required<br />
Chrome (each)....................... 50-0254-S<br />
6 pack .......................................106-3452<br />
Zinc (each) ..............................50-0117<br />
7. Washer, flat 5⁄16" x 11⁄16" x 1⁄16" - 8 required. 50-7034<br />
8. Bolt center case 1⁄4" -28 x 6" HHC Grade 8<br />
each ........................................50-0020<br />
5 pack .......................................50-0221<br />
9. Washer, flat, 1⁄4" x .474" x .050" (each) .... 50-7020<br />
10 pack ......................................50-7076<br />
10. Nut 1⁄4"-28 Grade 8 - 1 required ......... 50-5011<br />
11. Cylinder stud - 8 required (H-D® #16834-99A)<br />
USA<br />
each .............................. 31-2325-S<br />
USA<br />
8 pack ................................ 31-2340<br />
1<br />
4<br />
6<br />
37<br />
2<br />
38<br />
8<br />
3<br />
36<br />
7<br />
12<br />
11<br />
36<br />
40<br />
21<br />
37<br />
9<br />
35<br />
34<br />
41<br />
32<br />
12. Dowel, cylinder deck - 2 required (H-D® #16595-99A)<br />
each ........................................50-8177<br />
4 pack ....................................50-8177-4<br />
10 pack ......................................50-8179<br />
13. Bolt, cam plate 1⁄4" -20 x 1" SHC - 4 required (H-D® #4741A)<br />
each ........................................50-0084<br />
10 pack ......................................50-0244<br />
14. Bolt, cam plate 1⁄4" -20 x 11⁄4" SHC - 2 required<br />
each ........................................50-0008<br />
10 pack ......................................50-0153<br />
15. O-ring, cam plate - 9 required (H-D® #11301 )<br />
each ..................................... 50-8066-S<br />
10 pack ......................................50-8066<br />
16. Dowel, cam plate - 2 required<br />
(H-D® #16589-99A). ................... 50-8148-S<br />
USA<br />
17. Bearing, inner cam (H-D® # 9198).. TÜV 231-4080<br />
18. Bearing, pinion shaft – Fits all S&S and OEM 2000-’02<br />
(Balanced models only) & all OEM 2003-up<br />
(H-D® #24604-00D)..................<br />
TÜV 2 31-4085<br />
19. Retaining ring, internal, spiraloc - 2 required<br />
(H-D® #35114-02). ..................... 50-8160-S<br />
20. O-ring, oil pump 11⁄16" I.D. x 15⁄16" O.D. x 1⁄8" CS<br />
USA<br />
(H-D® #11190, 11157, 11293) ......... 50-8039<br />
USA<br />
10 pack ............................... 93-4110<br />
21. Plug, magnetic drain . USA TÜV 1,2,3 1,2,3,4,5,6,7 50-8335<br />
22. Baffle plate ........................ 31-0119-S<br />
23. Screw 10-24 x 3⁄8" pan head - 2 required<br />
each ........................................50-0050<br />
10 pack ......................................50-0139<br />
24. Dowel, case alignment - 2 required (H-D® #16573-83)<br />
each ........................................50-8023<br />
10 Pack ......................................50-8109<br />
11<br />
12<br />
22<br />
27<br />
26<br />
26c<br />
23<br />
39<br />
26b<br />
26a<br />
24<br />
11<br />
25<br />
15<br />
31<br />
28 30<br />
29<br />
20<br />
21<br />
11<br />
33<br />
19<br />
25. O-ring, case alignment,- 2 required (H-D® #26432-76A)<br />
9⁄16" I.D. x 11⁄16" O.D. x 1⁄6" CS . .......... 50-8034-S<br />
26. Piston Oiler Jet Kit (H-D® #22371-99) (each)... 31-2025B<br />
2 pack ............................................31-2026<br />
Piston Oiler Jet Kit includes:<br />
a. O-ring,(-014),.500" ID x .625" OD (H-D® #11140, 11273)<br />
each ..............................................50-8032<br />
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8130<br />
b. Jet, Assembly, Piston Cooling (H-D® #22307-99)<br />
each ............................................31-2025B<br />
C. Screw,Torx Panhead,8-32 x 3/8",Zinc,Steel (H-D® #68042-99)<br />
each ...........................................50-0054-S<br />
27. Hardware kit, oil line plugs. ................. N/A<br />
28. Fitting, crankcase vent<br />
<strong>1999</strong>-'00. ............................ 50-0454<br />
2001-'06 (each). ....................... 50-0449<br />
2 pack .....................................106-1171<br />
29. Plate, oil line cover. ..................106-1184<br />
30. BHSH CS 5/16" -18 x 3/4" (10 Pack) .........106-1178<br />
31. O-ring (H-D® #11105, 11275) (each) .............50-8008<br />
10 pack ......................................50-8078<br />
32. O-ring,<br />
9⁄16" I.D. x 11⁄16" O.D. x 1⁄6" CS. .......... 50-8034-S<br />
33. Pin, dowel (H-D® #18535-99)(each) ........ 50-8195-S<br />
2 pack .......................................50-8195<br />
These parts are for crankcases manufactured before 8-1-06:<br />
34. Washer, flat 1⁄4" chrome (each) ........... 50-7017<br />
12 pack ......................................50-7013<br />
35. Bolt, 1⁄4" -20 x 3⁄4" SHCS (each) ............. 50-0067<br />
12 pack ......................................50-0144<br />
36. Hose, oil, inlet/outlet. ................. 50-8157<br />
37. Spring clips ........................ 50-8156-S<br />
38. Oil line fittings, inlet/outlet - 2 required. ...... N/A<br />
39 . Oil line fitting- vent. ........................ N/A<br />
40. Plug, sump (H-D® #765). ....<br />
USA 1,2,3<br />
TÜV 4,5 50-8330<br />
41. Oil conduit block. ..................... 31-2076<br />
NOT SHOWN:<br />
42. Sensor,Kit,Crank Position,1984-2007 bt<br />
(H-D® #32707-01B) ............ USA 2,3 TÜV 4,5,7 55-1051<br />
16<br />
9<br />
14<br />
10 15<br />
17<br />
16<br />
18<br />
13<br />
14<br />
19<br />
Visit us at www.sscycle.com<br />
REPLACEMENT<br />
PARTS<br />
NOTE: All reference to H-D® part numbers is for identification<br />
purposes only. We in no way are implying that any of S&S<br />
<strong>Cycle</strong>’s products are original equipment parts or that they are<br />
equivalent to the corresponding H-D® part number shown.<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-81
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
REPLACEMENT<br />
PARTS<br />
CRANKCASE Breather REED VALVE<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Replacement Parts 2<br />
1. Valve,Assembly,Breather Reed<br />
Engines with Stock Oil Pumps<br />
<strong>1999</strong>-'02 bt with stock or S&S Super Stock® crankcases ......... 31-2070<br />
2003-up bt with stock or S&S Super Stock® crankcases.......... 31-2071<br />
S&S SA Crankcases ........................................ 31-2086<br />
Engines with S&S Oil Pumps<br />
<strong>1999</strong>-'02 bt with stock crankcases ........................... 31-2093<br />
3<br />
2003-up bt with stock crankcases and all S&S crankcases........ 31-2094<br />
2. O-ring,<br />
<strong>1999</strong>-'02 bt (-038),2.614" ID x 2.750" OD,Viton®..............50-8154-S<br />
2003-up bt (-036),2.364" ID x 2.500" OD,Viton® ..............50-8155-S<br />
3. Seal,Breather Reed Valve,<strong>1999</strong>-up bt .................... TÜV 2 31-4086<br />
4. Stop,Breather Reed Valve,Packaged,1984-up bt................ 31-2075<br />
7<br />
5. Reed,Breather Valve,bt (each)..............................31-2072-S<br />
4 pack ..................................................31-2072<br />
6. Screw,Torx BH,4-40 x 1/4",Black,Alloy Steel (each) .............50-0305-S<br />
10 pack .................................................50-0305<br />
7. Wave Spring ,2"OD X 1.6"ID X .375".......................... 50-8404<br />
8. Spring Adaptor (for S&S SA Crankcases) N/S................... 31-2103*<br />
* Required to accommodate the extra .375" case width of S&S Special Application big bore crankcases.<br />
N/S = Not Shown<br />
1<br />
4<br />
5<br />
6<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-82<br />
S&S ®<br />
Flywheel Replacement Parts<br />
1. Sprocket Shaft, <strong>1999</strong>-<strong>2006</strong> bt (includes key #5)..... TÜV 2 33-2009<br />
2. Sprocket Shaft, <strong>2006</strong> Dyna®, 2007-2012 bt ........ 33-2011<br />
3. Pinion Shaft, <strong>1999</strong>-2012 bt (includes key #5) ...... TÜV 2 33-2030<br />
4. Pinion Shaft, 2000-2012 w/ balancer (includes key #5) ..33-2042<br />
5. Key (each) ........................................50-8227<br />
5 pack ............................................50-1013<br />
6. Front Rod Race, <strong>1999</strong>-2012 ............ USA TÜV 3 1,6,7 34-4008<br />
7. Rear Rod Race ....................... USA TÜV 3 1,2,6,7 34-4013<br />
8. Crankpin (std.) ................................. 106-6239<br />
+.001...................................... 34-2176<br />
+.002..................................... 340-0018<br />
9. Crankpin Plug (each) ............................ 106-5256<br />
2 pack ..........................................50-8329-2<br />
12<br />
10. Race/Bearing Set .................................34-4011<br />
11. Wristpin Bushing,<br />
<strong>1999</strong>-2012* bt , straight bushing ..... USA TÜV 3 1,2,6,7 34-4012<br />
12. Connecting Rod Set, 7.668" length<br />
<strong>1999</strong>-<strong>2006</strong> bt, straight wristpin ends ...............34-7405<br />
2007-2012 bt, tapered wristpin ends............. 106-3373<br />
* 2007-2012 engines with stock pistons require trimming of the bushing to fit tapered 1 rod end<br />
Order toll free 866-244-2673<br />
2<br />
5<br />
Any Job is easy with the right tools<br />
S&S Sprocket Shaft Bearing and Seal Installation Tool, see page 9-5.<br />
7<br />
11<br />
7<br />
10 9<br />
8<br />
6<br />
11<br />
9<br />
5 4<br />
NOTES:<br />
• Due to different crankpin diameters, S&S® connecting rod assemblies cannot be used with stock Harley-Davidson® flywheels.<br />
• 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<br />
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<br />
to like new specifications. See Section 10: Dealer Services or call your S&S customer support representative for more information.<br />
3
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Oil Pump Replacement Parts<br />
For Harley-Davidson ® Twin Cam 88 ® Engines<br />
1. Cover, assembly, camchest<br />
Polished........................ TÜV 2 31-6506<br />
Chrome ............................ 106-3890<br />
2. Cover plate ...........................31-6507<br />
3. Bushing, cam support (each). .... TÜV 2 31-4087-S<br />
2 pack ..........................<br />
TÜV 2 31-4087<br />
4. Nut, gear retainer, rear cam .............31-6511<br />
5. O-ring, Viton (-220) (each). ............50-8245-S<br />
5 pack ................................50-8245<br />
6. Screw, SHC - 10-24 x 1" (each) ...........50-0044<br />
10 pack ...............................50-0194<br />
7. Alignment dowel (each). ..............50-8182-S<br />
2 pack ................................50-8182<br />
8. Idler gear shaft (each). ................31-2079-S<br />
2 pack ................................31-2079<br />
9. Divider plate.................. TÜV 1,2,7 31-6508<br />
10. Screw FHSC 10-24 x 1⁄2" (5 pack) ..........50-0312<br />
11. Gear, cam chest return. .................33-4291<br />
12. Gear assembly, pinion shaft. ............33-4170<br />
13. Gear, idler - Includes item PN 33-4214 bushing. ..33-4172<br />
14. Gear, cam drive........................33-4292<br />
15. Gear, spacer...........................33-4171<br />
16. Thread adapter......................31-2089-S<br />
17. Cam drive gear........................33-4293<br />
(For reference only, not included in pump kit.)<br />
18. Body assembly.................. TÜV 2 31-6505<br />
19. Spring, pressure control (each). ..... TÜV 2 31-6018<br />
10 pack .......................... TÜV 231-6084<br />
20. Plunger, pressure control valve. .... TÜV 2 31-6082<br />
21. Pressure control plug w/o-ring. ... TÜV 1,7 50-8326<br />
22. Fitting, flywheel cavity return ...........50-8183<br />
28<br />
1<br />
29<br />
40<br />
5<br />
3 4<br />
39<br />
23. Screw, SHC 8-32 x 5⁄8" ,(5 pack) ...........50-0293<br />
24. O-ring, Viton (H-D® #11301 )(each) ........50-8066-S<br />
10 pack ...............................50-8066<br />
25. Bushing, pinion shaft. ............ TÜV 2 31-4088<br />
26. Screw FHSC 10-24 x 3⁄4" (5 pack) .... TÜV 2 50-8328<br />
27. Screw FHSC 1⁄4"-20 x 2" (5 pack) ..........50-8163<br />
28. Kit, cover screw. .......................50-1035<br />
USA<br />
29. Gasket (H-D® #25244-99A) (each). ... 31-2032-S<br />
USA<br />
10 pack ......................... 31-2063<br />
30. Dowel pin, 3⁄32" diameter x 1" (each). ....50-8193-S<br />
5 pack ................................50-8193<br />
31. Retaining ring (5 pack). .................50-8241<br />
32. Bushing. .............................33-4214<br />
33. O-ring 5⁄16" O.D. x 1⁄16" Viton (-011). TÜV 2 50-8138-S<br />
34. O-ring (-209) Viton (H-D® #11190, 11157, 11293)<br />
USA<br />
each ................................. 50-8039<br />
USA<br />
10 pack ......................... 93-4110<br />
35. Washer, pinion gear. .................50-0331-S<br />
36. Screw, FHHC - 5⁄16"-18 x 3⁄4" G8<br />
(H-D® #25566-06) ........................50-0100<br />
37. Steel ball, 1/8" (each). .................50-8092-S<br />
10 pack ...............................50-1031<br />
38. Pin dowel - .275" I.D. x .3745" O.D. x .397"<br />
(H-D® #16589-99A) .....................50-8148-S<br />
NOTE: All reference to H-D® part numbers is for identification purposes only. We in no way<br />
are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are<br />
equivalent to the corresponding H-D® part number shown.<br />
27<br />
26<br />
2<br />
36<br />
8<br />
35<br />
31<br />
50<br />
13<br />
32<br />
8<br />
37<br />
14<br />
32<br />
11<br />
39. Viton o-ring (-207) (5 pack) ..............50-8244<br />
40. Viton o-ring (-225) (5 pack) ..............50-8243<br />
41. Viton o-ring (-16) (5 pack) ...............50-8242<br />
42. Screw, FLC 1⁄4"-20 x 13⁄4" (each). .......50-0334-S<br />
5 pack ................................50-0334<br />
43. Pipe plug 1⁄8"-27 (H-D® #45830-48) (each) ....50-8331<br />
10 pack ...............................50-1015<br />
44. Key kit - cams. ........................50-1038<br />
45. Camshafts<br />
See Cam Selection Chart below.<br />
46. Ball, pressure relief valve 3⁄8" diameter<br />
.................. USA 1,2,3 TÜV 1,3,4,5,6,7 50-8091<br />
47. Spring, pressure relief valve .............50-8408<br />
48. Gear rebuild kit (N/S) (Includes #11, 12, 13, 14)<br />
....................................33-4290<br />
49. Seal rebuild kit (N/S) (Includes #5, 24, 29, 34, 39, 40, 41)<br />
....................................31-2097<br />
50. Breather Valves (see page 2-82)<br />
N/S = Not Shown<br />
43 24<br />
16 47 46 7<br />
6<br />
17<br />
9<br />
15<br />
38<br />
41 6 7 16<br />
23 18 30<br />
26<br />
12 10<br />
25<br />
24<br />
19<br />
20<br />
33 21<br />
S&S® GEAR DRIVE CAMS FOR USE With S&S OIL PUMPS<br />
FOR <strong>1999</strong>-'06 Big twin (EXCEPT <strong>2006</strong> DYNA® MODELS)<br />
Cam* Easy Start Cams with Drive Gears Cams with Drive Gears<br />
510GP – 33-5220<br />
570GP 106-4751 –<br />
585GP 106-4771 33-5222<br />
625GP 106-5212 –<br />
640GP 106-4781 –<br />
675GP 106-5215 33-5225<br />
* See Cam listings in Section 1 of this catalog for further information on cam recommendations for<br />
different applications.<br />
44<br />
22<br />
REPLACEMENT<br />
PARTS<br />
34<br />
45<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-83
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-84<br />
REPLACEMENT<br />
PARTS<br />
Order toll free 866-244-2673<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Cylinder Heads Replacement Parts<br />
for <strong>1999</strong>-up Big Twin Engines<br />
1. Cylinder head (See page 2-49)<br />
2. Valve<br />
All S&S heads with 89cc chamber<br />
Intake<br />
2.000" diameter...................... 90-2000<br />
2.000" diameter + .085" ..................90-2004<br />
Exhaust<br />
1.605" diameter...................... 90-2001<br />
All S&S heads with 79cc chamber<br />
Intake – 1.940" diameter ................90-2025<br />
Exhaust – 1.575" diameter ...............90-2026<br />
3. Valve seat<br />
All S&S heads with 89cc chamber<br />
Intake - 2.000" diameter. USA 1,2,3 TÜV 1,4,5,6,790-2002<br />
Exhaust - 1.605" diameter. USA 1,2,3 TÜV 1,2,4,5,6,790-2003<br />
All S&S heads with 79cc chamber<br />
Intake - 1.940" diameter ..................90-2027<br />
Exhaust - 1.575" diameter .................90-2028<br />
4. Valve guide - Intake or Exhaust<br />
Standard<br />
(H-D® #18112-92).<br />
+.001" (H-D® #18130-83C) ............<br />
USA USA 1,2,3<br />
TÜV 1,2,4,5,6,7 90-2210<br />
USA<br />
90-2211<br />
+.002" (H-D® #18133-83A)............<br />
USA<br />
90-2212<br />
+.003" (H-D® #18131-83C)............<br />
USA<br />
90-2213<br />
+.030" ..............................<br />
USA<br />
90-2219<br />
5. Valve spring shim<br />
.015" (each) .............................90-2086<br />
5 pack .......................................50-7161<br />
.030" (each) .............................90-2087<br />
5 pack .......................................90-2198<br />
6. Bottom Collar (each) .... USA TÜV 1,2,3 4,5,6 90-2052<br />
4 pack .......................................90-2488<br />
7. Valve guide seal - intake or exhaust (H-D® #18001-83B)<br />
(Not included in valve spring kit)<br />
each ...........................<br />
USA<br />
90-2008<br />
USA<br />
8 pack ................................ 90-2158<br />
8. Outer Spring ........ USA TÜV 1,2,3 1,2,4,5,6,7 90-2050<br />
9. Middle Spring....... USA TÜV 1,2,3 1,2,4,5,6,7 90-2049<br />
10. Inner Spring.......... USA TÜV 1,2,3 4,5,6 90-2048<br />
11. Top Collar<br />
Steel (each)......................... 90-2051-S<br />
4 pack .......................................90-2486<br />
Titanium (each) ....................... 90-2046<br />
4 pack .......................................90-2487<br />
12. Keeper, valve spring, intake/exhaust<br />
each .............................. 90-2094-S<br />
8 pack .......................................50-7166<br />
13. Valve spring kit<br />
.640" lift - steel top collar .................90-2077<br />
.640" lift - titanium top collars ............90-2078<br />
14. Head bolt assembly – (8 Required)<br />
(Includes head bolt washer)<br />
88", 95", 96", 100", 107" & 111" ...........93-3030<br />
116", 117" .................................93-3037<br />
15. Head bolt washer<br />
.100" (each).................................50-7088<br />
5 pack .......................................50-7096<br />
.250" (H-D® #6016) (each) ....................50-7091<br />
10 pack ......................................50-7095<br />
16. Exhaust port stud (H-D® #16715-83) (each). . 50-0493<br />
5 pack .......................................50-1028<br />
17. Lock washer - 5⁄16" (H-D® #7041) ............50-7032<br />
18. Nut, flanged - 5⁄16" -24 (H-D® #7593)<br />
Zinc (each) ................................50-5025-S<br />
2 pack .................................... 50-5025-2<br />
5 pack .......................................50-1001<br />
Chrome (each) ............................50-5030-S<br />
2 pack .................................... 50-5030-2<br />
19. Exhaust pipe gasket, tapered (H-D® #65324-83A)<br />
each ........................................106-5029<br />
10 pack ......................................93-1072<br />
20. Intake manifold (See page 2-68)<br />
21. Manifold mounting screw<br />
SH - 5⁄16"-18 x 3⁄4" (H-D® #3275) (each) .... 50-0302-S<br />
10 pack ...................................50-0302<br />
SH - 5⁄16"-18 x 1". ..................... 50-0101<br />
HH - 5⁄16"-18 x 1" (H-D® #3987) (each). ...... 50-0108<br />
20 pack ...................................50-0155<br />
22. Flat washer - 5⁄16" (H-D® #6016). .......... 50-7034<br />
23. Manifold mounting flange<br />
USA<br />
Front (H-D® #27009-86A) (each). ....... 16-0232<br />
USA<br />
5 pack ............................... 16-0600<br />
USA<br />
Rear (H-D®#27010-86A) (each). ....... 16-0233<br />
USA<br />
5 pack ............................. 16-0601<br />
Set (Front & Rear) .................. 106-3516<br />
24. Manifold o-ring<br />
For S&S heads (each). .................. 16-0235<br />
10 pack ...................................16-0243<br />
For Stock heads (H-D®#26992-99, 26995-86A)<br />
each. .............................. 16-0236<br />
10 pack ...................................16-0244<br />
25. Head gasket<br />
For Stock Bolt Pattern<br />
33⁄4" x .043" Graphite (each). ........ 93-1045-S<br />
10 pack ...................................93-1060<br />
37/8"/3.927" x .030" Layered Steel (2 pack).900-0216<br />
37/8"/3.927" x .045" Layered Steel (each).106-3714<br />
10 pack ..................................900-0218<br />
4" x .043" Graphite (each) .......... 93-1043-S<br />
10 pack ...................................93-1058<br />
41/8" x .043" Layered Steel (each)..... 93-1091-S<br />
41/8" x .030" Layered Steel (2 pack) .... 900-0217<br />
For S&S Bores<br />
41/8" x .043" Graphite (each). ........ 93-1047-S<br />
10 pack ...................................93-1073<br />
41/8" x .045" Copper (each). ......... 93-1079-S<br />
10 pack ...................................93-1080<br />
43/8" x .045" Copper (Set of Two) ........ 93-1081<br />
26. Alignment dowel, base and head (H-D® #16595-99A)<br />
each ......................................... 50-8177<br />
4 pack .................................... 50-8177-4<br />
10 pack ......................................50-8179<br />
27. Alignment dowel o-ring – Base (all bore sizes)<br />
S&S heads 33⁄4" bore only (H-D® #11105, 11275)<br />
each .........................................50-8008<br />
10 pack ......................................50-8078<br />
28. Plug, HH - 14mm (each). ............... 90-4916<br />
2 pack .................................... 90-4916-2<br />
29. Washer, compression - 14mm<br />
507" x .705" x .047" (each). ............. 50-7094<br />
10 pack ......................................50-7102<br />
30. Head mount bolt - 3⁄8"-16 x 11⁄4" (H-D® #4716W)<br />
each ...................... USA TÜV 1,2,3 1,4,5,6 50-0168<br />
10 Pack .....................................106-3063<br />
31. Flat washer - 3⁄8" (H-D® #6019)<br />
each ...................... USA 1,2,3 TÜV 1,3,5,6 50-7051<br />
10 pack .....................................106-3064<br />
32. Vent hose fitting, (For 41/8" Bore Only)<br />
Front, 1⁄16"-27 pipe .......<br />
USA 3<br />
TÜV 1,2,6,7 50-8117<br />
Rear, 1⁄8"-27 pipe. ... USA 1,2,3 TÜV 1,2,3,4,5,6,7 50-8115<br />
33. Check Valve (For 41/8" Bore Only)....<br />
TÜV 2 50-8122<br />
34. Base Gaskets<br />
For S&S Bores<br />
43/8" x .018" Graphite (2 pack) ............93-1082<br />
41/8" x .018" Graphite (each) ...........93-1048-S<br />
4" x .018" Graphite (each) .............93-1050-S<br />
For Stock Bolt Pattern<br />
41/8" x .018" Graphite (each) ...........93-1092-S<br />
35. Base O-ring (Used for early S&S bores)<br />
4" x .103" (each) ............................50-8049<br />
35/8" or 31/2" x.103" (each) ..................50-8048<br />
.585" Lift Dual VAlve Springs<br />
36. Valve spring shim<br />
For <strong>1999</strong>-’04 bt<br />
.015" (each). ..................... 90-2086<br />
5 pack ........................50-7161<br />
.030" (each). ..................... 90-2087<br />
5 pack ........................90-2198<br />
For 2005-’12 bt<br />
.015” (each) .................... 500-0013<br />
.030” (each) .................... 500-0014<br />
37. Collar, bottom, steel ............ 900-0414<br />
38. Seal, valve guide<br />
<strong>1999</strong>-’04 bt. ..................... 90-2008<br />
2005-’12 bt. ................... 106-5688<br />
39. Spring, outer ...................... 90-2050<br />
40. Spring, middle ....................90-2049<br />
41. Collar, top, steel. ...............90-2065-S<br />
42. Valve keeper<br />
<strong>1999</strong>-'04 bt (each). ..............90-2094-S<br />
8 pack ........................50-7166<br />
2005-’12 bt (each). .............. 106-5692<br />
43. Valve spring kit, .585" lift Dual<br />
<strong>1999</strong>-'04 bt ..................... 90-2277<br />
2005-’12 bt. ................... 900-0420<br />
.650" Lift Sidewinder® VAlve Springs<br />
44. Valve Spring Shim<br />
.015" (each). ................... 500-0013<br />
.030" (each). ................... 500-0014<br />
45. Collar, Bottom, Steel (each). ...... 106-5691<br />
46. Seal,Valve Guide<br />
<strong>1999</strong>-'04, 5/16. ...................90-2008*<br />
2005-'12, 7mm ................ 106-5688<br />
47. Spring, Valve .650" ............. 106-5689<br />
48. Collar, Top, Steel. ............... 106-5690<br />
49. Valve Keeper<br />
<strong>1999</strong>-'04 (each). ................90-2094-S<br />
8 pack ........................... 50-7166<br />
2005-'12 (each). ................ 106-5692<br />
50. Valve spring kit<br />
.650" lift Sidewinder®<br />
<strong>1999</strong>-'04. ..................... 900-0050<br />
2005-'12. ..................... 106-5909<br />
*Not included in valve spring kit.
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Continued –<br />
S&S® Cylinder Heads Replacement Parts for <strong>1999</strong>-up Big Twin Engines<br />
Top End Rebuild Gasket Kits For S&S® Engines For Big Twins<br />
S&S Engine Family Year Group Bore Size Part No.<br />
T-Series <strong>1999</strong>-up S&S 43/8" 90-9511*<br />
T-Series <strong>1999</strong>-up S&S 41/8" 90-9506 USA TÜV 3 6<br />
T-Series <strong>1999</strong>-up 41/8" Stock Cases 90-9510<br />
T-Series <strong>1999</strong>-up 4" 90-9505<br />
T-Series <strong>1999</strong>-up 37/8" 90-9504<br />
Kits include: Intake and exhaust seals, head & base gaskets, o-rings, pushrod o-rings, and valve guide seals.<br />
* Does not include intake seals.<br />
REPLACEMENT<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
33<br />
21<br />
32<br />
19<br />
18<br />
28<br />
29<br />
17<br />
16<br />
30<br />
31<br />
13<br />
4<br />
7<br />
6<br />
5<br />
15<br />
8<br />
9<br />
10<br />
12<br />
11<br />
14<br />
.585" Lift Dual VAlve Springs<br />
42<br />
41<br />
43<br />
40<br />
39<br />
38<br />
37<br />
36<br />
.650" Lift Sidewinder® VAlve Springs<br />
49<br />
48<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
1<br />
50<br />
47<br />
Racing<br />
Products<br />
24<br />
46<br />
20<br />
21<br />
22<br />
23<br />
3<br />
27<br />
26<br />
45<br />
44<br />
Tools & Shop<br />
Supplies<br />
2<br />
25<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
NOTE: All reference to H-D® part numbers is for<br />
identification purposes only. We in no way are<br />
implying that any of S&S <strong>Cycle</strong>’s products are original<br />
equipment parts or that they are equivalent to the<br />
corresponding H-D® part number shown.<br />
35<br />
34<br />
Visit us at www.sscycle.com<br />
2-85
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
REPLACEMENT<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Die-Cast Rocker Cover Replacement Parts<br />
For <strong>1999</strong>-Up Big Twin Engines<br />
1. Screw, socket head 1⁄4"-20 x 3⁄4" (each). ...................... 50-0067<br />
12 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0144<br />
2. Washer, flat 1⁄4" (each) .................................. 50-7017<br />
12 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7013<br />
3. Washer, silicone coated 1⁄4" (each) ......................... 50-7015<br />
8 pack ...........................................................50-7015-8<br />
12 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7015-12<br />
4. Seal, o-ring<br />
(Included in gasket kit see #16 below.)<br />
5. Screw, socket head, 1⁄4"-20 x 1" (H-D® #4741A)<br />
each. ............................................................50-0092-S<br />
4 pack ............................................................50-0092P<br />
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0154<br />
6. Screw, socket head, 1⁄4"-20 x 2" .......................... 50-0013<br />
7. Screw, hex flange head, 5⁄16"-18 x 21⁄2" . .................... 50-0123<br />
8. Support, rocker arm. .................................... 90-4140<br />
9. Gasket, rocker cover, 4 1/8"<br />
Graphite (each) .....................................<br />
USA<br />
90-4071-S<br />
2 pack ......................................................<br />
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
USA<br />
90-4071<br />
USA<br />
90-4099<br />
For S&S 79cc heads ......................................90-4124<br />
10. Housing, rocker, Chrome .................... USA 3 TÜV 1,7 90-4107<br />
11. Screw, socket head, 5⁄16"-18 x 1" ........................ 50-0125-S<br />
12. Seal, rocker cover<br />
(Included in gasket kit see #16 below.)<br />
13. Washer, flat 5⁄16" (each). .................................. 50-7056<br />
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7082<br />
14. Screw, socket head 5⁄16"-18 x 21⁄4"<br />
each. ............................................................50-0115-S<br />
10 pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-0156<br />
15. Cover, rocker, chrome. .................<br />
USA 1,2,3<br />
TÜV 1,2,4,5,6,7 90-4089<br />
16. Gasket set - rocker cover, cast (Not Shown) . . . . . . . . . . . . . . . . . . 90-4111<br />
11<br />
14<br />
13<br />
4<br />
15<br />
5<br />
6<br />
2<br />
7<br />
8<br />
1<br />
2<br />
3<br />
10<br />
4<br />
12<br />
9<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
NOTE: All reference to H-D® part numbers is for identification purposes only. We in no way are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are<br />
equivalent to the corresponding H-D® part number shown.<br />
2-86<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Billet rocker cover Replacement Parts<br />
for <strong>1999</strong>-Up Big Twin Engines (Obsolete)<br />
1. Base assembly, rocker ................................N/A<br />
2. Top, rocker cover .....................................N/A<br />
3. SHCS, 1⁄4"-20 x 3⁄4" (H-D® #4069A) (each) ...............50-0067<br />
12 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-0144<br />
REPLACEMENT<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
4. Washer, flat, chrome, 260" x .425" x .060" (H-D® #6099)<br />
each ........................................50-7017<br />
12 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-7013<br />
5. Washer, flat, rubber coated, 1⁄4" x 7⁄16" x .020"<br />
each ........................................50-7015<br />
8 pack ..................................... 50-7015-8<br />
S&S Cover<br />
5<br />
3<br />
4<br />
Stock Cover<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
12 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7015-12<br />
6. SHCS, 5⁄16"-18 x 1" with flatwasher . ..............50-0125-S<br />
7. O-ring, rocker cover seal, Viton®<br />
(Included in gasket kit #90-4073. See below)<br />
2<br />
7<br />
11<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
8. O-ring, (-114), .625" ID x .937" OD (H-D® #11270)<br />
each ..................................50-8033<br />
9. Gasket, Breather Baffle, Stock Pattern, Paper, <strong>1999</strong>-’10 bt (H-D® #17592-99)<br />
each .........................................90-4078<br />
10. Gasket, Breather Cover, Stock Pattern, Paper, <strong>1999</strong>-’10 bt (H-D® #17591-99)<br />
each .........................................90-4077<br />
11. Gasket, Rocker Cover, Steel, <strong>1999</strong>-up bt (H-D® #17386-99A)<br />
6<br />
1<br />
8<br />
10<br />
9<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
each ................................ 90-4096-S<br />
12. Gasket, bottom rocker cover (H-D® #16719-99B)<br />
USA<br />
each ....................................... 90-4071-S<br />
Racing<br />
Products<br />
2 pack ..................................<br />
USA<br />
90-4071<br />
10 pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .<br />
USA<br />
90-4099<br />
9. Gasket kit, rocker cover (includes gaskets for 2 rocker covers)<br />
12<br />
Tools & Shop<br />
Supplies<br />
For S&S billet rocker covers<br />
(includes #5,7,8,9,10,12). ...........................90-4073<br />
For <strong>1999</strong>-'10 bt<br />
(includes #8,9,10,11,12). ........................ 90-4097<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
NOTE: All reference to H-D® part numbers is for identification purposes only. We in no way are implying that any of S&S <strong>Cycle</strong>’s products are original equipment parts or that they are<br />
equivalent to the corresponding H-D® part number shown.<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-87
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Super Stock ® STEALTH replacement parts<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
REPLACEMENT<br />
PARTS<br />
11<br />
12<br />
6<br />
13 14<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
9<br />
10<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
15<br />
1<br />
5<br />
2<br />
5<br />
3<br />
5<br />
4<br />
18<br />
16 17<br />
19<br />
OEM Cross Reference<br />
Appendix & Index<br />
6<br />
7<br />
7<br />
8<br />
1. Cover, Air Cleaner Air Stream<br />
Chrome ................................................170-0118<br />
Black Jack ..............................................170-0122<br />
2. Cover, Air Cleaner, Domed Bobber<br />
Chrome ................................................170-0120<br />
Black Jack ..............................................170-0124<br />
3. Cover, Air Cleaner, Dished Bobber<br />
Chrome ................................................170-0119<br />
Black Jack ..............................................170-0123<br />
4. Cover Air Cleaner, Muscle<br />
Chrome ................................................170-0121<br />
Black Jack ..............................................170-0125<br />
5. Air Cleaner Cover Screw, SHCB, 5/16"-18 UNC X .500"...............500-0051<br />
6. Screw, SHC, Flanged Button, 1/4-20 UNC x .750" ..................500-0060<br />
7. Top Plate, Air Filter, Molded, Plastic ............................170-0026<br />
8. Filter, Air, Tapered,<br />
Standard Pleated, Cotton, Stealth Air Cleaner Kit.............170-0126<br />
1" Taller Pleated, Cotton, Stealth Air Cleaner Kit .............170-0127<br />
1" Taller Pleated, Cotton Filter Only.........................170-0154<br />
9. Screw, SHCB, 1/4-20 UNC X .825"................................500-0059<br />
10. Backplate<br />
1993-up Stock CV Carb; 2001-up Delphi® EFI (except Throttle by Wire).170-0021<br />
Super E/G, Black, Die Cast, 1993-up bt ......................170-0049<br />
11. Screw, Backplate Vent, SHCB, 1/2-13 x 1-1/2", Chrome Plated.........170-0044<br />
12. Screw, Backplate Vent, SHCB, 3/8-16 x 1-1/2", Chrome Plated.........170-0045<br />
13. Washer,Flat, ,Nitrile Rubber Coated<br />
.520" x .880" x .024" BT 1993-’99 & xl 1991-'06,...............50-7055<br />
.380" x .880" x .024" BT <strong>1999</strong>-'06 ...........................50-7054<br />
14. Gasket,Backplate<br />
Stock CV Carb & EFI Throttle Body,1991-up xl/bt (except Throttle by Wire) .. 106-6022<br />
Super E/G,CV Adapter,....................................106-1724<br />
15. Lanyard, 6" Stainless Steel....................................500-0095<br />
16. Lynch Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-0083<br />
17. Washer, Fender, Chrome Plated................................500-0094<br />
18. Spring, Wave Washer, Stainless Steel ...........................500-0093<br />
19. Screw, Hex, Hood-pin, 1/4-20, UNC..............................500-0082<br />
2-88<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Single Bore Tuned Induction System<br />
replacement parts<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
1. Tuned Intake Kit, 2.19" Single Bore<br />
8. O-Ring, Adapter Plate Bracket<br />
Natural............................ 106-4968<br />
35/8" O.D. x 31/2" I.D. 1/16 CS, Viton ....... 50-0446<br />
Wrinkle Black ...................... 106-4969<br />
5 pack ........................ 50-1083<br />
Chrome Plated ..................... 106-4970<br />
9. Bracket Kit, 2.19" Single Bore Tuned Intake, Chrome<br />
2. Tuned Intake Assembly, 2.19" Single Bore<br />
Super E/G, S&S T124 ................ 106-4973<br />
Natural............................ 106-4965<br />
Super E/G, 1984-up BT .............. 106-4974<br />
Wrinkle Black ...................... 106-4966<br />
Single VFI, S&S T124 ................ 106-4976<br />
Chrome Plated ..................... 106-4967<br />
Single VFI, 1984-up BT .............. 106-4977<br />
3. Air Filter, w/clamp, .Stainless Cap – Conical – 27/16" I.D. x 4"<br />
Stock carb, Delphi® EFI, 1984-up BT ... 106-4978<br />
Red (1 Each)......................... 17-1020<br />
10. Backplate Screw<br />
Blue (1 Each)........................ 17-1023<br />
Screw, SHC, w/Threadlock, 1/4-20 x 1/2". 106-2084<br />
4. Gasket, Intake – Adapter Plate ........ 17-1022<br />
11. Screw, 5/16 -18 x 11/4, BHC, Chrome .... 50-0309-S<br />
5. Plate, Adapter, 2.19" Single Bore Tuned Intake<br />
2 pack ........................ 50-1078<br />
Chrome Steel........................ 17-1014<br />
12. Flat Washer 5/16" x 1/16" ................ 50-7034<br />
6. FHSC 1/4-20 x 5/8"..................... 50-0433<br />
13. Hose, Breather, 1/4" I.D., 90°. ........... 19-0178<br />
3 pack ........................ 50-1071<br />
14. Screw, Breather Fitting, 3/8 -16 x 11/4". ... 50-0436<br />
7. FHSC 5/16-18 x 5/8" .................... 50-0432<br />
15. Washer, Flat, 3/8" x 13/16" x 1/16", Chrome. 50-7106-S<br />
2 pack ........................ 50-1070<br />
16. Screw, Breather Fitting, 1/2 -13 x 1.25 ... 50-0435<br />
17. Shim Kit<br />
(a) 5/16" I.D. S&S 41/8" engines ......... 17-0314<br />
(b) 1/2" I.D. 1993-up BT. .............. 17-0464<br />
18. Enrichment Device, S&S Super E & G carbs<br />
(Use in place of enrichment device on air cleaner backplate)<br />
..............................11-2084<br />
19. Gasket, Backplate - E/G/SBEFI ....... 106-1724<br />
10 pack ......................106-2328<br />
20. Gasket, S&S SBEFI 58mm ............ 106-4662<br />
21. Gasket, Stock carb/Throttle Body. ..... 106-6022<br />
REPLACEMENT<br />
PARTS<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
17<br />
12<br />
15<br />
16<br />
3<br />
Racing<br />
Products<br />
21<br />
19, 20<br />
9<br />
10<br />
13<br />
14<br />
11<br />
8 6<br />
6<br />
5<br />
7<br />
7<br />
18<br />
4<br />
1<br />
3<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
2<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-89
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-90<br />
REPLACEMENT<br />
PARTS<br />
Air Cleaner Replacement Parts<br />
for stock fuel systems<br />
1. Air cleaner cover<br />
Chrome ........................................ 17-0078<br />
Chrome (Notched) <strong>2006</strong> Dyna® and all 2007 models. ......... 17-0073<br />
Black .......................................... 17-0075<br />
Slasher ......................................... 17-0004<br />
2. Element ........................................ 17-0079<br />
3. Backplate, BT 1993-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-0003<br />
4. Cover screw (each) ................................ 50-0072<br />
10 pack .....................................50-0094<br />
Black (each) .................................... 50-0310-S<br />
3 pack ......................................50-0310<br />
5. Screw<br />
a. BT <strong>1999</strong>-up, EFI Softail® 2001, All 2002 EFI BT, and <strong>2006</strong> Dyna®<br />
HHCS 1⁄4"-28 x 11⁄4" (each) ......................... 50-0077<br />
10 pack .....................................50-0265<br />
b. All others – HHCS 1⁄4"-28 x 7⁄8" .................. 50-0074<br />
6. Backplate screw, BT <strong>1999</strong>-up, All 2002-up EFI BT<br />
Zinc Plated (each) ................................ 106-2084<br />
10 pack ....................................106-2105<br />
7. Replacement shims, BT 1993-up<br />
Shim Kit, 12 pack (includes 4 each of .018", .030", .048"):. ..17-0464<br />
1⁄2" x .018" (each) ................................. 50-7085<br />
1⁄2" x .030" (each) ................................. 50-7086<br />
1⁄2" x .048" (each) ................................. 50-7087<br />
10 pack .....................................50-7098<br />
1⁄2" x .105" (each) ................................. 50-7089<br />
10 pack .....................................50-7097<br />
1⁄2" x .125" (each) ................................. 50-7090<br />
5pack ......................................50-7101<br />
BT <strong>1999</strong>-up, All 2002-up EFI BT<br />
a. 5⁄8" x .025" (each) ............................... 50-7113<br />
10 pack .....................................50-7110<br />
b. 5⁄8" x .050" (each) ............................... 50-7114<br />
10 pack .....................................50-7111<br />
c. 5⁄8" x .075" (each). ............................... 50-7115<br />
10 pack .....................................50-7112<br />
8. Breather screw seal<br />
a. BT 1993-’99, All 2002 EFI BT – Washer, .520 (each) .. 50-7055<br />
10 pack .....................................50-7057<br />
b. BT <strong>1999</strong>-up, All 2002 EFI BT – Washer, .380 (each) ... 50-7054<br />
10 pack .....................................50-7059<br />
c. All others – O-ring, 1⁄2" O.D. (each) ..........<br />
USA<br />
50-8006<br />
10 pack ...............................<br />
USA<br />
50-8077<br />
9. Breather fitting (each) ............................. 17-0350<br />
2 pack ......................................17-0355<br />
10. Crankcase breather vent hose, BT <strong>1999</strong>-up .... USA 1,2 17-0339<br />
11. Vent hose, with angle cut ......................... 17-0365<br />
12. Hose fitting ..................................... 50-8121<br />
13. Flatwasher, 1⁄4" (each) ............................. 50-7021<br />
10 pack .....................................50-7074<br />
14. Plug, press-in clear plastic . . . . . . . . . . . . . . . . . . . . . . . . . .50-8313<br />
15. Support bracket locknut - 1⁄4"-28 x 7⁄8" (each) .......... 50-5010<br />
10 pack .....................................50-5015<br />
16. Support bracket screw - 5⁄16"-18 x 11⁄4" .............. 50-0110<br />
17. Lockwasher, 5⁄16" ................................. 50-7032<br />
18. Rubber tubing - 1⁄4" x 5⁄8" x 3'. ................<br />
USA<br />
19-0169<br />
19. Wire tie (NS)..................................... 50-8003<br />
20. Hardware kit, air cleaner mounting (NS)<br />
BT 1984-'99 ..................................... 17-0244<br />
Order toll free 866-244-2673<br />
1<br />
1<br />
4<br />
1<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
21. Washer, flat - 3⁄8" x 7⁄8" x .146" (each). ................ 50-7053<br />
10 pack .....................................50-7075<br />
22. Carb support bracket, BT <strong>1999</strong>-up & EFI Softail® 2001. . 17-0308<br />
23. Shim - 1⁄4" x 3⁄4" x .200". ........................... 50-7024<br />
24. Screw vent fitting, BT <strong>1999</strong>-up ..................... 17-0345<br />
25. Screw air cleaner backplate ........................ 17-0346<br />
26. Spring clamps (NS) .............................. 50-8001<br />
4<br />
4<br />
5b<br />
5a<br />
13<br />
21<br />
21<br />
5a<br />
2<br />
2<br />
2<br />
25<br />
25<br />
25<br />
22<br />
22<br />
6<br />
6<br />
23<br />
6<br />
22<br />
7a-c<br />
23<br />
7c<br />
23<br />
13<br />
7<br />
NOTE: FI = fuel injected<br />
(NS) = Not Shown<br />
9<br />
24<br />
8a<br />
8b<br />
21<br />
11<br />
3<br />
24<br />
12<br />
8a<br />
9<br />
10<br />
<strong>2006</strong>-Up Dyna® Models &<br />
All 2007 Big Twin Models<br />
(with Stock EFI)<br />
(Obsolete) 17-0444<br />
8b<br />
13 17 12<br />
11<br />
10b<br />
<strong>1999</strong>-Up Big Twin with<br />
3<br />
CV Carburetor, 2001<br />
Harley-Davidson® EFI<br />
18<br />
Softail®, & All 2001-'06<br />
EFI Models except Dyna®<br />
(Obsolete) 17-0101<br />
24<br />
9<br />
8<br />
13 15 11<br />
3<br />
18<br />
12<br />
8<br />
10b<br />
1993-’06 Carbureted Big<br />
Twin Models, 2001 EFI<br />
Softail® Models, and<br />
2002-Up All EFI Models<br />
(except <strong>2006</strong>-Up Dyna®)<br />
(Obsolete) 17-0117
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Continued –<br />
Replacement Parts For S&S® Air Cleaners For Stock Fuel Systems<br />
1. Air cleaner cover<br />
Chrome .......................................<br />
TÜV 1,7 17-0378<br />
Wrinkle Black.........................................17-0384<br />
Slasher...............................................17-0004<br />
2. Element, pleated ....................................106-4722<br />
3. Backplate<br />
1993-2007 BT & 2007-up non-touring models .........106-0907<br />
2008 Touring ........................................106-2092<br />
4. Cover screw,<br />
Chrome (each).........................................50-0072<br />
10 pack ...............................................50-0094<br />
Black (each) .........................................50-0310-S<br />
3 pack .................................................50-0310<br />
5. Backplate screw, Zinc Plated (each) ....................106-2084<br />
10 pack ...............................................106-2105<br />
6. Backplate plug 1⁄8"-27 (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8331<br />
10 pack ................................................50-1015<br />
7. Gasket, backplate (each) ..............................106-1724<br />
10 pack ...............................................106-2328<br />
8. Adaptor assembly<br />
1993-up bt (except 2008 & up touring models) ................106-0881<br />
2008-up touring models .............................106-1716<br />
9. Hose, vent, breather, formed,<br />
.250" x .375" x 1.825", 1993-2007 BT. ..................17-0364<br />
2 pack ................................................106-0880<br />
10. Clamp, spring, 9/16" ...................................50-8001<br />
11. Banjo fitting (each) ....................................17-0350<br />
2 pack .................................................17-0355<br />
12. Washer, silicone coated steel<br />
<strong>1999</strong>-up BT, 3/8" (each). ................................50-7054<br />
10 pack ................................................50-7059<br />
13. Breather screw, <strong>1999</strong>-up BT ...........................17-0348<br />
14. Replacement shims<br />
5⁄8" x .025" (each). .....................................50-7113<br />
10 pack ................................................50-7110<br />
5⁄8" x .050" (each) .....................................50-7114<br />
10 pack ................................................50-7111<br />
5⁄8" x .075" (each) ..................................... 50-7115<br />
10 pack ................................................50-7112<br />
15. Screw, LSHC, 1/4-20 x 1/2", zinc plated (each). ............106-2037<br />
10 pack ....................................................106-2125<br />
16. Gasket, throttle body, throttle by wire, 2008-up BT (each) 106-2643<br />
10 pack ....................................................106-2664<br />
17. Hose, vent, breather ...........................<br />
USA 1,2 17-0339<br />
18. Washer, flat, .375" x .813" x .063", zinc, steel<br />
each ......................................... USA 1,2,3 TÜV 1,3,5,650-7051<br />
10 pack ....................................................106-3064<br />
19. Washer, silicone coated steel 3/8" (each). ................50-7055<br />
10 pack ..................................................... 50-7057<br />
20. Banjo fitting (each) ....................................17-0350<br />
2 pack ...................................................... 17-0355<br />
21. Washer, silicone coated steel 1/2" (each). ................50-7054<br />
10 pack ..................................................... 50-7059<br />
22. Screw, breather, 3/8-16 UNC, +.250, 2008 Touring (each) 106-2667<br />
2 pack .....................................................106-2668<br />
23. Cover, breather screw, chrome, aluminum .............106-2022<br />
24. Screw, LSHC, 5/16-24 x 1/2", stainless steel ...............106-2023<br />
4<br />
1993-up bt stock CV and delphi® Single bore efi<br />
(except 2008-up touring models) 17-0450<br />
4<br />
1<br />
6<br />
1<br />
2<br />
2<br />
5<br />
8<br />
Replacement Parts for S&S® Teardrop Air Cleaner<br />
For 2008-up Baggers with stock EFI throttle body 106-2091<br />
7<br />
15<br />
16<br />
15<br />
3<br />
5<br />
3<br />
14<br />
7<br />
13<br />
8<br />
10<br />
17<br />
9<br />
7<br />
24 23<br />
10<br />
12<br />
11<br />
10<br />
18<br />
20<br />
19<br />
22 21<br />
REPLACEMENT<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-91
S e ction 2:<br />
Continued –<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
REPLACEMENT<br />
PARTS<br />
Replacement Parts For S&S® Air Cleaners For Stock Fuel Systems<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
14<br />
19<br />
12<br />
13<br />
17<br />
16<br />
22<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
2<br />
5<br />
18<br />
15<br />
17<br />
20 21 23 9 10<br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
1<br />
5<br />
8<br />
7<br />
7<br />
6<br />
11 14<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
4<br />
5<br />
3<br />
106-4589<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
S&S Teardrop Air Cleaner replacement parts<br />
for Magneti Marelli® EFI<br />
1. Cover ................................................<br />
TÜV 1,7 17-0378<br />
2. Filter ...................................................... 106-4722<br />
3. Backplate, Assembly, Air Cleaner, Stock EFI,<br />
Magneti Marelli®, 1995-2001 ............................... 106-4615<br />
4. Screw, PHIL/OH 1/4-20x1" (each) ...............................50-0072<br />
10 pack .................................................50-0094<br />
5. Spacer, 1/2" Hex, Threaded .........................................N/A<br />
6. Stud, Fully Threaded<br />
<strong>1999</strong>-’01 5/16-18 x 1.25", Zinc Plated ......................... 106-4676<br />
7. SHCS, 1/4-20 x 3/4 SEMS .......................................50-0066<br />
8. Screw, SHCS,<br />
1995-’98, 1/4-20 x 3/4", SEMS ...................................50-0066<br />
<strong>1999</strong>-’01, 5/16-18 x 3/4" (each) .................................50-0302-S<br />
10 pack .................................................50-0302<br />
9. Screw, LSHC 5/16-24, x 1/2" Stainless SteelFront Head ........... 106-2023<br />
10. Cover, Breather Screw, Chrome, Aluminum, Front Head ....... 106-2022<br />
11. Screw, Backplate Vent (Front Head)<br />
<strong>1999</strong>-’01, 5/16-18 .............................................17-0345<br />
12. Screw, Backplate (Rear Head), Socket Panhead<br />
5/16-24 x .360", Zinc, Alloy Steel ................................17-0346<br />
13. Screw, Breather, +.250" (Rear Head)<br />
<strong>1999</strong>-’01 ....................................................17-0348<br />
14. Washer, glat, Nitrile Rubber Coated, Cold Rolled Steel<br />
<strong>1999</strong>-’01, .380" x .880" x .024" (each) ..........................50-7054<br />
10 pack .................................................50-7059<br />
15. Clamp Spring, 9/16" ...........................................50-8001<br />
16. Hose, vent Breather, Epichlorohydrin Polymer ...........<br />
USA 1,2 17-0339<br />
17. Fitting, Vent, Aluminum Alloy (each) ...........................17-0350<br />
2 pack ..................................................17-0355<br />
18. Washer, Flat, .375" x .875" x .146", Zinc, Steel (each) ............50-7053<br />
10 pack .................................................50-7075<br />
19. Bracket, Support, Air Cleaner To Head, Nickel Plated<br />
1991-Up xl ................................................ 106-1285<br />
20. Washer, Flat, .281" x .625" x .080", Zinc, Steel (each) ............50-7021<br />
10 pack .................................................50-7074<br />
21. Washer, Lock, .250" ...........................................50-7019<br />
22. Screw, SHCS, 1/4-20 x 11/4" (each) .................................50-0008<br />
10 pack .................................................50-0153<br />
23. Clamp, Spring, .660" (each) ....................................50-8076-S<br />
10 pack ............................................... 106-1174<br />
2-92<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
Super E & G Air Cleaner Replacement Parts<br />
For <strong>1999</strong>-'06 Big Twins<br />
1. Air cleaner assembly<br />
Includes: Chrome cover, backplate, filter element, & hardware<br />
BT <strong>1999</strong>-'06 .......................... 17-0403<br />
41/8" Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-0416<br />
2. Air cleaner cover –<br />
Chrome ....................... TÜV 1,7 17-0378<br />
Black ................................ 17-0384<br />
Slasher .............................. 17-0004<br />
3. Element, pleated..................... 106-4722<br />
Element, pleated carbon ....... TÜV 1,2,3,7 17-0375<br />
4. Backplate<br />
BT <strong>1999</strong>-'06 ..............<br />
USA 1,2<br />
TÜV 4,5 17-0336<br />
41/8" Bore<br />
Manufactured after 1-1-03 ...<br />
USA 3<br />
TÜV 1,6,7 17-0387<br />
5. Cover screw (each). .......................... 50-0072<br />
10 pack ............................. 50-0094<br />
Black (each). ...............................50-0310-S<br />
3 pack. .............................. 50-0310<br />
TÜV style (each) .................... TÜV 5 50-0347-S<br />
10 pack ....................... TÜV 5 50-0347<br />
6. Backplate screw<br />
Zinc Plated (each). ..........................106-2084<br />
10 pack ............................106-2105<br />
7. Backplate plug 1⁄8"-27 (each) ............... 50-8331<br />
10 pack ............................. 50-1015<br />
8. Screw, air cleaner to head .............. 17-0346<br />
9. Fast idle friction washer (each) .............. 50-7035<br />
10 pack ............................. 50-7058<br />
10. Fast idle steel washer (each) ................ 50-7037<br />
10 pack ............................. 50-7061<br />
11. Fast idle nylon washer (each)................ 50-7036<br />
10 pack ............................. 50-7060<br />
12. Fast idle lever ...... USA TÜV 1,2,3 1,3,4,5,6,7 17-0329<br />
13. Fast idle brass washer (each) ................ 50-7007<br />
10 pack ............................. 50-7010<br />
14. Fast idle lever screw (one required for current<br />
backplate) (each) ........................... 50-0041<br />
10 Pack ............................. 50-0062<br />
15. Shim, .850" x .325" x .400"<br />
S&S 41/8" Bore. ............. USA 3 TÜV 1,7 50-7027<br />
16. Shims<br />
a. BT 1984-’92, S&S 41/8" Bore<br />
5⁄16" x .018" (each) ........................ 50-7038<br />
10 pack ............................. 50-7107<br />
12 pack .............................106-2087<br />
5⁄16" x .030" (each) . . . . . . . . . . . . . . . . . . . . . . . 50-7039<br />
10 pack ............................. 50-7070<br />
5⁄16" x .048" (each) ...................... 50-7040<br />
10 pack ............................. 50-7028<br />
12 pack ............................. 17-0314<br />
b. BT 1993-'06<br />
5⁄8" x .025" (each)......................... 50-7113<br />
10 pack ............................. 50-7110<br />
5⁄8" x .050" (each) ........................ 50-7114<br />
10 pack ............................. 50-7111<br />
5⁄8" x .075" (each) ........................ 50-7115<br />
10 pack ............................. 50-7112<br />
17. Screw vent fitting<br />
b. BT <strong>1999</strong>-up ........................ 17-0345<br />
1<br />
3<br />
8<br />
16b<br />
6<br />
17<br />
18<br />
12<br />
9 10 11<br />
18. Washer, silicone coated steel<br />
BT <strong>1999</strong>-up, .520" (each) .................50-7055<br />
10 pack ..................................50-7057<br />
BT <strong>1999</strong>-up, .380" (each) ..................50-7054<br />
10 pack ..................................50-7059<br />
19. Breather fitting (each) .....................17-0350<br />
2 pack ..................................17-0355<br />
20. Crankcase breather hose<br />
b. BT 1993-’99. .............. USA 1,2 17-0339<br />
21. Flatwasher – 5⁄16" x 1⁄16" .............. 50-7034<br />
22. Mounting bracket bolt – big twin<br />
S&S 41/8" Bore – 5⁄16"-18 x 11⁄4" ....... 50-0110<br />
23. Hose clamp (NS) .................... 50-8002<br />
24. Mounting hardware package (NS)<br />
Includes all parts needed to install following style air cleaners:<br />
BT <strong>1999</strong>-'06 ........................ 17-0437<br />
41/8" Bore . . . . . . . . . . . . . . . . . . . . . . . . . . .17-0460<br />
38. Spring clamps (NS) ................. 50-8001<br />
4<br />
(NS) = Not Shown<br />
19<br />
13<br />
11<br />
7<br />
7<br />
14<br />
20b<br />
REPLACEMENT<br />
PARTS<br />
<strong>1999</strong>-'06 Carbureted Harley-Davidson®<br />
Twin Cam 88®<br />
17-0403<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
5<br />
2<br />
1<br />
22<br />
21<br />
4<br />
16a<br />
15<br />
9<br />
13<br />
11<br />
10 11<br />
9<br />
7<br />
14<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
6<br />
7<br />
Warranty &<br />
Company Policy<br />
NOTE: The line drawing is used for illustration purposes only. Not all of the parts shown<br />
are included and used in every carb installation. Parts followed by an N/A are no longer<br />
available. Those followed by an (NS) means parts are not shown.<br />
5<br />
3<br />
1984-'05 Big Twin 41/8" Bore<br />
2<br />
17-0416<br />
Visit us at www.sscycle.com<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-93
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
REPLACEMENT<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Teardrop Air Cleaner replacement parts<br />
for S&S ® Single Bore EFI<br />
1. Air Cleaner Cover<br />
Slasher (slotted chrome).................. 17-0004<br />
Chrome...........................<br />
TÜV 1,7 17-0378<br />
2. Element, pleated. ....................106-4722<br />
3. Backplate SBFFI<br />
BT <strong>1999</strong>-up........................... 17-0120<br />
S&S 41/8" bore engines.................. 17-0380<br />
4. Screw, Cover, oval 1/4-20 x 1<br />
Chrome (each) .............................50-0072<br />
10 pack .................................50-0094<br />
Black (each) ..............................50-0310-S<br />
3 pack ...............................50-0310<br />
5. Backplate screw<br />
Zinc Plated (each) .........................106-2084<br />
10 pack .............................106-2105<br />
6. Pipe plug, 1/8, air cleaner backplate (each) . 50-8331<br />
10 pack .................................50-1015<br />
7. Mounting bracket bolt, hex 5/16-18 x 11/4 .. 50-0110<br />
8. Flat washer, 5/16" x 1/16" ................ 50-7034<br />
9. Shim, .850" x .325" x .400"...<br />
USA 3<br />
TÜV 1,7 50-7027<br />
10. Shim kit for 41/8" bore.................. 17-0314<br />
Individual shims:<br />
5/16" x .018" (each) ..........................50-7038<br />
10 pack .................................50-7107<br />
12 pack ................................106-2087<br />
5/16" x .030" (each) ..........................50-7039<br />
10 pack .................................50-7070<br />
5/16" x .048" (each) ..........................50-7040<br />
10 pack .................................50-7028<br />
12 pack .................................17-0314<br />
5/16" x .105" (each) .........................50-7041<br />
5 pack ...................................50-7062<br />
11. Screw, cable guide & air cleaner backplate<br />
10-24 x 1/4 (each) ...........................50-7042<br />
2 pack ..................................50-7042P<br />
5 pack ...................................50-7066<br />
12. Breather hardware for 41/8" bore....<br />
USA<br />
31-2104<br />
(Not included in air cleaner kit)<br />
13. Shims, individual<br />
5/8 x 7/8 x .025 (each) ........................50-7113<br />
10 pack .................................50-7110<br />
5/8 x 7/8 x .050 (each) ........................50-7114<br />
10 pack .................................50-7111<br />
5/8 x 7/8 x .075 (each) ........................50-7115<br />
10 pack .................................50-7112<br />
14. Silicone washer, 1/2" ID (each) ..............50-7055<br />
10 pack .................................50-7057<br />
15. Silicone washer, 3/8" ID (each) ..............50-7054<br />
10 pack .................................50-7059<br />
16. Breather hardware for<br />
<strong>1999</strong>-up BT .......................... 17-0455<br />
(Not included in air cleaner kit)<br />
4<br />
4<br />
1<br />
1<br />
1995 1 /2-'06 Big Twin<br />
Except Harley-Davidson ® <strong>2006</strong> Dyna ® Models<br />
Chrome Air Cleaner Cover ............17-0498<br />
Slasher Air Cleaner Cover .............17-0497<br />
17. Screw, wide head, 5/16-24 x .36. .......... 17-0346<br />
18. Air cleaner hardware kit (N/S)<br />
BT <strong>1999</strong>-up .......................... 17-0482<br />
S&S 41/8" bore......................... 17-0481<br />
19. Breather vent fitting<br />
BT 1993-'99 .......................... 17-0347<br />
BT <strong>1999</strong>-up........................... 17-0345<br />
20. Breather fitting (each) .....................17-0350<br />
2 pack ...................................17-0355<br />
21. Check Valve .......................... 50-8122<br />
22. Seal, backplate, neoprene, ............106-1667<br />
23. Screw, SHC, 5/16-18 x 11/4" .......... USA 50-0121<br />
2<br />
2<br />
7<br />
5<br />
17<br />
8<br />
5<br />
5<br />
6<br />
6<br />
3<br />
5<br />
15<br />
20<br />
14<br />
5<br />
6<br />
9<br />
19<br />
11<br />
10<br />
11<br />
21<br />
S&S 4 1 /8" Bore Engines<br />
3<br />
12<br />
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-0496<br />
(N/S) = Not shown<br />
NOTE: Breather hardware not included in<br />
these air cleaner kits.<br />
16<br />
13<br />
2-94<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
S&S ®<br />
single bore EFI Throttle Body<br />
and Related Replacement parts<br />
1. Throttle body<br />
52mm 1995-'05................... 16-5101.<br />
52mm <strong>2006</strong>-Up................... 16-5153.<br />
58mm 1995-'05.................. 106-3954.<br />
58mm <strong>2006</strong>-Up.................. 106-3957.<br />
2. Cap, canister purge ...............50-8266-S<br />
5 pack ..........................50-1062<br />
3. Manifold (See page 2-68)<br />
4. Cap, rubber, manifold, fitting ....... 50-8372<br />
5. Throttle cable guide packet with hardware<br />
................................. 55-5084<br />
6. Screw, cable guide & air cleaner backplate<br />
each ...........................50-0041<br />
10 pack .........................50-0062<br />
7. O-ring, throttle body to manifold .. 50-7967-S<br />
8. Intake air temperature sensor with hardware<br />
(H-D® #27270-95).................... 55-5041<br />
9. Gasket, IAT ......................16-5009-S<br />
10. Screw, M3, IAT ...................50-0357-S<br />
11. Idle air control motor SS EFI with hardware<br />
1995-'05 (H-D® #27628-01). ........... 55-5085<br />
12. O-ring, IAC ......................50-8149-S<br />
13. Screw, 10-24, IAC<br />
1995-'05 (each) ....................50-0356-S<br />
10 pack .........................50-1060<br />
<strong>2006</strong>-Up (each) ....................50-0358-S<br />
10 pack .........................50-1056<br />
14. Fuel rail kit<br />
2001-'05 (Fuel inlet tube not included.)<br />
................................. 16-5202.<br />
1995-'01 (Fuel inlet tube included) (Not Shown).<br />
................................. 16-5207<br />
15. Tube clip, fuel rail inlet 2001-'07<br />
each .........................50-0391-S<br />
5 pack ..........................50-1054<br />
16. O-ring, fuel rail inlet, 2001-'07<br />
each ........................50-8137-S<br />
10 pack .........................50-1055<br />
17. Backing washer, fuel rail inlet<br />
2001-'07 ..................... 50-0349-S<br />
18. Screw, rail, 1995-Up<br />
each ...........................50-0039<br />
10 pack .........................50-0146<br />
19. Fuel injector<br />
each .........................55-5052A<br />
2 pack .........................55-5052<br />
20. O-ring, injector top, black. ...... 50-8264-S<br />
21. O-ring, injector bottom, orange<br />
............................. 50-8265-S<br />
22. Throttle position sensor VFI with hardware<br />
1995-'05 (H-D® #27271-95). .......... 55-5058<br />
23. Screw, TP sensor & fuel rail<br />
each ........................50-0358-S<br />
10 pack .........................50-1056<br />
24. Washer, TP sensor (each)......... 50-7145-S<br />
10 pack ........................50-1057<br />
25. MAP sensor (H-D® #32316-99)........ 55-5057<br />
26. Screw, throttle body to manifold<br />
each ........................50-0359-S<br />
10 pack ........................50-1063<br />
27. Washer, lock , #10,<br />
throttle body to manifold ........ 50-7000<br />
28. Gasket, backplate<br />
52mm (each) ......................106-1724<br />
10 pack .......................106-2328<br />
58mm (each)....................106-4662<br />
29. Harness, injector adapter kit<br />
1995-'05. ........................ 55-5074.<br />
<strong>2006</strong>-Up ....................<br />
TÜV 7 55-5209<br />
30. Fuel inlet tube 45°, 2002-up . ....... 50-0485<br />
29<br />
23<br />
15<br />
26<br />
27<br />
23<br />
14<br />
30<br />
24<br />
17<br />
3<br />
16<br />
19<br />
8<br />
18<br />
Fuel Rail Parts For 1995-’01 (Not Shown)<br />
31. Spacer, throttle position – 2002-up .. 55-5200<br />
32. Pressure regulator, 1995-'01 ........ 16-5297<br />
33. Screw, pressure regulator, 6-32 x 3/16", 1995-'01<br />
................................50-0279-S<br />
34. Clamps, Hose, 1/2" diameter, smooth, 1995-'01<br />
each ...........................50-8352<br />
2 pack ........................ 106-1299<br />
35. Plug, assembly, MAP sensor hole, 1995-'01<br />
................................. 50-8350<br />
35. O-ring, MAP plug, 1995-'01<br />
each .........................50-8133-S<br />
10 pack .........................50-1101<br />
4<br />
22<br />
10<br />
9<br />
29<br />
20<br />
7<br />
2<br />
25<br />
13<br />
1<br />
19<br />
12<br />
11<br />
6<br />
28<br />
21<br />
5<br />
6a<br />
REPLACEMENT<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-95
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
REPLACEMENT<br />
PARTS<br />
1. Carb body assembly<br />
17⁄8" Super E ...........................11-2381<br />
21⁄16" Super G ...........................11-2390<br />
2. Throttle shaft<br />
17⁄8" Super E – Includes two plate screws .......11-2383<br />
21⁄16" Super G – Includes two plate screws ......11-2483<br />
3. Throttle plate screw - (two required)<br />
each .......................................50-0055-S<br />
10 pack ......................................50-0064<br />
4. Throttle plate<br />
17⁄8" Super E .............................11-2055<br />
21⁄16" Super G ............................11-2355<br />
5. Throttle return spring (each) ................11-2382<br />
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3502<br />
6. Throttle spool ..............................11-2385<br />
7. Throttle shaft lock washer (two required). ... 50-7031<br />
10 pack ......................................50-7073<br />
8. Throttle shaft nut (two required) (each). ...... 11-2350<br />
5 pack .......................................11-2363<br />
9. Throttle shaft nylon washer (each) .........50-7050<br />
10 pack ......................................50-7072<br />
10. Pump actuator lever .......................11-2376<br />
11. Actuator spring (each) ....................11-2375-S<br />
5 pack .......................................11-3501<br />
12. Pump actuator arm ........................11-2377<br />
13. Idle mixture screw (each) ...................11-2354<br />
5 pack .......................................11-2378<br />
14. Idle mixture screw spring (each) ............11-2052<br />
10 Pack ......................................11-2060<br />
15. Idle speed screw (each) .....................50-0038<br />
10 Pack ......................................50-0150<br />
16. Pump adjustment screw (each) .............50-0039<br />
10 Pack ......................................50-0146<br />
17. Idle speed/pump adjuster spring (each) ....11-2048<br />
10 pack ......................................11-2053<br />
18. Plunger nut (each) ..........................11-2344<br />
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2372<br />
19. Plunger spring (each) .......................11-2340<br />
10 Pack ......................................11-2359<br />
20. Fast idle plunger . ..........................11-2343<br />
21. Cable guide assembly<br />
Use with butterfly style cables .............11-2339<br />
Use with constant velocity style cables .......11-2338.<br />
2004 - 06 XL ................................11-2337<br />
22. Cable clamp/float pin screw (each) .........50-0041<br />
10 Pack ......................................50-0062<br />
23. O-ring<br />
17⁄8" Super E (each) ..........................50-8016<br />
10 Pack ......................................50-8094<br />
21⁄16" Super G (each) .........................50-8015<br />
10 pack ......................................50-8093<br />
24. Bellows seal (each) ..........................11-2266<br />
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2279<br />
25. Bowl vent plug (each) .......................50-0105<br />
10 pack ......................................50-0151<br />
26. Main discharge tube .......................11-2085<br />
27. Main jet – See Chart<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
Super E & G Carburetor Replacement Parts<br />
28. Intermediate Jets – See Chart<br />
Series #94 fits all Super 17⁄8", 21/16", 21⁄4" gas<br />
carburetors. Sizes available: .025", .0265", .028",<br />
.0295", .031", .032", .033", .036", .040".<br />
29. Bowl gasket (each) ..........................11-2386<br />
10 pack ......................................11-2387<br />
30. Float ........................................11-2187<br />
31. Float pin (each). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2369<br />
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2370<br />
32. Bowl screw<br />
10-24 x 3⁄4" - Three required. (each) .........50-0034<br />
10 Pack ......................................50-0063<br />
10-24 x 23⁄8" - One required (each) ..........50-0040<br />
10 Pack ......................................50-0061<br />
33. Carb bowl (only) .............................11-2388<br />
Carb bowl complete assembly ........... 11-2388P<br />
34. Bowl plug (each) ............................11-2090<br />
5 pack .......................................11-2092<br />
35. Seat o-ring* – (required with part #11-2465 & #11-2466<br />
only when replaces 360°style fuel inlet.) (each) .....50-8009<br />
10 pack ......................................50-8095<br />
36. Needle<br />
17⁄8" Super E & 21⁄16" Super G ...............11-2195<br />
Racing only .................................11-2197<br />
37. Seat<br />
17⁄8" E & 21⁄16" G (Replaces part #11-2347)<br />
Uses part #11-2195 needle. ................11-2465<br />
Racing only (Replaces part #11-2348)<br />
Uses part #11-2197 needle. ................11-2466<br />
Racing only -threaded fuel inlet (6AN .157" ID for Super E or G)<br />
Uses part #11-2195 needle. ................11-2395<br />
Racing only -threaded fuel inlet – (6AN .235" ID for Super E or G)<br />
Uses part #11-2197 needle. ................11-2396<br />
Permeation Compliant fuel inlet seat Super E or G.<br />
Uses part #11-2195 needle. ...............106-2011<br />
38. Ejector nozzle o-ring (each) .................50-8011<br />
10 Pack ......................................50-8096<br />
39. Pump pushrod (each) .......................11-2373<br />
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2393<br />
40. Ball check - (two required) (each) ............50-8090<br />
10 pack ......................................50-8125<br />
41. Ball check spring (each) .....................11-2374<br />
5 Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2392<br />
42. Pump cap o-ring - (two required) (each) .....50-8012<br />
10 Pack ......................................50-8100<br />
43. Pump cap assembly ........................11-2389<br />
44. Overflow hose per 24" (each) .............19-0262-S<br />
10 Pack ......................................19-0263<br />
45. Pump cap screw 8-32 - (two required) (each).50-0042<br />
10 Pack ......................................50-0098<br />
46. Diaphram spring (each) .....................11-2275<br />
10 pack ......................................11-2278<br />
47. Diaphragm .................................11-2282<br />
48. Gasket, backplate (each) ...................106-1724<br />
10 pack .....................................106-2328<br />
49. Enrichment device (Use with air horn only).. 11-2084<br />
50. Fuel line With 90° bend* 19"<br />
Use with part #11-2465 or #11-2466<br />
USA<br />
........................... 19-0475A<br />
Permeation Compliant straight, 311" x .563" x 17.5"<br />
Use with part #106-2011 , 90° seat .......190-0001<br />
51. Fuel line insulator – 12"<br />
USA<br />
...............<br />
USA 1,2,3<br />
TÜV 1,2,3,6,719-0172<br />
52. Spacer,Kit, with o-ring<br />
17/8" x 1". ............................ 16-0057*<br />
21/16" x 1". ........................... 16-0357*<br />
21/4" x 1". ............................ 16-0157*<br />
* Use with 1" Spacer Block. ............. 16-0058<br />
53. Insulator Block,Manifold,Super E,w/ O-ring<br />
17/8" x 1/4". ............................ 16-0491<br />
17/8" x 3/8". ............................ 16-0497<br />
21/16" x 1/4" ............................ 16-0492<br />
21/16" x 3/8" ............................ 16-0498<br />
21/4" x 1/4". ............................ 16-0499<br />
54. Screw,<br />
1" x 3⁄8"-16 ........................... 50-0161<br />
11⁄4" x 3⁄8"-16 ......................... 50-0162<br />
13⁄8" x 3⁄8"-16 ......................... 50-0163<br />
2" x 3⁄8"-16. ........................... 50-0164<br />
21⁄4" x 3⁄8"-16. ......................... 50-0165<br />
21⁄2" x 3⁄8"-16. ......................... 50-0166<br />
11⁄4" x 1⁄4"-20. ......................... 50-0008<br />
11⁄2" x 1⁄4"-20. ......................... 50-0079<br />
21⁄4" x 1⁄4"-20 ......................... 50-0078<br />
55. Tube,Fast Idle Pick-Up, .125" x 2.350",Brass ..0381F<br />
56. Tube,Ejector Nozzle,Flared,Brass .......106-6124<br />
CARBURETOR REBUILD KITS<br />
Body Rebuild Kit<br />
Super E (includes: #4, 5, 7, 8, 9, 11, 24, 29, 38).11-2906<br />
Super G(includes: #3, 5, 7, 9, 11, 23, 29, 38) . 11-2907<br />
Accelerator Pump Rebuild Kit<br />
Super E & G (includes: #39,40,41,42,46,47) . 11-2918<br />
Master Rebuild Kit<br />
Super E<br />
(includes Body Rebuild Kit #11-2906 & Accelerator Pump<br />
Rebuild Kit #11-2918 & #3, 13,14,15,16,17,19,22,23,31,32,<br />
35,36,37,39,40,41,42,44,45,46) ...........11-2923<br />
Super G<br />
(includes Body Rebuild Kit #11-2907 & Accelerator Pump<br />
Rebuild Kit #11-2918 & #3, 13,14,15,16,17,19,22,23,31,32,<br />
35,36,37,39,40,41,42,44,45,46) ...........11-2924<br />
RADIUSED INLETS (NOT SHOWN)<br />
Radiused Inlet;Kit;Carb;Super E/G. . . . . . . . . . . . 11-2163<br />
Kit Includes:<br />
(3) Screw;SLTD FH;w/ Lock Washer ....... 50-0073<br />
(3) Screw,SHC,w/ Thread Lock ..........106-2084<br />
(1) Cap,VOES Fitting. ................... 50-8372<br />
(1) Radiused Inlet. ......................... N/A<br />
(1) Fitting, Hose, Straight ................... N/A<br />
2-96<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
6<br />
5<br />
2<br />
13<br />
3<br />
14<br />
18<br />
19<br />
20<br />
22<br />
21<br />
16<br />
17<br />
4<br />
23<br />
53<br />
54<br />
REPLACEMENT<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
49<br />
15<br />
17<br />
48<br />
1<br />
25<br />
55<br />
26<br />
27<br />
28<br />
9<br />
24<br />
10<br />
11<br />
12<br />
7<br />
8<br />
52<br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
*Early Super E & G Carburetors equipped with a 360° fuel inlet that require service must be converted to the<br />
bottom feed style fuel inlet. To update production Super E and G carburetors equipped with an early 360°<br />
style inlet use part #50-8095 o-ring (1 each) #11-2465 seat (1 each) and #19-0475A fuel line (1 each). To<br />
update an early Super E or G carb equipped with a 360° style racing size inlet, use parts #50-8095 o-ring (1<br />
each) #11-2466 seat (1 each) and #19-0475A fuel line (1 each) .<br />
MAIN JETS - SERIES #72 INDIVIDUAL SIZE SELECTION CHART<br />
Size Each 5 Pack Size Each 5 Pack Size Each 5 Pack<br />
.040 11-4040 11-7220 .068 11-4068 11-7234 .096 11-4096 11-7248<br />
.042 11-4042 11-7221 .070 11-4070 11-7235 .098 11-4098 11-7249<br />
.044 11-4044 11-7222 .072 11-4072 11-7236 .100 11-4100 11-7250<br />
.046 11-4046 11-7223 .074 11-4074 11-7237 .102 11-4102 11-7251<br />
.048 11-4048 11-7224 .076 11-4076 11-7238 .104 11-4104 11-7252<br />
.050 11-4050 11-7225 .078 11-4078 11-7239 .106 11-4106 11-7253<br />
.052 11-4052 11-7226 .080 11-4080 11-7240 .108 11-4108-S 11-7254<br />
.054 11-4054 11-7227 .082 11-4082 11-7241 .110 11-4110 11-7255<br />
.056 11-4056 11-7228 .084 11-4084 11-7242 .115 11-4115 11-7256<br />
.058 11-4058 11-7229 .086 11-4086 11-7243 .120 11-4120 11-7257<br />
.060 11-4060 11-7230 .088 11-4088 11-7244 Blank 11-4040 11-7258<br />
.062 11-4062 11-7231 .090 11-4090 11-7245<br />
.064 11-4064 11-7232 .092 11-4092 11-7246<br />
.066 11-4066 11-7233 .094 11-4094 11-7247<br />
Intermediate JETS - SERIES #94 INDIVIDUAL SIZE SELECTION CHART<br />
Size Each 3 Pack Size Each 3 Pack<br />
.025 11-0250 11-7107 .033 11-0330 11-7113<br />
.0265 11-0265 11-7108 .036 11-0360 11-7114<br />
.028 11-0280 11-7109 .040 11-0400 11-7115<br />
.0295 11-0295 11-7110 Blank 11-0000 11-7116<br />
.031 11-0310 11-7111<br />
.032 11-0320 11-7112<br />
37<br />
35<br />
36<br />
31<br />
32<br />
33<br />
22<br />
35<br />
34<br />
50 50<br />
37<br />
NOTE: Early Series #94 gas jets were stamped with single<br />
digit numbers. Conversions for these numbers are:<br />
1 ............................................ .025"<br />
2 ............................................ .028"<br />
3 ............................................ .031"<br />
4 ............................................ .033"<br />
5 ............................................ .036"<br />
6 ............................................ .040"<br />
Visit us at www.sscycle.com<br />
30<br />
38<br />
56<br />
29<br />
40<br />
42<br />
41<br />
45<br />
44<br />
51<br />
39<br />
47<br />
32<br />
46<br />
43<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-97
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
REPLACEMENT<br />
PARTS<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
6-Speed Transmission And Cassette<br />
Replacement Parts<br />
1. Trap door, S&S 6-speed transmission<br />
2000-'06 Harley-Davidson® Softail® and 1991-'06 FLT models ....... 56-1221<br />
1991-'05 Dyna®, 1991-'99 Softail, and 1991-up FXR models ........ 56-1253<br />
2. Kit, gaskets and seals - 1991-'06 Softail (S&S complete transmission) . . . 56-1226<br />
3. Hardware kit, 6-speed transmission ............................. 56-1227<br />
4. Kit, ball and ramp, 6-speed transmission 18° ..................... 56-1228<br />
5. Kit, throwout bearing ......................................... 56-1229<br />
6. Kit, speed sensor hole cover .................................... 56-1230<br />
7. Kit, bearings, thrust washers, and retaining clips .................. 56-1231<br />
8. Mainshaft nut, jam hex nylon, 3⁄4-16, UNF-2B ................... 56-1278-S<br />
9. Kit, shift pawl, 6-speed transmission ............................ 56-1225<br />
9a. Sleeve, Shaft .................................................. 56-0001-S<br />
10. Shift fork, 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-1275<br />
11. Shift fork, 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-1276<br />
12. Shift fork, 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-1277<br />
13. Shaft, shift rail ............................................... 56-1274<br />
14. Drum, shift .................................................. 56-1273<br />
15. Nut, hex 11⁄2-24 UNS-2B LH .................................... 56-3003<br />
16. Sprocket, 34 tooth ................................................. N/A<br />
17. Hardware, kit sprocket. ........................................ 56-1272<br />
18. Spacer, sprocket .............................................. 56-1293<br />
19. Ring, retaining beveled internal 3.346 ........................... 50-8469<br />
20. Cover, top - S&S complete transmission and cassette applications<br />
Die cast – 1991-’99 Softail® and 1991-'00 FLT models<br />
S&S or stock transmission case. ............................<br />
USA<br />
56-5115<br />
Billet chrome – <strong>1999</strong>-'05 Dyna® models ........................ 106-3886<br />
21. Switch, neutral ............................................... 56-5113<br />
22. Shaft, counter, S&S 6-speed, with integral main gear .............. 56-5114<br />
23. Gear, fifth, countershaft, S&S 6-speed ........................... 56-5116<br />
24. Assembly, carrier, drum, LH .................................... 56-1294<br />
25. Gear, second, countershaft, S&S 6-speed ......................... 56-5117<br />
26. Gear, first, countershaft, S&S 6-speed. ........................... 56-5118<br />
27. Gear, third/fourth, countershaft, S&S 6-speed. .................... 56-5119<br />
28. Nut, bearing retainer, trap door, 115⁄16 - 20 UN-2B .................. 50-8477<br />
29. Collar, shift .................................................. 56-5149<br />
30. Assembly, carrier, drum, RH .................................... 56-1295<br />
31. Sleeve, shift collar .......................................... 56-0010-S<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
48<br />
3<br />
Racing<br />
Products<br />
21<br />
20<br />
Tools & Shop<br />
Supplies<br />
42<br />
17<br />
15<br />
49<br />
16<br />
2 & 43<br />
3<br />
3<br />
Dealer Services<br />
& Promo Items<br />
3<br />
18 2<br />
7<br />
9 2 24<br />
14<br />
30<br />
Warranty &<br />
Company Policy<br />
19<br />
7 & 46<br />
OEM Cross Reference<br />
Appendix & Index<br />
39<br />
2-98<br />
Order toll free 866-244-2673
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
38<br />
Continued –<br />
Replacement Parts For S&S® 6-Speed Transmissions And Cassettes<br />
32. Spacer, thrust, mainshaft, S&S 6-speed .......................... 56-1302<br />
33. Gear, fourth, main, S&S 6-speed ................................ 56-5126<br />
34. Gear, third, mainshaft, S&S 6-speed ............................. 56-5127<br />
35. Mainshaft with first gear S&S 6-speed ........................... 56-5128<br />
36. Gear, second, mainshaft, S&S 6-speed ........................... 56-5129<br />
37. Gear, fifth, mainshaft, S&S 6-speed. ............................. 56-5131<br />
38. Gear, main drive (with bearings and seal) S&S 6-speed ............. 56-5123<br />
39. Case, transmission, S&S 6-speed – 1991-'99 Harley-Davidson® Softail®<br />
Natural ..................................................... 56-1125<br />
Black ............................................................ N/A<br />
Polished..................................................... 56-1127<br />
2 & 44<br />
10<br />
1<br />
9a<br />
11<br />
12<br />
22<br />
3<br />
9<br />
13<br />
23<br />
40. Cover, side, S&S 6-speed transmission<br />
Mechanically actuated ....................................... 106-4035<br />
Hydraulically actuated. ....................................... 106-3885<br />
41. Assembly, dipstick ........................................... 56-5132<br />
42. S&S inner primary bearing race- optional (Not shown) ........<br />
USA<br />
56-5089<br />
43. Gasket, top cover<br />
Softail, FLT. ................................................ 56-5107-S<br />
<strong>1999</strong>-'05 Dyna® .............................................. 56-1256<br />
44. Gasket, trap door .........................................56-5108-S<br />
10 pack .................................................56-5108<br />
45. Gasket, side cover .........................................56-5111-S<br />
10 pack .................................................56-5111<br />
46. Bearing, main drive gear .....................................56-1281<br />
47. Spacer kit, oil filter – Optional for FLT only (Not shown) .............56-1292<br />
48. Hardware kit, 1991-'98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106-0850<br />
49. Gasket kit, 1991-'98 Dyna ...................................106-0882<br />
50. Bearing, Ball, S&S 6 speed, 20mm x 47mm x 14mm. .............. 56-1282-S<br />
25<br />
7<br />
31<br />
29<br />
26<br />
27<br />
REPLACEMENT<br />
PARTS<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
2<br />
Racing<br />
Products<br />
29<br />
6<br />
31<br />
37<br />
3<br />
7 & 50 28<br />
8<br />
5<br />
4 2 & 45<br />
41<br />
Tools & Shop<br />
Supplies<br />
36<br />
35<br />
40<br />
3<br />
Dealer Services<br />
& Promo Items<br />
7<br />
34<br />
31<br />
29<br />
33<br />
32<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
Visit us at www.sscycle.com<br />
2-99
S e ction 2:<br />
S&S ®<br />
Parts for<br />
Twin Cam 96 /103 <br />
2007-2012<br />
Parts for<br />
Twin Cam 88 ®<br />
<strong>1999</strong>-<strong>2006</strong><br />
Parts for<br />
Evolution ®<br />
1984-<strong>1999</strong><br />
Parts for<br />
Sportster ® & Buell ®<br />
1986-2012<br />
Parts for<br />
Vintage Engines<br />
1926-1984<br />
Parts for<br />
X-Wedge®<br />
2007-2012<br />
Parts for<br />
Victory®, Off-road<br />
& Metric<br />
Racing<br />
Products<br />
Tools & Shop<br />
Supplies<br />
Dealer Services<br />
& Promo Items<br />
Warranty &<br />
Company Policy<br />
OEM Cross Reference<br />
Appendix & Index<br />
2-100<br />
REPLACEMENT<br />
PARTS<br />
Order toll free 866-244-2673<br />
<strong>1999</strong>-<strong>2006</strong> <strong>BIG</strong> <strong>TWINS</strong><br />
CHROME PLATED BILLET TRANSMISSION SIDE COVER<br />
Replacement Parts<br />
1. Hydraulic Clutch Side Cover (Chrome Billet). .........106-3885<br />
Cable Actuated (Chrome Billet) ....................106-4035<br />
2. Gasket Side Cover (each) ........................ 56-5111-S<br />
10 pack ....................................56-5111<br />
3. Dipstick Assembly (H-D® #37071-87, 37075-87) .......... 56-5132<br />
4. Piston, Hydraulic Clutch (Billet). .................... 56-1303<br />
5. O-ring, 1 1/4 ID x 1/8 CS, Buna-N 70 (each). .......... 50-8283-S<br />
10 pack ....................................50-1099<br />
6. O-ring, 1 1/4 ID x 1/8 CS, Viton ..................... 50-8282-S<br />
7. Banjo Bolt 3/8-24 x 3/4 ........................... 50-0426-S<br />
8. Adapter, Hydraulic Clutch Line. .................... 56-5198<br />
9. Crush Washer, Copper .400 ID x .590 OD x .050 . .... 50-0423-S<br />
10. Valve, Bleed Fitting, 1/4-28 .........................50-0498<br />
11. Washer, Flat .260 x .420 x .06 Chrome ........... 50-8451-S<br />
12. Screw, Cap Hex SH 1/4-20 UNC x 1.75 Zinc ........ 50-0010-S<br />
13. Screw, Cap Hex SH 1/4-20 UNC x 2.75 Zinc .......... 50-0459<br />
13<br />
10 1<br />
12 11 9<br />
S&S ®<br />
High performance Clutch Replacement Parts<br />
.<br />
1. Race, inner primary bearing, 5/6 speed main shaft<br />
All 1991-'05 BT and <strong>2006</strong> Harley-Davidson® Softail® models<br />
..........................<br />
USA<br />
56-5089<br />
2. Basket,<br />
Clutch, 36-tooth............................<br />
USA<br />
56-5081<br />
Clutch, 37-tooth............................<br />
USA<br />
56-5082<br />
3. Bearing, clutch (basket to hub). ..............<br />
USA<br />
56-5102<br />
4. Hub, clutch ...............................<br />
USA<br />
56-5075<br />
5. Washer, thrust, 19.5 mm I.D. x 35.6 mm O.D. .............N/A<br />
6. Nut, mainshaft, clutch hub, 3⁄4-18 UNS-2B.................N/A<br />
(Recommended early style mainshaft nut H-D® #37496-84)<br />
(Recommended late style mainshaft nut H-D® #37496-90)<br />
7. Plate, pressure - clutch<br />
Mechanical (3-piece pushrod actuated). .......<br />
USA<br />
56-5076<br />
Hydraulic (1-piece pushrod actuated). ............. 106-3147<br />
8. Spring, pressure plate, clutch<br />
Light duty, 334 lbs. (6 pack) .................. USA<br />
56-5109<br />
Standard, 370 lbs. .......................<br />
USA<br />
56-5105-S<br />
Heavy duty, 408 lbs. (each). ................<br />
USA<br />
56-5106-S<br />
6 pack .........................<br />
USA<br />
56-5106<br />
9. Nut, flange, M10 x 1.25". ....................<br />
USA<br />
50-8411<br />
10. Screw, clutch adjuster, M10 x 1.25". ...........<br />
USA<br />
50-8414<br />
11. Bolt, special, M6 x 30, w/washer. ...........<br />
USA<br />
50-8413-S<br />
12. Jutter spring with seat ......................<br />
USA<br />
56-5110<br />
13. Clutch pack, 11 frictions, 10 steels. ..........<br />
USA<br />
56-5085-S<br />
14. Kit, shim, clutch inner race. ..................<br />
USA<br />
56-5090<br />
Shim, 5/6 speed main shaft<br />
1.300" O.D. x .960" I.D. x .0075" (36 gauge) thick. ...<br />
USA<br />
56-5092-S<br />
1.300" O.D. x .960" I.D. x .0150" (28 gauge) thick. ...<br />
USA<br />
56-5093-S<br />
1.300" O.D. x .960" I.D. x .0240" (24 gauge) thick. ...<br />
USA<br />
56-5094-S<br />
1.300" O.D. x .960" I.D. x .0470" (18 gauge) thick ....<br />
USA<br />
56-5095-S<br />
1<br />
OPTIONAL:<br />
15. Pinion Gear ...............................<br />
USA<br />
56-1037<br />
16. Loctite®, fast cure epoxy .12 ounce (Not Shown). .....51-9007-S<br />
14<br />
12<br />
15<br />
2<br />
13<br />
3<br />
6<br />
1<br />
4<br />
5<br />
7<br />
5<br />
8<br />
4<br />
6<br />
3<br />
7<br />
10<br />
9<br />
8<br />
2<br />
11