screamin` eagle street legal big bore stage 2 kit - Harley
Contents
1. 20 3 Nm h Loosen each flange screw one full turn i Tighten crank flange screw to 24 ft lbs 32 5 Nm final torque value j Tighten primary cam sprocket flange screw to 34 ft lbs 46 0 Nm final torque value k Remove sprocket locking tool and follow instructions in Service Manual for unloading primary cam chain tensioner 5 Install cam cover according to ENGINE BOTTOM END OVERHAUL Cam Support Plate Disassembly Assembly instructions in applicable Service Manual NOTE Replace cam cover gasket Figure 10 item 3 Figure 7 Camshaft Crankshaft Sprocket Locking Tool J03172 Install Pistons Cylinders and Clutch Components Install pistons cylinders and cylinder heads from kit Refer to ENGINE section of appropriate Service Manual N Refer to DRIVE section of appropriate Service Manual Install diaphragm spring retainer clutch diaphragm spring Table 2 item 15 and primary chaincase cover Install High Performance Air Cleaner Refer to instructions included with Air Cleaner Kit 29440 99C on Instruction Sheet J03252 Final Assembly WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 1 2004 2005 Softail Models a Connect battery cables positive cable first b Install seat according to th2. Assembly Camshaft Camshaft Bearings section s in appropriate Service Manual Use spacers provided in kit in place of those listed in Service Manual NOTES Verify alignment at crank and primary cam sprocket punch marks as described in Service Manual Verify alignment at crank and primary cam sprocket faces Use spacers provided in kit to maintain alignment at plus or minus 0 01 in 3 See Figure 10 Use cam flange screw 12 washer 11 crank flange screw 10 and washer 9 from kit WARNING Apply threadlocker to maintain clamp load on flange bolt A loose flange bolt can cause engine failure which could result in death or serious injury 00476c 4of8 4 Install new flange screws and washers as follows a Ensure threads are clean and free from oil then apply Loctite Primer 7649 b Apply Loctite 262 red 94759 99 to threads of flange screws c Apply a thin film of clean H D 20W50 engine oil to both sides of flat washers d Start flange screw with flat washer to secure crank sprocket to end of crankshaft e Start flange screw with flat washer to secure primary cam sprocket to end of camshaft f See Figure 7 Position Camshaft Crankshaft Sprocket Locking Tool HD 42314 between the crank and pri mary cam sprockets to prevent rotation The handle of the tool is stamped Cam and Crank to ensure proper orientation g Tighten crank and primary cam sprocket flange screws to 15 ft lbs
3. Bore Stage 2 Kit Table 2 Service Parts Screamin Eagle Street Legal Big Bore Stage 2 Kit Item Description Quantity Part Number Item Description Quantity Part Number 1 Gasket rock cover base 2 16719 99A 10 Umbrella valve 2 26858 99 2 Gasket rocker cover top 2 17386 99A 11 Filter element breather 2 63815 99 3 Gasket tappet cover 2 18635 99B 12 Seal exhaust Not Shown 17048 98 4 O ring middle push rod cover 4 11132 13 Seal EFI intake 2 Not Shown 26995 86B 5 O ring lower push rod cover 4 111145 14 Valve seal kit Not Shown 18004 86 6 O ring upper push rod cover 4 11293 15 Spring clutch diaphragm Not 37951 98 Shown 7 O ring rocker arm support 2 11270 16 Air cleaner kit Not Shown 29440 99C 8 Gasket breather 2 Not Sold Separately 17 Product Information Label Not Not Sold Separately Shown 9 Gasket breather 2 Not Sold Separately Breather gasket kit includes items 17162 03 8 through 11 J03172 7 of 8 is03232 Figure 10 Service Parts Screamin Eagle Street Legal Big Bore Stage 2 Kit Table 3 Service Parts Screamin Eagle Street Legal Big Bore Stage 2 Kit Item Description Quantity Part Number Item Description Quantity Part Number 1 Retaining ring 2 11031 8 Roller bearing kit rear cam 8983 2 O ring oil pump to cam plate 11286 9 Washer cra
4. primary cam sprocket spacer and sprocket on camshaft and secure using thicker flat washer and long flange screw e See Figure 2 Wrap a shop rag 1 around camshaft to get a firm grip and also to protect hand from sharp edges of sprocket Using a 9 16 in box wrench 2 turn flange screw in a clockwise direction Bearing inner race 3 is fully installed when it makes firm contact with the thrust washer 4 f Verify thrust washer is locked in place and cannot be rotated If necessary install shaft in vise using brass jaw inserts and further tighten flange screw until desired result is achieved g Remove flange screw flat washer sprocket and spacer NOTES Be aware that the front and rear cam bearings are not inter changeable The rear cam utilizes a roller bearing while the front cam utilizes a ball bearing See Figure 3 Bearing fit may be a light press or slightly loose fit If deemed necessary clean bearing O D and apply Loctite 243 blue before installation but exercise caution to avoid getting com pound on rollers or bearing I D 2of8 2 Install new cam bearings into cam support plate according to the following a See Figure 4 Obtain the Camshaft Remover Installer HD 43644 b With the secondary cam chain side facing upward place cam support plate on support block so that outer races of bearings are properly supported Note that one corner of the support block is contoured to accommodate the chain
5. aring I D J03172 CAUTION Be sure rear camshaft is aligned during press procedure Misalignment can cause inner race to catch on bearing rollers resulting in bearing damage 00475b 9 Slowly apply pressure to driver on front camshaft while wiggling rear camshaft as necessary to guide inner race between bearing rollers 10 When inner race on rear cam is started into roller bearing apply pressure to driver until front camshaft is fully seated If necessary keep finger pressure at top of rear camshaft to ensure that assembly remains square and inner race moves to installed position in roller bearing 11 After installing new cams check for proper cam to cam timing using straightedge along punch marks as described in Service Manual 12 Install retaining ring from kit in groove at end of front camshaft NOTES Inspect cam needle bearings in crankcase and replace if nec essary Replace oil pump to cam plate O ring Figure 10 item 2 and cam plate to crankcase O ring Figure 10 item 6 Install Cam Support Plate Install cam plate according to ENGINE BOTTOM END OVERHAUL Cam Support Plate Disassembly Assembly instructions in applicable Service Manual Install Rear Cam Sprocket Crank Sprocket and Primary Cam Chain 1 Apply a thin film of clean H D 20W50 engine oil to the splines of the rear cam 2 Install splined sprocket onto rear camshaft Refer to ENGINE BOTTOM END OVERHAUL Cam Support Plate Disassembly
6. cMOTOR HARLEY DAVIDSON WY J03172 INSTRUCTIONS REV 2006 04 19 SCREAMIN EAGLE STREET LEGAL BIG BORE STAGE 2 KIT GENERAL Kit Number 29858 04A Models This kit fits Twin Cam 88 1450 cc engines on the following models equipped with Electronic Fuel Injection EFI and stock mufflers e 2004 2005 Dyna models e 2004 2005 Softail models except 2005 FLSTFI 15th Anniversary Additional Parts and Tools Required Proper installation of this kit requires the separate purchase of the following parts and tools which are available from a Harley Davidson dealer e Camshaft Crankshaft Sprocket Locking Tool HD 4361 4 Camshaft Remover Installer HD 43644 e Loctite 243 blue 99642 97 e Primary Cover Gasket See Parts Catalog e Spacer Kit 25938 00 Proper installation of this kit requires the use of Digital Techni cian at a Harley Davidson dealer WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson dealer Kit Conten
7. e instructions in the Service Manual 2004 2005 Dyna Models a Install maxi fuse Refer to MAXI FUSE INSTALLA TION in Service Manual WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b Recalibrate ECM CAUTION You must recalibrate the ECM when installing this kit Failure to properly recalibrate the ECM can result in severe engine damage 00399b Download the new ECM calibration using the Digital Techni cian at a Harley Davidson dealer 5 of 8 SERVICE PARTS is03129 Figure 8 Service Parts Screamin Eagle Street Legal Big Bore Stage 2 Kit Table 1 Service Parts Screamin Eagle Street Legal Big Bore Stage 2 Kit Item Description Quantity Part Number Item Description Quantity Part Number 1 Cylinder assembly Silver 2 16548 99 6 Head gasket 2 16787 99A 2 Piston 2 Not Sold Separately 7 O ring cylinder deck ring dowel 11273 2 3 Piston ring set 2 21918 99 8 O ring cylinder spigot 2 11256 4 Piston pin 2 22132 99 Piston kit includes items 2 22851 99A through 5 5 Piston pin circlip 4 22097 99 Note Do not install O ring item 7 to top cylinder dowels J03172 6 of 8 is03151 _ go Figure 9 Service Parts Screamin Eagle Street Legal Big
8. guide blocks cast into the front of the support plate c Center new bearing over bearing bore with the let tered side up Slide pilot shaft of bearing driver through bearing into hole of support block d See Figure 5 Center bearing driver under ram of arbor press Press on driver until bearing makes firm contact with counterbore in cam support plate Repeat Steps 2a through 2c to install second bearing is03136 1 Roller bearing rear cam 2 Ball bearing front cam Figure 3 Cam Bearings 3 Apply Loctite 243 blue to threads of four bearing retainer plate screws 4 Using a T20 Torx drive head secure bearing retainer plate to cam support plate 5 Tighten four bearing retainer screws to 20 30 in Ibs 2 3 3 4 Nm in a crosswise pattern Verify that hole in retainer plate is properly aligned with secondary cam chain oiler J03172 is03137 1 Support block 2 Bearing pilot driver 3 Camshaft driver Figure 4 Camshaft Remover Installer is03138 1 Bearing pilot driver 2 Bearing 3 Support block Figure 5 Press Bearings into Cam Support Plate 3 of 8 Install Camshafts 1 Start camshafts into cam bearings 2 Place cam support plate back on support block if removed The block properly supports inner races of bearings as camshafts are installed 3 See Figure 6 Align punch marks on teeth of secondary cam sprockets outboard faces Using a colored marke
9. nk 2 Not Sold Separately 3 Gasket cam cover 25244 99A 10 Screw flange crank 2 Not Sold Separately 4 Retaining ring camshaft 11494 11 Washer rear cam 6294 5 Ball bearing front camshaft 8990A 12 Screw flange rear cam 996 6 O ring cam plate to crankcase 2 11301 13 Loctite 262 red 0 5 ml packet Not Sold Separately Not Shown 7 Camshaft kit includes front and 25937 99B Notes Items 9 and 10 are only available as part of Cam Drive rear Gear Retention Kit 25533 99A Loctite item 13 is only available in 6 ml tube part number 94759 99 J03172 8 of 8
10. ppropriate Service Manual Install New Cam Bearings CAUTION To center thrust washer be sure o ring is installed in relief groove Damage to bearing cage and engine can occur if thrust washer is not centered 00473b NOTE If not enough of the splined shaft is exposed to install the sprocket leave out the spacer and proceed to Step 1e Once the bearing inner race has been started onto the machined area remove the flange screw washer and sprocket then assemble using the spacer Repeat Step 1e to fully install bearing inner race is03134 Roller bearing O ring Thrust washer Bearing inner race Pena Figure 1 Rear Cam Roller Bearing Kit J03172 is03135 1 Shop rag 2 Box wrench 9 16 in 3 Bearing inner race 4 Thrust washer Figure 2 Install Bearing Inner Race with O Ring and Washer 1 See Figure 1 Install rear cam roller bearing kit Figure 10 item 8 onto rear camshaft a Install O ring in grinding relief groove Groove is on the splined end between the machined area and the secondary cam sprocket Exercise caution to avoid stretching or breaking the O ring Since the O ring is not sold separately damage will require purchase of new roller bearing kit b Slide thrust washer down rear camshaft until centered over O ring in grinding relief position c Slide bearing inner race down rear camshaft until contact is made with shoulder of machined area d Install
11. r carefully mark the punch mark locations on the inboard side of the sprocket teeth These marks are needed to observe proper orientation of the camshafts when they are pressed into the bearings is03139 1 Punch marks 2 Front camshaft 3 Rear camshaft Figure 6 Align Punch Marks on Teeth of Camshaft Sprockets 4 Place secondary cam chain around the sprockets of both the front and rear camshafts To maintain the original direction of rotation be sure that the colored mark placed on the chain link during disassembly is facing opposite the cam support plate during installation 5 Orient the camshafts so that they are positioned on opposite ends of the chain and then verify that the colored marks placed on the inboard side of the sprocket teeth are still in alignment 6 Maintaining the position of the camshafts on the chain with the colored marks in alignment place the sprocket ends of the camshafts into the bearings NOTE Be sure not to mix camshafts during the press procedure The rear camshaft which can be identified by the splined shaft must go into the roller bearing at the rear of the cam support plate 7 Place cup of camshaft driver over end of front camshaft only CAUTION During press procedure keep tensioner shoe clear of chain to prevent damage to tensioner assembly 00474b 8 Center end of front camshaft under ram and slowly apply pressure to driver just to start front camshaft into be
12. s negative cable first 2004 2005 Dyna Models a Remove maxi fuse Refer to MAXI FUSE REMOVAL in Service Manual CAUTION Head gaskets provided in the 1550 conversion kit eliminate the need for original equipment O E O rings Do not install the two O rings from the kit on the top cylinder dowels or severe engine damage can occur 00484c 2 Remove existing cylinder heads cylinders and pistons Refer to ENGINE section of appropriate Service Manual w Remove existing primary chaincase cover diaphragm spring retainer and clutch diaphragm spring Refer to DRIVE section of appropriate Service Manual 1of8 INSTALLATION Remove Existing Cam Bearings NOTE Both crank and primary cam sprocket flange screws are spe cially hardened while the flat washers are of a special diameter and have ground surfaces Therefore use only the parts pro vided in the Cam Drive Gear Retention Kit 25533 99A when performing this upgrade The crank and primary cam sprocket flange screws are not interchangeable 1 Remove existing crank and primary cam sprocket flange screws and washers according to instructions in Service Manual Discard cam drive sprocket flange screws and washers 2 Remove existing cam drive sprocket according to instruc tions in Service Manual 3 Remove and discard existing cam bearings Refer to ENGINE BOTTOM END OVERHAUL Cam Support Plate Disassembly Assembly Camshaft Camshaft Bearings section s of a
13. ts See Figure 8 Table 1 to Figure 10 Table 3 NOTES Installation of this kit by an authorized Harley Davidson dealer will not impact your limited vehicle warranty J03172 This Big Bore Stage 2 kit is intended for High Performance applications only This engine related performance part is legal for sale or use in California on pollution controlled motor vehi cles Engine related performance parts are intended for the experienced rider only The air cleaner contained in these kits is designed to perform with this kit only Any other combination of components is not confirmed to be legal for street use The Product Information Label contained in this kit is a requirement of the California Air Resource Board CARB emission regulation Place the label on the right side of the frame directly beneath the VIN sticker This label is not required outside the state of California REMOVAL WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a 2004 2005 Softail Models a Remove seat according to the instructions in the Service Manual e b Disconnect battery cable
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