Get XiED(tm)! Performance Parts

Don't let the Harley heat monster ruin your riding.
Reduce  Engine Surging
Improve Throttle Response
Reduce Engine Ping


HD 2007/2008 Engines

High Heat on 2007/08 HD engines

HD 2007/08 Performance Recommendations

Cool your exhaust temperature with the Wide Band O2 upgrade for 2007/08 HD

Harley Camshaft Specification Tables

HD Twin Cam Engine Builds
TC 128 HP 95 CID
TC 100HP Street Engine

The basics of Fuel Injection explained

Rammer Performance Air Cleaners
TC Performance Heads 100+HP

Pro Tuning on a Shade Tree Budget


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

bulletMake sure the cylinder stud holes are clean and dry.
bulletAlways use new head gaskets. Do not re-use head gaskets under any circumstances.
bulletPlace new O-rings on the inserts and position the head gasket on the inserts.
bulletBe 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.
bulletClean and lubricate the cylinder head bolt threads. Dip the head bolt threads in engine oil and wipe off any excess.
bulletCarefully place each cylinder head in its proper position, making sure not to move the head gasket from the proper position.
bulletInstall the cylinder head bolts finger tight
bulletTighten the cylinder head bolt using either the factory method or torque wrench method in the proper tightening sequence.
bulletIf 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.


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


Table of Contents
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Modification, Installation, Maintenance and Tuning Index  will help you find most of the information you want on one page.

How to get Professional Tuning Results at home
Testing the Innovate Motorsport LM-1 portable air fuel meter

Profession Tuning on a Shade Tree Budget

Veypor VR2 Data Logger and Instrument Panel
Video Installation and Demo
Purchase VR2

Engine Performance
How to Build a
TC96 2007 Engines
TC88 70HP Stage1  
TC95 128HP Stage 3
TC95 100HP Street
TC96 2007 Stage 1/2
EVO 64 HP Stage 1
EVO 74 HP Stage 2
EVO 82 HP Stage 3
EVO 95 HP Stage 3
883 to 1200 Upgrade
Shovelhead Modifications

New EFI for EVO and TC

Performance Gallery
Horsepower Gallery
Evolution 80
Twin Cam 88/95
Evolution Unlimited
Sportster Unlimited
Drag Strip Gallery
Land Speed Racing Gallery
CV Carburetor
Modifying the CV carb
Tuning a CV carb
Selecting a cam
Install a TC 88/95 cam
Install a Big Twin cam
Install Sportster cams

Camshaft Specifications
Twin Cam

Exhaust Systems
EVO Exhaust Testing
TC Exhaust Testing
Khrome Werks AR100 test
Making Drag Pipes Work

Shop Manual
Carburetor Troubleshooting
Finding Manifold Leaks
Cylinder Heads
Pistons and Cylinders
Belt Drive
Shop Manual Appendix
$20 Bike Lift
Plug Wires
Spark Plugs
Engine Tuning
Nitrous Oxide
Motor Oil
Stutter Box
General Information
WEB Links
Buy Books and Manuals
Performance Calculations
Estimate Horsepower
Estimate 1/4 Mile Time
Estimate Top Speed

Engine Displacement
Exhaust Length
Gear Ratios
Air Density

The Nightrider Diaries
The ramblings of a genius a, a madman and something in between.

Where is Sifton Cams?

Autocom Active-7 tested

Harley-Davidson EFI
-EFI basics explained
-EFI modifications explained

183 HP, 2 carbs, 2680cc

Copyright 1997-2006  Stephen Mullen, Oldsmar, FL -+-