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S&S Cycle, Inc.
14025 County Hwy. G P.O. Box 215
Viola, Wisconsin 54664
Phone 608-627-1497 Fax 608-627-1488
Instruction Sheet No. 51-1003
2-8-01
Copyright ©, 2001
by S&S Cycle, Inc.
All rights reserved. Printed in the U.S.A.
Installation Instructions for
TÜV Long Block Assembly
Safe Installation and Operation Rules:
Before installing your new S&S engine it is your responsibility
to read and follow the installation procedures in these instructions
and follow the basic rules below for your personal safety.
● Gasoline is extremely flammable and explosive under certain
conditions and toxic when inhaled. Do not smoke. Perform
installation in a well ventilated area away from open flames or
sparks.
● If compressed air is used during installation, be particularly
careful. Compressed air and particles dislodged by compressed
air are harmful to eyes and body. Wear protective goggles, and
always direct air stream away from body parts such as hands and
eyes and other people near you.
● When using solvents, degreasers and other chemicals during
cleaning and installation, read manufacturer’s instruction label for
proper use. Exposure of some chemicals to skin, eyes and/or
other body parts may be harmful. Many items are flammable and
present a fire hazard. Use in well ventilated area and wear
protective clothing when using them to avoid personal injury.
● If motorcycle has been running, wait until engine and exhaust
pipes have cooled down to avoid getting burned before performing
any installation steps.
● Before performing any installation steps disconnect battery to
eliminate potential sparks while working on electrical components.
● Read instructions thoroughly and carefully so all procedures
are completely understood before performing any installation steps.
Contact S&S with any questions you may have if any steps are
unclear or any abnormalities occur during installation or operation
of motorcycle.
● Consult an appropriate authorized H-D service manual for
correct disassembly and reassembly procedures for any parts other
than those outlined in these instructions.
● Use good judgement when performing installation and
operating motorcycle. Good judgement begins with a clear head.
Don’t let alcohol, drugs or fatigue impair your judgement. Start
installation when you are fresh.
● Be sure all federal, state and local laws are obeyed with the
installation.
● Be sure all fuel lines, supply and overflow, are routed correctly
and fuel line clamps are in place and tightened. Lines must not
contact exhaust pipes or other extremely hot surfaces where they
could melt or leak and catch fire.
● Before starting engine and riding motorcycle, be sure throttle
opens and closes smoothly. Turn handlebars to left and test throttle.
Then, turn bars to right and test throttle. To avoid possible loss of
control of motorcycle and potential personal injury to yourself or
others due to throttle sticking in open position, throttle must work
smoothly and return to a fully closed position when hand is removed
from throttle grip.
● Motorcycle exhaust fumes are toxic and poisonous and must
not be breathed. Run motorcycle in a well ventilated area where
fumes can dissipate.
IMPORTANT NOTICE:
Statements in this instruction sheet preceded by the following
words are of special significance:
WARNING
Means there is the possibility of injury to yourself or others.
CAUTION
Means there is the possibility of damage to the engine or
motorcycle.
NOTE
Other information of particular importance has been placed in italic
type.
S&S recommends you take special notice of these items.
IMPORTANT NOTE: Read Carefully
S&S engines are designed for high-performance applications. The
installation of an S&S engine may void or adversely affect your
vehicle warranty.
This kit, comprised of compatible S&S high-performance engine
parts has been approved by Teschnischer Überwachungs Verein
(TÜV) for sale in the European Union (EU). The TÜV approved V
2
Style Long Blocks have been certified to meet all current emissions
standards for exhaust, noise, and electronic interference. In order
to be compliant with TÜV standards, Long Blocks are furnished
complete and assembled by S&S engine builders. As a result, this
kit can be legally installed as a stock replacement for all applicable
used and new Harley-Davidson motorcycles. Any deviation,
substitution of other S&S parts or parts from another manufacturer
for an S&S part included in the certified kit, or unauthorized
modification of a part or parts included in the certified kit may void
the engine warranty or violate pollution laws.
It is the sole and exclusive responsibility of the user to determine
the suitability of the product for his or her use. Be advised that the
user shall assume all legal responsibility for personal liability and
liability for others, as well as all other obligations, duties and risks
associated with the installation and use of high-performance parts.
The words Harley, Harley-Davidson, H-D, Big twin, Sportster,
Evolution and all H-D part numbers and model designations are
used in reference only. S&S Cycle is not associated with Harley-
Davidson, Inc.
PRESENT S&S CRANKCASES AND FLYWHEELS ARE NOT COMPATIBLE WITH
HARLEY-DAVIDSON ELECTRONIC FUEL INJECTION (EFI) MODELS.
(20 pages)
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