S&S Cycle Replacement Cylinder Heads for 1984-1999 Harley-Davidson Evolution Engines and 1986-2003 Sportster Motorcycles - Manual (Page 3)

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INTRODUCTION
S&S ® Super Stock ® cylinder heads are designed to fit all Harley-
Davidson ® Evolution ® big twins and Sportster ® models. These
heads require no additional clearancing when replacing stock
heads on engines installed in stock chassis. All the parts needed
for installation are included. Stock parts not supplied such as
rocker arms, rocker cover assemblies and some mounting
hardware should be reused when reassembling the engine.
NOTE: S&S cylinder heads are designed to work with all
aftermarket roller rocker arm assemblies also.
Special Features of the Major Kit Components:
The shapes of the S&S cylinder head combustion chamber and
piston dome are identically matched to create a high quench,
closed combustion chamber designed to improve mixture
turbulence and flow. For optimum performance it is
recommended that these parts be used together.
The intake and exhaust ports are a cast to shape design that
yields approximately 25% more flow than stock heads.
The special intake manifold included for improved flow has
larger runners, 1.780", to match the larger intake ports on the
heads and a directional vane to help split the incoming mixture
as it passes the valve guide.
The valve train components are designed to improve flow and
work with any present day fuel. Clearances are set for any S&S
camshaft with a lift of up to .630" without modification. If cams
with lift of over .630" lift are to be used, head kits may be
ordered with special high lift, racing spring kits, allowing the use
of cams of up to .660" lift.
KIT CONTENTS:
● One set of S&S Super Stock cylinder head assemblies
complete with valves, valve springs, valve guide seals and
keepers installed.
● One set of S&S pistons complete with rings, wristpins and
wristpin keepers.
● One S&S intake manifold with O-ring seals and mounting
flanges.
● Rocker cover gaskets, cylinder head and base gaskets,
exhaust pipe gaskets and pushrod tube and alignment
dowel O-rings.
● Hardware which includes cylinder head alignment
dowels, exhaust port stud lockwashers and nuts, cylinder
head mounting bracket bolts and washers, and manifold
mounting screws and washers.
● Installation instructions.
NOTE: Other S&S products such as adjustable chrome moly
pushrods, cam, Hydraulic Lifter Limited Travel kit, and Super
carburetor which may enhance the operation of S&S Super
Stock cylinder heads may be purchased separately. In some
instances many of these parts are sold with S&S heads as part of
a stroker or Sidewinder
® big bore kit or one of our popular Hot
Set Up Kit TM .
INSTALLATION STEPS
1. Remove Components and Inspect Parts
2. Check Piston Alignment in Cylinder Bore
3. Piston and Cylinder Fitting
4. Rebalance Flywheels (883 & 1100 Sportster ® models only)
5. Install Pistons, Cylinders and Heads
6. Finish Assemble Top End, Install Carburetor and Replace
Gas Tanks
7. Engine Break-In Procedure
8. Performance Notes
INSTALLATION INSTRUCTIONS
Installation of an S&S Super Stock cylinder head kit is easy and
can be performed by any Harley-Davidson
® repair shop equipped
to do engine overhauls. No special tools other than those used
in normal overhaul repair work are required.
Read instructions thoroughly before starting work. When they
are completely understood proceed with installation.
1. Remove Components and Inspect Parts
Follow procedures outlined in appropriate Harley-Davidson
®
service manual to prepare motorcycle for top end service.
NOTE: Disconnect battery and drain all gasoline from gas tanks
before doing any work.
Gasoline is extremely flammable and explosive under certain
conditions and toxic when breathed. Do not smoke. Perform
installation in a well ventilated area away from open flames
or sparks.
A. Remove gas tanks and all other parts required to
perform top end service.
B. Remove carburetor, rocker covers, pushrods and
pushrod tube assemblies, cylinder heads and cylinders.
Also remove piston rings from piston. Do not remove
pistons.
NOTE: Be careful not to introduce any dirt or other foreign
material into crankcase during disassembly of engine.
Metal filings, dirt and any other foreign contamination in
engine may cause premature wear and/or irreversible
damage to bearings and other internal engine components.
C. Thoroughly clean and inspect all parts that are to be
reused. Any parts that show signs of wear or damage
should be replaced.
WARNING
CAUTION