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SCREAMIN' EAGLE PERFECT FIT PUSHRODS
J039982006-01-11
GENERAL
Kit Number
18421-06 and 18424-06
Models
Kit 18421-06 fits 1991-later XL's with stock cylinder heads, 1992-2003 XL's equipped with Screamin' Eagle Pro Dual Plug Cylinder Heads 16457-96B or 16458-96B.
Kit 18424-06 fits 1992 and later XL's equipped with Screamin' Eagle Pro Sportster Cylinder Heads 16677-05.
Additional Information Required
WARNING
Rider 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
Table 1. Kit Contents
Kit
Description
Length
18421-06
Pushrod intake
Pushrod exhaust
Stock
Stock
18424-06
Pushrod intake
Pushrod exhaust
-0.05 in. (-0.13 cm)
-0.05 in. (-0.13 cm)
There are no Service Parts available with this kit.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
INSTALLATION
Remove Original Equipment
1. Prepare motorcycle for top end overhaul disassembly.
a. 2003-Earlier: Refer to STRIPPING MOTORCYCLE FOR ENGINE REPAIR in Service Manual.
b. 2004-Later: Refer to STRIPPING MOTORCYCLE FOR TOP END REPAIR in Service Manual.
1Outer rocker cover
2Umbrella valve
3Rocker cover spacer
4Inner rocker cover
5Rocker arm
6Rocker arm
Figure 1. Rocker Covers (2003-Earlier)
1Outer rocker cover
2Breather assembly
3Inner rocker cover
4Rocker arm
5Rocker arm
Figure 2. Rocker Covers (2004-Later)
2. Remove spark plugs.
3. 2003-Earlier: See Figure 1. Disassemble outer rocker cover (1), umbrella valve (2), rocker cover spacer (3), inner rocker cover (4), and rocker arms (5, 6). Refer to CYLINDER HEAD, REMOVAL in Service Manual. 2004-Later: See Figure 2. Disassemble outer rocker cover (1), breather assembly (2), inner rocker cover (3), and rocker arms (4, 5). Refer to CYLINDER HEAD, DISASSEMBLING ROCKER COVERS in Service Manual.
NOTE
All washers and fasteners used in the engine are hardened. Do not mix hardened washers and fasteners with unhardened parts. Do not reuse fiber cover seals.
Mark rocker arm shafts for reassembly in their original positions. Valve train components must be reinstalled in their original positions during reassembly or increased engine wear may result.
4. Place motorcycle on a center stand with rear wheel raised off the ground.
5. 2003-Earlier: See Figure 3. 2004-Later: See Figure 4.
a. With transmission in gear, use rear wheel to turn engine over until both front cylinder tappets (3) are at their lowest point.
b. Remove and discard original equipment pushrods (1) from pushrod covers (2).
c. With transmission in gear, use rear wheel to turn engine over until both front cylinder tappets (3) are at their lowest point.
d. Remove and discard original equipment pushrods (2) from pushrod covers (1).
Install Perfect Fit Pushrods
1. 2003-Earlier: See Figure 3. Identify respective pushrod (1) and position in engine. Slide intake and exhaust pushrods down inside pushrod covers (2) until they rest on seat at top of tappet (3). Refer to top end overhaul assembly: CYLINDER HEAD, INSTALLATION in Service Manual. 2004-Later: See Figure 4. Identify respective pushrod (2) and position in engine. Slide intake and exhaust pushrods down inside pushrod covers (1) until they rest on seat at top of tappet (3). Refer to top end overhaul assembly: PUSH RODS, COVERS, AND RETAINERS in Service Manual.
NOTE
Perfect fit pushrods are engraved on the sides to make identification easier.
Perfect fit pushrods are tapered and must be installed with the wider end down into the Intake and Exhaust locations of the cylinders, and down through the pushrod covers.
1Pushrod
2Pushrod cover
3Tappet
Figure 3. Pushrod and Cover (2003-Earlier)
2. Repeat installation for rear cylinder.
NOTE
Check for contact between the pushrods and outer rocker covers. Check by rotating engine slowly until both valves are in closed position on the cylinder you are checking. If contact occurs, the rocker arm supports should be shifted toward the engine's cam side.
The components listed above are to be used on Harley-Davidson motorcycles only.
3. 2003-Earlier: See Figure 1. Assemble rocker arms (6, 5), inner rocker cover (4), rocker cover spacer (3), umbrella valve (2), and outer rocker cover (1). Refer to CYLINDER HEAD, INSTALLATION in Service Manual. 2004-Later: See Figure 2. Assemble rocker arms (5, 4), inner rocker cover (3), breather assembly (2), and outer rocker cover (1). Refer to top end overhaul assembly: ROCKER COVERS in Service Manual.
4. Complete top end overhaul assembly.
a. 2003-Earlier: Refer to INSTALLING THE ENGINE in the Service Manual.
b. 2004-Later: Refer to ASSEMBLING MOTORCYCLE AFTER TOP END REPAIR in Service Manual.
5. Return transmission to neutral.
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)
6. Install spark plugs.
1Pushrod cover
2Pushrod
3Tappet
Figure 4. Pushrod and Cover (2004-Later)