S&S Cycle Billet Rocker Cover Assemblies for Harley-Davidson evolution engines User Manual

Page 3

INTRODUCTION
S&S® billet rocker covers are two-piece assemblies designed to fit most Harley-Davidson® Evolution® engines that accept stock style rocker covers.

NOTE: At present, S&S billet rocker covers are not recommended for Buell® motorcycles because of interference with the front cylinder head-frame mount.
S&S is currently testing a modified mount. Call Technical Services at 608-627-1497 for additional information.

S&S rocker covers are machined from billet aluminum, then polished and chromed to a show quality finish. O-ring sealing insures reliable, leak-free
operation.

NOTE: Plain, unpolished and unplated versions are available for custom applications. They may be powdercoated or otherwise finished to individual
specifications. S&S plain billet aluminum rocker covers must be inspected and burrs/sharp edges carefully removed by customer before installation.

S&S rocker covers are designed to accept valve springs up to 1.660" O.D. with no modification. In most instances, they will accept valve lifts to .710"
(S&S street head or OEM) or .810" (S&S Special Application cylinder head) without modification.

NOTE: It remains engine builder’s responsibility to check operating clearances. Clearances should be checked between valve spring/collar and rocker cover
base as well as between rocker arm and top rocker cover. S&S recommends minimum of .060". Cylinder head must also be “set up” for correct lift.

Failure to establish correct operating clearances can result in extensive engine damage not covered under the warranty.

S&S rocker covers are compatible with both crankcase and cylinder head vent arrangements. Provided umbrella valves 90-4030 must be installed for
correct cylinder head vent operation, or combination crankcase-head venting as utilized in S&S big twin engines.
S&S rocker covers can usually be installed with engine in frame. Taller engines such as S&S 98" and 103" may require removal of engine for installation
and removal of rocker covers.

INSTALLATION
1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas

tanks, and all parts required to access original rocker covers. Remove top and center sections of rocker housings. Refer to authorized Harley-
Davidson® Service Manual as necessary.

Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming
engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding.

Gasoline is toxic if fumes are inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and
perform installation in a well ventilated area away from sparks and open flame.
2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest

point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson® Service Manual as necessary, remove rocker
assemblies, pushrods and lower rocker cover from front cylinder head.

NOTE: Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake,
and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris.

Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty.

CAUTION

WARNING