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by S&S Cycle, Inc. Phone 608-627-2080 • Fax 608-627-1488 Technical ServicePhone: 608-627-TECH (8324) All rights reserved. Printed in the U.S.A. Technical Service Email: sstech@sscycle.com Because every industry has a leader Website: Installation Instructions for S&S Air Cleaner for Stock Tillotson, Bendix, and Keihin Carburetors on all OHV H-D's, 1994-up Buells and All 2000-up Single Runner Fuel Injected Models INTRODUCTION Installing an S&S air cleaner on a stock carburetor is simple and straightforward. Because this modification increases airflow, larger carburetor jets may be required. Additionally, S&S air cleaners for stock carburetors have no provision for the emissions canister purge valve required in some areas. As a result, installing this product may render the motorcycle illegal for street use in California and other areas with similar emissions standards. It is solely the owner’s responsibility to determine the suitability of this product for his use and application. S&S air cleaner kits for stock carburetors are available for Big Twins, Sportsters and 1994-up carbureted Buells. Kit #17-0199 fits 1966-1984 Shovelheads and 1966-1985 XL’s. Kit #17-0105 fits 1994-up carbureted Buells. Kit #17-0108 fits 1984-1989 Big Twins and 1986-1987 Sportsters. Kit #17-0110 fits 1991-up Sportsters and1993-up Big Twins. Kit #17-0101 fits 1999-up Twin Cam models with carburetor or single runner fuel injected models. Kits are not available for 1989-1992 Big Twins,1988-1990 XL’s or any dual runner fuel injected models. WARNINGS Gasoline is highly flammable, explosive under certain conditions, and the fumes toxic when inhaled. Be sure gasoline petcock is “OFF” before beginning installation, provide adequate ventilation, and disconnect battery ground cable to avoid sparks and accidental engagement of electric starter. Improperly mounted carburetor may become detached from motorcycle, resulting in immediate health and fire hazard. CAUTIONS If improperly tightened or loosened by vibration, bolts, screws, etc. located inside air cleaner assembly may fall into engine, causing extensive damage not covered under warranty. S&S recommends applying Loctite 242 or equivalent thread locking compound to threads of all bolts, screws, and nuts located inside air cleaner assembly. Mounting bracket bolt of incorrect length may cause parts damage not covered under warranty. It is the owner’s responsibility to determine if the installation of this air cleaner assembly is in accordance with applicable legal and emissions requirements. Crankcase and cylinder head vents must be open and free of restriction. To meet C.A.R.B. and similar standards if applicable, crankcase pressure must be vented into air cleaner assembly, not directly into atmosphere. Pressure relief passages in crankcase and/or cylinder heads must not be plugged as gasket failure and oil leakage may result. AC B AC B D E E Figure A NOTES Air cleaner assembly must be firmly supported. S&S includes support brackets only with kits for OEM carb or single runner fuel injection. Brackets for other applications are listed in the S&S catalog and may be purchased separately. Parts from different year group installed on motorcycle by previous owners may require different support bracket. Adjustable bracket #16-0471 attaches to center case bolt and lower carb-manifold bolt. It is recommended for 1983-’84 Shovels and works on most other models as well. Kits may contain wire ties or metal clamps for securing vent hoses depending on application. A 36” length of hose is provided for race applications. This hose may be used to route crankcase fumes/oil mist to a ‘catch can’ or similar device as required and approved by race organizer. INSTALLATION KIT# 17-0199 1966-1984 Shovels and 1957-1985 Sportsters (See line drawing on page 6.) 1. Remove existing air cleaner assembly and related hardware, if applicable. Refer to authorized Harley-Davidson Service Manual as needed. 2. Prepare air cleaner backplate. A. 1966-1979 Shovels and 1957-1979 Ironhead Sportsters -Press plugs #50-8313 into holes “D” in backplate. (See Figure A) B. 1980-84 Shovels and 1980-1985 Ironhead Sportsters -Apply Teflon tape or thread lubricant to threads of crankcase breather vent elbow fitting #50-8110 and install in hole “A” in backplate. (See Figure A) 3. Attach mounting bracket to engine. Do not tighten bracket completely at this time. A. 1966-1982 Shovels normally utilize bracket #17-0092, which attaches to bottom of front rocker box and air cleaner backplate. B. Ironhead Sportsters normally utilize bracket #17-0093, which attaches to front intake lifter guide bolt and air cleaner back plate. NOTE-Backplate screws supplied with this kit have thread locking compond on threads. If screw without thread locking compound is used, a thread locking compound such as Loctite 242 must be applied, and screws properly tightened. 5. Align hole in other end of bracket with hole in backplate. Bracket may ...