S&S Cycle Three Piece Flywheel Assemblies for S&S V-Series Engines for 1984-99 Harley-Davidson Big Twins User Manual
Page 2
Special Tool Requirements
• Harley Davidson service manual or S&S service manual for your
specific engine
• Timken® bearing installing tool
• 2" “C” or “V” micrometer with .0001" accuracy
• Digital or dial calipers
• Dial indicator
• Torque wrench
General Information
• Thoroughly read and understand these instructions. In addition
to this instruction sheet you may wish to purchase S&S 4 1/8" bore
V-Series Service Manual #510-0104.
• Please inspect your flywheels and confirm that they are the correct
style and stroke for your engine. See the chart below.
• If you don’t have the required tools for installing these flywheels
either acquire them or refer installation to a professional mechanic.
• It is the engine builders responsibility to confirm proper clearances
when assembling an engine
SPECIAL NOTE - Camside case of S&S 4 1/8" bore crankcase sets with
serial numbers lower than NE00203X must be machined to provide
adequate clearance for current production flywheel assemblies. See
Page 4 for more information.
NOTE: If you do not have machining capabilities, crankcases may be
sent to the S&S Service and Speed Center® and we can machine them for
you. Contact your S&S dealer. Dealers, please contact your S&S Customer
Service Representative at 608-627-1497 for a return authorization number.
Flywheel Installation
1. Remove flywheels assembly from packaging material. Handle with
care to avoid dropping assembly. Avoid any sharp blows to the
mainshafts which could potentially shift the flywheels out of true.
2. Using a clean lint free cloth, thoroughly clean flywheel assembly to
remove rust preventative oil. Rust preventative oil is not suitable for
use as engine oil and must be removed prior to installation. Be sure
that assembly remains free of foreign material or contamination
before and during installation.
NOTE: Do not immerse or wash assembly in solvent. Connecting
rod bearings are coated with assembly grease, which may become
contaminated by dirt and grit unless absolutely new, clean solvent is used.
3. Refer to the Harley Davidson service manual for the specific model
of motorcycle you are working on for the correct engine removal
procedure.
4. Remove engine from the frame of the motorcycle and completely
disassemble.
5. Inspect crankcases carefully. If pinion bearing race is damaged or
oversized, it must be replaced according to procedure outlined in
the S&S 4 1/8" bore V-Series Service Manual #510-0104.
6. Clean all lower end parts for final assembly. Ensure that all
passages, including piston oilers, are open and free from debris or
contamination.
7. Wash the cases in warm soapy water, rinse and blow dry. Wipe
them one last time with a clean, dry cloth.
8. Thoroughly clean crankcase mating surfaces with solvent and
a scrubbing pad to remove any residual sealant from the sealing
surfaces.
NOTE: Cleaning parts prior to and during assembly and keeping parts
clean after final assembly are imperative to minimize contaminants that
may circulate in oil and shorten engine life. Many parts can be cleaned
with soap and water first. Then, reclean all internal parts and gasket
mating surfaces using high quality solvent that does not leave any harmful
residues.
9. Measure the pinion shaft bearing surface outside diameter and
pinion race inside diameter to an accuracy of .0001". Use the
following table to select the correct pinion bearing. See Picture 1.
10. Check Timken® sprocket shaft bearing end play.
2
Picture 1
Stroke Codes
Code
Stroke
9
3.600"
21
3 7/8"
17
4"
19
4 1/8"
9
4 3/16"
5
4 ¼"
1
4 3/8"
2
4 ½”
6
4 5/8"
3
4 ¾"
7
4 13/16"
4
5"
Engine Style
Code
Engine Style
SGX3
4 1/8” Bore
V-Series
Flywheel Diameter
Code
Diameter
X
8 ¼"