performer rpm twin cam®cnc-machined

performer rpm twin cam®cnc-machined
PERFORMER RPM TWIN CAM® CNC-MACHINED CYLINDER HEADS
FOR FUEL-INJECTED & CARBURETED TWIN CAM® ENGINES
Catalog #1694, #1697 (88cc)
Catalog #3020, #3024, #3049, #3080, 3187, 3188 (72cc)
INSTALLATION INSTRUCTIONS
PLEASE study these instructions carefully before beginning this installation. If you have any questions or problems, do not hesitate to call our
Technical Hotline at: 1-800-416-8628, or e-mail us at [email protected]
•
DESCRIPTION: Performer RPM Twin Cam CNC-ported aluminum heads are the ultimate heads for high performance power in 88-inch and larger
Twin Cam 88 engines. They provide superior flow for maximum horsepower and torque. These heads are completely CNC-ported in all critical
areas…combustion chamber, intake port and exhaust port. The patented design of Edelbrock cylinder heads (U.S. Patent #5,671,709 and
#5,598,820), along with this CNC-porting, work together to provide more efficient combustion and awesome horsepower. Performer RPM Twin
Cam CNC-ported heads come with high-grade, stainless steel, swirl-polished valves (1.940" intake and 1.625" exhaust); ductile iron seats and
guides, 1.460" O.D. valve springs, teflon valve stem seals, titanium retainers, locks, and a three-angle valve job. They accept up to .650" max
valve lift. They are cast out of 356 aluminum and heat treated to T-6 specs. Performer RPM Twin Cam CNC-ported heads have a 72cc combustion
chamber. This chamber size will produce a 9.5:1 compression ratio with 88 cid and 10.25:1 compression ratio with a 95 cid with flat top piston.
Matching Edelbrock/JE forged pistons are recommended for higher performance applications.
•
These heads 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 because of 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. When used with the listed engine sizes and head gasket
thickness recommended (.045"), nominal compression is raised to 9.5:1 on the stock bore 88 cid engine and 10.25:1 on “big-bore” 95 cid engine.
The “D” shaped exhaust port provides a larger area for increased flow. It was designed to create a mismatch between the exhaust pipe and the
exit which reduces power robbing exhaust gas reversion.
INTAKE MANIFOLD APPLICATION CHART - PERFORMER RPM TWIN CAM HEADS
Cyl.
Length
Stock Using 72cc Heads
Stock Using 88cc Heads
Flange
Mount
#3120
#1780
Carbureted Applications
Spigot
S & S “G”,
Mount
48mm Mikuni
#3121
#3122
#1781
#1782
S & S “D”
#3128
#1783
45mm Mikuni,
44mm CV
#3123
#1784
Electronic Fuel Injection Applications
NOTE: All Edelbrock 95” Twin Cam ® Electronic Fuel Injection Power Packages Use Intake Manifold #1768
•
1.
2.
3.
IMPORTANT NOTES BEFORE BEGINNING INSTALLATION
It is highly recommended that the installation of Performer RPM Twin
Cam cylinder heads be performed by a qualified engine builder with
experience in high performance or racing modifications to HarleyDavidson® engines.
Prior to installation, it is mandatory that valve-to-piston clearances
are checked and corrected to minimum specs, if necessary. These
heads have larger-than-stock valve sizes and will not work with the
valve pockets in stock pistons. The use of aftermarket pistons (such
as Edelbrock/JE pistons) and/or custom machining to your pistons is
required. Actual valve-to-piston clearance should be specified by
your camshaft manufacturer.
Prior to installation, it is mandatory that valve-to-valve clearance is
checked to determine if these heads are compatible with the
camshaft you intend to run. This procedure is outlined on the
following page.
Catalog #1694, 1697, 3020, 3024, 3049, 3080, 3187, 3188
Rev. 3/07 - RS/mc
4.
5.
6.
Page 1 of 5
Due to a higher rocker arm mounting pad dimension, the use of
adjustable pushrods is required. Stock pushrods will not work, even
with mild camshaft profiles.
Check valve spring/retainer-to-rocker box clearance before
installation. It is frequently necessary to machine or grind the rocker
box to achieve the recommended .050" clearance.
If additional milling of the heads is desired, remove approximately
.0065" for each 1cc reduction. This is only an approximate number;
you must stop and measure the chamber size before the final cut to
be sure your rate of removal is correct.
TWIN CAM 88 “B” MOTOR LIMITATIONS
The Twin Cam 88 B motor, used in 2000 and later Softail models,
has a pair of balance shafts that are chain driven from the pinion
shaft. This engine has a design operating limit of 6,000 RPM.
Operating a “B” engine above 6,000 RPM can result in severe
engine damage.
©2007 Edelbrock Corporation
Brochure #63-0289
CHECKING VALVE-TO-VALVE CLEARANCE
1. Before installing heads on engine, remove valve springs, retainers
and locks from one head. Leave the valve seals on to hold the
valves in position during the clearance check.
2. Use a 6" caliper to measure valve tip height from the valve spring
pocket.
3. Find the cam manufacturers "Valve lift at Top Dead Center" specs
and subtract this dimension from the valve tip height you measured
in step 2.
4. Using the calipers to check the new valve tip height, open the valve
by the amount calculated in step 3.
5. Repeat this process for the other valve. Note that intake and
exhaust "Valve lift at Top Dead Center" dimensions are usually
different.
6. With both intake and exhaust valves open to the correct
specifications, use a .060" feeler gauge to check clearance
between the valve heads. If less than .060" clearance exists, you
run the risk of valves hitting during engine operation, voiding any
warranty on these cylinder heads. If there is less than .060"
clearance, select another cam for your engine.
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.
5.
Remove upper cylinder head motor mount or stabilizer assembly
from cylinder heads. Do not loosen stabilizer jam nuts.
6. Remove spark plugs.
7. Remove exhaust system.
8. Remove air cleaner cover, filter element and back plate.
9. Remove fuel hose from carburetor.
10. Loosen throttle cable adjusters, remove carburetor from manifold
and disengage throttle cables from carburetor.
11. Unplug MAP sensor wire harness at intake manifold.
12. Remove intake manifold flange bolts and remove manifold.
REMOVING CYLINDER HEADS
1. See Figure #1. Remove two spring cap retainers on pushrod covers
and collapse upper and lower pushrod covers.
EDELBROCK/JE SPORTSMAN PISTONS
• Edelbrock/JE Sportsman forged aluminum big-bore pistons (3-7/8”)
increase the displacement to 95 cubic inches. These pistons have
a 10.25:1 compression ratio with the Performer RPM Twin Cam
heads. Edelbrock/JE Sportsman forged pistons are the best pistons
to use for high performance applications. Available in big-bore (37/8”), +.005", +.010", and +.020" bore sizes.
ADJUSTABLE PUSHRODS
• Adjustable pushrods must be used with Edelbrock Performer RPM
Twin Cam cylinder heads. We recommend the Harley-Davidson
Screamin' Eagle Quick-Install Pushrod Kit P. N. 17997-99A. This kit
includes special pushrod tube assemblies, which the adjustment
procedure easier.
DISASSEMBLY
Figure #1 Pushrod Tube
Spring Clip
2.
NOTE: BEFORE STARTING DISASSEMBLY
Due to the diversity of models that the Twin Cam 88 engine is used in,
there may be additional steps needed to remove and/or disassemble
parts from the chassis and engine. You should obtain the factory
service manual for the specific model bike that the these heads are to
be installed on and follow the instructions in the “stripping motorcycle
for service” and “top end overhaul” headings in section #3.
Following the pattern shown in Figure #2, loosen and remove the six
rocker cover bolts, (“A through F”).
F
C
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.
B
A
STRIPPING ENGINE
1. Using a suitable motorcycle lift, raise the motorcycle until the rear
wheel is off the ground.
2. Remove seat.
3. Remove instrument cover (Softail and Dyna Glide models).
4. Drain fuel tank. Disconnect fuel line and plug end of fuel line with
5/16" bolt. Use a 1/4" bolt and rubber cap to plug fuel line
crossover. Disconnect any wires and vacuum lines from tank.
Remove fuel tank.
D
E
Figure 2 - Rocker Cover Bolts
Catalog #1694, 1697, 3020, 3024, 3049, 3080, 3187, 3188
Rev. 3/07 - RS/mc
Page 2 of 5
©2007 Edelbrock Corporation
Brochure #63-0289
3.
4.
5.
6.
Remove the rocker cover and gasket.
Rotate the engine so both valves are closed on the head being
removed.
See Figure #3. Remove the two breather cover bolts, (“G & H”),
remove breather assembly and place in a plastic bag.
Following the pattern shown in Figure #3, loosen and remove the four
rocker arm support plate bolts, (“I through L”).
10. Remove the rocker housing and gasket.
CAUTION
Loosen head bolts gradually, in the pattern shown in Figure #5,
to prevent distorting the head, cylinder and crankcase studs.
11. See Figure #5. Loosen each head bolt (“S thru V”) 1/8 turn.
Figure 5 - Head Bolts
Figure 3 - Breather Cover & Rocker Support
7. Remove the rocker arm support plate assembly from the rocker
housing and place in plastic bag.
8. Remove the two pushrods and discard. These must be replaced with
adjustable pushrods. Remove pushrod cover assemblies.
12.
13.
14.
15.
16.
Continue loosening in 1/8 turn increments until bolts are loose.
Remove head bolts.
Remove cylinder head.
Remove cylinder head gasket.
Remove the two o-rings from the cylinder head dowels. Note: bigbore engines (95 cid) do not use these o-rings
17. Repeat steps 1 through 16 for the other head.
CAUTION
The upper cylinder dowel o-ring, H-D, P. N. 11273, is only used on
stock bore 88 cid cylinders. If your motor has been bored to 95 cid, do
not install this o-ring on the upper cylinder dowel. Use gasket kit P. N.
3155 on big-bore 95 cid cylinders.
9.
See Figure #4. Remove the six bolts (“M through R”) holding the
rocker housing to the cylinder head.
Figure 4 - Rocker Housing
Catalog #1694, 1697, 3020, 3024, 3049, 3080, 3187, 3188
Rev. 3/07 - RS/mc
1. Cylinder (2)
2. Cylinder head (2)
3. Valve (1) intake, (1) exhaust
4. Valve seat (2)
5. Valve guide (2)
6. Lower collar (2)
7. Valve stem seal (2)
8. Outer valve spring (2)
9. Inner valve spring (2)
10. Upper collar (2)
11. Valve keeper (4)
12. Cylinder head gasket
13. O-ring and insert (2)*
14. Cylinder base gasket
15. Head bolt, long (2)
16. Head bolt, short (2)
*Only 1 used on Big-Bore,
95 cid cylinders
Figure 6 - Cylinder Head Parts and Cylinder
Page 3 of 5
©2007 Edelbrock Corporation
Brochure #63-0289
HEAD GASKETS
• You must use the correct head gaskets to achieve the correct
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 #3155. 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, P. N.
16787-99, if desired. They vary in thickness, so it is advisable to
measure your gasket before use. Recommended thickness is .045".
CAUTION
Use only original equipment head bolts and studs for your year vehicle
to ensure proper torque and head gasket life.
a.
b.
c.
See Figure 8. With a torque wrench, start at the cylinder head bolt
numbered "1" and tighten to 7-9 ft./lbs. Then tighten "2", "3", and
"4" in order to 7-9 ft./lbs.
Following the torque sequence, tighten each bolt to 12-14 ft./lbs.
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.
CYLINDER HEAD INSTALLATION
CAUTION
See Figure #7. On 88 cid cylinders, 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.
On 95 cid cylinders install the new head gasket directly over the
cylinder dowels.
1
3
Front cylinder
2
4
2
4
Rear cylinder
1
3
Figure 7 - 88 cid Cylinder O-Rings and Inserts
Figure 8 - Cylinder Head Bolt Torque
Sequence
CAUTION
Use only original equipment specification head bolts and other
hardware. All original hardware is hardened grade 8 material, which is
required for proper performance of these parts.
1.
2.
Put a few drops oil on head bolt threads and bottom face of bolt head;
then wipe off any excess. Install the head bolts (15 & 16, Figure 6)
finder tight.
See Figures 8 & 9. 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.
CYLINDER HEAD BOLT TORQUE SEQUENCE
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. Screw the
bolts onto the crankcase studs by hand to be sure there is no friction.
Catalog #1694, 1697, 3020, 3024, 3049, 3080, 3187, 3188
Rev. 3/07 - RS/mc
Figure 9– Tighten Head Bolts
Page 4 of 5
©2007 Edelbrock Corporation
Brochure #63-0289
5.
Install the rocker arm support plate, Figure #3. Tighten the four
bolts, in 1/4 turn increments to 15-18 ft./lbs. following the
alphabetical pattern.
6. Install the breather cover assembly, Figure #3. Tighten the two bolts
to 90-120 in./lbs.
7. Install the rocker cover gasket and cover, Figure #2. Tighten the six
bolts, in 1/4 turn increments to 9-12 ft./lbs. following the
alphabetical pattern.
8. Install the Air-Temperature sensor and reconnect the sensor plug.
9. Install intake manifold per the instructions included with it. Tighten
manifold bolts very carefully, using Locktite #242 non-permanent
thread locker to prevent loosening.
10. Install the carburetor, air filter and exhaust components.
11. Re-assemble all components removed during disassembly, connect
battery cables, and re-fuel gasoline tank.
12. 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.
Figure 10 - Torque head bolts in sequence with a good
quality torque wrench
PUSHROD INSTALLATION
NOTE
Adjustable length pushrods must be used. Follow manufacturer's
recommendations for pushrod installation and adjustment.
1.
2.
REPLACEMENT ITEMS
Rotate the engine so that both lifters of the cylinder being serviced
are on the base circle (lowest position) of the cam.
See Figure 1. Install pushrod covers and associated parts, using new
O-rings. Install pushrods.
NOTE
Be sure to use new O-rings on pushrod tubes to prevent leaks. Also
check carefully to be certain old O-rings were removed from pushrod
tubes and lifter bores.
3.
4.
Install cylinder head/rocker housing gasket, note position of breather
channel and orientate gasket correctly. Place rocker housing in
position.
Install the six bolts and washers that secure the housing. Slowly
snug rocker housing fasteners in small increment (one at a time) in
the alphabetical order, see Figure #4. Tighten the bolts to 10-14
ft./lbs. Install o-ring in groove around breather hole.
Replacement Items
Intake
Exhaust
Seats:
Standard O.D. . . . . . . . #9262. . . . . . . . #9261
+.002" O.D. . . . . . . . . #9269. . . . . . . . #9287
+.003" O.D. . . . . . . . . #9270. . . . . . . . #9288
+.010" O.D. . . . . . . . . #9280. . . . . . . . #9268
Intake
Exhaust
Guides
Standard O.D. . . . . . . . #1628. . . . . . . . #1633
+.001" O.D. . . . . . . . . #1629. . . . . . . . #1634
+.002" O.D. . . . . . . . . #1630. . . . . . . . #1635
+.003" O.D. . . . . . . . . #1631. . . . . . . . #1636
+.030" O.D. . . . . . . . . #1632. . . . . . . . #1637
Exhaust Valve . . . . . . . . . . . . . . . . . . . . #9263
Intake Valve . . . . . . . . . . . . . . . . . . . . . . #9264
Valve Seals - set of 4. . . . . . . . . . . . . . . #1649
Valve spring, retainer & lock kit . . . . . . . #1626
The words Twin Cam, Evolution, Harley and Harley-Davidson are registered trademarks of Harley-Davidson®, Inc., Milwaukee, Wisconsin, USA and are
used in this instruction sheet for reference only.
Catalog #1694, 1697, 3020, 3024, 3049, 3080, 3187, 3188
Rev. 3/07 - RS/mc
Page 5 of 5
©2007 Edelbrock Corporation
Brochure #63-0289
®
Edelbrock Corporation • 2700 California St. • Torrance, CA 90503
Tech Line: 800-416-8628 • E-Mail: [email protected]
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