S&S Cycle Cylinder Heads for Harley-Davidson Twin Cam 88 Engines - Manual (Page 3)

Installation Steps
1. Strip Motorcycle, Disassemble, and Inspect Parts
2. Check Clearances and Install S&S ® Cylinder Heads
3. Finish Assembly of Top End, Install Carburetor and Replace
Gas Tanks
4. Engine Break-In Procedure (For installations that include
new pistons.)
5. 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. Strip Motorcycle, Disassemble, and Inspect Parts
Follow Harley-Davidson
® factory procedures outlined in
Harley-Davidson ® service manual for stripping 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, pushrod
tube assemblies, and cylinder heads.
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.
D. If S&S compression releases are to be used, they should
be installed in the new S&S cylinder heads at this time.
Compression releases can be installed with the engine in
the frame, but the procedure is much easier before the
heads are installed. Install compression releases per S&S
instruction sheets #51-1065 (manual) or #51-1109
(electric). If cylinder heads are machined for compression
releases, but compression releases are not going to be
used, #90-4916 threaded plug and #50-7094 washer
must be installed in the compression release hole of each
head and torqued to 30 ft.-lbs. See Picture 1.
2. Check Clearances and Install S&S Cylinder Heads
NOTES -
G Since it is nearly impossible to anticipate every possible
engine combination, it is the engine builder’s responsibility
to check for proper running clearances. S&S considers
checking and establishing all running clearances as standard
engine building practice that must be performed during
engine assembly. Engine failure due to improper clearances
between moving parts is not covered under warranty.
G These instructions are for cylinder head removal and
replacement only. If replacing pistons and/or cylinders, refer
to the OEM or S&S Instructions for those components.
Contact between moving engine components may cause
damage or destruction of the parts involved and produce
abrasive particles which may cause damage or premature
wear to other engine components.
A. While applying pressure to hold cylinders in position,
rotate flywheels so front piston is positioned at top
dead center. Note where piston deck (See Figure 1) is
positioned in relationship to head gasket surface. Piston
deck (flat located just above top compression ring
groove), not dome, must be flush with or slightly below
gasket surface. If piston deck is higher than cylinder at
top dead center, something is wrong and S&S should be
notified.
NOTE - Stock and S&S engines are designed so that at top dead
center, piston deck should be flush with or slightly below head
gasket surface of cylinder. Piston to head clearance is provided by
thickness of head gasket (.045” for S&S engines).
3
WARNING
CAUTION
Picture 1
CAUTION
#90-4916 plug and #50-7094 washer
installed when compression releases are
not used.
Figure 1
Dome (Pop-up)
Deck