INSTRUCTIONS - Harley
Contents
1. d Start flange bolt with flat washer to secure crank sprocket to end of crankshaft e Start flange bolt with flat washer to secure primary cam sprocket to end of camshaft i02067 Sprocket locking tool Figure 7 Crankshaft Camshaft Sprocket Locking Tool Part Number HD 42314 f See Figure 7 Position CRANKSHAFT CAMSHAFT SPROCKET LOCKING TOOL HD 42314 between the crank and primary cam sprockets to prevent rotation The handle of the tool is stamped Crank and Cam to ensure proper orientation g Tighten crank and primary cam sprocket flange bolts to 15 ft lbs 20 3 Nm h Loosen each flange bolt one full turn i Tighten the crank flange bolt to 24 ft lbs 32 5 Nm final torque value j Tighten the primary cam sprocket flange bolt to 34 ft lbs 46 0 Nm final torque value k Remove the sprocket locking tool 1 and follow instructions in Service Manual for unloading the primary cam chain tensioner 21 Install the cam cover according to ENGINE BOTTOM END Cam Support Plate Disassembly Assembly instructions in the applicable Service Manual NOTE Replace original cam cover gasket with new cam cover gas ket Part Number 25244 99A from Cam Service Kit Part Number 17045 99B 22 Apply E O Label to frame tube 4 of 42. MTOR HARLEY DAVIDSON AUA J03817 INSTRUCTIONS REV 07 13 2005 Kit Number 29791 05 SCREAMIN EAGLE TWIN CAM 203 CAMSHAFT KIT STAGE Il STREET LEGAL General This kit is designed for installation on 2005 Model Year 1550cc Anniversary Edition FLSTFI motorcycles NOTE A Service Manual for your motorcycle is available from your Harley Davidson Dealer Additional Parts Required Installation of the camshafts included in this kit requires the separate purchase of the following kits from your Harley Davidson Dealer Description Part Number Spacer Kit 25938 00 Cam Service Kit 17045 99B Drive Gear Retention Kit 25533 99A 1999 Models will require the purchase of Splined Cam Drive Sprocket 25716 99 The rider s safety depends upon the correct installation of this kit Use the appropriate service manual proce dures 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 Kit Contents Qty Description Part Number 1 S E 203 camshaft front not sold 1 S E 203 camshaft rear not sold Awarnina To prevent accidental vehicle start up which could cause death or serious injury disconnect negative bat tery cable before proceeding 00048a To prevent accidental vehicle start up which could cause death or serious injury disconnec
3. all New Cam Bearings 1 See Figure 1 Obtain new Rear Cam Roller Bearing Kit Part Number 8983 from Cam Service Kit Part Number 17045 99B and install according to the following 2 Install O ring 1 thrust washer 2 and bearing inner race 3 onto rear camshaft as follows i02061 O 3 Bearing inner race 4 Roller bearing 1 O ring 2 Thrust washer Figure 1 Rear Cam Roller Bearing Kit Part Number 8983 1of4 a To properly locate thrust washer 2 first install O ring 1 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 CAUTION The thrust washer will be offset to one side if the O ring is not installed in the grinding relief groove Damage to the bearing cage can occur if the thrust washer is not properly centered b Slide thrust washer 2 down rear camshaft until centered over O ring 1 in grinding relief position c Slide bearing inner race 3 down rear camshaft until contact is made with shoulder of machined area d Install primary cam sprocket spacer and sprocket on camshaft and secure using thicker flat washer and long flange bolt NOTE If not enough of the splined shaft is exposed to install the sprocket leave out the spacer and proceed to Step 2 e Once the bearing in
4. bearings as camshafts are installed J03817 i02066 7 y 1 Camshaft rear 3 Punch marks 2 Camshaft front Figure 6 Align Punch Marks on Teeth of Camshaft Sprockets 6 See Figure 6 Align punch marks 3 on teeth of secondary cam sprockets outboard faces Using a colored marker carefully mark the punch mark 3 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 7 Place the secondary cam chain around the sprockets of both the front 2 and rear 1 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 8 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 9 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 10 Place cup of camshaft driver over end of front camshaft only CAUTION Be sure that tensioner shoe is clear of the
5. in applicable Service Manual 17 Apply a thin film of clean H D 20W50 engine oil to the splines of the rear cam 18 Install splined sprocket onto rear camshaft according to ENGINE BOTTOM END Cam Support Plate Disassembly Assembly Camshaft Camshaft Bearings instructions in applicable Service Manual Use new spacers provided in kit Part Number 25938 00 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 Part Number 25938 00 to maintain alignment at 0 10 in 19 Use new cam drive sprocket flange bolt Part Number 996 new washer Part Number 6294 new crank flange bolt Part Number 898A and new flat washer Part Number 6278A provided in kit Part Number 25533 99A 20 Install new flange bolts and washers as follows a Ensure threads are clean and free from oil then apply Loctite Primer 7649 Part Number 98968 99 b Apply Loctite High Strength Threadlocker 262 red Part Number 94759 99 to threads of flange bolts J03817 Awarnine Failure to use Loctite 262 red may result in a joint that will not maintain proper clamp load and may loosen under certain circumstances causing engine failure which could result in death or serious injury c Apply a thin film of clean H D 20W50 engine oil to both sides of flat washers
6. n the CAMSHAFT CAMSHAFT BEARING REMOVER INSTALLER HD 43644 NOTE Bearings may be a press to loose fit If deemed necessary clean bearing OD and apply Loctite Low Strength Threadlocker 242 blue before installation but exercise caution to avoid getting compound on rollers or bearing ID b With the secondary cam chain side facing upward place cam support plate on support block 1 so that outer races of bearings are properly supported Note that one corner of the support block 1 is contoured to accommodate the chain guide blocks cast into the front of the support plate 2 of 4 c Center new bearing over bearing bore with the lettered side up Slide pilot shaft of bearing driver 2 through bearing into hole of support block 1 i02065 1 Bearing pilot driver 2 Bearing 3 Support block Figure 5 Press Bearings into Cam Support Plate d See Figure 5 Center bearing driver 1 under ram of arbor press Press on driver until bearing 2 makes firm contact with counterbore in cam support plate Repeat steps to install second bearing 4 Apply a small amount of Loctite Medium Strength Threadlocker 243 blue to threads of four bearing retainer plate screws Using a T20 TORX drive head secure bearing retainer plate to cam support plate Tighten screws to 20 30 in Ibs 2 3 3 4 Nm in a cross wise pattern 5 Place cam support plate back on support block 3 if removed The block properly supports inner races of
7. ner race 3 has been started onto the machined area remove the flange bolt washer and sprock et then re assemble using the spacer Repeat Step 2 e to fully install bearing inner race i02062 3 Thrust washer 4 Shop rag 1 Box wrench 9 16 in 2 Inner race Figure 2 Install Bearing Inner Race with O Ring and Thrust Washer e See Figure 2 Wrap a shop rag 4 around camshaft to get a firm grip and also to protect hand from sharp edges of sprocket Using a 9 16 in box wrench 1 turn flange bolt in a clockwise direction Bearing inner race 2 is fully installed when it makes firm contact with the thrust washer 3 f Verify that thrust washer 3 is locked in place and cannot be rotated If necessary install shaft in vise using brass jaw inserts and further tighten flange bolt until the desired result is achieved g Remove flange bolt flat washer sprocket and spacer J03817 3 Install new cam bearings into cam support plate accord ing to the following 1 Rear cam roller bearing 2 Front cam ball bearing Figure 3 Cam Bearings NOTE See Figure 3 Be aware that the front and rear cam bearings are no longer interchangeable The rear bearing 1 is now the roller type while the front bearing 2 remains the ball type i02064 3 Camshaft driver 1 Support block 2 Bearing pilot driver Figure 4 Camshaft Camshaft Bearing Remover installer Part Number HD 43644 a See Figure 4 Obtai
8. secondary cam chain during the press procedure Contact can result in damage that requires replacement of the ten sioner assembly 11 Center end of front camshaft under ram and slowly apply pressure to driver just to start front camshaft into bearing ID 3 of 4 CAUTION If rear camshaft is not properly aligned edge of installed inner race can catch on bearing rollers Bearing damage can result if contact occurs during the press procedure 12 Slowly apply pressure to driver on front camshaft while wiggling rear camshaft as necessary to guide inner race between bearing rollers 13 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 14 After installing new cams check for proper cam to cam timing using straightedge along punch marks as described in Service Manual 15 Install new retaining ring in groove at end of front camshaft NOTES Replace original oil pump to cam plate O ring with new O ring Part Number 11286 from Service Kit Part Number 17045 99B Replace original cam plate to crankcase O ring with new O ring Part Number 11301 from Service Kit Part Number 17045 99B 16 Install cam plate according to ENGINE BOTTOM END Cam Support Plate Disassembly Assembly instructions
9. t battery cables negative cable first before proceeding 00307a 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 Installation Procedure Installation of this kit requires removal and re installation of the cam support plate Refer to Section 3 ENGINE BOTTOM END Cam Support Plate Removal and Disassembly Assembly Camshaft Camshaft Bearings of the applicable Service Manual for instructions Replace information pertaining to cam compartment components with the following information NOTE Both crank and primary cam sprocket flange bolts are spe cially hardened while the flat washers are of a special diam eter and have ground surfaces Therefore use only the parts provided in the Drive Gear Retention Kit Part Number 25533 99A when performing this upgrade The crank and primary cam sprocket flange bolts are NOT interchangeable 1 Remove crank and primary cam sprocket flange bolts and washers according to applicable Service Manual Discard cam drive sprocket flange bolts and washers 2 Remove existing cam drive sprocket according to instructions in applicable Service Manual 3 Remove cam bearings according to ENGINE BOTTOM END Cam Support Plate Disassembly Assembly Camshaft Camshaft Bearings instructions in applica ble Service Manual Discard cam bearings Inst
Download Pdf Manuals
Related Search