This Video is brought to you by Lowbrow Customs https://www.lowbrowcustoms.com
Part 3 - Assembly - In this How to video, Todd walks you through the installation on a S&S Cycles Hooligan 1200cc conversion kit with oversized cams on a 2003 Harley-Davidson Sportster 883cc engine. These kits work on 2000-2018 Harley-Davidson Sportsters and can be installed on your motor with in a day spent in the garage. This episode covers from the setting of the rings on the pistons to installing the cylinders & cylinder heads and prepping the rocker boxes for install.
So, break out the tool box and follow along. See how "There's no big mystery going on in there!" This step by step and does not skip anything, and will help you understand how easy it is to install this kit, beef up your motor and add some real horsepower to it.
If you missed part 1 - the disassembly: https://youtu.be/7DuwSXFSx3o
If you missed part 2 - first steps of assembly: https://youtu.be/DopRVi3qCeM
You can purchase the S&S Cycles Hooligan Here:
Sliver: https://www.lowbrowcustoms.com/products/s-and-s-cycle-hooligan-kit-883cc-to-1200cc-for-2000-2018-harley-davidson-sportster-models-silver
Black: https://www.lowbrowcustoms.com/products/s-and-s-cycle-hooligan-kit-883cc-to-1200cc-for-2000-2018-harley-davidson-sportster-models-wrinkle-black
00:01 - installing locating dowels into the top of the cylinders.
01:46 - Staggering the ring end gaps on the front piston accordingly.
05:00 - Make sure to remove rags out of the crank case from front cylinder.
05:06 - Install the base gasket on the front part of crank case, line up accordingly.
05:26 - Using a ring compressor, lube and compress the rings on the front piston.
06:14 - "Alright, let's give a whirl!" Introduce the cylinder back onto the front studs sliding it over the piston and rings.
06:37 - Take ring compressor off and slide the cylinder down the rest of the way.
07:49 - Be Careful and don't crunch your fingers.
08:14 - Repeat steps and do to install the rear cylinder.
08:23 - Staggered ring end gap overview.
08:51 - Using a ring compressor, lube and compress the rings on the rear piston.
09:24 - Install cylinder over the rear studs sliding it over the piston and rings.
10:14 - Scrape and clean gasket surfaces on cylinder heads
11:07 - Remove exhaust ring from the cylinder head.
11:20 - Remove the top pushrod o-rings from the cylinder head.
12:14 - Bath time! Scrubba dub dub, cylinder heads are going in the tub.
12:51 - Give'm a quick blow job. Ha!
13:13 - Installing the front cylinder head and pushrod tubes.
13:25 - Installing the new exhaust ring and upper push rod o-rings.
14:06 - Installing lower pushrod seals and pushrods onto the motor loosely.
15:58 - Put the MLS head gasket on and then introduce the cylinder head to the engine lining up the MLS head gasket and pushrod tubes.
16:53 - Installing the head bolts.
18:57 - Torque the front cylinder head properly.
22:15 - According to S&S, loosen and torque all over again in same sequence.
24:51 - Tighten the pushrod tubes at the bottom of the front cylinder.
25:35 - Installing the rear cylinder head and pushrod tubes.
26:38 - Torque the rear headbolts, note its a different sequence pattern.
28:37 - According to S&S, loosen and torque all over again in same sequence.
30:34 - Tighten the pushrod tubes at the bottom of the rear cylinder.
31:02 - Rocker box cleaning and preparation.
32:27 - Rocker shaft inspection and overview how to remove and reinstall.
34:28 - Clean up and remove any gaskets from rocker box ring and rocker box top.
36:48 - Need to replace gaskets on top 8 bolts or replace bolts with Colony
37:53 - Installing new breather valve on the intake side of the middle rocker box ring.
37:42 - Make sure to prep both rocker box assembly the same way.
38:24 - To Be Continued....