4.060 inch bore, 11.1 compression, ivan chamber - Harley
Contents
1. 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 J04823 Piston Wear Limit in Fit in cylinder 0 005 Compression ring gap 1 Thumb orientation Top 0 032 2 Circlip 85 seated Second 0 049 Figure 2 Install Circlip Oil control rail gap 0 055 7 See Figure 2 Position your thumb 1 as shown and press firmly until approximately 85 of the circlip 2 is seated in the groove 8 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 9 Refer to the ENGINE ASSEMBLING MOTORCYCLE AFTER STRIPPING section of the Service Manual for final re assembly procedures NOTE Always follow the break in procedure outlined in the appropriate Owner s Manual after rebuilding an engine 20f3 SERVICE PARTS is05105 Figure 3 Service Parts Screamin Eagle Pro Twin Cam Stroker Piston Kits Table 4 Service Parts Table Front and Rear Piston Kits Piston accessory kit includes items 4 through 6 22594 08 e Ring set 0 010 Not Sold Separately e Piston pin Not Sold Separately Kit Item Description Quantity Part Number Kit 21915 08 1 Piston front standard Not sold separately Piston K2. YCLE FOR SERVICE and TOP END OVERHAUL DISASSEMBLY sections of the Service Manual for cylinder head cylinder and piston removal procedures 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 w 1of3 4 See the ENGINE SUBASSEMBLY SERVICE AND REPAIR CYLINDER section of the Service Manual for boring and honing instructions NOTES Install piston rings having dots or bevels with the dots or bevels facing UP Rings with no markings can be installed either side up Piston dimensions to be measured 0 285 inches above the lowest part of the skirt 5 Refer to the ENGINE TOP END OVERHAUL ASSEMBLY section of the Service Manual for piston cylinder and cylinder head installation procedures Table 2 Piston Manufacturing Tolerances Piston Tolerance in Fit in cylinder w o coating Fit in cylinder w coating 0 0025 0 0035 0 0015 0 0025 is02626 1 Circlip 2 Notch 3 Groove Figure 1 Circlip and Piston Compression ring gap e Top 0 012 0 022 e Second 0 012 0 022 Oil control rail gap 0 015 0 055 Table 3 Piston Service Wear Limits is02627 Piston Pin Retaining Ring Circlip Installation NOTE Circlip gap must be at 12 00 or 6 00 position when installed 6 See Figure 1 Insert the open end of the circlip
3. cMOTOR HARLEY DAVIDSON WY J04823 INSTRUCTIONS REV 2008 09 11 4 060 INCH BORE 11 1 COMPRESSION IVAN CHAMBER PISTON KIT GENERAL NOTES All dimensions listed on these instructions are in inches Kit Numbers 21915 08 21914 08 Models These kits fit Harley Davidson Twin Cam engines with the fol lowing items installed Screamin Eagle Big Bore 4 060 inch Cylinder Kit e 1999 and later stock 4 375 in stroke flywheels e Screamin Eagle Pro 110 or Screamin Eagle Pro ACR Performance Cylinder Heads 110 head or MVA perfor mance heads Table 1 Models Kit Application 21915 08 Standard 3 875 in front amp rear 21914 08 0 010 front amp rear 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 You must recalibrate the ECM when installing this kit Failure to properly recalibrate the ECM can result in severe engine damage 00399b 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 thi
4. it 2 Piston rear standard Not sold separately Standard 3 Piston accessory kit includes items 4 through 6 22593 08 4 e Ring set standard Not Sold Separately 5 e Piston pin Not Sold Separately 6 e Circlip 2 Not Sold Separately Kit 21914 08 1 Piston front 0 010 Not sold separately Ae ae 2 Piston rear 0 010 Not sold separately 3 4 5 6 e Circlip 2 Not Sold Separately Items common to all Piston Kits 5 Piston pin 2 22455 03 6 Retaining ring Circlip 4 22456 03 J04823 3 of 3
5. s performance product J04823 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 WINN IN IN 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 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 MOTORC
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