S&S Cycle Replacement Cylinder Heads for 1984-1999 Harley-Davidson Evolution Engines and 1986-2003 Sportster Motorcycles - Manual (Page 7)

M. Bolt heads on cylinders. Clean threads of head bolts and
cylinder studs. Place one or two drops of oil on threads
of each head bolt just prior to final assembly to reduce
friction and insure accurate torque readings. Tighten
bolts in stages using crossing pattern. If using S&S
® or
stock crankcases, follow the the torque and sequence
chart. See Figure 4. If using other aftermarket
crankcases, contact the manufacturer for recommended
head bolt torque specifications.
NOTE: Light coating of oil on head bolt threads minimizes friction
so torque values are not distorted. It cannot be emphasized
enough how important it is to do these steps carefully.
Maintaining a good head gasket seal depends on it.
Improper torquing sequence and head bolt torque values may
cause head gasket failure. Excessive torque values may cause
studs to pull out of crankcase.
6. Finish Assemble Top End, Install Carburetor and Replace
Gas Tanks
Follow Harley-Davidson
® factory procedures outlined in
Harley-Davidson ® service manual to assemble rocker cover
components and other parts that were removed for top end
service.
A. Install rocker arm bases per Harley-Davidson ® specs.
B. Assemble rocker arms, pushrods and pushrod tube
assemblies and adjust pushrods.
C. Install rocker covers using gaskets provided.
D. Install intake manifold, mounting flanges and O-ring
seals provided. Be sure O-rings and flanges are
assembled in correct sequence. See Figure 5.
Use
flange marked "F" on front head and flange marked
"R" on rear. Slotted end of mounting flange goes
toward lower manifold mounting hole. Flat washer
provided is used on slotted end of flange. Do not
tighten mounting flange screws.
NOTE: Special S&S manifold must be used with S&S heads
because intake port diameters of S&S heads are larger than
stock. Special S&S manifold requires O-ring seals which also
have larger than stock diameter to fit O.D. of manifold runners.
These O-rings, S&S part 16-0235, are included and cannot be
used in stock applications.
E. Bolt carburetor and air cleaner assembly in place using
carburetor instructions supplied from manufacturer.
NOTE: S&S cylinder heads are machined for use on all big twin
engines. Heads are drilled and tapped to accept
1 ⁄
2
"-13 air cleaner
mounting bolts used on 1992 big twin heads or 1 ⁄
2
"-13 threaded
cylinder head vent fittings used on 1991 and later Sportster ®
models and 1993-up big twins. For installation on 1984 to '91 big
twins and 1986 to '90 Sportster
® models, screw thread reducing
inserts, part 90-4026, in carburetor backplate mounting holes in
cylinder heads. Surface of insert should be just slightly below
machined surface of head so backplate rests against head and
not insert. See Picture 2. Insert (threadsert) will reduce hole to
5 ⁄
16
"-18 threads to accept stock 1984 to '91 air cleaner mounting
bolts. Threadserts may be supplied with or without a thread
locking compound already applied to threads. Loctite or
equivalent thread locking compound should be applied sparingly
to threads of those not pre-coated during installation.
Threadserts with preapplied thread locking compound should be
installed in desired position and left in place. IMPORTANT -
Screwing threadsert in hole activates compound and locks it in
position making it difficult to change after compound has set up.
1 2
4 3
Rear Head
2 1
3 4
Front Head
Top View
Driveside
Camside
Figure 4
S&S
®
Crankcases Stock Crankcases
Stage 1 8 ft-lbs. 7-9 ft-lb
Stage 2 18 ft-lbs. 12-14 ft-lbs.
Stage 3 Turn Additional 90° Turn additional 90°
CAUTION
Figure 5
Flange
O-ring Manifold
Screw
Washer
Picture 2
7