SCREAMIN' EAGLE 1550 TWIN CAM (HTCC HEADS) 10.5:1 FORGED PISTON KIT
J025892008-10-08
GENERAL
Kit Number
22439-00A, 22440-00A, 22441-00A
Models
This High Torque Combustion Chamber (HTCC) 1550 forged piston kit is designed for installation on Harley-Davidson Twin Cam motorcycles equipped with a 1550 Screamin' Eagle HTCC manifold (P/N 29634-00) and Screamin' Eagle HTCC heads (P/N 16933-99 ,black) or (P/N 16926-99, silver).
NOTE
All dimensions listed on these instructions are in inches.
Table 1. Models
Kit | Application |
|---|---|
22439-00A | Standard (front & rear) |
22440-00A | +0.005 (front & rear) |
22441-00A | +0.010 (front & rear) |
NOTE
Harley-Davidson motorcycles equipped with some Screamin' Eagle high-performance engine parts may not be used on public roads, and in some cases must be restricted to closed course competition. This engine related performance part is intended for racing applications, and is not legal for sale or use on pollution-controlled motor vehicles.
Additional Parts Required
Service Gasket kit (P/N 17052-99) is required for assembly.
1550 Kits require separate purchase of two head gaskets (P/N 16787-99).
NOTE
Re-jetting or re-timing of the engine may be required to realize the full potential of this performance product.
For optimal performance, exhaust seals should be replaced with Screamin' Eagle exhaust seals (P/N 17048-98).
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 ENGINE REPAIR, CYLINDER HEAD REMOVAL sections of the service manual. | |
| 3. | Follow the procedures in the ENGINE: CYLINDER AND PISTON, REPAIR, BORING AND HONING CYLINDER. | |
| 4. | See the ENGINE: CYLINDER AND PISTON INSTALLATION AND ASSEMBLY. 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. 1550 cylinders do not use O-rings on the top cylinder dowels. Do not install them when using torque plates or at final assembly of engine. |
Table 2. Piston Manufacturing Tolerances
Piston: | Tolerance (in.) |
|---|---|
Fit in cylinder | 0.0025-0.0035 |
Compression ring gap | |
Top Second | 0.009-0.015 0.019-0.029 |
Oil control rail gap | 0.010-0.030 |
Table 3. Piston Service Wear Limits
Piston: | Wear Limit (in.) |
|---|---|
Fit in cylinder | 0.005 |
Compression ring gap | |
Top Second | 0.025 0.039 |
Oil control rail gap | 0.030 |
Piston Pin Retaining Ring (Circlip) Installation
NOTE
Circlip gap must be at 12:00 or 6:00 position when installed.
| 5. | 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 (generic piston shown) 
Figure 2. Install Circlip (generic piston shown) | ||||||||||
| 6. | See Figure 2. Position your thumb (1) as shown, and press firmly until approximately 85% of the circlip (2) is seated in the groove. | |||||||||||
| 7. | 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. | |||||||||||
| 8. | 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
Figure 3. Service Parts: Screamin' Eagle Twin Cam (103 cu. in. Heads) Stroker Forged Piston Kits
Table 4. Service Parts Table, Front and Rear Piston Kits
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 22439-00A Piston Kit Standard | 1 | Piston (front, standard) | Not sold separately |
2 | Piston (rear, standard) | Not sold separately | |
3 | Ring set (standard) (2) | 22431-00 | |
Kit 22440-00A 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) | 22432-00 | |
Kit 22441-00A 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) | 22433-00 | |
Items common to all Piston Kits: | |||
4 | Piston pin (2) | 22419-00 | |
5 | Retaining ring (Circlip) (4) | 22420-00 | |