screamin` eagle pro 11:1 compression, 3.875 - Harley
Contents
1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 2 Refer to the ENGINE STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL DISASSEMBLY 1of3 sections of the Service Manual for cylinder head cylinder and piston removal procedures 3 Follow the procedures in the ENGINE SUBASSEMBLY SERVICE AND REPAIR TOP END CYLINDER UPPER CONNECTING ROD sections of the Service Manual for inspection of parts 4 See the ENGINE SUBASSEMBLY SERVICE AND REPAIR CYLINDER section of the Service Manual for boring and honing instructions NOTES Install the top ring barrel faced and second ring taper faced Napier with the N marking facing up Oil ring rails can be installed either side up The 4 060 inch cylinder base gaskets and cylinder head gas kets included in the kit eliminate the need for O rings 11273 Do not use O rings on cylinder dowels or cylinder spigots When installing new base gasket install with the embossed side down and the concave side up Piston dimensions to be measured 0 281 inches above the lowest part of the skirt 5 The pistons in this kit are front and rear specific Install the piston marked FRONT in2. cMOTOR HARLEY DAVIDSON WY J04992 INSTRUCTIONS REV 2009 07 07 SCREAMIN EAGLE PRO 11 1 COMPRESSION 3 875 INCH BORE PISTONS GENERAL NOTES Always check piston to valve clearance when using non stock camshafts All dimensions listed on these instructions are in inches High compression piston applications require installation of appropriate compression release in cylinder heads The pistons in this kit have an Electroless Nickel plating in the piston pin bores and require the use of a non plated piston pin only 22304 08 Kit Numbers 21916 08A 21928 08A Table 1 Kits Kit Application 21928 08A Standard 3 875 in front amp rear 21916 08A 0 010 front amp rear Models These kits fit Harley Davidson Twin Cam models equipped with the following items e Cylinder heads Screamin Eagle Pro MVA 110 or ACR Performance cylinder heads e Cylinders Screamin Eagle Pro 3 7 8 Big Bore cylinders e Flywheels Screamin Eagle Pro 4 3 8 stroke flywheels or 07 later original equipment 4 3 8 stroke flywheel assembly NOTE This engine related performance part is intended for high per formance or racing applications and is not legal for sale or use on pollution controlled motor vehicles This kit may reduce or void the limited vehicle warranty Engine related performance parts are intended for the experienced rider only Additional Parts Required CAUTION Y
3. ip and Piston is02627 1 Thumb orientation 2 Circlip 85 seated Figure 2 Install Circlip 8 See Figure 2 Position your thumb 1 as shown and press firmly until approximately 85 of the circlip 2 is seated in the groove 9 Being careful not to scratch or mar the piston use a small bladed screwdriver to wedge the circlip into the remainder of the groove Repeat for the remaining circlips NOTE Make sure the piston circlip is fully seated or ENGINE DAMAGE WILL OCCUR 10 Refer to the ENGINE ASSEMBLING MOTORCYCLE AFTER STRIPPING section of the Service Manual for final re assembly procedures NOTES Always follow the break in procedure outlined in the appropriate Owner s Manual after rebuilding an engine 20f3 SERVICE PARTS isO6003a Figure 3 Service Parts Screamin Eagle Pro 11 1 Compression 3 875 Inch Bore Pistons Table 4 Service Parts Table Front and Rear Piston Kits Kit Item Description Quantity Part Number Kit 21928 08A 1 Piston front standard Not sold separately eed 2 Piston rear standard Not sold separately 3 Ring set standard 2 22457 10 4 e Piston pin 2 22304 08 5 Je Circlip 4 22097 99 Kit 21916 08A 1 Piston front 0 010 Not sold separately fee a 2 Piston rear 0 010 Not sold separately 3 e Ring set 0 010 2 22459 10 4 e Piston pin 2 22304 08 5 Je Circlip 4 22097 99 J04992 3
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5. ou must recalibrate the ECM when installing this kit Failure to properly recalibrate the ECM can result in severe engine damage 00399b J04992 NOTE ECM recalibration is required which can be performed with the Screamin Eagle Race Tuner Kit Part Number 32107 01F See a Harley Davidson dealer Re jetting and or re timing of the engine may be required to realize the full potential of this performance product 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 Contents See Table 4 and Figure 3 INSTALLATION 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 1
6. the front cylinder with the arrow pointing towards the front of the engine Install the piston marked REAR in the rear cylinder with the arrow pointing towards the front of the engine 6 Refer to the ENGINE TOP END OVERHAUL ASSEMBLY section of the Service Manual for piston cylinder and cyl inder head installation procedures Table 2 Specifications Piston Clearance in 0 0015 0 0025 0 0003 0 0008 Fit in cylinder Loose Piston pin fit Loose Top Ring End Gap 0 012 0 020 Second Ring End Gap 0 016 0 024 Oil Control Ring Rail Gap 0 007 0 030 0 0015 0 0029 0 0015 0 0029 0 0010 0 0072 Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance Table 3 Service Wear Limits Fit in Cylinder Loose Wear Limit in Fit in cylinder Loose 0 005 Piston Pin Fit Loose 0 0011 Top Ring End Gap 0 030 Second Ring End Gap 0 034 Oil Control Ring Rail Gap 0 040 Top Ring Side Clearance 0 0037 Second Ring Side Clearance 0 0037 Oil Control Ring Side Clearance 0 0081 J04992 Piston Pin Retaining Ring Circlip Installation NOTE Circlip gap must be at 12 00 or 6 00 position when installed 7 See Figure 1 Insert the open end of the circlip 1 into the notch 3 on the groove 2 around the piston pin boss so that the gap is at the 12 00 or 6 00 position when installed is02626 1 Circlip 2 Notch 3 Groove Figure 1 Circl
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