S&S Cycle Sidewinder 3 5/8 Big Bore Cylinders for 1936–1999 Big Twins - Manual (Page 2)

2
Introduction
Installation of an S&S® big twin 35⁄8" bore stroker Sidewinder® Kit is easy and can be performed by any motorcycle repair shop equipped to do
complete engine overhauls.
NOTE: To make installation of S&S Sidewinder series 35⁄8" bore kits easier, S&S has designed several special tools worth considering. They are:
• Part #53-0002—Connecting Rod Checking Pin —helps check piston alignment in cylinder bore.
• Part #53-0020—Degree Wheel Kit—used to check and set crankcase breather timing and ignition timing.
• Part #53-0005 and #53-0009—Crankpin Nut Clearancing Gauges—used to set crankpin nut to crankcase clearance.
• Part #53-0006, #53-0007 and #53-0008—Cylinder Head and Crankcase Boring Fixture and Crankcase Boring Spacers—adapts most boring bars
so cylinder heads and crankcases can be bored to fit larger diameter spigots and fire rings on big bore cylinders. Enables qualified operator to bore
heads and cases in about an hour after initial setup.
Read instructions thoroughly before starting work. When they are completely understood proceed with installation.
Installation Steps: Page
1. Bore Heads (shovelhead and panhead only) ...........................................................................2
2. Relocate Head Bolt Hole (knucklehead only) .........................................................................3
3. Crankcase Alignment & Cylinder Mounting Studs (All) ......................................................4
4. Bore Crankcases (All) ........................................................................................................................4
5. Clearance Frame (All) .......................................................................................................................6
6. Modify Crankcases for Oil Returning from Heads (All crankcases 1953 and later) ...6
7. Crankcase and Piston Skirt Clearancing (All) ..........................................................................7
8. Breather Timing (All)* ......................................................................................................................10
9. Cam, Lifters and Tappet Blocks (All) ...........................................................................................12
10. Connecting Rod Preparation (All) ...............................................................................................12
11. Lower End Assembly (All) ...............................................................................................................13
12. Connecting Rod Alignment (All)* ...............................................................................................15
13. Modify knucklehead heads for S&S Oil Return Conversion Kit
(knucklehead Installations on 1948 and later Crankcases) ................................................17
14. Piston to Valve Clearancing and Piston Installation (All) ....................................................17
15. Final Top End Assemble and Engine Installation (All) .........................................................19
16. Timing, Carburetion, Exhaust, Gearing, and Break-in (All) ................................................22
*NOTE: S&S recommends that engine builder consider performing some steps during initial engine disassembly. Breather timing check requires that
most components be assembled, and performing check upon disassembly may save reassembly and cleaning time. While some or all related
parts concerned in connecting rod alignment check may be replaced, it is helpful to check original parts combination and note discrepancies
which may alter installation of new parts.
Installation
1. Bore Head (shovehead and panhead only)
Procedure for enlarging cylinder head recess to accept larger Sidewinder cylinder flange is as follows:
A. Bolt boring plate to bench or stand leaving rounded end of plate protrude over edge approximately 65⁄8".
B. Clean head gasket surface and bolt head to plate using three 7⁄16-20 allen head screws furnished with plate. Cylinder head combustion
chamber will correctly line up with hole in plate when correct three holes are used for front or rear head.
C. Center boring bar in hole in plate. Diameter of hole in plate is 3.878" to 3.880" which is identical to dimension of recess to be bored inhead.
D. Bore head to 3.878" to 3.880" diameter by .200" deep. Measure depth from head gasket surface to bottom of cut.
NOTE: We normally take three cuts to bore heads, 3.800" diameter, 3.850" and final size 3.879".
E. Repeat steps B through D for other head.
NOTE: Cylinder head mounting holes in plate are correctly located to place head fire ring counterbore concentric with head bolt pattern if instructions
are followed.