S&S Cycle Die-Cast Rocker Covers for 1984–99 and 1999–14 Harley-Davidson Big Twin Engines and S&S V-Series and T-Series engines - Manual (Page 2)

Introduction
S&S® die-cast rocker cover kits for Harley-Davidson® Evolution® engines
(1984-'99) and Twin Cam 88®, 96™ and 103™ engines (1999-2014) are
similar, but not identical. Mounting holes are larger in the bases for
1999-2014 engines and in slightly different locations. Because of the
different vent systems and mounting-bolt patterns, different rocker
housing bases and rocker housing base gaskets are required for the two
engines.
All S&S V-Series engines for 1984-’99 models, except 41/8" bore, require
1984-’99 style rocker cover kit. S&S 41/8" bore V-Series engines require
1999-’14 style rocker covers. Make sure you have the correct rocker
cover kit, and follow the appropriate installation procedure.
Removal of existing rocker covers and installation of S&S die-cast covers
is similar for 1984-’99 and 1999-2014 engines. Steps 4, 7, and 9 detail
procedures or components for required for both engine types. Where
applicable, procedures and illustrations are clearly designated for each
engine type. Otherwise, installations for both engines are identical. S&S
recommends that the installer become thoroughly familiar with the Top
End Overhaul Procedure section in an appropriate Harley- Davidson®
service manual and refer to this section as required.
S&S wrench set 53-0040 will prove helpful when installing S&S rocker
covers. As an alternative, conventional Allen wrenches can be shortened
by grinding. Otherwise, the motorcycle frame may interfere with the
tightening of some fasteners. S&S strongly recommends the use of a
torque wrench and Loctite® 242 (included) on all fasteners.
S&S rocker covers accept valve springs up to 1.660" O.D. with no
modification. In most instances, they will accept valve lifts to .710"
without modification. It remains the installer’s responsibility to confirm
all clearances. For your own protection and to prevent damage to your
motorcycle during the installation, thoroughly familiarize yourself with
these instructions before proceeding.
NOTES
• Threads should be cleaned with Loctite® primer or an equivalent before
applying Loctite®. S&S has used lacquer thinner with excellent results.
• The installer must check clearances between the valve spring/top
collar and rocker cover housing as well as between the rocker arm and
top cover. These procedures are described in Steps 10 and 16.
CAUTION
Failure to establish correct clearances can result in extensive engine
damage not covered under warranty.
It is the installer’s responsibility to use Loctite according to
directions printed on the container, and to tighten fasteners to
correct torque values. Failure to install fasteners correctly may
result in the fastener vibrating loose and causing extensive engine
damage not covered under warranty.
WARNING
Gasoline, lacquer thinner, and many solvents are extremely
flammable. Fumes may be explosive and toxic if inhaled. Read and
follow the manufacturers’ instructions if applicable, and use these
materials only in a well ventilated area away from sparks and open
flame.
Installation
1. Prepare for rocker cover installation by washing motorcycle, taking
special care to remove dirt from engine and surrounding area.
Disconnect battery, ground cable. Remove gas tanks and clean
engine and surrounding area with compressed air.
CAUTION
Dirt and other contaminants can cause extensive damage if allowed
to fall into engine.
WARNING
Sparks from motorcycle electrical system can ignite gasoline
fumes, resulting in an explosion. Removing battery eliminates
the possibilities of explosion and injury arising from inadvertent
activation of the electric starter.
High-pressure air is potentially hazardous. Wear eye protection
during use and direct air stream away from face and others nearby.
2. Remove original top rocker cover. Remove pushrod cover retainers
from front cylinder pushrods and collapse pushrod covers.
3. Lift the rear wheel of the motorcycle with a jack. remove sparkplugs,
place motorcycle in fifth gear, and turn wheel to rotate engine and
place intake and exhaust pushrods/lifters for front cylinder at their
lowest point of travel. Front piston will be at TDC on compression
stroke with pushrods/lifters at lowest point. Confirm that both
pushrods can be rotated with light finger pressure. See Picture 1.
CAUTION
Failure to confirm correct pushrod position can result in damage to
rocker arm support plates and other parts.
2
Picture 1
Picture 2