How To Install S&S Cycles 1200cc Hooligan kit 883cc Harley-Davidson Sportsters - Part 4 - Assembly

This Video is brought to you by Lowbrow Customs https://www.lowbrowcustoms.com

Part 4 - 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 installation of both rocker boxes and how to properly install your manifold onto your engine.

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:    • How To Install S&S Cycles 1200cc Hool...  
If you missed part 2 - first steps of assembly:    • How To Install S&S Cycles 1200cc Hool...  
If you missed part 3 -    • How To Install S&S Cycles 1200cc Hool...  

You can purchase the S&S Cycles Hooligan Here:

Sliver: https://www.lowbrowcustoms.com/produc...

Black: https://www.lowbrowcustoms.com/produc...

00:01 - Part 4 the finale!
00:29 - Reinstalling the pushrods. What the colors on the pushrods mean?
00:49 - Put the bike in gear and rotate the engine so the pushrods are at their lowest point.
01:33 - New gaskets. Always use new gaskets!
01:52 - Installing the front rocker box. Pay attention to your rocker arms and that your bolts are setting the gasket correctly.
02:59 - Install 3 smaller hex head bolts.
04:06 - Install the smaller 2 allen bolts.
04:25 - Start with the four large bolts tightening them evenly so the rocker box goes down a little at a time.
05:33 - Snug up the other fasteners. 3 hex and 2 allen bolts.
06:35 - Torque the 9 bolts accordingly starting with the 4 large bolts, 3 hex and then 2 allen.
08:04 - Install gaskets onto rocker box, center and the outside ring, they just rest inside the grooves.
08:43 - Install middle rocker box ring, make sure breather valve is on the intake side.
09:00 - Install the gasket on the outer groove of the middle rocker box ring.
09:29 - Installing the top lid of the rocker box.
11:10 - Make sure the top lid, middle ringer and rocker box are even on all sides before tightening the lid down evenly.
14:09 - Alright let's do it again but this time on the rear cylinder and Todd will walk you through every step again. There are a few small things to note with the rear that you didn't have to do with the front.
*Note before starting this process have the pushrods in the rear cylinder and rotate the engine to their lowest point then remove the pushrods -explanation at 16:02.
14:21 - Put on the gasket.
14:25 - Then put the rocker box on only have two large bolts on facing the right side of the bike.
14:47 - Doh!? See what happens when you dont keep an eye on your rocker arms!
15:05 - Install the pushrods in the pushrod tubes one at a time by lifting up the rocker box on each side. Note the colors and where they go.
15:45 - Install the other two larger fasteners on the left side of the rear rocker box.
16:02 - Forgot to mention note above
16:30 - install the 3 hex head and 2 small allen bolts onto rocker and lower the rocker box down evenly.
21:28 - Torque the 9 bolts starting with the 4 larger bolts, then the 3 hex followed by the 2 allen head bolts.
24:43 - Install the 2 gaskets on the rocker box, center and the outside ring making sure they are set in the grooves correctly.
25:08 - Install the middle ring make sure the breather valve is installed on the intake side. This one can be tricky because its such a tight area and little clearance. Note how Todd puts the left corner in first and how it falls into place.
25:34 - Install last gasket on outside grooves of the middle ring.
26:05 - The hardest part Installing the top lid on the rear rocker box. Note again how Todd starts with the right side, lifts up and shifts forward and back ever so slightly to get to the right position.
27:19 - Check alignment of rocker box, middle ring and top lid before tightening the 4 lid bolts completely.
29:49 - And there you have it a complete new S&S Cycles 1200 Hooligan kit install.
30:31 - Install some new Spark Plugs.
32:17 - How to change out gaskets on the manifold.
34:22 - Installing the manifold correctly onto the engine. What to do to make sure the manifold ends up straight on the motor.
42:07 - Thats all folks! WHOOOO! Well the bikes not done yet. We will have more videos coming with this motorcycle and we promise once its done you will see it running!