Caution – S&S Cycle Big Twin Engines with 3-1/2 and 3-5/8 Bore Crankcases and Special Application (SA) 4 Bore Crankcases User Manual
Page 11
INSTALL LOWER ROCKER COVERS (All big twin)
Rocker covers must be installed with hardened flat washers and
grade 8 bolts of proper length. Correct hardware is available
from aftermarket suppliers and Harley-Davidson
®
.
Note - Consult S&S
®
shovelhead Cylinder Head instruction sheet
#00-9001 for assembly and installation of shovelhead cylinder
heads and rocker cover assemblies.
Lockwashers should not be used inside engine. Lockwashers
cut metal surfaces and can cause damaging metal particles to
be distributed through engine by circulating oil.
1. All parts must be clean and dry. To install, place lower rocker
cover gaskets on cylinder head with silicone bead facing up.
A small amount of Hylomar
®
or other thin gasket sealant
may be used in corners to hold gasket in place on head. No
other sealant should be used.
2. Place lower rocker cover on gasket and cylinder head and
hold loosely in place with 1/4” bolts and flatwashers. Verify
that cover is positioned so as not to interfere with valve
spring operation (See Picture 26), then tighten bolts to
10-13 ft-lbs as described in Harley-Davidson
®
service
manual. In cases where clearance between cover and spring
is insufficient, bolts may be loosened and cover
repositioned slightly to gain clearance. It is also possible to
take cover off engine and remove small amount of metal
from cover to increase clearance. After clearance
confirmed, install two short 5/16” bolts and washers on left
or drive side of engine and tighten to 15-18 ft-lbs.
Operating engine without sufficient clearance between valve
spring and rocker cover will cause engine damage not
covered under warranty.
3. Clean rocker arms and shafts and dry with compressed air.
Coat rocker shafts, rollers, bushings, valves and pushrod tips,
and ends of rocker arms with assembly lube.
ROCKER ARM/PUSHROD INSTALLATION AND
ADJUSTMENT (big twin)
NOTE - S&S pushrods are designed with emphasis on strength.
Weaker pushrods may flex under load, resulting in loss of power,
increased cranking compression, or detonation.
1. Rotate flywheels in direction of normal engine rotation until
both lifters for front cylinder at lowest position on camshaft.
Front piston will be at or near TDC on compression stroke
when lifters in correct position.
2.
Identify pushrods as explained in Step 6, “Pushrods” section.
Hold pushrod tube for front intake in place and pass correct
pushrod, adjuster end down, through cylinder head and
pushrod tube. Repeat for front exhaust.
NOTE - Some engine builders prefer to install and adjust pushrods
one at a time, beginning with intake.
3. Place front rocker arms in lower rocker cover and install
shafts, confirming that reliefs in shafts align with bolt holes
in rocker covers. Rocker arms must sit squarely on valve tips.
If not, loosen rocker cover bolts and reposition cover slightly
to obtain correct alignment. Do not overlook valve spring-
cover clearance as described previously. With proper rocker-
valve stem alignment and valve spring-rocker cover
clearance confirmed, install two 5/16” bolts and flat washers
in lower cover and tighten to 15-18 ft-lbs.
4. If
HL
2
T kit is used, pushrods must be adjusted according to
Installation Instructions for S&S Hydraulic Lifter Limited
Travel Kit #51-1039.
NOTE - Recommended pushrod adjustment with kit is 3 flats
or 1/2 turn shorter than zero lash with lifters completely
bled down.
Pushrods will be noisy if set at zero lash. If HL
2
T kit not
used, adjust pushrods according to S&S Pushrod Instruction
Sheet #51-1035.
5. Install middle and upper rocker covers and gaskets on
front head. If applicable, install center sections with
umbrella valves towards center off engine. Insure that
small center gasket in lower cover does not become
dislodged. A dab of grease or adhesive may be used to
hold gasket in place. Tighten screws to 10-13 ft-lbs. Install
pushrod cover retainer clips.
6. Rotate flywheels until rear piston reaches TDC on
compression stroke (315 flywheel degrees past front piston
TDC) and both rear lifters are in lowest position on cam.
Repeat procedure for installing pushrods, rockers, and
covers, installing longest remaining pushrod in exhaust.
7. After pushrod adjustment completed per instructions, rotate
flywheels several revolutions in direction of normal flywheel
travel to confirm that engine turns freely.
NOTE - Do not force engine. If resistance encountered, determine
and correct cause before continuing.
Forcing engine against resistance may cause damage not
covered under warranty.
11
Picture 26
CAUTION
CAUTION
CAUTION