S&S Cycle Performance Replacement Cylinder Head Kit for 1984-99 Big Twin Engines and Harley-Davidson Sportster Models - Manual (Page 4)

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.
2. 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 ® service manual guidelines.
B. Assemble rocker arms, pushrods and pushrod tube assemblies and adjust pushrods.
C. Install rocker covers using gaskets provided.
D. Install intake manifold, (using stock manifold, can use an S&S ® ) mounting flanges and O-ring seals. Be sure O-rings and flanges
are assembled in correct sequence. 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.
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 Harley-Davidson ® Evolution ® 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 1. 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.
Installation of threadsert where it protrudes above air cleaner backplate mounting boss surface may damage air cleaner backplate.
F. Reassemble gas tanks and all other parts that were dissembled during preparation for top end service. Be sure there are no
gasoline leaks and that throttle opens and closes smoothly and snaps shut when released.
NOTE: Throttle must not bind and must snap shut to fully closed position when released.
If throttle does not return to fully closed position when released, it may inadvertently stick open possibly causing loss of control
of motorcycle and personal injury to you or others.
4
CAUTION
Picture 1
CAUTION
WARNING