SCREAMIN` EAGLE TWIN CAM 110 (1800 CC - Harley
Contents
1. E is03456 J04961 Figure 2 Cylinder Wall Crankcase Boring Preparation NOTE During final reassembly of the engine Harley Davidson recommends 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 3 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 Tighten to specifications listed in service 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 One can be purchased separately from a Harley Davidson dealer 5 Install modified top center screw 1093 between the cyl inders 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 Modify Crankcase NOTE To2. 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 engine crankcase halves as necessary 2 See Figure 2 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 Use a 5 8 in 16 mm ball end mill and milling a 5 16 in 7 94 mm radius at the two points shown 2of8 6 Refer to the appropriate service manual and assemble the engine with the following changes e See Figure 6 Install the top center engine crankcase screw 15 supplied in kit but do not tighten e Tighten all of the engine crankcase screws to the specified torque except the top center engine crankcase screw NOTE The cylinder spigot seal is a rectangular O ring Seat the seal at base of cylinder before the cylinder being assembled to the crankcase Using the crankcase to seat the rectangular O ring to t
3. recalibrate the ECM when installing this kit Failure to properly recalibrate the ECM can result in severe engine damage 00399b NOTICE Installation of this kit requires a calibration update using Digital Technician Failure to download calibration update before starting motorcycle will result in ACR failure 00567b 2 Calibrate the ECM before connecting the ACR overlay harness connectors to the ACR solenoids in the cylinder heads 3 Install fuel tank according to the instructions in the service manual WARNING After installing seat pull upward on seat to be 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 4 Install seat according to the instructions in the service manual 5 Install left side cover and left saddlebag Refer to service manual 6 Start and run engine Repeat several times to verify proper operation Operation Refer to the owner s manual to break in the motorcycle 3of8 o lt 6 gt 1 Tap hole with 5 16 18 UNC 2B bottoming tap 6 Extend hole depth 1 00 in 25 4 mm maximum 2 Extend 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 i
4. 0 CC Conversion Kit Item Description Quantity Part Number ACR Overlay Wire Harness Kit Refer to Instruction Sheet J04441 70623 08 J04961 8 of 8
5. cMOTOR HARLEY DAVIDSON WY J04961 INSTRUCTIONS REV 2014 08 26 SCREAMIN EAGLE TWIN CAM 110 1800 CC CONVERSION KIT GENERAL Kit Number 27501 10A 27504 10A 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 Installation Requirements This kit requires the separate purchase of the Cam Drive Retention Kit 25566 06 which is 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 verify 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 installers who wish to use their own boring fixture See appropriate sections in service manual for the special tools required to install this kit Proper installation of this kit also requires the use of Digital Technician at a Harley Davidson dealer 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
6. 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 One is available from a Harley Davidson dealer Kit Contents See Figure 4 to Figure 7 and Table 2 to Table 5 NOTES Installation of this kit by an authorized Harley Davidson dealer will not impact your limited vehicle warranty The kit is intended for High Performance applications only This engine related performance kit is legal for sale or use in select countries or regions on pollution controlled motor J04961 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled vehicles Check with your local Harley Davidson dealer for compliance requirements in your area A new partial emissions tune up label is included as a requirement of the California Air Resource Board CARB EPA emissions regulation Place the new partial label over the upper part of the original emissions tune up label REMOVAL Prepare for Service 1 Raise the motorcycle NOTE Disarm security system WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect negative battery cable 3 Remove seat according to the instructions in the service manual a Refer to service manual to remove left sadd
7. gle Pro TC 103 1690 cc Stage 3 Upgrade Kit Table 3 Service Parts Screamin Eagle Twin Cam 110 1800 CC Conversion Kit Item Description Quantity Part Number Item Description Quantity Part Number 1 Gasket rocker cover base 2 16719 99B 9 Breather assembly 2 17025 03A 2 Gasket rocker cover top 2 17386 99A 10 Baffle assembly 2 26500002 3 Gasket tappet cover 2 18635 99B 11 Seal EFI intake 2 26995 86B 4 O ring middle push rod cover 4 11132A 12 Spring clutch diaphragm 2 Not 37951 98 Shown 5 O ring lower push rod cover 4 11145A 13 High capacity tappet 4 Not Sold Separately 6 O ring upper push rod cover 4 11293 Notes Items 1 through 11 are included in Engine Overhaul 7 O ring rocker arm support 2 11270 Gasket Kit 16500228 Item 13 is included in High Capacity Tappet Kit 18572 13 8 Breather bolt 4 4400 J04961 6 of 8 is03590b Figure 6 Service Parts Screamin Eagle Pro Twin Cam 110 1800 cc Conversion Kit Table 4 Service Parts Screamin Eagle Twin Cam 110 1800 CC Conversion Kit Item Description Quantity Part Number 1 Gasket cam cover 25244 99A 2 Washer 6294 3 Cam drive retention kit w 6294 screws and washer 25566 06 4 Retaining ring 11461 5 Camshaft front Not Sold Separately 6 Camshaft rear Not Sold Separately 7 Bearing needle 2 must be purcha
8. he base of the cylinder can roll spiral the O ring during assembly A rolled Spiraled O ring creates a leak path at the cylinder crankcase interface e After the cylinders and heads have been installed and the hardware tightened to specification tighten top center engine crankcase screw to 50 90 in Ibs 5 6 10 2 Nm INSTALLATION Install Engine and Clutch Components 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 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 service manual 5 Install exhaust head pipe assembly and mufflers previously removed Refer to service manual 6 Install Air Cleaner Kit 29592 05 according to the instructions in the Instruction Sheet Install ACR Overlay Wire Harness See Figure 7 Install the ACR Overlay Wire Harness Kit 70623 06 according to the instructions in the Installation Sheet J04961 Final Assembly IWIN 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 1 Connect both battery cables positive battery cable first NOTICE You must
9. lebag and side cover 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 5 Remove fuel tank according to the instructions in the ser vice manual Remove Engine Components e Remove existing air cleaner assembly Refer to service manual 2 Remove existing exhaust system Refer to 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 sections in service manual 5 Remove existing clutch diaphragm spring Refer to service manual 1 of 8 Please dispose of materials responsibly MACHINE CRANKCASE NOTICE 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 is03517 1 O ring counterbore 2 Spigot bore Figure 1 Spigot Bore and O Ring Counterbore Dimensions Table 1 Spigot Bore and O Ring Counterbore 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
10. n 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 J04961 40f 8 SERVICE PARTS is04669b Figure 4 Service Parts Screamin Eagle Twin Cam 110 1800 cc Conversion Kit Table 2 Service Parts Screamin Eagle Twin Cam 110 1800 CC Conversion Kit Item Description Quantity Part Number Item Description Quantity Part Number 1 Cylinder assembly Black 2 17285 07A 8 Backplate air cleaner 29764 08A Cylinder assembly Silver 2 16815 07A 9 Cylinder head front black w ACR 17288 08A 2 Piston 2 Not Sold Separately Cylinder head front silver w ACR 17289 08A 3 Piston Ring Set 2 21951 11 10 Cylinder head rear black w ACR 17252 07A 4 Piston pin 2 22269 07 Cylinder head rear silver wW ACR 17262 07A 5 Piston pin circlip 4 22097 99 11 Automatic Compression Release 28861 07A ACR 6 Gasket cylinder head 2 16801 07C Notes Piston Kit 21991 11 includes 2 through 5 Item 5 through 7 are also included in Engine Overhaul Gasket Kit 17350 07B Refer to 2010 FLHTCUSE5 Parts Catalog 99428 10 for cylinder head assembly 9 10 components 7 O ring cylinder spigot 2 Not Sold Separately J04961 5 of 8 is03589c Figure 5 Service Parts Screamin Ea
11. sed 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 J04961 7 of 8 Table 4 Service Parts Screamin Eagle Twin Cam 110 1800 CC Conversion Kit Item Description Quantity Part Number 12 Retaining ring internal 35114 02 13 O ring crankcase dowel 2 Not Sold Separately 14 Seal main bearing oil 12068 15 Screw top center crankcase long 1090A 16 O ring CPS not shown 11289A 17 Seal exhaust 2 not shown 65324 83B 18 Seal oil interconnect not shown Softail models only 45359 00 19 Valve seal 4 not shown not required 18067 09 20 Bearing main 24605 07 21 Thrust washer 8972 22 Bearing Kit w 8972 24607 07 35114 02 and inner race not shown 24004 03B 23 Screw modified crankcase boring Not Shown must be purchased separately 1093 Items 5 and 6 are available in Cam Kit 25638 07 Items 8 through 22 are included in Engine Overhaul Gasket Kit 17350 07B Items 13 and 7 table 2 are available in Seal Kit 11907 which is included in the Engine Overhaul Gasket Kit is03616b Ci Figure 7 Service Parts Screamin Eagle Twin Cam 110 1800 cc Conversion Kit Table 5 Service Parts Screamin Eagle Twin Cam 110 180
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