AUTOMATIC COMPRESSION RELEASE TOOLS
Contents
1. could result in death or serious injury 00333a Kit Contents See Figure 7 and Table 1 INSTALLATION AWARNING Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a J04654 WARNING Wear safety glasses or goggles while drilling Flying debris could result in serious eye injury 00565b Drill 1 250 inch Drill stop collar 1 250 inch Drill stop gauge Socket head screw 5 16 inch Socket head screw 1 4 inch Dowel pin Top plate N 1 2 3 4 5 6 7 Figure 1 Top Plate and Drill Bit Stop Collar Installation 1 Remove valves from cylinder heads NOTE Do not allow the threaded studs to damage the gasket sealing surface of the cylinder head 2 See Figure 7 and Table 1 Mount a cylinder head to the tooling plate 1 1of5 3 Place a head bolt spacer 7 over each stock head bolt and lubricate threads and thrust faces dowels and studs Tighten head bolts in a crisscross pattern to 10 ft lbs 13 5 Nm 4 See Figure 1 Align the top plate 7 bolt and dowel holes with the head hole pattern Screamin Eagle logo towards the spark plug This plate will only fit one way for the cyl inder head it is being installed on If the plate does not align with the head turn it over keeping the logo tow2. Drill through to ACR cross hole 3of5 SERVICE PARTS Figure 7 Service Parts Kits Automatic Compression Release Tools J04654 40f5 Table 1 Service Parts Table Kit Item Description Quantity Kit 94648 08 Auto Compression Release Tool Kit Base plate assembly 2 Drill jig assembly top plate 3 Rear exhaust assembly drill jig 4 Front exhaust assembly drill jig 5 7 8 inch drill bushing 6 Tap extension 7 Head bolt spacer 8 1 25 inch drill stop collar 9 Drill stop gauge 10 Form drill 7 8 inch 11 Form drill 1 25 inch 12 Stop collar 7 8 inch drill 13 Tap 12 mm 1 25 spiral point 14 Machined transfer punch 3 16 inch 15 13 jobber drill 16 13 Taper length drill 17 Set screw 3 8 24 x 1 4 inch 18 Set screw 5 16 18 x 1 4 inch 19 Drill bushing lock screw 20 Set screw 1 4 28 x 3 16 inch 21 Screw 5 16 18 x 1 inch SHCS 22 Dowel 9 5 mm x 1 inch 23 Screw 1 4 20 x 1 inch SHCS The following kits break down the above items into catagories that can be purchased as separate kits Kit 94049 09 Cutting Tools Kit This kit contains items 6 9 10 11 13 14 15 and 16 Kit 94050 09 Bushings Collars and Spacers Kit This kit contains items 5 7 8 12 19 and 22 Kit 94051 09 Drill Jigs Kit This kit contains items 3 and 4 J04654 5 of 5
3. ards the spark plug and install the cylinder head 5 Lubricate the two dowel pins 6 and insert in the top plate and into the cylinder head 6 Apply lubricant to the two socket head screws 4 and 5 Insert into their respective holes in the plate to the cylinder head and tighten to 5 ft lbs 6 8 Nm 1 Drill bushing 0 875 inch ID 2 Wide head socket screw Figure 2 Install bushing for 0 875 inch drill 7 Install the 1 25 inch drill stop collar 2 over the 1 25 drill 1 Hold the drill stop gauge 3 with the short side marked Large Drill Set over the flat end of the drill and the other end up against the stop collar Install and tighten set screw in the collar to 5 ft lbs 6 8 Nm 8 Install the drill assembly in the press and lower the drill into the drill bushing of the top plate for alignment and clamp the head down to the table to hold it in a centered position 9 Drill at 350 to 600 rpm use adequate lubricant and drill slowly 10 Drill 1 4 inch at a time and remove all chips Repeat pro cess until the stop collar bottoms out on the plate 11 See Figure 2 Lubricate the long 0 875 inch ID drill bushing 1 and insert into the plate Secure bushing with the lub ricated wide head socket screw 2 and tighten the screw to 5 ft lbs 6 8 Nm 12 See Figure 3 Remove the 1 25 inch drill from the press and install the 0 875 inch drill 2 13 Install the drill stop collar 3 to the chuck sid
4. cMOTOR HARLEY DAVIDSON WY J04654 INSTRUCTIONS REV 2010 09 16 AUTOMATIC COMPRESSION RELEASE TOOLS GENERAL Kit Number 94648 08 Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required Separate purchase and installation of additional parts or accessories is required for proper installation of this kit on your model motorcycle Required tools include e Cylinder head holding fixture HD 39786 e Cylinder head fasteners cylinder head screw 16480 92A 2 required cylinder head screw 16478 85A 2 required exhaust mounting nuts 7593 2 required e Valve spring compressor HD 34736 B e Valve guide seal tools depending on year and type of cyl inder head Brass hammer e Other hand tools required include cutting fluid tapping fluid for aluminum hand drill with 3 8 inch chuck 15 heavy duty drill press or mill 4 table clamps to mount tool plate to press calipers torque wrench in ft lbs or Nm 1 2 12 point socket 5 15 socket set of allen wrenches tap handle assembly lube 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
5. e nuts to 10 ft lbs 13 5 Nm NOTE In the following step you will need to tap the transfer punch hard enough and straight enough to leave a punch mark about 0 030 inch deep so the drill will not slide off the wall of the exhaust port To check this depth you can use calipers to check the amount the transfer punch is out of the drill jig before and after you have tapped it with a hammer J04654 20 Lubricate and slide transfer punch through the hole in the jig and tap with a hammer 21 See Figure 6 Set the short 13 drill bit 2 to be 2 5 inches from its tip to the jaws of the drill chuck Drill a hole slowly using lubricant and remove chips after drilling 1 4 inch at a time Keep the drill going as straight as possible using lubricant to keep the chips wet Continue drilling until the drill chuck comes close to making contact with the drill jig then stop and remove the drill bit 22 Install the long 13 drill bit Use your calipers to set the drill length to 4 5 inches from the drill chuck jaws to the tip of the drill bit Drill the hole slowly using lubricant and remove chips after 1 4 inch at a time until the drill enters the ACR cross hole drilled previously 23 Carefully remove all metal chips and shavings with com pressed air or by washing is05447 1 Exhaust Port Drill Jig 2 Stock exhaust nut Figure 5 Install Drill Jig is05448 1 Exhaust port drill jig 2 0 875 inch drill Figure 6
6. e of drill with the flange at the top J04654 op D 3 1 Q 49 a 1 Drill stop gauge 2 0 875 inch drill 3 Drill stop collar Figure 3 Install collar for 0 875 inch drill 14 Use the short side of the drill stop gauge 1 marked Small Drill Set over the flat end of the drill and the other end up against the stop collar Install the set screw in the collar and tighten to5 ft lbs 6 8 Nm 15 Drill down 1 4 inch at a time using lubricant then remove chips Drill down until the stop collar bottoms out on the top of the drill bushing When finished carefully remove the drill assembly 2of5 1 Tap 12 mm Figure 4 Tapping head for ACR 16 See Figure 4 Install the 12 mm tap 1 into the tap guide extension and handle Tighten extension set screw to 5 ft lbs 6 8 Nm 17 Lubricate tap and drilled hole Tap hole turning clockwise and reverse tap 1 2 turn after one full turn and continue until the hole is fully tapped Apply cutting fluid liberally each time you reverse the tap 18 Remove head from plates Lube and install cylinder head holding fixture and clamp tool in vise with access to exhaust port 19 See Figure 5 If you are working with the rear head install the rear exhaust port drill jig 1 Use two lubricated stock exhaust nuts to fasten the jig to the cylinder head Hold the jig against the exhaust port and finger tighten the nuts snug Alternately tighten th
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