SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT

Transcription

1 -J0 REV SCREAMIN' EAGLE TWIN CAM 0 (00 CC) CONVERSION KIT GENERAL Kit Number 0-0A Models For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of (English only). Additional Parts Required This kit requires the separate purchase of the Cam Drive Retention Kit (-0) which is available from a Harley- Davidson dealer. The separate purchase of Crankcase Boring Tool Kit (- 0) is recommended for installing this high performance engine conversion kit. Crankcase Boring Tool Kit (-0) includes a modified top center screw (0) 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 those 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. 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. (00a) 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 to Figure and Table to Table. S Installation of this kit by an authorized Harley-Davidson dealer will not impact your limited vehicle warranty. This conversion kit is intended for high performance applications only. This engine related performance part is legal for sale or use in California on pollution controlled motor vehicles. REMOVAL Prepare for Service. Position motorcycle on a suitable lift. If vehicle is equipped with Harley-Davidson Smart Security System, see owner's manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (000a). Disconnect battery cables, negative (-) battery cable first.. Remove seat according to the instructions in the service 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. (000a). Remove fuel tank according to the instructions in the service Remove Engine Components. Remove existing air cleaner assembly. Refer to service. Remove exhaust system. Refer to service. Remove engine from chassis following the instructions in the service. Disassemble engine top end and bottom end. Refer to appropriate sections in service. Remove existing clutch diaphragm spring. Refer to service MACHINE CRANKCASE The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00b) -J0 Many Harley-Davidson Parts & Accessories are made of plastics and metals which can be recycled. Please dispose of materials responsibly. of

2 is0. O-ring counterbore. Spigot bore Figure. Spigot Bore and O-Ring Counterbore Dimensions Table. Spigot Bore and O-Ring Counterbore Dimensions Description Spigot Bore O-Ring Counterbore is0 Bore.0 +/ in. (0 +/- 0. mm). +/ in. ( +/- 0.0 mm) Figure. Cylinder Wall Crankcase Boring Preparation Depth. +/ in. (. +/- 0. mm) 0.0 +/ in. (. +/- 0.0 mm) During final reassembly of the engine, Harley-Davidson recommends replacing the Original Equipment cylinder studs with Screamin' Eagle High Tensile Studs (0-0).. Remove cylinder studs from the engine crankcase.. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas.. Inspect and clean engine case mating surfaces.. See Figure. Reassemble engine case with original screws, except the top center screw between the cylinders, and tighten to specifications listed in service To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (0). This screw is included in the Crankcase Boring Tool Kit (-0) and can be purchased separately from a Harley- Davidson dealer.. Install modified top center screw (0) between the cylinders and tighten to 0-0 in-lbs (.-0. Nm). To aid in crankcase boring, a Screamin' Eagle Crankcase Boring Tool Kit (-0) is available. Modified top center screw (0) is included in this kit. Refer to Harley-Davidson Genuine Motor Accessories and Genuine Motor Parts catalog or Screamin' Eagle Pro catalog.. See Figure and Table. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase To prevent severe engine damage, thoroughly clean and remove all chips and debris from the engine crankcase after boring.. Disassemble crankcase and wash (or clean) chips and debris from engine crankcase halves as necessary.. See Figure. Using a / in. (. mm) drill bit, drill out the existing threads of the top center screw hole. Drill to a depth of 0. in. (0 mm) from the gasket surface.. Using a size "F" in. (. mm) drill bit, extend the top center screw hole.00 in. (. mm) maximum to a depth of. in. (. mm) from the gasket surface.. Using a bottoming tap (purchased separately) size /- UNC-B, tap the screw hole to a minimum depth of. in. (0. mm) from the gasket surface.. See Figure and Figure. Remove the thin material between the cylinders next to the top center screw as shown, by using a / in. ( mm) ball end mill and milling a / in. (. mm) radius at the two points shown.. Refer to the appropriate service manual and assemble the engine with the following changes: See Figure. Install the top center engine crankcase screw () supplied in kit but do not tighten. Tighten all of the engine crankcase screws to the specified torque, except the top center engine crankcase screw. Note that the cylinder spigot seal is a rectangular o-ring which should be seated at base of cylinder prior to the cylinder being assembled to the crankcase. Using the crankcase to seat the rectangular o-ring to the base of the cylinder can roll -J0 of

3 (spiral ) the o-ring during assembly. A rolled (spiraled) o-ring will create a leak path at the cylinder/crankcase interface. After the cylinders and heads have been installed and the hardware tightened to specification, tighten top center engine crankcase screw to 0-0 in-lbs (.-0. Nm) INSTALLATION Install Engine and Clutch Components. See Figure. Inspect camshaft needle bearings () and replace if necessary.. See Figure through Figure. Assemble engine top end and bottom end using parts from kit. Refer to appropriate sections in service. Install engine in chassis following the instructions in the service. Install clutch diaphragm spring from kit. Refer to service. Install exhaust assembly previously removed. Refer to service. See Figure. Install Air Cleaner Kit (-0) according to the instructions in the Instruction Sheet. Install ACR Overlay Wire Harness See Figure. Install the ACR Overlay Wire Harness Kit (0-0) according to the instructions in the Installation Sheet. Final Assembly 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. (000a). Connect battery cables, positive cable first. You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00b) Installation of this kit requires a calibration update using Digital Technician. Failure to download calibration update before starting motorcycle will result in ACR failure. (00b). Calibrate the ECM before connecting the ACR overlay harness connectors to the ACR solenoids in the cylinder heads.. Install fuel tank according to the instructions in the service 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. (0000b). Install seat according to the instructions in the service. Start and run engine. Repeat several times to verify proper operation. Operation Refer to the owner's manual for instructions to break-in the motorcycle. is00a 0 0. Tap hole with /- UNC-B bottoming tap. Extend hole depth -.00 in. (. mm) maximum. Extend full thread depth in. (0 mm). Unthreaded screw hole depth - 0. in. (0 mm). Distance - 0. in. ( mm). Distance to center of crank -.0 in. (0 mm). Distance - 0. in. ( mm). Distance to center of crank -.00 in. ( mm). Drilled hole diameter - 0. in. (. mm) 0. Radius - 0. in. (. mm) - use / in. ( mm) ball end mill Figure. Top Center Engine Crankcase Screw Hole Modification -J0 of

4 SERVICE PARTS is0b 0 Figure. Service Parts: Screamin' Eagle Twin Cam 0 (00 cc) Conversion Kit Table. Service Parts: Screamin' Eagle Twin Cam 0 (00 CC) Conversion Kit Cylinder assembly (Black) () -0A O-ring, cylinder spigot () Piston () Cylinder head, front (black) with ACR -0B Piston Ring Set () - Cylinder head, rear (black) with ACR -0A Piston pin () -0 0 Automatic Compression Release (ACR) -0A Piston pin circlip () 0- Air Cleaner Kit (not shown) -0 Gasket, cylinder head () 0-0C Notes: Piston Kit (-) includes through. through are also included in Engine Overhaul Gasket Kit (0-0B). Refer to 00 FXDFSE Parts Catalog (0-0) for cylinder head assembly (, ) components. -J0 of

5 is0c 0 Figure. Service Parts: Screamin' Eagle Pro TC 0 (0 cc) Stage Upgrade Kit Table. Service Parts: Screamin' Eagle Twin Cam 0 (00 CC) Conversion Kit Gasket, rocker cover base () -B Breather assembly () 0-0A Gasket, rocker cover top () -A 0 Baffle assembly () 0000 Gasket, tappet cover () -B Seal, EFI intake () -B O-ring, middle push rod cover () A Spring, clutch diaphragm () (Not Shown) - O-ring, lower push rod cover () A High capacity tappet () O-ring, upper push rod cover () O-ring, rocker arm support () Breather bolt () 0 00 Notes: s through are included in Engine Overhaul Gasket Kit (00) is included in High Capacity Tappet Kit (-). -J0 of

6 is00b 0 0 Figure. Service Parts: Screamin' Eagle Pro Twin Cam 0 (00 cc) Conversion Kit Table. Service Parts: Screamin' Eagle Twin Cam 0 (00 CC) Conversion Kit 0 Gasket, cam cover Washer Cam drive sprocket retention kit w/, screws and washers Retaining ring Camshaft, front Camshaft, rear Bearing, needle () (must be purchased separately, if needed) O-ring, oil pump to cam plate O-ring, cam plate to crankcase () O-ring, crankcase ring dowel () O-ring, piston cooling () -A A 0 -J0 of

7 0 Retaining ring, internal O-ring, crankcase dowel () Seal, main bearing oil Table. Service Parts: Screamin' Eagle Twin Cam 0 (00 CC) Conversion Kit Screw, top center crankcase, long O-ring, CPS (not shown) Seal, exhaust () (not shown) Seal, oil interconnect (not shown) (Softail models only) Valve seal () (not shown) (not required) Main bearing Thrust washer Bearing kit, w/, 0-0, -0 + inner race (not shown) Screw, modified, crankcase boring (not shown) (must be purchased separately) A A -B B Notes: s and are available in Cam Kit (-0) s through are included in Engine Overhaul Gasket Kit (0-0B) s and (table ) are available in Seal Kit (0) which is included in the Engine Overhaul Gasket Kit 0 is0b Figure. Service Parts: Screamin' Eagle Twin Cam 0 (00 cc) Conversion Kit Table. Service Parts: Screamin' Eagle Twin Cam 0 (00 CC) Conversion Kit ACR Overlay Wire Harness Kit (Refer to Instruction Sheet J00) 0-0 -J0 of