Cylinder Head Installation

Installing Cylinder Heads
Cylinder Head bolt Torque Values

Technical information on cylinder head installation for Evolution Big Twin and Sportster Harley-Davidson motorcycles.

Cylinder Head Installation

	Make sure the cylinder stud holes are clean and dry.
	Always use new head gaskets. Do not re-use head gaskets under any circumstances.
	Place new O-rings on the inserts and position the head gasket on the inserts.
	Be sure to clean and lubricate the cylinder head bolts before tightening them to the correct torque. Any dirt or grime on the bolts can cause additional friction, causing the torque wrench readings to be incorrect. Thoroughly clean the threads on the cylinder studs.
	Clean and lubricate the cylinder head bolt threads. Dip the head bolt threads in engine oil and wipe off any excess.
	Carefully place each cylinder head in its proper position, making sure not to move the head gasket from the proper position.
	Install the cylinder head bolts finger tight
	Tighten the cylinder head bolt using either the factory method or torque wrench method in the proper tightening sequence.
	If you reuse the OEM pushrods, make sure you place them in the proper order based on color codes.

We recommend the use of James Gaskets in your Harley-Davidson engine.

Warning

Install new O-rings over the cylinder dowels before installing the new head gasket. Installation of the O-ring first will ensure proper alignment of the head gasket.

The procedure for tightening the head bolts is extremely critical. Proper installation is required to prevent head gasket leaks, cylinder head stud failure, cylinder distortion or head distortion.

Head Bolt Installation
Factory Method

For each cylinder head, start with head bolt numbered one. In increasing number sequence (1-2-3-4), tighten the head bolt in three stages.

1. Tighten each bolt to 7-9 foot pounds of torque.

2, Tighten each bolt to 12-14 foot pounds of torque.

3. Mark each head bolt and head with aligning marks. Tighten each bolt 1/4 turn (90 degrees).

The factory method for installing cylinder head bolts is the same for all Evolution Big Twin and Sportster engines.

Head Bolt Installation
Torque Wrench Method

For each cylinder head, start with head bolt numbered one. In increasing number sequence (1-2-3-4), tighten the head bolt in four stages.

1. Tighten each bolt to 7-9 foot pounds of torque.

2. Tighten each bolt to 12-15 foot pounds of torque.

3, Tighten each bolt to 22-25 foot pounds of torque.

4, Tighten each bolt to 38-42 foot pounds of torque.

The torque wrench method of cylinder head bolt installation is used by James Gaskets and S&S

headbolt.GIF (1346 bytes)

Pushrod Color Codes

Front Exhaust is Green

Front Intake is Yellow

Rear Intake is Blue

Rear Exhaust is Purple