SCREAMIN' EAGLE BIG BORE EFI STAGE 2 KIT FOR EFI MODELS
J041732010-12-15
GENERAL
Kit Number
29905-07, 29907-07, 29918-07, 29919-07, 29920-07, 29921-07, 29922-07, 29924-07, 29925-07
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Table 1. Screamin' Eagle Big Bore EFI 1690 Stage 2 Kits
Description (Quantity) | Part Number |
|---|---|
Street Legal (Black) (Touring only) | 29905-07 |
Street Legal (Silver) (Touring only) | 29907-07 |
Street Legal (Black) (FXDBI, FXDRI, FXDWGI) | 29918-07 |
Street Legal (Silver) (FXDI, FXDCI) | 29919-07 |
Street Legal Shotgun (Black) (FXSTDI, FLSTFI) | 29920-07 |
Street Legal Shorty-Dual (Black) (FXSTBI, FXSTSI, FLSTCI) | 29921-07 |
Street Legal Shorty-Dual (Silver) (FXST, FLST) | 29922-07 |
Street Legal (Black Deluxe) (FLSTNI) | 29924-07 |
Street Legal (Black) (FLSTSCI) | 29925-07 |
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.
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.
Gaskets provided in the 1690 conversion kit eliminate the need for original head gasket O-rings. For this reason, DO NOT install the Original Equipment (OE) O-rings (11273) to the top of cylinder dowels, or severe engine damage may occur.
Big-Bore Cylinder and Piston Conversion
NOTE
Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to Section 3, ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL of the applicable service manual for instructions.
High Performance Camshafts
NOTE
Installation of this kit requires removal and re-installation of the cam support plate. Refer to Section 3, ENGINE: BOTTOM END Cam Support Plate, Removal and Disassembly/Assembly (Camshaft, Camshaft Bearings) of the applicable 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 0.080 inch (2.03 mm) 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 0.135 inch (3.43 mm).
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 0.040 inch (1.016 mm) clearance between the two valve heads, the margins (3) must be measured as follows: 0.031 inch (0.787 mm) minimum margin on exhaust valves and 0.015 inch (0.381 mm) minimum margin on intake valves. | 
Figure 1. Beveling Valve Heads | ||||||
| 2. | A 0.040 inch (1.016 mm) clearance is required between the two valve heads. Use a 0.040 inch 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. |
Install 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' Big-Bore EFI Stage 2 Kit
Table 2. Service Parts: Screamin' Eagle Big-Bore EFI Stage 2 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | O-ring, middle push rod cover (4) | 11132 |
2 | O-ring, lower push rod cover (4) | 11145 |
3 | O-ring, cylinder spigot (2) | 11256 |
4 | O-ring, rocker arm support (2) | 11270 |
5 | O-ring, cylinder deck ring dowel (2) | 11273 |
6 | O-ring, upper push rod cover (4) | 11293 |
7 | Assembly, 1690 cylinder, black (2) | 16547-99 |
Assembly, 1690 cylinder, silver (2) | 16548-99 | |
8 | Gasket, rocker cover base (2) | 16719-99A |
9 | Kit, head gasket (2) | 16787-99A |
10 | Gasket, rocker cover top (2) | 17386-99A |
11 | Ring set, piston, 1690 standard (2) | 21918-99 |
12 | Lock wire, piston pin (4) | 22097-99 |
13 | Kit, Piston, 1690 standard (2) | 21966-07 |
14 | Bolt (4) | 4400 |
15 | Breather assembly | 17025-03A |
16 | Baffle assembly | 26500002 |
17 | Pin, piston (2) | 22132-99 |
Kit, exhaust gasket (not shown) | 17048-98 | |
Seal, intake manifold (not shown) (2) | 26995-86B | |
Clutch diaphragm spring, high performance (not shown) | 37951-98 | |
Loctite 262, red, 0.5 ml tube (not shown) | 94673-99 | |
Label, EO (not shown) (Street Legal Kits only) | 32874-07 |
Figure 3. Service Parts: Screamin' Eagle Big-Bore EFI Stage 2 Kit
Table 3. Service Parts: Screamin' Eagle Big-Bore EFI Stage 2 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Capscrew, flanged (crank) | 898A |
2 | Capscrew, flanged (cam) | 996 |
3 | Washer (crank) | 6278A |
4 | Washer (cam) | 6294 |
5 | O-ring, oil pump-to-cam plate | 11286 |
6 | O-ring, cam plate-to-crankcase (2) | 11301 |
7 | Gasket, cam cover | 25244-99A |
8 | Camshaft, front, SE255 (included in Kit 25638-07) | Not Sold Separately |
9 | Camshaft, rear, SE255 (included in Kit 25638-07) | Not Sold Separately |
Kit, Camshaft, SE255 (includes items 8 and 9) | 25638-07 |
Figure 4. Service Parts: Screamin' Big-Bore EFI Stage 2 Kit
Table 4. Service Parts: Screamin' Eagle Big-Bore EFI Sgtage 2 Kit Mufflers
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
Kit 29905-07 (fits Touring only) | 1 | Muffler, RH | 66080-06A |
Muffler, LH | 65913-06A | ||
2 | Clamp, Muffler (2) | 65283-94 | |
Kit 29907-07 (fits Touring only) | 1 | Muffler, RH | 66080-06A |
Muffler, LH | 65913-06A | ||
2 | Clamp, Muffler (2) | 65283-94 | |
Kit 29925-07 (fits FLSTSCI only) | 1 | Muffler, RH | 80485-06 |
Muffler, LH | 80484-06 | ||
2 | Clamp, Muffler (2) | 65283-94 | |
Kit 29924-07 (fits FLSTNI only) | 1 | Muffler, RH | 80606-07 |
Muffler, LH | 80605-07 | ||
2 | Clamp, Muffler (2) | 65283-94 | |
Kit 29922-07 (fits FXST, FLST) | 1 | Muffler, Slash-down with catalyst (2) | 80609-07 |
2 | Clamp, Muffler (2) | 65283-94 | |
Kit 29921-07 (fits FXSTBI, FXSTSI, FLSTCI) | 1 | Muffler, Slash-down with catalyst (2) | 80609-07 |
1 | Clamp, Muffler (2) | 65283-94 | |
Kit 29920-07 (fits FXSTDI, FLSTFI) | 1 | Muffler, Rear | 80608-07 |
Muffler, Front | 80607-07 | ||
2 | Clamp, Muffler (2) | 65283-94 | |
Kit 29919-07 (fits FXDI, FXDCI) | 1 | Muffler (2) | 80610-07 |
2 | Clamp, Muffler (2) | 65283-94 | |
Kit 29918-07 (fits FXDBI, FXDRI, FXDWGI) | 1 | Muffler (2) | 80610-07 |
2 | Clamp, Muffler (2) | 65283-94 |