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.