screamin` eagle pro tc 110 (1800 cc) conversion kit - Harley
Contents
1. alog or contact a Harley Davidson dealer AWARNING 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 Figure 4 to Figure 6 and Table 2 to Table 4 J04478 NOTES This conversion kit is intended for High Performance or Racing applications only and is not legal for sale or use on pollution controlled motor vehicles This kit may may reduce or void the limited vehicle warranty Engine related performance parts are intended for the experienced rider only REMOVAL Prepare for Service 1 Position motorcycle on a suitable lift NOTE If vehicle is equipped with Harley Davidson Smart Security System see Owner s Manual for instructions to disarm the system 2 Remove seat according to the instructions in the Service Manual 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 0032. 30a 3 Remove fuel tank according to the instructions in the Service Manual 4 Remove Maxi fuse Refer to Service Manual for your motorcycle Remove Engine Components 1 Remove existing air cleaner assembly Refer to AIR CLEANER REMOVAL in Service Manual 2 Remove existing exhaust system Refer to EXHAUST SYSTEM REMOVAL in Service Manual 3 Remove engine from chassis following the instructions in the Service Manual 4 Disassemble engine top end and bottom end Refer to appropriate ENGINE sections in Service Manual 5 Remove existing clutch diaphragm spring Refer to CLUTCH REMOVAL in Service Manual MACHINE CRANKCASE CAUTION The procedures in this instruction sheet should be per formed by one experienced in precision measuring tech niques Failure to meet tolerances called for in this instruction sheet can result in engine damage 00511b 1 of 7 Crankcase Boring Preparation NOTE During final reassembly of the engine Harley Davidson recom mends replacing the Original Equipment cylinder studs with Screamin Eagle High Tensile Studs 16505 01 1 Remove cylinder studs from the engine crankcase 2 Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas Inspect and clean engine case mating surfaces 4 See Figure 6 Reassemble engine case with original screws except the top center screw between the cylinders and tighten to specifications listed in Se
3. cMOTOR HARLEY DAVIDSON WY J04478 INSTRUCTIONS REV 2007 06 28 SCREAMIN EAGLE PROTC 110 1800 CC CONVERSION KIT GENERAL Kit Number 29931 08 Black and 29932 08 Silver Models For model fitment information please see the P amp A Retail Cat alog or the Parts and Accessories section of www harley davidson com English only Notice This kit is not intended for installation on 08 Dyna models see your dealer for correct 08 Dyna kit number Additional Parts Required This kit requires the separate purchase of the Cam Drive Retention Kit 25566 06 The kit also requires an ACR Overlay Wire Harness Kit 70623 06 except for 2008 Touring models which require ACR overlay harness kit 70623 08 These kits are available from a Harley Davidson dealer The separate purchase of Crankcase Boring Tool Kit 94419 06 is recommended for installing this high performance engine conversion kit NOTE Crankcase Boring Tool Kit 94419 06 includes a modified top center screw 1093 to ensure the crankcase boring tool does not get damaged when installing the conversion kit This screw can also be purchased separately from a Harley Davidson dealer for those who wish to use their own boring fixture Please see appropriate sections in Service Manual for the special tools required to install this kit Proper installation of this kit also requires ECM recalibration using EFI Race Tuner Kit Refer to Screamin Eagle Pro Cat
4. e 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 CAUTION You must recalibrate the ECM when installing this kit Failure to properly recalibrate the ECM can result in severe engine damage 00399b 4 Download the new ECM calibration using EFI Race Tuner Kit Refer to Screamin Eagle Pro Catalog or contact a Harley Davidson dealer 5 Start and run engine Repeat several times to ensure proper operation Operation Refer to BREAK IN RIDING RULES in the Owner s Manual for instructions to break in the motorcycle 3 of 7 SERVICE PARTS is03918 Figure 4 Service Parts Screamin Eagle Pro TC 110 1800 CC Conversion Kit Table 2 Service Parts Screamin Eagle Pro TC 110 1800 cc Conversion Kit Item Description Quantity Part Number Item Description Quantity Part Number 1 Cylinder assembly Black 2 17285 07 7 O ring cylinder spigot 2 10956 used in Kit 29931 08 Cylinder assembly Silver 2 16815 07 8 Cylinder head assembly front 17288 08 used in Kit 29932 08 black 2 Piston 2 Not Sold Separately Cylinder head assembly front 17289 08 silver 3 Piston Ring Set 2 22285 07 9 Cylinder head assembly rear 17252 07 black 4 Piston pin 2 22558 07 Cylinder head assembly rear 17262 07 silver 5 Piston pin circlip 4 22097 99 10 Automatic C
5. gine crankcase halves as necessary 2 See Figure 3 Using a 11 32 in 8 7 mm drill bit drill out the existing threads of the top center screw hole Drill to a depth of 0 79 in 20 mm from the gasket surface 3 Using a size F in 6 6 mm drill bit extend the top center screw hole 1 00 in 25 4 mm maximum to a depth of 1 79 in 45 5 mm from the gasket surface 4 Using a bottoming tap purchased separately size 5 16 18 UNC 2B tap the screw hole to a minimum depth of 1 59 in 40 4 mm from the gasket surface 5 See Figure 2 and Figure 3 Remove the thin material between the cylinders next to the top center screw as shown by using a 5 8 in 16 mm ball end mill and milling a 5 16 in 7 94 mm radius at the two points shown Figure 2 Cylinder Wall 6 Refer to the appropriate Service Manual and assemble the engine with the following changes a Tighten all of the engine crankcase screws to the specified torque except the top center engine crankcase screw b See Figure 6 After the cylinders and heads have been installed and the hardware tightened to specifi cation install the top center engine crankcase screw 15 supplied in kit Tighten screw to 50 90 in lbs 5 6 10 2 Nm 2 of 7 is03502 ae Cal Ad Ki oy 1 Tap hole with a 5 16 18 UNC 2B bottoming tap 6 Extend hold depth 1 00 in 25 4 mm maximum 2 Exte
6. gure 6 Service Parts Screamin Eagle Pro TC 110 1800 CC Conversion Kit Table 4 Service Parts Screamin Eagle Pro TC 110 1800 cc Conversion Kit Item Description Quantity Part Number 1 Gasket cam cover 25244 99A 2 Washer Not Sold Separately 3 Capscrew flanged Not Sold Separately 4 Retaining ring 11461 5 Camshaft front Not Sold Separately 6 Camshaft rear Not Sold Separately 7 Bearing needle 2 must be purchased separately if needed 9215 8 O ring oil pump to cam plate 11293 9 O ring cam plate to crankcase 2 11301 10 O ring crankcase ring dowel 2 26432 76A 11 O ring piston cooling 2 11140 J04478 6 of 7 Table 4 Service Parts Screamin Eagle Pro TC 110 1800 cc Conversion Kit ltem Description Quantity Part Number 12 Retaining ring internal 35114 02 13 O ring crankcase dowel 2 11273 14 Seal main bearing oil 12068 15 Screw top center crankcase long 1090 16 Screw modified crankcase boring Not Shown must be purchased separately 1093 17 Flywheel bearing sprocket shaft not shown 24004 03A Notes Cam Drive Retention Kit 25566 06 includes 2 and 3 Items 8 through 14 are included in Engine Overhaul Gasket Kit 17053 99B Items 5 and 6 available in Cam Kit 25475 06 J04478 7 of7
7. nded full thread depth 0 80 in 20 mm 7 Unthreaded screw hole depth 0 79 in 20 mm 3 Distance 0 48 in 12 mm 8 Distance to center of crank 5 90 in 150 mm 4 Distance 0 48 in 12 mm 9 Distance to center of crank 6 00 in 152 mm 5 Drilled hole diameter 0 34 in 8 6 mm 10 Radius 0 31 in 7 94 mm use 5 8 in 16 mm ball end mill Figure 3 Top Center Engine Crankcase Screw Hole Modification INSTALLATION 2 Install fuel tank according to the instructions in the Service Manual Install Engine and Clutch Components f 3 Install seat according to the instructions in the Service 1 See Figure 6 Inspect camshaft needle bearings 7 and replace if necessary 2 See Figure 4 through Figure 6 Assemble engine top end and bottom end using parts from kit Refer to appropriate ENGINE sections in Service Manual 3 Install engine in chassis following the instructions in the Service Manual 4 Install clutch diaphragm spring from kit Refer to CLUTCH INSTALLATION in Service Manual 5 Install exhaust system Refer to EXHAUST SYSTEM INSTALLATION in Service Manual 6 Install air cleaner assembly Refer to AIR CLEANER INSTALLATION in Service Manual Install ACR Overlay Wire Harness Refer to Instruction Sheet in ACR Overlay Wire Harness Kit Final Assembly 1 Install Maxi fuse Refer to Service Manual for your motorcycle J04478 Manual WARNING After installing seat pull upward on seat to b
8. ompression Release 28861 07 ACR 6 Gasket cylinder head 2 16801 07A Notes Piston Kit 22502 07 includes 2 through 5 Item 5 is also included in Engine Overhaul Gasket Kit 17053 99B For cylinder head assembly 8 9 components refer to 2008 FLHTCUSES 99428 08 2008 FXDSE2 99430 08 and 2008 FXSTSSE2 99458 08 Parts Catalogs J04478 4 of 7 is03589 Figure 5 Service Parts Screamin Eagle Pro TC 110 1800 CC Conversion Kit Table 3 Service Parts Screamin Eagle Pro TC 110 1800 CC Conversion Kit Item Description Quantity Part Number Item Description Quantity Part Number Gasket rocker cover base 2 16719 99A 9 Gasket breather 2 Not Sold Separately 2 Gasket rocker cover top 2 17386 99A 10 Umbrella valve 2 26858 99 3 Gasket tappet cover 2 18635 99B 11 Filter element breather 2 63815 99 4 O ring middle push rod cover 4 11132A 12 Seal EFI intake 2 Not Shown 29995 86B 5 O ring lower push rod cover 4 11145A 13 Seal map sensor Not Shown 11291 6 O ring upper push rod cover 4 11293 14 Spring clutch diaphragm Not 37951 98 Shown 7 O ring rocker arm support 2 11270 Notes Breather Gasket Kit 17162 03 includes 8 through 11 Items 1 through 13 are included in Engine Overhaul Kit 17053 99B 8 Gasket breather 2 Not Sold Separately J04478 5 of 7 is03590 Fi
9. rvice Manual NOTE To prevent damage to crankcase boring tool it is important to replace the top center screw with a modified top center screw 1093 This screw is included in the Crankcase Boring Tool Kit 94419 06 and can be purchased separately from a Harley Davidson dealer 5 Install modified top center screw 1093 between the cylinders and tighten to 50 90 in Ibs 5 6 10 2 Nm NOTE To aid in crankcase boring a Screamin Eagle Crankcase Boring Tool Kit 94419 06 is available Modified top center screw 1093 is included in this kit Refer to Harley Davidson Genuine Motor Accessories and Genuine Motor Parts catalog or Screamin Eagle Pro catalog 6 See Figure 1 and Table 1 Machine crankcase cylinder spigot bore and O ring counterbore to the dimensions shown is03517 1 O ring counterbore 2 Spigot bore Figure 1 Spigot Bore and O Ring Counterbore Dimensions J04478 Table 1 Spigot Bore and O Ring Couniterbore Dimensions Description Bore Depth Spigot Bore 4 205 0 010 in 107 0 25 mm 1 625 0 010 in 41 3 0 25 mm O Ring Counter bore 4 415 0 002 in 112 0 05 mm 0 085 0 003 in 2 16 0 08 mm Modify Crankcase NOTE To prevent severe engine damage thoroughly clean and remove all chips and debris from the engine crankcase after boring 1 Disassemble crankcase and wash or clean chips and debris from en
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