Edelbrock 1624, 1606, 16061, 16041, 1604 user manual

...

Brochure #63-16041 of 6

Catalog #1604, 1606, 1607, 1624, 16041 & 16061 Rev. 3/07 - RS/mc

PERFORMER RPM™ CNC MACHINED CYLINDER HEADS

For 1984 & Later Harley-Davidson

Evolution®“Big Twin” Engines

Catalog #1604, 1606, 1607, 1624, 16041 & 16061

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.

DESCRIPTION: The Edelbrock Performer RPM™ Cylinder Heads are designed to provide increased performance in the idle to 6000+ RPM range, in

1984 and later, 80-inch and larger, Evo Big Twin engines. They feature a CNC-machined, rectangular intake port to provide a noticeable increase in air flow. The intake port is also raised .125" to help 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 promotes a better mix and more efficient combustion. The CNC-machined, “D” shaped exhaust port provides a larger area for increased flow, and is designed to create a mis-match between the exhaust pipe and the exit to reduce power-robbing exhaust reversion. Performer RPM™ heads #1604, 1606, 1607, 1624, 16041, & 16061 fit 1984 and later Evolution

"Big Twin" engines. Performer RPM™ cylinder heads are assembled with stainless steel valves (1.940" intake and 1.625" 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. The increased valve sizes require the use of aftermarket or modified pistons. In 80-inch Evo engines, we recommend using Edelbrock/JE Sportsman Pistons, which match the uniquely shaped combustion chambers of the Performer RPM cylinder heads. Other engine sizes require modified stock, or other aftermarket pistons.

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 RPM 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 Edelbrock Performer RPM 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.

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

Brochure #63-16042 of 6

Catalog #1604, 1606, 1607, 1624, 16041 & 16061 Rev. 3/07 - 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" dimentions are usually different.

6. With both intake and exhaust valves open to the correct specifications, use a .060" feeler gage 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.

+ 4 hidden pages