XL 1200 CC HIGH COMPRESSION PISTON KITS - Harley
Contents
1. Kit ltem Description Quantity Part Number Kit 22711 04 Piston front and rear Not Sold Separately Standard 2 Piston Ring Set 2 21925 04 3 Pin piston 2 22481 04 4 Circlip piston pin 4 22482 04 Kit 22712 04 1 Piston front and rear Not Sold Separately 0 005 Inch 2 Piston Ring Set 2 21926 04 3 Pin piston 2 22481 04 4 Circlip piston pin 4 22482 04 Kit 22713 04 1 Piston front and rear Not Sold Separately 0 010 Inch 2 Piston Ring Set 2 21927 04 3 Pin piston 2 22481 04 4 Circlip piston pin 4 22482 04 J03624 4 of 42. cMOTOR HARLEY DAVIDSON WY J03624 INSTRUCTIONS REV 2007 01 10 XL 1200 CC HIGH COMPRESSION PISTON KITS GENERAL Kit Number 22711 04 22712 04 and 22713 04 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 Additional Parts Required Service Gasket Kit 17049 04A is required for assembly and must be purchased separately Piston Pin Retaining Ring Installer HD 34623 C is required for assembly and must be purchased separately Carbureted models Screamin Eagle Pro Ignition Race Tuner or Screamin Eagle Pro Ignition Module is required and must be purchased separately EFI models Screamin Eagle Pro EFI Race Tuner is required and must be purchased separately IWAN IN 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 and Table 1 NOTE This engine related performance part is intended for H
3. d washers HD 33446 4 3 Tighten the bolts Refer to CYLINDER HEAD INSTALLA TION section in Service Manual NOTE Torque plates properly tightened and installed with gaskets simulate engine operating conditions Measurements vary as much as 0 0017 in without torque plates 4 Bore the cylinder with gaskets and torque plates attached Bore the cylinder to 0 003 in under the desired finished size NOTE Use the piston to determine finished size Piston fit to the cylinder must be within the range 0 0025 in to 0 0035 in 1 of 4 is00120 y lt Cie pees eee 1 Piston width 2 Measurement area Figure 1 Piston Measurements 5 See Figure 1 Measure the piston width 1 90 degrees horizontally from both sides of the pin piston pin hole and at 1 2 in above 2 the lowest portion of the skirt above the chamfer 6 Hone the cylinder to its finished size using a 280 grit rigid hone followed by a 240 grit flexible ball hone Honing must be done with torque plates attached All honing must be done from the bottom crankcase end of the cylinder Maintain a 60 degree crosshatch pattern in the piston travel area 7 See Figure 2 After machining and honing chamfer the bottom inner edge 1 of the cylinder liner The chamfer provides a beveled surface for easier installation of the cylinder over the piston rings Break leading edge of liner to a flat surface The bott
4. igh Performance or Racing applications and is not legal for sale or use on pollution controlled motor vehicles This kit reduces or voids the limited vehicle warranty Engine related perfor mance parts are intended for the experienced rider only DISASSEMBLY IWAN IN To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a J03624 IWIN NIN 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 Disconnect battery cables negative cable first 2 Refer to appropriate ENGINE sections of Service Manual to remove cylinder heads cylinders and pistons INSPECTION After removing the cylinders e Check the head gasket and base gasket surfaces for flat ness e Remove burrs from all gasket surfaces Before installing the new pistons e Check the clearance between the new piston pin and the connecting rod bushing e Replace the bushing if pin clearance is 0 002 in or more BORING AND HONING PROCEDURE 1 Check again for burrs on the cylinder gasket surfaces and remove burrs before continuing to Step 2 2 Install the following components a Original head and base gaskets b Cylinder torque plates HD 33446 B c Evolution bolts an
5. ne NOTE Engine re jetting or re timing may be required to achieve full potential of this performance product MIWA NIN 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 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 J03624 2 Connect battery cables positive cable first CAUTION You must recalibrate the ECM when installing this kit Failure to properly recalibrate the ECM can result in severe engine damage 00399b 3 Carbureted models Use Screamin Eagle Pro Ignition Race Turner or Screamin Eagle Pro Ignition Module to ensure proper installation of kit EFI models Use Screamin Eagle Pro EFI Race Turner to ensure proper installation of kit NOTE This diagnostic equipment must be purchased separately and are available at a Harley Davidson dealer BREAK IN RIDING RULES Refer to BREAK IN RIDING RULES in the Owner s Manual for instructions to break in the motorcycle 3of4 SERVICE PARTS is04292 Figure 4 Service Parts XL 1200 cc High Compression Piston Kits Table 1 Service Parts XL 1200 cc High Compression Piston Kits
6. om edge of the liner 2 will be somewhat sharp after machining This sharp edge could easily cause damage during installation of the cylinder is00123 Inside chamfer Cylinder liner bottom edge 1 2 3 Cylinder liner outside wall 4 Cylinder liner inside wall Figure 2 Inside Chamfer and Bottom Edge of Cylinder Liner J03624 PISTON INSTALLATION NOTE The 1200 cc pistons in this kit are coated with electroless nickel coating The pistons are directional and the arrow must point forward These pistons are not specific to front or back cylinders and can be installed in either of the two cylinders 1 Check the piston rings for proper side clearance and end gap Refer to appropriate ENGINE sections in Service Manual The end gaps of adjacent rings must be installed 90 degrees apart Install the piston rings with dots and bevels facing up Piston rings with no markings can be installed either side up PISTON PIN CIRCLIP INSTALLATION 1 See Figure 3 Insert the circlip 4 onto the Piston Pin Retaining Ring Installer Squeeze handles of tool together and insert circlip into slot of the piston Release the handles and remove tool Repeat steps for remaining circlips is00125 1 Piston pin lock ring 2 Piston pin retaining ring installer HD 34623 C Figure 3 Seating Circlip 2 of 4 ASSEMBLY 1 Refer to appropriate ENGINE sections of Service Manual to assemble the engi
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