SCREAMIN' EAGLE STREET LEGAL BIG-BORE (EFI) STAGE 2 KIT
J038662010-12-15
GENERAL
Kit Numbers
29871-06, 29872-06, 29879-06, 29886-06, 29880-06
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
These kits are only 49 state street legal and cannot be used in California.
Table 1. Screamin' Eagle Street Legal Big Bore (EFI) Stage 2 Kits
Description (Quantity) | Part Number |
|---|---|
FHLTI, FLHTCI, FLHTCUI, FLHRI BLACK, 49 STATE | 29871-06 |
FLHTI, FLHTCI, FLHTCUI, FLHRI SILVER, 49 STATE | 29872-06 |
FLHRSI, FLHRCI, FLTRI BLACK, 49 STATE | 29879-06 |
FLHRSI, FLHRCI, FLTRI SILVER, 49 STATE | 29886-06 |
FLHXI BLACK, 49 STATE | 29880-06 |
Additional Parts Required
Installation of the camshafts included in this kit requires the separate purchase of spacers from a Harley-Davidson dealer. Refer to the parts catalog for the correct part number for the spacer needed.
Proper installation of this kit requires the separate purchase of two muffler clamps (65296-95A).
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.
NOTICE
You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b)
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)
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)
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)
INSTALLATION
Installation of this kit is divided into six steps:
- Big Bore Cylinder and Piston Conversion
- High Performance Camshafts
- High Performance Clutch Diaphragm Spring
- High Performance Air Cleaner
- Calibrate the ECM
- Exhaust
NOTE
This Big Bore Stage 2 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 air cleaner contained in these kits is designed to perform with these kits only. Any other combination of components is not confirmed to be legal for street use.
The Product Information Label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the Product Information Label on the right side of the frame, directly beneath the VIN sticker. Do not place the label on motorcycles other than those specified in the Instruction Sheet.
Big Bore Cylinder and Piston Conversion
Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to the service manual for instructions.
High Performance Camshafts
Installation of this kit requires removal and re-installation of the cam support plate. Refer to the service manual for instructions.
Measuring Piston-to-Valve Clearance
After installing non-stock cams, check piston-to-valve clearance.
- Apply 1/8-inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons.
- Refer to the appropriate service manual and assemble the heads and valve train, and tighten cylinder studs to torque specified.
- Turn engine through two complete revolutions by hand.
- Remove heads and measure clay at its thinnest point.
NOTE
Clay must measure 2.03 mm (0.080 in) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 3.43 mm (0.135 in).
Measuring Valve-to-Valve Clearance
NOTE
Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents you from bending push rods or valves.
| 1. | Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust and intake valve heads cross, where both valves are off their seats by an equal amount. NOTE See Figure 1. If it is necessary after inspection to grind the intake and exhaust valves in order to meet the 1.016 mm (0.040 in) clearance between the two valve heads, the margins (3) must be measured as follows: 0.787 mm (0.031 in) minimum margin on exhaust valves and 0.381 mm (0.015 in) minimum margin on intake valves. | |||||||
| 2. | A 1.016 mm (0.040 in) clearance is required between the two valve heads. Use a 0.040 in wire gauge (1) to measure this. To adjust the clearance, grind the edges of the intake and exhaust valves at a 45-degree angle (2). | |||||||
| 3. | Repeat steps 1 and 2 for the rear cylinder. | 
Figure 1. Beveling Valve Heads |
New Pistons, Cylinders, and Cylinder Heads
- Assembly - Refer to the ENGINE section of the appropriate service manual for installing pistons, cylinders and cylinder heads.
High Performance Clutch Diaphragm Spring
- Disassembly - Refer to the DRIVE section of the appropriate service manual to remove primary chain case, chain, diaphragm spring retainer and diaphragm spring.
- Assembly - Refer to the DRIVE section of the appropriate service manual for installing diaphragm spring retainer, diaphragm spring, chain and primary chain case.
High Performance Air Cleaner
Follow the instructions included with the High Performance air cleaner in this kit for installation.
Calibrate the ECM
Have dealer recalibrate the ECM prior to starting vehicle.
Exhaust
Refer to the appropriate service manual for exhaust installation procedure, if required.
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)
- Connect the battery cables, positive (+) cable first.
- Refer to the service manual, and follow instructions to install the seat.
SERVICE PARTS
Figure 2. Service Parts: Screamin' Eagle Street Legal Big-Bore (EFI) Stage 2 Kit
Table 2. Service Parts: Screamin' Eagle Street Legal Big Bore (EFI) Stage 2 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Assembly, 1550 cylinder, black (2) | 16547-99 |
2 | Piston, 1550 standard (2) | 17162-03 |
3 | Pin, piston (2) | 22132-99 |
4 | Lock wire, piston pin (4) | 22097-99 |
5 | O-ring, cylinder spigot (2) | 11256 |
6 | O-ring, cylinder deck ring dowel (2) | 11273 |
7 | Kit, head gasket (2) | 17386-99 |
8 | Ring set, piston, 1550 standard (2) | 21918-99 |
9 | Gasket, rocker cover top (2) | 11132 |
10 | O-ring, upper push rod cover (4) | 11293 |
11 | O-ring, middle push rod cover (4) | 11132 |
12 | O-ring, lower push rod cover (4) | 11145 |
13 | Gasket, rocker cover base (2) | 16719-99A |
14 | O-ring, rocker arm support (2) | 11270 |
15 | Bolt (4) | 4400 |
16 | Breather assembly | 17025-03A |
17 | Baffle assembly (2) | 26500002 |
18 | Kit, exhaust gasket (not shown) (2) | 217048-98 |
19 | Seal, intake manifold (not shown) | 26995-86B |
20 | Kit, performance A/C CARB/EFI (not shown) | 29440-99C |
21 | Label, EO (not shown) | 29875-06 |
22 | Clutch diaphragm spring, high performance (not shown) | 37951-98 |
Figure 3. Service Parts: Screamin' Eagle Street Legal Big Bore (EFI) Stage 2 Kit
Table 3. Service Parts: Screamin' Eagle Street Legal Big Bore (EFI) Stage 2 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Cap screw, flanged (crank) | 898A |
2 | Cap screw, flanged (cam) | 996 |
3 | Washer (crank) | 6278A |
4 | Washer (cam) | 6294 |
5 | Assembly, roller bearing | 8983 |
6 | Bearing camshaft | 8990A |
7 | O-ring, oil pump-to-cam plate | 11286 |
8 | O-ring, cam plate-to-crankcase (2) | 11301 |
9 | Retaining ring, camshaft | 11494 |
10 | Gasket, cam cover | 25244-99A |
11 | Camshaft, 1450/1550 stage 2, front | 25342-99 |
12 | Camshaft, rear machining, SHE-203 Loctite 262 (red) | 94673-99 |
Figure 4. Service Parts: Screamin' Eagle Street Legal Big Bore (EFI) Stage 2 Kit
Table 4. Service Parts: Screamin' Eagle Big Bore (EFI) Stage 2 Kit Mufflers
Kit/Model | Item | Description (Quantity) | Part Number |
|---|---|---|---|
29871-06 FLHTCI,FLHTCUI, FLHRI 29872-06 FLHTI | 1 | Muffler, LH DOM-CAT, chrome | 65554-95B |
2 | Clamp, muffler (2) | 65283-94 | |
29879-06 FLHRSI, FLHRCI 29886-06 FLTRI | 1 | Muffler, LH DOM-CAT, chrome | 65418-04 |
2 | Clamp, muffler (2) | 65283-94 | |
29880-06 FLHXI | 1 | Muffler, LH DOM-CAT, chrome | 65566-06 |
2 | Clamp, muffler (2) | 65283-94 |