Edelbrock 1602 Automobile Parts User Manual
Contents
1. 1615 Rev 4 06 RS mc Page 2 of 6 Figure 1 Rocker Arm Cover Assembly 1 Bolt 4 11 Bolt and washer 2 2 Seal 4 12 Bolt and washer 2 3 Upper rocker arm cover 13 Bolt and washer 3 4 Middle rocker arm cover 14 Bolt and washer 3 5 Gasket 15 Gasket 6 Gasket 16 Gasket 7 Gasket 17 Lower rocker arm cover 8 Rocker arm shaft 2 18 Umbrella valve 9 Rocker arm 19 Rocker arm bushing 4 10 Rocker arm 2006 Edelbrock Corporation Brochure 63 1602 1 Push rod 2 2 Spring cap retainer 2 3 Upper push rod cover 2 4 Spring cap 2 5 Spring 2 6 Spacer 2 7 O ring 2 8 Lower push rod cover 2 9 O ring 2 10 Spacer 2 11 O ring 2 12 Tappet 2 13 Bolt 4 14 Lifter guide 2 d15 Gasket 2 Figure 2 Pushrod and Cover Assembly REMOVE ROCKER ARM COVERS 1 2 3 Remove bolts 1 and seals 2 See Figure 1 Use a shortened 3 16 allen wrench Remove top 3 and middle 4 sections of rocker box Remove gaskets 5 6 and 7 and discard Rotate the engine so both valves are closed on the head being removed Remove the rocker arm retaining bolts 11 and washers nearest the rocker arm shafts at the push rod end NOTE Remove lower rocker boxes as an assembly then disassemble if necessary Remove the push rods 1 and mark their location and orientation top and bottom See Figure 2 Remove spring cap retainers 2 on push rod cover2. 2 17 Cylinder 2 9 Valve 1 intake 1 exhaust 18 Piston 2006 Edelbrock Corporation Brochure 63 1602 INSTALLATION PROCEDURE HEAD GASKETS You must use the correct head gaskets to achieve a 9 5 1 compression ratio for best power Thicker gaskets will lower compression and power and thinner gaskets will raise compression higher than advisable for use with today s unleaded pump gasoline 1 Use Edelbrock gasket set 1640 for 1984 91 or 1641 for 1992 and later engines This set includes the proper thickness head gaskets 045 and the special intake manifold gaskets required for these cylinder heads 2 You may use standard Harley Davidson head gaskets if desired They vary in thickness so it is advisable to measure your gasket before use See Figure 5 Recommended thickness is 045 CAUTION If you use copper head gaskets be aware that they must be properly annealed prior to installation Even if gaskets were annealed when new copper can re harden during storage Failure to anneal before installation may lead to head gasket failure Figure 5 Measuring Cylinder Head Gasket CYLINDER HEAD INSTALLATION CAUTION Install new O rings over the cylinder dowels before installing the head gasket Install the O rings first to ensure alignment of the head gasket and prevent gasket leaks CAUTION Use only original equipment specification head bolts and other hardware All original hardware is hardened grad
3. 1602 CAUTION Do not turn engine over until push rods spin freely Damage could occur to valves NOTE If the original push rods are being installed be sure you do not turn them end for end from their original position because they have worn into their mating components 4 Install the middle 4 and top 3 rocker arm covers using new gaskets and new fiber seals The fiber seals must be under the steel washers Be sure the middle cover section is spaced evenly on all sides before tightening the cover screws Tighten the screws to 10 13 ft lbs following a crisscross pattern If a torque wrench cannot be used tighten securely by hand 5 Install intake manifold according to the instructions provided with the Edelbrock intake manifold Install the carburetor V 0 E S and ignition components gt 7 Reassemble all components removed during disassembly connect Figure 11 Rocker Arm Shaft Bolt Notches battery cables and re fuel gasoline tank 8 To prevent discoloration when the engine reaches operating temperature carefully wipe off grease fingerprints stains etc from all chrome and polished surfaces with a lint free cloth and alcohol Windex etc before starting engine REPLACEMENT ITEMS The following replacement items are available separately Exhaust Seat 0 cc cece eee eee eee 1643 Intake Seat 0 cece eee eee 1644 Exhaust Valve 00 ccc cece eee eee ee eee 1645 Intake Valve 2
4. Figure 10 Be sure to color match each push rod to its correct valve and cam lobe purple to rear exhaust blue to rear intake yellow to front intake and green to front exhaust PUSH ROD POSITION COLOR CODE Rear Exhaust Purple Rear Intake Blue Front Intake Yellow Front Exhaust Green Figure 10 Push Rod Color Code amp Position Rotate the engine so that both lifters of the cylinder being serviced are on the base circle lowest position of the camshaft Refer to Figure 1 Install push rod covers and associated parts using new O rings Install push rods NOTE Be sure to use new O rings on push rod tubes to prevent leaks Also check carefully to be certain old O rings were removed from push rod tubes and lifter bores Install gaskets 15 and 16 Place lower rocker box assemblies 17 with rocker arms and shafts in position NOTE Rocker arm shafts are notched to accept the rocker arm retaining bolts Align the notches with the bolt holes before installing the bolts See Figure 11 Install bolts and washers 11 and 12 13 and 14 Slowly snug lower rocker box fasteners in small increment one at a time in a cross pattern This will bleed the lifters Check carefully as you go to be certain push rods are still in their proper position in the rocker arm Tighten the 5 16 bolts 11 12 to 15 18 ft lbs and tighten the 1 4 bolts 13 14 to 10 13 ft Ibs 2006 Edelbrock Corporation Brochure 63
5. PERFORMER CYLINDER HEADS For 1984 amp Later Harley Davidson Evolution Big Twin Engines Catalog s 1602 amp 1615 INSTALLATION INSTRUCTIONS PLEASE study these instructions carefully before beginning this installation Most installations can be accomplished with common tools and procedures However you should be familiar with and comfortable working on your vehicle If you do not feel comfortable performing this installation it is recommended to have the installation completed by a qualified mechanic If you have any questions please call our Technical Hotline at 1 800 416 8628 7 00 am 5 00 pm Pacific Standard Time Monday through Friday or e mail us at Edelbrock Edelbrock com If your question is motorcycle carburetor related please call our Edelbrock Motorcycle Carburetor division at 1 877 888 7504 Ext 2 IMPORTANT NOTE Proper installation is the responsibility of the installer Improper installation will void your warranty and may result in poor performance and engine or vehicle damage PLEASE complete and mail your warranty card Be sure to write the model number of this product in the Part space THANK YOU DESCRIPTION The Edelbrock Performer Cylinder Heads are designed for street high performance use and are interchangeable with stock Harley Davidson cylinder heads on the Evolution Big Twin engines Edelbrock Performer heads can be used with unmodified stock pistons and the stock valve
6. RANCE Before installing heads on engine remove valve springs retainers 5 Repeat this process for the other valve Note that intake and and locks from one head Leave the valve seals on to hold the exhaust Valve lift at Top Dead Center dimensions are usually valves in position during the clearance check different Use a 6 caliper to measure valve tip height from the valve spring 6 With both intake and exhaust valves open to the correct pocket specifications use a 060 feeler gauge to check clearance between Find the cam manufacturer s Valve lift at Top Dead Center specs the valve heads If less than 060 clearance exists you run the risk and subtract this dimension from the valve tip height you measured of valves hitting during engine operation voiding any warranty on in step 2 these cylinder heads If there is less than 060 clearance select Using the calipers to check the new valve tip height open the valve another cam for your engine by the amount calculated in step 3 DISASSEMBLY WARNING To avoid accidental start up of vehicle and possible personal injury disconnect the battery cables negative cable first before performing any of the following procedures 1 2 3 11 12 13 14 15 16 Remove seat Remove instrument cover FX Softail and Dyna Glide models Drain fuel tank Disconnect fuel line and plug end of fuel line with 5 16 bolt For split tanks use a 1 4 bolt and rubber cap to plug fuel lin
7. at the cylinder head bolt numbered 1 and tighten to 7 9 ft Ibs Then tighten 2 3 and 4 in order to 7 9 ft Ibs 2 Following the torque sequence tighten each bolt to 15 17 ft lbs 3 Following the torque sequence tighten each bolt to 24 26 ft Ibs CAUTION The cylinder head bolts are not to be checked for tightness after final torquing at reassembly is completed Retightening the bolts to specified torque at regular intervals will place undue stress on bolts and bolt anchoring threads B Cylinder Head Torque Sequence for 1986 95 Models CAUTION Use only original equipment head bolts and studs for your year vehicle to ensure proper torque and head gasket life 1 See Figure 8 With a torque wrench start at the cylinder head bolt numbered 1 and tighten to 7 9 ft Ibs Then tighten 2 3 and 4 in order to 7 9 ft lbs 2 Following the torque sequence tighten each bolt to 12 14 ft lbs 3 See Figure 9 Mark a line on the cylinder head and a corresponding line on the head of the cylinder head bolt as shown in View A Following the same sequence 1 2 3 then 4 turn each bolt one at a time one quarter turn 90 using the marks as a guide When marks are all positioned as in View B the procedure is completed Catalog 1602 1615 Rev 4 06 RS mc Page 5 of 6 Figure 9 Tightening 1986 1995 Head Bolts PUSH ROD INSTALLATION NOTE There is one length push rod for each of four locations See
8. ccc ee eee eee eee 1646 Exhaust Guide 0 0 cece cece eee 1647 Intake Guide 0 cc cece cece eee 1648 Edelbrock Corporation 2700 California St Torrance CA 90503 Tech Line 1 800 416 8628 E Mail Edelbrock Edelbrock com Catalog 1602 1615 Rev 4 06 RS mc Page 6 of 6 2006 Edelbrock Corporation Brochure 63 1602
9. e 8 material which is required for proper performance of these parts 1 Be sure the gasket surfaces and stud holes are clean and dry See Figure 6 Place new O rings 13 on the cylinders and position the head gaskets on the inserts 13 See Figure 7 2 Dip the head bolt threads and bottom face of bolt head in oil then wipe off any excess Install the head bolts 1 and 2 Figure 4 finger tight Catalog 1602 1615 Rev 4 06 RS mc Page 4 of 6 Figure 7 Cylinder O Rings and Inserts Front cylinder 2Q 4O 2Q 4O Rear cylinder 1O 3O Figure 8 Cylinder Head Bolt Torque Sequence 2006 Edelbrock Corporation Brochure 63 1602 Cylinder Head bolt torque sequence See Figure 8 The procedure for tightening the head bolts is extremely critical not only to prevent gasket leaks but to prevent stud failure and heads and cylinders distortion CAUTION Be sure you thoroughly clean and lubricate the cylinder head bolts before tightening to the correct torque Friction because of dirt or grime will cause the torque wrench readings to be incorrect Clean and lubricate the threads with engine oil and screw the bolts onto the crankcase studs by hand to be sure there is no friction A Cylinder Head Torque Sequence for 1984 85 Models CAUTION Use only original equipment head bolts and studs for your year vehicle to ensure proper torque and head gasket life 1 See Figure 8 With a torque wrench start
10. e and opening Disconnect any wires from tank Remove fuel tank WARNING Gasoline is flammable and fumes are explosive To avoid possible personal injury drain gasoline in well ventilated area away from fire or flame Drain gasoline into approved gasoline container only NOTE FX Softail Models An access hole has been provided through the frame to remove the left rear rocker box bolt A rolled up paper tube should be inserted through the hole in the frame and around the bolt head during removal to prevent accidentally dropping the bolt into the frame opening Remove upper cylinder head stabilizer from frame and cylinder head bracket Do not loosen stabilizer jam nuts On FXR model remove ignition switch Remove spark plugs On FLT models remove lower attaching bolts from right side footboard Remove exhaust system Remove air cleaner cover filter element and back plate Remove fuel and V 0 E S Vacuum Operated Electric Switch hoses from carburetor Remove carburetor Remove intake manifold flange screws and remove intake manifold Support engine with small jack and piece of wood then remove large center bolt from front engine mount On some bikes it may be necessary to remove ignition module first Remove bolt from outer end of front stabilizer Remove both front engine mount bolts and remove front engine mounting plate with stabilizers Use the jack to raise and lower engine as needed for clearance Catalog 1602
11. ntake and 1 610 exhaust ductile iron valve seats and guides 1 460 0 D heavy duty valve springs teflon valve stem seals and machined valve spring retainers and locks They are cast out of 356 aluminum and heat treated to T 6 specs INTAKE MANIFOLD APPLICATION CHART Performer Cylinder Heads 3 Piece 3 Piece 3 Piece S amp S Cyl Length S amp S Kit Flange Intake Spigot Intake G Intake stock 80 1671 1670 1669 stock 89 1671 1670 1669 050 93 1676 1677 1683 175 88 3031 3030 3032 015 96 1671 1670 1669 075 98 1674 1675 1684 IMPORTANT NOTES BEFORE BEGINNING INSTALLATION e itis recommended that the installation of Performer cylinder heads be performed by a qualified engine builder with experience in high performance or racing modifications to Harley Davidson engines e if you are using any cam other than stock or Edelbrock Performer Plus cam 1740 it is mandatory that valve to valve clearance is checked to determine if these heads are compatible with the camshaft you intend to run See Page 2 The words Evolution Harley and Harley Davidson are registered trademarks of Edelbrock is a registered trademark of Edelbrock Corp Torrance CA USA Harley Davidson Inc Milwaukee Wisconsin USA and are used in this instruction sheet for reference only Catalog 1602 1615 2006 Edelbrock Corporation Rev 4 06 RS mc Page 1 of 6 Brochure 63 1602 CHECKING VALVE TO VALVE CLEA
12. s and remove push rod covers and associated parts 3 through 11 See Figures 2 amp 3 CAUTION All valve train components must be reinstalled in their original positions Remove Spring Cap Retainers Figure 3 Removing Spring Cap Retainers Catalog 1602 1615 Rev 4 06 RS me Page 3 of 6 7 Remove the remaining fasteners 12 13 and 14 holding the lower rocker arm cover 17 to the cylinder head See Figure 1 8 Remove the lower rocker cover and gaskets 15 and 16 9 See Figure 4 Loosen each head bolt 1 2 1 8 turn following the cross pattern sequence shown in Figure 9 CAUTION Loosen head bolts gradually in a cross pattern to prevent distorting the head cylinder and crankcase studs 10 Continue loosening in 1 8 turn increments until bolts are loose 11 Remove bolts 12 Remove cylinder head and head gasket 13 Repeat steps 1 through 14 for the other head NOTE It may be necessary to raise or lower endgine in frame for clearance Use small jack under engine SSD ig PALS aie A Sa H i Figure 4 Cylinder Head and Cylinder 1 Head bolt long 2 10 Valve stem seal 2 2 Head bolt short 2 11 Cylinder stud 4 3 Cylinder head gasket 12 Cylinder base gasket 4 Inner valve spring 2 13 O ring and insert 2 5 Outer valve spring 2 14 Valve guide 2 6 Valve keeper 4 15 Valve seat 2 7 Upper collar 2 16 Cylinder head 2 8 Lower collar
13. train with cam lifts up to 580 for bolt on performance These heads make excellent power increases in the stock RPM range of the Harley Davidson Big Twin engine idle to 5500 rpm Cam lifts higher than 580 or engine speeds higher than 5500 rpm will require different valve springs and other valve train modifications please consult a qualified performance mechanic These heads will work with bore sizes up to 3 13 16 and feature a rectangular shaped intake port for a noticeable increase in air flow This 125 raised rectangular intake port also helps to increase the velocity of the incoming air for more power Edelbrock intake manifolds must be used with these heads due to the unique port shape see application chart below The dual quench combustion chamber features a revolutionary new design that directs the air fuel mixture into a tumbling and swirling motion for a better mix and more efficient combustion The 72cc combustion chamber increases the compression ratio to 9 5 1 for more power The D shaped exhaust port provides a larger area for increased flow and was designed to create a mis match between the exhaust pipe and the exit which reduces power robbing exhaust reversion Performer heads fit 1984 and later Evolution Big Twin engines They are machined with 1992 and later crankcase breather holes and include block off plugs for use on 1984 1991 engines Performer cylinder heads are assembled with stainless steel valves 1 850 i
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