S&S Cycle Sidewinder 3 5/8 Big Bore Cylinders for 1936–1999 Big Twins - Manual (Page 4)

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3. Crankcase Alignment and Cylinder Mounting Studs (All)
NOTE: Some crankcase base gasket surfaces on which cylinders are positioned do not align properly. This usually occurs when crankcase halves used
are from different crankcase assemblies and were not paired and machined together at the factory. It is recommended to check for crankcase
misalignment even if crankcase halves are correctly matched to prevent potential oil leaks and other mechanical problems.
Mismatched gasket surfaces due to improperly aligned crankcase halves may cause unwarranted stress on cylinder base flanges which
could result in cylinder flange failure.
A. Clean cases thoroughly and assemble both halves without flywheels. Tighten all case bolts as in final assembly.
B. Place straight edge ruler across base gasket surface. See Picture 1.
C. If any misalignment exists, remove cylinder base studs and place masking tape over cam and mainshaft bearings to keep chips out.
NOTE: Early Harley-Davidson® Evolution® crankcases equipped with female style studs must be changed to later male style studs because S&S Sidewinder
cylinders are designed for later design studs and head bolts. Consult your Harley-Davidson® service manual for proper removal and installation
procedures.
Be careful when removing studs so as not to damage threads in cases. If stud does not come out easily, carefully heat case around studs
as heat may help loosen them. Damaged studs may cause stress risers which can lead to stud failure and possible damage to engine
components.
D. Place cases squarely in mill and machine gasket surface taking minimum necessary to clean surface.
E. Knucklehead, panhead, shovelhead engines- If stock cylinder studs are to be used, thoroughly clean and reinstall to 1.175" to 1.225"
measured from top of stud to gasket surface. If studs are provided in kit, install to height that equals: (thickness of cylinder base flange) +
(base gasket) + (cylinder base plate) + (washers) + (base nut).
NOTE: Use Loctite® Stud and Bearing Mount to secure studs to ensure they don’t turn out during future disassembly.
F. Evolution engines—Consult your Harley-Davidson® service manual for proper stud installation procedure and stud installation height.
4. Bore Crankcases (All)
NOTE: Early panhead crankcases, 1948–1952, have cylinder head oil feed passageways drilled closer to cylinder spigot bore. When boring cases for larger
diameter spigots, bore cut may break into passageway. It is recommended to use aftermarket crankcases if at all possible. Aftermarket cases are
stronger, enhance engine life because of Timken® bearing design and eliminate breaking into oil passage because they are drilled differently.
Hole in oil feed passageway to cylinder heads will cause loss of oil pressure to heads resulting possible damage to rocker arms and/or
other engine components.
CAUTION
CAUTION
CAUTION
Picture 1