SCREAMIN' EAGLE BIG BORE STAGE 1 KIT
J021222010-12-15
GENERAL
Kit Number
29491-99C
Models
This kit fits Twin Cam 88 (1450 cc) engines on 1999-2001 Touring models equipped with Electronic Fuel Injection (EFI).
Additional Parts and Tools Required
Proper installation of this kit requires the use of Digital Technician™ at a Harley-Davidson dealer.
WARNINGRider and passenger safety depend 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. (00333b)
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
NOTE
Installation of this kit by an authorized Harley-Davidson dealer will not impact your limited vehicle warranty.
This Stage 1 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. Engine related performance parts are intended for the experienced rider only.
The Product Information Label contained in this kit is a requirement of the California Air Resource Board (CARB) emission regulation. Place the label on the right side of the frame directly beneath the VIN sticker. This label is not required outside the state of California.
The air cleaner contained in this kit is designed to perform with this kit only. Any other combination of components is not confirmed to be legal for street use.
REMOVAL
| 1. | Remove seat according to the instructions in the Service Manual. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) WARNINGDisconnect negative (-) 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. (00049a) | ||
| 2. | Disconnect battery cables, negative (-) cable first. | |
NOTICE Head gaskets provided in the Big Bore kit eliminate the need for original equipment (O.E.) O-rings. Do not install the two O-rings from the kit on the top cylinder dowels or severe engine damage can occur. (00484d) WARNINGWhen 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) | ||
| 3. | Remove existing cylinder heads, cylinders, and pistons. Refer to ENGINE section of appropriate Service Manual. | |
| 4. | Remove existing primary chaincase cover, diaphragm spring retainer, and clutch diaphragm spring. Refer to DRIVE section of appropriate Service Manual. |
INSTALLATION
Install Pistons, Cylinders, and Clutch Components
- Install pistons, cylinders, and cylinder heads from kit. Refer to ENGINE section of appropriate Service Manual.
- Install diaphragm spring retainer, clutch diaphragm spring ( Table 2 , item 15) and primary chaincase cover. Refer to DRIVE section of appropriate Service Manual.
Install High Performance Air Cleaner
Refer to instructions included with Air Cleaner Kit (29441-99A) on Instruction Sheet J02590.
Warm-Slow Idle Speed Adjustment
| 1. | Remove air cleaner cover | |||||
| 2. | Start vehicle and run until both engine and oil are fully warm. Using the Digital Technician verify engine temperature is above 250° F (121° C). This step is very important or adjustment will be incorrect. NOTE For proper charging at idle, maintain an idle speed of approximately 950-1050 RPM. Insufficient idle speed may drain the battery in excessive idle situations, resulting in insufficient voltage to the ECM, ignition coil and fuel pump (which can result in a variety of operating problems). | |||||
| 3. | See Figure 1. Locate set screw (1) through hole in air cleaner backplate (2) (lower right corner of the intake air inlet). NOTE For best results, use the Digital Technician to adjust the idle speed. | 
Figure 1. Air Cleaner Backplate | ||||
| 4. | Using a T10 Torx® drive head, turn set screw clockwise to increase or counterclockwise to decrease idle speed. | |||||
| 5. | When idle speed is set, turn Ignition/Light key Switch to OFF. | |||||
| 6. | Install air cleaner. NOTE Installation of air cleaner cover may affect idle speed. | |||||
| 7. | Disconnect Digital Technician and then remove both 5 amp and 15 amp fuses (ECM power and fuel pump) for 15 minutes. This step is necessary to clear the ECM memory of the previously learned minimum throttle position. | |||||
| 8. | Verify correct idle speed after installing air cleaner assembly. Repeat adjustment procedure, if necessary. |
Cold Idle Speed Adjustment
NOTE
All sensors and actuators must be in proper working order and the engine must be in good condition in order for this procedure to have correct and consistent results.
| 1. | Start vehicle and run until engine, primary case and transmission are fully warmed up. Using the Digital Technician, verify engine temperature is above 250° F (121° C). Shut off engine. | |||||||
| 2. | Remove air cleaner and backplate assembly. | |||||||
| 3. | See Figure 2. Unplug wire harness connector (1) from idle speed control actuator (2). | |||||||
| 4. | Start and run engine until idle speed has stabilized approximately one minute. | |||||||
| 5. | Using a T10 Torx drive head, turn cold idle speed set screw (3) until engine speed is 1500-1600 RPM. Be sure not to move the idle speed lever while turning the screw. | 
Figure 2. Induction Module (Top View) | ||||||
| 6. | Reconnect wire harness connector (1) to idle speed control actuator (2). | |||||||
| 7. | Shut off engine and wait approximately 10 seconds. | |||||||
| 8. | Install air cleaner and backplate assembly. |
Final Assembly
WARNINGConnect 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 battery cables, positive (+) cable first. | |
| 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) | ||
| 2. | Install seat according to the instructions in the Service Manual. |
Recalibrate ECM
NOTICE
You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b)
Download the new ECM calibration using the Digital Technician™ at a Harley-Davidson dealer.
SERVICE PARTS
Figure 3. Service Parts: Screamin' Eagle Big Bore Stage 1 Kit
Table 1. Service Parts: Screamin' Eagle Big Bore Stage 1 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Cylinder assembly (Black) (2) | 16547-99 | 6 | Head gasket (2) | 16787-99A | |
2 | Piston (2) | Not Sold Separately | 7 | O-ring, cylinder deck ring dowel (2) | 11273 | |
3 | Piston ring set (2) | 21918-99 | 8 | O-ring, cylinder spigot (2) | 11256 | |
4 | Piston pin (2) | 22132-99 | -- | Piston kit (includes items 2 through 5) | 22851-99A | |
5 | Piston pin circlip (4) | 22097-99 | Note: Do not install O-ring (item 7) to top cylinder dowels. | |||
Figure 4. Service Parts: Screamin' Eagle Big Bore Stage 1 Kit
Table 2. Service Parts: Screamin' Eagle Big Bore Stage 1 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, rock cover base (2) | 16719-99A | 11 | Seal, exhaust (Not Shown) | 17048-98 | |
2 | Gasket, rocker cover top (2) | 17386-99A | 12 | Seal, EFI intake (2) (Not Shown) | 26995-86B | |
3 | Gasket, tappet cover (2) | 18635-99B | 13 | Valve seal kit (Not Shown) | 18004-86 | |
4 | O-ring, middle push rod cover (4) | 11132 | 14 | Spring, clutch diaphragm (Not Shown) | 37951-98 | |
5 | O-ring, lower push rod cover (4) | 11145 | 15 | Flange, front (Not Shown) | 27009-86A | |
6 | O-ring, upper push rod cover (4) | 11293 | 16 | Flange, rear (Not Shown) | 27010-86A | |
7 | O-ring, rocker arm support (2) | 11270 | 17 | Air cleaner kit (Not Shown) | 29441-99A | |
8 | Bolt (4) | 4400 | 18 | Product information label (Not Shown) | Not Sold Separately | |
9 | Baffle assembly (2) | 26500002 | -- | Breather gasket kit (includes items 8 through 10) | 17025-03A | |
10 | Breather Assembly | 17025-03A |