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S&S® Cycle, Inc ® Instruction 106-3353 . 7-31-08 S&S Cycle, Inc 235 Causeway Blvd. Copyright © 2008 La Crosse, Wisconsin 54603 by S&S® Cycle, Inc. Phone: 608-627-1497 • Fax: 608-627-1488 Technical Service Phone: 608-627-TECH (8324) All rights reserved. Technical Service Email: [email protected] Printed in the U.S.A. Website: www.sscycle.com Because every industry has a leader Emission-Related Installation Instructions for S&S® 49-State Certified X-Wedge™ Engines DISCLAIMER: IMPORTANT NOTICE: S&S parts are designed for high performance, off road, racing applications Statements in this instruction sheet preceded by the following words are of and are intended for the very experienced rider only. The installation of S&S special significance. parts may void or adversely effect your factory warranty. In addition such installation and use may violate certain federal, state, and local laws, rules WARNING and ordinances as well as other laws when used on motor vehicles used on Means there is the possibility of injury to yourself or others. public highways, especially in states where pollution laws may apply. Always check federal, state, and local laws before modifying your motorcycle. It is CAUTION the sole and exclusive responsibility of the user to determine the suitability Means there is the possibility of damage to the part or motorcycle. 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 NOTE therewith. Other information of particular importance has been placed in italic type. The words Harley®, Harley-Davidson®, H-D®, Sportster®, Evolution®, and all S&S recommends you take special notice of these items. H-D part numbers and model designations are used in reference only. S&S Cycle is not associated with Harley-Davidson, Inc. WARRANTY: SAFE INSTALLATION AND OPERATION RULES: All S&S parts are guaranteed to the original purchaser to be free of Before installing your new S&S part it is your responsibility to read and follow manufacturing defects in materials and workmanship for a period of twelve the installation and maintenance procedures in these instructions and follow (12) months from the date of purchase. Merchandise that fails to conform to the basic rules below for your personal safety. these conditions will be repaired or replaced at S&S’s option if the parts are returned to us by the purchaser within the 12 month warranty period or within • Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed. Do not smoke. Perform installation in a well 10 days thereafter. ventilated area away from open flames or sparks. In the event warranty service is required, the original purchaser must call or • If motorcycle has been running, wait until engine and exhaust pipes write S&S immediately with the problem. Some problems can be rectified by have cooled down to avoid getting burned before performing any a telephone call and need no further course of action. installation steps. A part that is suspect of being defective must not be replaced by a dealer • Before performing any installation steps disconnect battery to eliminate without prior authorization from S&S. If it is deemed necessary for S&S to potential sparks and inadvertent engagement of starter while working make an evaluation to determine whether the part was defective, a return on electrical components. authorization number must be obtained from S&S. The parts must be packaged • Read instructions thoroughly and carefully so all procedures are properly so as to not cause further damage and be returned prepaid to S&S completely understood before performing any installation steps. with a copy of the original invoice of purchase and a detailed letter outlining Contact S&S with any questions you may have if any steps are unclear or the nature of the problem, how the part was used and the circumstances at any abnormalities occur during installation or operation of motorcycle the time of failure. If after an evaluation has been made by S&S and the part with an S&S part on it. was found to be defective, repair, replacement or refund will be granted. • Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be ADDITIONAL WARRANTY PROVISIONS: removed to facilitate installation. (1) S&S shall have no obligation in the event an S&S part is modified by any Use good judgment when performing installation and operating • other person or organization. motorcycle. Good judgment begins with a clear head. Don’t let (2) S&S shall have no obligation if an S&S part becomes defective in whole or in alcohol, drugs or fatigue impair your judgment. Start installation part as a result of improper installation, improper maintenance, improper use, when you are fresh. abnormal operation, or any other misuse or mistreatment of the S&S part. Be sure all federal, state and local laws are obeyed with the installation. • (3) S&S shall not be liable for any consequential or incidental damages • For optimum performance and safety and to minimize potential damage to carb or other components, use all mounting hardware that is resulting from the failure of an S&S part, the breach of any warranties, the provided and follow all installation instructions. failure to deliver, delay in delivery, delivery in non-conforming condition, or for any other breach of contract or duty between S&S and a customer. • Motorcycle exhaust fumes are toxic and poisonous and must not be breathed. Run motorcycle in a well ventilated area where fumes can (4) S&S parts are designed exclusively for use in Harley-Davidson® and other dissipate. American v-twin motorcycles. S&S shall have no warranty or liability obligation if an S&S part is used in any other application. Installation Overview This S&S® 49-State Certified X-Wedge™ Engine is approved for use in assembled highway motorcycles and conforms to USEPA exhaust emissions regulations applicable to the model year in which it was produced. A small volume manufacturer, kit manufacturer or assembler using this engine does not have to apply for a separate emission certificate with the EPA. A vehicle built according to the given requirements is considered a certified vehicle by the EPA. Included in these instructions are requirements the manufacturer of the motorcycle, kit manufacturer, or assembler is required to follow in order to insure the engine meets exhaust and permeation emission standards. Prior to starting installation of this engine these requirements should be read and understood. Failure to meet the requirements outlined in the instructions is a violation of the Clean Air Act and will make the manufacturer of the motorcycle, kit manufacturer, or assembler subject to penalties and fines. Installation REQuirements No changes may be made to the engine that could reasonably be expected to increase its exhaust emissions for any pollutant. This includes changes to the fuel metering system; changes to the ignition system; changes to the camshaft; and modifying, recalibrating, removing, or failing to properly install any other specified component. The following requirements for gear ratio, weight, exhaust, label, and permeation must also be met when installing this engine. Gear Ratio This engine may only be installed in a highway motorcycle or kit with an N/V ratio less than or equal to 44.7. The N/V ratio is the engine RPM divided by the vehicle speed in miles per hour in high gear. This determines the maximum RPM of the engine for a given vehicle speed in high gear. To find the N/V ratio for your application divide the engine speed by the vehicle speed while traveling in high gear. The following table gives maximum RPM’s for the given speed and N/V ratio. N/V Ratio Speed (mph) Maximum RPM 44.7 55 2458 44.7 60 2682 44.7 65 2905 44.7 70 3129 The N/V ratio can also be calculated based on the number of teeth on primary and secondary sprockets, transmission gear ratio in high gear, and rear tire loaded radius. To calculate the N/V ratio first find the final drive ratio using the following formula: Primary drive ratio = clutch sprocket teeth/engine sprocket teeth Secondary ratio = rear sprocket teeth/front sprocket teeth Transmission ratio = internal gear ratio in top gear Final drive ratio = (primary ratio) x (secondary ratio) x (transmission ratio) Next the rear tire circumference must be calculated based on the loaded radius of the tire: Measure the loaded radius (LR) of the rear wheel by measuring the distance from the ground to the center of the rear axle in inches. This can be performed with the motorcycle positioned upright on level ground and the rider sitting in a normal riding position. It may be helpful to average the measurements on both the left and right sides to ensure an accurate number. Circumference= (6.2832) x (LR) Next calculate the N/V ratio using the following formula: N/V ratio= (Final drive ratio x 1056)/(Circumference) Weight This engine may only be installed in a highway motorcycle with a final curb mass that is equal to 1,058 lbs or less. Exhaust The exhaust system used on the motorcycle must meet backpressure specifications. The total (stagnation) pressure must be in the range of 2.7 to 6.8 inches of water. This measurement is taken 5.5” from the inlet of the front exhaust head pipe with the engine operating at 2000 RPM ±100 RPM in neutral. The total stagnation pressure can be measured using a pitot tube facing into the exhaust stream and a manometer that reads in inches of water.
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