SCREAMIN' EAGLE PRO TWIN CAM STROKER PISTON KITS FOR 103+ CYLINDER HEADS
J037742008-10-06
GENERAL
NOTE
All dimensions listed on these instructions are in inches.
Kit Number
22516-04, 22518-04 through 22519-04.
Models
These kits fit Harley-Davidson Twin Cam engines with the following items installed:
- Screamin' Eagle® Bigger-Bore (4.060 in.) Cylinder Kit,
- Screamin' Eagle Pro Stroker flywheel and Rod Assembly, AND
- Screamin' Eagle Pro 103+ Cylinder Heads.
Table 1. Models
Kit | Application |
|---|---|
22516-04 | Standard, 4.060 in. (front & rear) |
22518-04 | +0.005 (front & rear) |
22519-04 | +0.010 (front & rear) |
NOTE
This engine-related performance part is intended for high-performance 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
NOTICE
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 this performance product.
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.
INSTALLATION
WARNINGTo 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)
| 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 MOTORCYCLE FOR SERVICE and TOP END OVERHAUL, DISASSEMBLY sections of the Service Manual for cylinder head, cylinder and piston removal procedures. | |
| 3. | 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. | |
| 4. | See the ENGINE: SUBASSEMBLY SERVICE AND REPAIR, CYLINDER section of the Service Manual for boring and honing instructions. NOTE Install piston rings having dots or bevels with the dots or bevels facing UP. Rings with no markings can be installed either side up. Unlike the stock cylinders, 4.060 in. cylinders do not use the "O"-rings (Part Number 11273) on the cylinder-to-crankcase dowel pins. Therefore, do not install them when using torque plates or at final assembly of the engine. 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 | 0.0025-0.0035 |
Compression ring gap: | |
| 0.012-0.022 |
| 0.012-0.022 |
Oil control rail gap | 0.015-0.055 |
Table 3. Piston Service Wear Limits
Piston: | Wear Limit (in.) |
|---|---|
Fit in cylinder | 0.005 |
Compression ring gap: | |
| 0.032 |
| 0.049 |
Oil control rail gap | 0.055 |
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 (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. | 
Figure 1. Circlip and Piston 
Figure 2. Install Circlip | ||||||||||
| 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.
SERVICE PARTS
Table 4. Service Parts Table, Front and Rear Piston Kits
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 22516-04 Piston Kit (Standard) | 1 | Piston (front, standard) | Not sold separately |
2 | Piston (rear, standard) | Not sold separately | |
3 | Ring set (standard) (2) | 22526-04 | |
Kit 22518-04 Piston Kit (+0.005) | 1 | Piston (front, +0.005) | Not sold separately |
2 | Piston (rear, +0.005) | Not sold separately | |
3 | Ring set (+0.005) (2) | 22528-04 | |
Kit 22519-04 Piston Kit (+0.010) | 1 | Piston (front, +0.010) | Not sold separately |
2 | Piston (rear, +0.010) | Not sold separately | |
3 | Ring set (+0.010) (2) | 22529-04 | |
Items common to all Piston Kits: | |||
4 | Piston pin (2) | 22455-03 | |
5 | Retaining ring (Circlip) (4) | 22456-03 | |
Figure 3. Service Parts, Screamin' Eagle Bigger-Bore (103+) Stroker High Compression Piston Kits