Edelbrock 1602, 1615 user manual

©2006 Edelbrock Corporation

Brochure #63-1602Page 1 of 6

Catalog #1602, 1615
Rev. 4/06 - RS/mc

PERFORMER™ CYLINDER HEADS

For 1984 & Later Harley-Davidson

®

Evolution®“Big Twin” Engines

Catalog #s 1602 & 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 [e-mail]

. 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 train with cam lifts up to .580" for bolt-on performance. These heads make excellent power increases in the stock RPM range of the Harley­Davidson

®

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" intake and 1.610" exhaust), ductile iron valve seats and guides, 1.460" O.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&S

Cyl. Length S&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

• It is 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.

• 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
Harley-Davidson, Inc., Milwaukee, Wisconsin, USA and are used in this
instruction sheet for reference only.

Edelbrock is a registered trademark of Edelbrock Corp, Torrance, CA, USA.

©2006 Edelbrock Corporation

Brochure #63-1602Page 2 of 6

Catalog #1602, 1615
Rev. 4/06 - RS/mc

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 manufacturer’s "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.

CHECKING VALVE-TO-VALVE CLEARANCE

1. Bolt (4)

2. Seal (4)

3. Upper rocker arm cover

4. Middle rocker arm cover

5. Gasket

6. Gasket

7. Gasket

8. Rocker arm shaft (2)

9. Rocker arm

10. Rocker arm

DISASSEMBLY

11. Bolt and washer (2)

12. Bolt and washer (2)

13. Bolt and washer (3)

14. Bolt and washer (3)

15. Gasket

16. Gasket

17. Lower rocker arm cover

18. Umbrella valve

19. Rocker arm bushing (4)

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. Remove seat.

2. Remove instrument cover (FX/Softail and Dyna Glide models).

3. 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 line 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.

4. Remove upper cylinder head stabilizer from frame and cylinder head
bracket. Do not loosen stabilizer jam nuts.

5. On FXR model remove ignition switch.

6. Remove spark plugs.

7. On FLT models remove lower attaching bolts from right side
footboard.

8. Remove exhaust system.

9. Remove air cleaner cover, filter element and back plate.

10. Remove fuel and V.O.E.S. (Vacuum Operated Electric Switch) hoses
from carburetor.

11. Remove carburetor.

12. Remove intake manifold flange screws and remove intake manifold.

13. 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.

14. Remove bolt from outer end of front stabilizer.

15. Remove both front engine mount bolts and remove front engine
mounting plate with stabilizers.

16. Use the jack to raise and lower engine as needed for clearance.

Figure 1 - Rocker Arm Cover Assembly.

©2006 Edelbrock Corporation

Brochure #63-1602Page 3 of 6

Catalog #1602, 1615
Rev. 4/06 - RS/mc

REMOVE ROCKER ARM COVERS

1. Remove bolts (1) and seals (2)

(See Figure 1)

. Use a shortened

3/16" allen wrench.

2. Remove top (3) and middle (4) sections of rocker box. Remove
gaskets (5, 6, and 7) and discard.

3. Rotate the engine so both valves are closed on the head being
removed.

4. 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.

5. Remove the push rods (1) and mark their location and orientation,
top and bottom

(See Figure 2)

.

6. Remove spring cap retainers (2) on push rod covers and remove
push rod covers and associated parts (3 through 11)

(See Figures

2 & 3)

.

CAUTION

All valve train components must be reinstalled in their
original positions. Remove Spring Cap Retainers.

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

Figure 3 - Removing Spring Cap Retainers

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.

1. Head bolt, long (2)

2. Head bolt, short (2)

3. Cylinder head gasket

4. Inner valve spring (2)

5. Outer valve spring (2)

6. Valve keeper (4)

7. Upper collar (2)

8. Lower collar (2)

9. Valve (1) intake, (1) exhaust

10. Valve stem seal (2)

11. Cylinder stud (4)

12. Cylinder base gasket

13. O-ring and insert (2)

14. Valve guide (2)

15. Valve seat (2)

16. Cylinder head (2)

17. Cylinder (2)

18. Piston

Figure 4 - Cylinder Head and Cylinder

©2006 Edelbrock Corporation

Brochure #63-1602Page 4 of 6

Catalog #1602, 1615
Rev. 4/06 - RS/mc

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
grade 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.

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 re­harden during storage. Failure to anneal before
installation may lead to head gasket failure.

INSTALLATION PROCEDURE

Figure 5 - Measuring Cylinder Head Gasket

Figure 7 - Cylinder O-Rings and Inserts

Figure 6 - Cleaning Gasket Surfaces

Figure 8 - Cylinder Head Bolt Torque Sequence

1

Front cylinder

2

2

Rear cylinder

1

3

4

4

3

©2006 Edelbrock Corporation

Brochure #63-1602Page 5 of 6

Catalog #1602, 1615
Rev. 4/06 - RS/mc

PUSH ROD INSTALLATION

NOTE: There is one length push rod for each of four

locations (See 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.

3. 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 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.

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./lbs.

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./lbs. 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.

Figure 9 - Tightening 1986-1995 Head Bolts

PUSH ROD POSITION COLOR CODE

Rear Exhaust Purple

Rear Intake Blue

Front Intake Yellow

Front Exhaust Green

Figure 10 - Push Rod Color Code & Position

1. Rotate the engine so that both lifters of the cylinder being serviced
are on the base circle (lowest position) of the camshaft.

2. 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.

3. 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).

4. 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./lbs.

©2006 Edelbrock Corporation

Brochure #63-1602Page 6 of 6

Catalog #1602, 1615
Rev. 4/06 - RS/mc

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 10­13 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.

6. Install the carburetor, V.O.E.S. and ignition components.

7. Reassemble all components removed during disassembly, connect
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.

Edelbrock Corporation • 2700 California St. • Torrance, CA 90503

Tech-Line: 1-800-416-8628 • E-Mail: [e-mail]

Figure 11 - Rocker Arm Shaft Bolt Notches

REPLACEMENT ITEMS

The following replacement items are available separately:

Exhaust Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .#1643

Intake Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .#1644

Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .#1645

Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .#1646

Exhaust Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .#1647

Intake Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .#1648