Cycle, Inc Cty Hwy G, PO Box 215 Viola, Wisconsin Phone: Fax:

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1 Manual Revison Copyright 0, 0 by S&S Cycle, Inc. All rights reserved. Printed in the U.S.A. S&S Cycle, Inc. 0 Cty Hwy G, PO Box Viola, Wisconsin Phone: 0-- Fax: 0-- Technical Service Phone: 0--TECH () Technical Service sstech@sscycle.com Website: S&S Billet Pro Stock Engine Assembly Designed by S&S Cycle, Inc. SAFE INSTALLATION AND OPERATION RULES: Before installing your new S&S part it is your responsibility to read and follow the installation and maintenance 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 breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks. 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 and inadvertent engagement of starter 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 with a S&S part on it. Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation. Use good judgment when performing installation and operating motorcycle. Good judgment begins with a clear head. Don t let alcohol, drugs or fatigue impair your judgment. Start installation when you are fresh. Be sure all federal, state and local laws are obeyed with the installation. For optimum performance and safety and to minimize potential damage to carb or other components, use all mounting hardware that is provided and follow all installation instructions. Motorcycle exhaust fumes are toxic and poisonous and must not be breathed. Run motorcycle in a well ventilated area where fumes can dissipate. DISCLAIMER: S&S parts are designed for high performance, closed course, racing applications and are intended for the very experienced rider only. The installation of S&S parts may void or adversely affect your factory warranty. In addition such installation and use may violate certain federal, state, and local laws, rules and ordinances as well as other laws when used on motor vehicles used on public highways, especially in states where pollution laws may apply. Always check federal, state, and local laws before modifying your motorcycle. It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use, and the user shall assume all legal, personal injury risk and liability and all other obligations, duties, and risks associated therewith. The words Harley, Harley-Davidson, H-D, 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. 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 part or motorcycle. NOTE Other information of particular importance has been placed in italic type. S&S recommends you take special notice of these items. WARRANTY: S&S Cycle Inc. does not offer any warranty on race only products.

2 S&S BILLET PRO STOCK ENGINE The S&S Billet Pro Stock is the same engine you have seen used in competition at NHRA and AHDRA races. It is a 0-cubic inch four cam, 0 degree V-Twin pushrod engine. It is built with special S&S billet crankcases, cylinders, and heads, and features an integral -speed automatic transmission, and dual downdraft manifolds and large diameter EFI throttle bodies. 0ci four-cam, 0 degree pushrod V-Twin Billet crankcases with integral transmission housing Billet steel Pro Stock style flywheel assembly Billet aluminum rods with.00 crankpin Billet Pro Stock cylinder heads Six-speed automatic transmission ACCOMPLISHMENTS 00 Won NHRA's "Best Engineered Vehicle Award" 00 - Current - Every race had S&S Pro Stock teams in the bike field on Sunday. 00 S&S powered Buell motorcycles won championships on three separate continents. - Matt Smith Racing NHRA Pro Stock bike - Brett Stevens Racing ANDRA Pro Stock bike - Tim Tinndahn Racing UEM Pro Stock bike 00 - Brett Stevens Racing ANDRA Pro Stock bike championship 00 - Hector Arana Racing NHRA Pro Stock bike championship - Ulf Ogge Racing UEM Pro Stock bike championship 00 -Ulf Ogge Racing UEM Pro Stock bike championship 0 -Matt Smith Racing NHRA Pro Stock Bike SPECIFICATIONS AND OTHER INFORMATION GENERAL SPECIFICATIONS Crank Position Sensor Gap Cam Position Sensor Gap Intake Rocker Arm Ratio... : Exhaust Rocker Arm Ratio....: Primary Drive Ratio, -...: Transmission High (th) Gear Output Ratio...0: Drive Sprocket Teeth -0 Chain x T Wheel : Teeth -0 Chain x T Wheel : Overall Drive Ratio, T T, Average...: Normal Piston Size Piston Fitment Top Ring Gap nd Ring Gap Oil Ring Gap Valve Stem to Rocker Arm Clearance Cold Hot...0.0" Valve Stem to Guide Clearance " " Cam End Play Anticipated Valve lift; Intake Exhaust...0." Torque Specifications: Head Bolt "...0 ft-lb Head Bolt "... ft-lb See Diagram below. CYLINDER HEAD - TOP VIEW TORQUE SEQUENCE DIAGRAM All nuts to 0 ft-lb " first then " next all " to 0 ft-lb then all " to ft-lb. Diagram Rocker Arm Stand Bolts...00 ft-lb Use red Loctite requires TP Torx Plus wrench Rocker Arm Screws... ft-lb Use red Loctite requires TP Torx Plus wrench Timing Cover Screws (Use blue Loctite )... in-lb Bolts "... ft-lb Screws " in-lb Pinion Gear Nut ft-lb Use green Loctite on gear and red Loctite on nut threads & face. Cam Gear Nut ft-lb Use green Loctite on gear and red Loctite on nut threads & face. Transmission Trap Door and Case Bolts (Use red Loctite)... ft-lb Left Side Main Bearing Nut - Coat Left Hand threads lightly with non-setting thread sealer such as Loctite and torque with S&S Wrench (PN -0) to 0 ft-lbs. Coat Right Hand threads lightly with red Loctite and torque with S&S Wrench (PN -0) to 0 ft-lbs.

3 EXHAUST PIPES Front & Rear Cylinders Section (/ O/D X / long) Section (/ O/D X / long) Section (/ OD X / long) Section ( O/D X long) LUBRICATION Engine Oil - 0 or wt, / quarts Transmission and Primary Lube - w0, ounces in primary, fill transmission fluid level to overflow hole, to ounces There is a.00 restrictor installed in the oil line that feeds the bottom end, in the cam cover fitting check it often to ensure that it is free of debris There is a.0 restrictor in the left main bearing oil feed line check it often to ensure it is free of debris Oil lines must be made from - AN braided hose STARTING PROCEDURE Due to the large displacement and high compression of this engine, it is important to make sure the front piston is just past TDC on the compression stroke before starting. This gives the starter a chance to get the crankshaft turning before it has to push the engine through a compression stroke.. Make sure the ignition switch is turned off.. Remove the timing plate in the primary cover.. Use a " RATCHET handle and a short extension if needed, insert extension into the engine sprocket and turn the engine counter clockwise (forward) until it rolls over TDC. The compression will make it snap over TDC with some force.. Check in the timing window to be sure the front cylinder is at TDC. You may have to turn the engine clockwise (backward) slightly to see the timing mark.. If the front TDC timing mark (TF) is visible, the engine is ready to start. If the rear TDC mark (TR) appears in the window, repeat the above procedure.. Mark the oil pump pulley for future reference. This eliminates the need to remove the timing window. MAINTENANCE TIPS VISUAL INSPECTION AFTER EACH RUN Moly valve coating for cracking or flaking Bottom spring collar for cracks Valve tips, lash caps Pushrod ends and rocker cups Top collar and keepers for excessive wear Check valve spring pressure - replace or shim if below 0 lbs. NOTE: Must maintain.00 minimum before coil bind at maximum lift. Recommend replacement of questionable springs rather than shim Drain and inspect oil and if necessary, pull pan and check for debris. If OK, oil may be re-used VISUAL INSPECTION AS NECESSARY DURING EVENT Cylinders/Pistons Check wristpin for straightness and coating integrity Visually inspect for cracks or signs of scuffing Verify ring land straightness Check piston domes for signs of detonation Crankshaft Check rod side clearance against build sheet Visually inspect crankpin weld Check drive hub and pinion shaft runout max is.00 Cam Chest Inspect cam gears and keys Inspect cam shafts for excess wear Inspect tappets and tappet blocks for wear or bad bearings REBUILD/REPLACEMENT SPECIFICATIONS Heads Run out of valve, service limit is.00 T.I.R. Run out of seat, service limit is.00 T.I.R. Valve stem wear, service limit is.0 intake,.0 exhaust Measure spring clearance to coil bind, service limit.00 or greater Measure spring installed pressure, service minimum is 0 lbs Set valve lash cold at , lash hot at approx..0" Replace valves at 0 runs or sooner if necessary Replace valve springs at runs or sooner if necessary Replace rocker arms at 0 runs or sooner if necessary

4 Cylinders/Pistons Measure piston/cylinders for fitment, service limit is.0" Measure piston ring land lateral clearance, service limit is.00 st,.00 nd New ring installation gaps.0,.0,.00 Measure cylinders, service limit is. Hone cylinder as necessary without exceeding service limit for fitment Replace piston if collapsed, service limit is.00 smaller than specification on original build sheet Check wristpin/piston fitment, service limit is.00 Replace pistons at 0 runs or sooner if necessary Crankshaft Check rod side clearance against build sheet Visually inspect crankpin weld Drive hub and pinion shaft runout not to exceed.00 Replace main bearing on crankshaft every 0 runs Replace the pinion bearing every 0 runs Replace crankshaft at 0 runs or sooner if necessary Cam Chest Tappet blocks and lifters, service limit is.000 maximum Inspect cam gears and keys Inspect cam shafts for excess wear and cracked welds Inspect tappets and tappet blocks for wear or bad bearings Replace cams at 0 runs or sooner if necessary Replace lifter at 0 runs or sooner if necessary Replace pushrods at 0 runs or sooner if necessary Transmission Replace transmission bearings as necessary or after failure of any transmission component Replace shift forks after backing out of any gear except sixth or if routine inspection shows sign of wear Replace shift drum after backing out of any gear except sixth or if routine inspection shows sign of wear Replace detent arm spring as necessary Replace shift pawl as necessary Oil Pump Replace pump if gears/rotors are scored or as necessary Replace pump belt if edges fray or contaminated by oil, etc.

5 S&S BILLET PRO STOCK ENGINE ASSEMBLY. Flywheel assembly Standard porkchop Full diameter (R)...0- Standard porkchop w/" rods Full diameter (R) w/" rods LOWER END PARTS PRO STOCK CRANKCASE ASSEMBLY. Flywheel to main bearing spacer Crankcase assembly With cam chest Without cam chest Bearing, Right, Main, bt Mainshaft bearing rebuild kit *(Includes PN -00-S and PN -0-S). Ring, Lock, Main Bearing RH thread...-0 LH thread Retaining Ring, Internal, Notched, -/" Cylinder stud S 0. Seal, Left, Main Bearing, Pro Stock...-0-S. Main bearing, drive side S. Spacer, Driveside PRO STOCK OIL PICK-UP PLATE. Oil pick-up plate with hardware Oil adapter fitting with hardware O-ring string s. O-ring S. Screw Magnet Screw

6 LOWER END PARTS PRO STOCK CAM CHEST. Intermediate plate assembly...-. Cam pinion/drive gear kit Cam chest cover assembly...-. Pushrod tube cover set ( Pieces Upper pushrod tube o-ring S. Lower pushrod tube o-ring S. Tappet block set (Front & Rear) Cam chest (Part of -0)... N/A. O-ring string s 0. Pinion shaft bearing...-0-s. O-ring, (-0), Viton O-ring, (-0),." ID x.00" OD, Viton Bearing, Needle, Cam, Late -'0 XL Bearing, # Cam, PS Retaining Ring, Internal,.0" x.0", Carbon Steel, SAE Gear, Cam Drive, #, Tooth, PS Key, Woodruff,." x.00", PS Nut, HH, /-0 UNEF-B x.", Black, Steel, Gear, Pinion, Tooth, PS Pin, Dowel, /" x -/" S. Seal, Cam S. Seal, Pinion S. Washer Screw Screw Washer, Cam, Thrust, Double,.0", Steel Washer, Cam, Thrust, Single,.0", Steel

7 PRO STOCK CAM CHEST KIT 0-0 (CAMS NOT INCLUDED). Cam chest, assembly, packaged, natural, billet, PS0, ( Req) Bearing, assembly, needle, 0 PS0, ( Req) Screw, shc, /- x -/", zinc, ASTM, A-A, ( Req) S. Washer, flat,." X." X.0", Zinc, low carbon steel,( Req) Fitting, pipe,, /- npt x.00", Zinc, brass PS0,( Req) s. Plug, pipe, / taper, /- nptf x.", Zinc, steel, ( Req)... 0-a. Pin, dowel,." X ", steel, ( Req) Pin, dowel,.0" X.00", Steel, ( Req) Plug, press-in, black, plastic, ( Req) Fitting, pipe, 0, -N to / NPT, dichromate, steel PS0, ( Req) s. SHCS, 0- x /", ( Req) O-ring, (-),.0" Id x." OD, nitrile, PS0, (Req) s. Plug, drain, magnetic, zinc, steel, ( Req) Cover, assembly, cam chest, packaged, natural, billet, PS0, ( Req) Cup, cam position sensor, PS0, ( Req) Seal, cam cover/cam,." X." X.0", Nitrile, PS0, ( Req)...-0-s. Screw, SHCS, w/ flat washer, /-0 x ", zinc, ASTM A-A, ( Req) s. O-ring, cord stock,.0" Od x l, black, Viton, a durometer, (" Req) S. Seal, cam cover/pinion shaft,." X.0" X.", PS0, ( Req) S 0. Screw, SHCS, 0- x /", alloy, ( Req)...0--S. Plate, assembly, cam support, packaged, PS0, ( Req) Screw,SHCS,w/ Flat Washer,/- x " ( Req) S. Bearing, inner primary, mm x mm x mm, ( Req) Retaining ring, internal,.0" X.0", Carbon steel, SAE 00-00, ( Req) Plate, assembly, pinion, packaged, natural, billet, PS0, ( Req) Bearing, pinion shaft, PS0, ( Req)...-0-S. Camshaft, set, 0 PS0 (available seperately - not included in kit), ( Req) Special order, CTO, 0 PS0, ( Req) Gear, idler, packaged, PS0, ( Req) Pushrod cover, set, PS0, ( Req) O-ring, pushrod cover, mm x mm, Viton, durometer, PS0, ( Req) Retaining ring, external, inverted, MM, ( Req)

8 PRO STOCK PRIMARY COVER. Clutch cover with hardware Clutch hub cover spacer kit Primary cover with hardware Clutch cable tab with hardware Timing hole cover with hardware Outboard bearing support assembly Drive hub with hardware Primary drive gear, teeth, with hardware Reluctor wheel with dowel pins O-ring string s. 0 tooth oil pump drive pulley external retaining rings...0--s. Outboard support bearing...-0-s. Clutch assembly, teeth...na. Screw, SHC, 0- x /", Alloy...0--S. Spacer, Outer, Primary Cover Bearing,.0 x.00 x pacer, Inner, Primary Cover Bearing,.0 x.00 x Pin,Dowel,." x.",alloy PS Screw,SHCS,Machined,0- x /",PS Screw,SHCS,w/ Flat Washer,/-0 x ",Zinc,ASTM A-A S. Screw,SHC,w/ Flat Washer,/-0 x /",Zinc, ASTM A-A PS Washer,Flat,.0" x." x.00",chrome,steel Screw,SHCS,/-0 x -/",Zinc Plug,Pipe,w/Sealant Patch,/ Taper,/- NPTF x.",zinc,steel.0-a. Screw,SHCS,/-0 x -/",Zinc Suzuki parts not included: Seal, Clutch Shaft Bearing, Needle, Clutch Shaft, Inner Shaft,Clutch Bearing, Needle,Clutch Shaft, Outer

9 CYLINDER HEADS AND PARTS. Head Assembly Front head assembly... 0-F Rear head assembly...0-r. Valve Intake S Exhaust S. Valve Guide Intake Exhaust Valve Seat Intake Exahust Exhaust flanges with gaskets and hardware - Front and rear Exhaust flange gasket S. Screw,SHC,/- x ",Zinc,ASTM A-A Rocker cover with hardware Screw,SHC,w/ Flat Washer,/-0 x /",Zinc, ASTM A-A PS Rocker arm support set with hardware - Front and rear Bolt, rocker arm, Torx head s. Button-head cap screw S. Pushrod cover with hardware Front...-0 Rear Cylinders Cylinder set front and rear without pistons...-0 Front cylinder only... -0F Rear cylinder only...-0r. Stud, cylinder head attachment... --S. O-ring, head and base...0--s. Hardware, cylinder stud, billet PS Lash caps...0--s. Keepers Titanium top collars ( pack) Cup, spring...0-a. Seal, valve guide, /" O-ring string s 0 0

10 PISTON PART. Circlips Each Wristpin Each... - INTAKE MANIFOLDS AND PARTS. Radiused inlet and hardware Front...- Rear...-. Throttle body assembly Front Rear Intake manifold with hardware Front...- Rear...-. Injector hat Throttle position sensor Rear manifold only Screw Screw Screw Washer

Miscellaneous Parts. MSD spark plug wires,.mm (Set of )...-0. Map sensor...-0. Air temperature sensor...-0. Crank position sensor...-00. Head temperature sensor... -0. Champion spark plugs... -0-S.

11 Miscellaneous Parts. MSD spark plug wires,.mm (Set of ) Map sensor Air temperature sensor Crank position sensor Head temperature sensor Champion spark plugs S. " Drive sprocket spacers...-0a. " Drive sprocket spacer...-0a. Dailey oil pump Oil pump trash screen... --S. Tooth oil pump driven pulley with set screw Oil pre-filter, with hardware ( pack fitting S. fitting s. Threaded Lock Ring Tool...-0 Additional Parts Not Shown. Plug, NPT /-...0-A. SCHS, /-0 x / O-Ring String S. # AN fitting, straight,.0" restrictor # AN fitting, 0,.00" restrictor Woodruff key, /" x /"` Washer Washer

12 TRANSMISSION PARTS. Left side trap door assembly Right side trap door assembly Hardware Kit, Transmission sensor bracket with screws Gear shift cam stopper with hardware Left shifting cover with hardware Right shifting cover with hardware x 0 degree vent fitting S. Transmission speed sensor rotor with magnets Retaining ring... Liberty's Gears Part -. Second gear input, teeth... Liberty's Gears Part -. Splined bushing... Liberty's Gears Part -0. Sixth gear input, teeth... Liberty's Gears Part -. Splined input thrust washer...liberty's Gears Part 0-. Spring, coil...liberty's Gears Part 0-0. Fourth gear input, teeth... Liberty's Gears Part -. Gear spacer... Liberty's Gears Part -. Third gear input, teeth... Liberty's Gears Part -0. Bushing, fifth gear input... Liberty's Gears Part Fifth gear input, teeth...liberty's Gears Part -0. Input shaft... Liberty's Gears Part -0. Spacer, right side output shaft... -0A. Output shaft... Liberty's Gears Part -0. Second gear output, teeth,. ratio...liberty's Gears Part -0. Washer, splined output thrust... Liberty's Gears Part

13 . Ring, external retaining,.0"diameter x.00" thick,... Liberty's Gears Part -0. Sixth gear output, 0 teeth,.0 ratio...liberty's Gears Part -0. Bearing, splined-plain... Liberty's Gears Part -0. Fourth gear output, teeth,. ratio...liberty's Gears Part Ring, external retaining,.0"diameter x.0" thick,... Liberty's Gears Part -0. Third gear output, teeth,.00 ratio...liberty's Gears Part -0. Fifth gear output, teeth,. ratio...liberty's Gears Part -0. Thrust washer... Liberty's Gears Part 0-. Bearing, plain... Liberty's Gears Part -0. First gear output, teeth,. ratio...liberty's Gears Part -0. Ring, external retaining, constant cross-section,.0" diameter x.00",... Liberty's Gears Part -0. Spring long...liberty's Gears Part 0-0. Spring medium...liberty's Gears Part 0-0. Spring short...liberty's Gears Part Output forks...liberty's Gears Part -0. Shift fork shaft out... Liberty's Gears Part -0. Pole gear shift no.... Suzuki Part -0. Pole gear shift no.... Suzuki Part -0. Shifting pawl roller...suzuki Part Spring, shift pawl...suzuki Part Gear shift cam...suzuki Part -0. Shift drum... Liberty's Gears Part -00. Output shaft retaining washer A. - " FHCS output shaft S 0. Spacer clutch, trans input, pro stock B Input fork... Liberty's Gears Part " x.00 thick washer shaft input... Liberty's Gears Part -0. Retaining Ring, Internal,.00" x.00", Carbon Steel, SAE Bearing, Ball, 0mm x mm x mm, -00 XL Retaining Ring, Internal,.0" x.0", Carbon Steel, SAE Bearing, Transmission Output Shaft S. Retaining Ring, Internal,."... --S. Bearing, Left, Transmission Shift Drum...-0-S. Bearing, Right, Transmission Shift Drum...-0-S 0. Bearing, Input Shaft...--S. Seal, Sensor, Right Side Trap Door S. Bushing, Output, Second Gear... Liberty's Gears Part -0. Bearing, Output Shaft...--S. Seal, Transmission Output Shaft...-0-S. O-ring, (-) S. Washer, Compression Release,." x." x.00", Zinc, Low Carbon Steel Plug, Drain, w/ O-ring, Magnetic, /-0, Zinc, Steel Spring, Gear Shift Shaft, Transmission... Suzuki Part 0-0. Spacer, Return Spring,." x."...suzuki Part Guide, Gear Shift Cam, Drum Stopper... Suzuki Part -0. Guide, Gear Shift Cam, Pawl Stopper... Suzuki Part Shaft, Gear Shift, Short... Suzuki Part 0-00A00. Detent Arm... Liberty's Gears Part -. Detent Arm Spring...-. Shift Fork Shaft, Input... Liberty's Gears Part -0. Screw, Detent Arm Spring O-ring S. Oring S NOTE: Parts indicated as "Liberty's Gears Part" or "Suzuki Part" are not available from S&S, and must be ordered directly from the manufacturer

S&S Billet Pro Stock Engine Assembly # (Complete), # (No Electrics), # (No Electrics)

S&S Billet Pro Stock Engine Assembly # (Complete), # (No Electrics), # (No Electrics) Manual -00 --0 Copyright 0 by S&S Cycle, Inc. All rights reserved. Printed in the U.S.A. S&S Cycle, Inc. 0 Cty Hwy G, PO Box Viola, Wisconsin 66 Phone: 608-67-97 Fax: 608-67-88 Technical Service Phone: