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 User Manual

Page 3

4. Remove existing components

A. 1999-up big twin only:

1. Remove breather and baffle assembly. See Picture 2.
2. Gradually loosen rocker arm support bolts in sequence shown.

See Figure 1, above. Loosen rocker support bolts in 1⁄4-turn
increments for first 3⁄4 turn, then remove.

3. Remove rocker arms/support assembly from cylinder head.

Loosen bolts in 1⁄4-turn increments for first 3⁄4 turn, then remove
bolts and remove rocker housing from cylinder head.

B. 1984-'99 big twin:

1. Gradually loosen and remove five rocker housing screws. Loosen

screws in 1⁄4-turn increments for first 3⁄4 turn, then remove.

2. Remove rocker housing with rocker arms and shafts from cylinder

head.

5. Taking care to keep parts in same order as removed, remove rocker

shafts and arms from support (1999-up engines) or lower rocker
housing (1984-'99 engines). Mark components according to location:
“front intake,” etc., so they can be returned to their original locations.

6. Remove oil and any remaining gasket material from cylinder head

gasket surface. Clean gasket surface with lacquer thinner.

CAUTION

Lacquer thinner is extremely flammable, potentially explosive, and
the fumes toxic when inhaled. Read manufacturer’s cautions on
container and use only in a well-ventilated area away from sparks
and open flame.

7. Place lower rocker housing gasket(s) supplied in kit on cylinder head.

A. 1999-up engines: One gasket required. Gasket must be positioned

to cover breather channel in cylinder head. If necessary, use a
small amount of gasket adhesive or sealant to hold gasket in place.
Otherwise, gasket should be installed dry.

NOTE: It is possible to install gasket incorrectly. Before proceeding, confirm
that gasket is placed correctly and covers breather channel. See Pictures 3
& 4, below.

B. 1984-'99 engines: Two gaskets required. Factory-applied silicone

beads should face up. If necessary, use a small amount of gasket
adhesive or sealant to hold gaskets in place. Otherwise, gaskets
should be installed dry.

8. Prepare lower rocker housing screws according to instructions on

Loctite® container and apply thin film of Loctite® to threads.

A. 1999-up engines: Lower rocker housing screws are 5/16-18 x 3⁄4 (6 ea.)

(Screws for remaining holes in bottom of rocker housing base for Twin
Cam 88® engine will be installed in Step 14-A.)

B. 1984-'99 engines: Lower rocker housing screws are 1⁄4-20 x 3⁄4 (4 ea.)

(Screw for center right bolt hole in Evolution® engine will be installed
in Step 14-B.)

9. Install rocker housing on cylinder head.

A. 1999-up engines:

1. Place rocker housing screws in front and rear left (drive side) holes

of rocker housing and place housing on cylinder head. Tighten
screws two turns to hold rocker housing and gasket in place.

2. Install four remaining rocker housing screws. Gradually tighten

six screws to 15-18 ft-lbs. using sequence illustrated in Figure 2,
next page.

3. Measure clearance between rocker housing and valve spring.

See Picture 5, next page. Minimum is .025". If necessary, loosen
screws and reposition housing to increase clearance, then
retighten screws.

4. Place new o-ring in center of rocker housing.

B. 1984-'99 engines:

1. Place two rocker housing screws in left (drive side) holes of rocker

housing and place housing on cylinder head.

Picture 3, CORRECT

Picture 4, INCORRECT

Figure 1

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driveside

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