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V-Rod® Screamin' Eagle® Big Bore Stage Kit
J034042005-01-19
GENERAL
Kit Number
29863-04
Models
The street legal V-Rod® Screamin' Eagle® (SE) Big Bore Stage Kit fits Harley-Davidson® 2005 and later VRSCA/B model motorcycles.
NOTE
A V-Rod with an installed V-Rod® Screamin' Eagle® Big Bore Stage Kit is street legal in 50 states when used with the stock mufflers.
NOTICE
You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM for this exhaust system can result in severe engine damage. (00349a)
ECM calibration is required and is available for use with stock mufflers.
Additional Parts Required
Engine removal from the chassis and engine disassembly requires a number of new replacement parts. The new gaskets are found in the Engine Overhaul Gasket Kit (part number 17011-01K) which is included in the V-Rod® SE Big Bore Stage Kit.
The connecting rod journal bearings and the crankshaft journal bearings must be replaced with new bearings regardless of service wear limits.
NOTE
The Specifications and Service Wear Limits for the V-Rod® SE big bore engine are the same as the those for the VRSCSE Screamin' Eagle 1250 engine found in the VRSCSE Service Manual Supplement.
Inspection of other parts for service wear limits may indicate additional part replacement.
Part numbers for any required new or worn part replacements can be found in the VRSC or the VRSCSE parts catalog.
Additional Tools Required
Each Service Manual or Supplement procedure will require special tools. These tools are specified in the Service Manual or Supplement and are available through the SPX Kent-Moore Special Service Tools catalog.
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 directs the installer to both Service Manual and Service Manual Supplement. A Service Manual and a Service Manual Supplement for the year and model motorcycle is available at any Harley-Davidson dealer.
Kit Contents
See Figure 14 and Table 1.
Prepare the Motorcycle for Service
1. Remove the right side cover and the maxi-fuse.
2. Follow Service Manual instructions to remove the air box cover.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
Disconnect 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)
3. Disconnect the battery, negative (-) cable first.
INSTALLATION
The V-Rod® SE Big Bore Stage Kit is installed in 8 steps:
  1. Remove the engine from the chassis.
  2. Remove the cam drive and cylinder heads.
  3. Separate the upper and lower crankcase.
  4. Prepare the upper crankcase for machining.
  5. Order/packaging procedure for crankcase machining.
  6. Install the SE liners and pistons in the upper crankcase.
  7. Assemble the engine.
  8. Install the engine in the chassis.
    9. NOTE
    The box and foam hold down blocks found in the kit are used to ship the upper crankcase for machining necessary to fit the big bore cylinder liners. May Technology and MFG, Inc. will ship completed upper crankcase back in the same box.
Step 1. Remove the Engine from the Chassis
WARNING
Coolant mixture contains toxic chemicals, which may be fatal if swallowed. If swallowed, do not induce vomiting; call a physician immediately. Use in a well ventilated area. Irritation to skin or eyes can occur from vapors or direct contact. In case of skin or eye contact, flush thoroughly with water and go to hospital, if necessary. Dispose of used coolant according to federal, state and local regulations. (00092a)
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)
  1. Follow the Service Manual CHASSIS: ENGINE REPLACEMENT procedure to remove the engine from the chassis.
  2. See Figure 1. Follow the Service Manual ENGINE: STRIPPING MOTORCYCLE FOR SERVICE procedure to mount the engine in the engine cradle and stand.
Step 2. Remove the Cam Drive and Cylinder Heads
1. Follow Service Manual ENGINE: THROTTLE BODY procedures to remove the throttle body.
2. Follow the Service Manual ELECTRICAL: ALTERNATOR procedure to remove the alternator cover.
3. See Figure 2. Break the cam cover fasteners loose in reverse order of torque sequence and remove the covers.
4. Follow the Service Manual ENGINE: TOP END DISASSEMBLY procedure to remove the cam drive and the cams.
NOTE
Set the journal caps, bolts and exhaust cam aside for installation. Remove the bolts from the intake cam drive sprockets and set the sprockets and bolts aside. The intake cams will be replaced with new cams from the V-Rod® Screamin' Eagle® (SE) Big Bore Stage Kit.
5. Inspect the following components for service wear limits or wear indicators and replace as required:
a. Chain guides
b. Sprockets
6. Follow Service Manual ENGINE: CYLINDER HEAD SERVICE procedure to remove the cylinder heads.
NOTE
Follow the procedures only through removing the heads from the upper crankcase. The heads and valve train components will be replaced with new parts from the V-Rod® SE Big Bore Stage Kit.
7. Remove the front cylinder head cam drive cavity breather tube and O-ring and set aside for installation on the SE cylinder head.
1Engine
2Engine cradle
3Engine stand
Figure 1. Engine in Cradle
Figure 2. Cam Cover Torque Sequence
8. See Figure 3. Clean the oil film from the tappets. Number each tappet with the number cast in the cylinder head.
9. Remove the tappets and the valve shims.
10. Inspect the tappets and shims for wear indicators and replace as required. Set aside for installation in same location.
Step 3. Separate the Upper and Lower Crankcase
  1. See Figure 4. Remove the clutch side crankcase cover fasteners in reverse order of torque sequence and remove the clutch cover.
  2. Follow the Service Manual ENGINE: CLUTCH procedure to remove the clutch.
  3. Follow the Service Manual ENGINE: OIL PUMP procedure to remove the oil pump.
  4. Follow the Service Manual ENGINE: UPPER AND LOWER CRANKCASE SERVICE, Disassembly procedure to separate the upper and lower crankcases.
  5. Follow the procedure to break the counterbalancer drive gear fastener loose.
  6. Invert the engine and follow the procedure to remove the oil pan, the oil pickup and the gasket/baffle.
  7. Follow the procedure to loosen the input bearing retainer fasteners.
  8. Follow the procedure to loosen all 4 output shaft seal retainer fasteners. Remove the 2 output shaft seal retainer fasteners from the upper case leaving the loosen output shaft seal retainer fasteners in place in the lower case.
  9. Find the crankcase torque sequence figure in the Service Manual. In reverse of the torque sequence, break each of the 19 case fastener loose a 1/4 turn only. Then remove the case fasteners.
  10. See Figure 5. Carefully split the crankcase halves. If necessary, use a rubber mallet.
    11. NOTE
    Follow the Service Manual procedure through splitting the cases. Mark the Service Manual page and step number to reference the starting point for reassembly. Unless there is reason, do not remove the transmission gear shafts. Set aside the lower case complete with transmission.
Step 4. Prepare Upper Crankcase for Machining
1. Follow Service Manual ENGINE: CRANKSHAFT, PISTON AND CYLINDER LINER procedure to remove the the piston rods and caps and the crankshaft.
2. To separate the pistons from the rods. remove and discard the wrist pin retaining rings.
3. Follow the procedure to install and torque the rod caps for measurement of the big end and the small end.
NOTE
It is not necessary to measure the piston diameter nor the cylinder bore. These parts will be replaced with new.
Figure 3. Cylinder Head
Figure 4. Clutch Side Crankcase Cover Torque Sequence
Figure 5. Separate the Lower from the Upper Crankcase
4. See Figure 6. Select the remover insert for the 1130 cc engine from the Cylinder Liner Remover/Installer (HD-45313) kit and follow the instruction sheet to remove cylinder liners.
NOTE
Follow the Service Manual procedure through removing the liners. Mark the Service Manual page and step number to reference the starting point for reassembly. Inspect The upper crankcase for wear or damage and clean the case for shipping. Refer to Step 6. Order/Packaging Procedure for Crankcase Machining.
5. See Figure 7. Measure or inspect the following components for service wear limits or wear indicators and replace as required:
a. Primary gear
b. Rod big and small end
c. Crankshaft journal
d. Crankshaft journal bearings (These are replaced anytime the upper and lower case is separated.)
NOTE
Case machining turn around is 2 weeks. Carefully store the chassis and loose chassis components for reassembly. Sort engine components by Service Manual procedures. Lubricate and store as required to prevent damage, corrosion or loss.
Step 5. Order/Packaging Procedure for Crankcase Machining
1. Place an order electronically in the system for crankcase machining under Part No. 24282-05K/MS.
NOTE
Enter the shipper tracking number in the "Comment" line of the system order.
2. Print and save a copy of the order acknowledgment.
3. See Figure 8. Fill out all information on the tag supplied in kit. (dealer number and name, a dealer contact name, the COPS order number, the Picklist number, and the crankcase number)
4. Wipe off upper crankcase and attach the original tag to the upper crankcase.
NOTE
If the crankcase arrives at May Technology and MFG, Inc. without the tag attached, the crankcase will not be machined.
5. Place crankcase in the provided bag.
6. Place bag and crankcase in the V-Rod® SE Big Bore Stage Kit box.
7. Place a copy of the order acknowledgement in the box.
Figure 6. Remove the Original Equipment Piston Liner
Figure 7. Measuring for Service Wear Limit
Figure 8. Tag
8. See Figure 9. Fit the top hold down blocks on top of the crankcase.
9. Close and seal the box.
NOTE
Seal the box with a minimum of packaging tape. Box will be opened at the machinists and after machining will be used to return ship the upper crankcase.
10. Address the box and ship to: May Technology and MFG., Inc.2922 WheelingKansas City, MO 64129
NOTE
Dealer is responsible for all shipping and insurance costs.
If the crankcase is not received at May Technology and MFG, Inc within 30 days of order placement, the order will be cancelled and the dealer will be contacted.
For questions on order status, dealers should contact their SPOC representative.
Step 6. Install the SE Liners and Pistons in the Upper Crankcase
1. Wash the upper case with soap and water. Lightly lubricate as required.
2. Inspect and clean the new parts from the SE kit as required. Lubricate the liner O-rings with engine oil.
3. See Figure 10. Return to the Service Manual ENGINE: CRANKSHAFT, PISTON AND CYLINDER LINER procedure and begin assembly. Select the 1250cc cylinder liner installer and install the SE cylinder liners following the instructions for the Cylinder Liner Remover/Installer (HD-45313).
4. See Figure 11. Switch to the VRSCSE Service Manual Supplement ENGINE: PISTON PIN procedure to orient the pistons to the exhaust valves and fit the SE pistons to the original equipment (OE) connecting rods.
5. Use Piston Pin Clip Installer (HD-47189) to seat the clips.
6. Check piston ring end gap with V-Rod® SE Big Bore Stage Kit piston rings located in cylinder liner.
NOTE
Specifications for ring end gap are found in the Service Manual Supplement for the VRSCSE Model.
7. Return to the Service Manual ENGINE: CRANKSHAFT, PISTON AND CYLINDER LINER procedure. Select the rod bearings from the Rod Bearing Journal Diameter table in the Service Manual, select the correct size rod bearings and complete installation of the pistons, rods and rod bearing journals in the upper engine case.
8. Continue with the procedures to select and install new main bearings, install the crankshaft and connecting rod caps.
1Top hold down blocks
2Crankcase
Figure 9. Case in Shipping Box w/Top Hold Blocks (shown without bag for clarity)
Figure 10. Install the SE Piston Liner
Figure 11. Orient SE Pistons to the Exhaust (EX) Valve (piston shown in cylinder liner)
Step 7. Assemble the Engine
1. Return to the Service Manual ENGINE: UPPER AND LOWER CRANKCASE SERVICE and page forward to the Assembly procedure and assemble the upper crankcase to the lower crankcase.
2. From the Main Bearing Journal Diameter table found in the ENGINE: CRANKSHAFT, PISTON AND CYLINDER LINER procedure, select and replace the crankshaft main bearings.
3. Return to the ENGINE: UPPER AND LOWER CRANKCASE SERVICE, Assembly procedure and mate the upper and lower engine cases.
4. Follow the procedure to install and tighten the case fasteners in the specified sequence to the specified torque value.
5. Follow the procedure to tighten the upper and lower transmission shaft bearing retainers, the drive sprocket flange seal retainers, and the oil pan.
6. Follow Service Manual ENGINE: CAM DRIVE procedures to assemble the triple gear, the primary chain and the fixed tensioners.
7. Holding the drive sprocket of the intake camshafts in a soft jawed vise, break loose the two bolts holding the camshaft to the sprockets and remove the camshafts.
NOTE
The drive sprockets will only fit the intake cams in one orientation. Match the cam and drive sprocket with the double dots to the front cylinder and the cam and drive sprocket with 3 dots to the rear cylinder.
8. Install the SE intake camshafts to the sprocket and tighten the drive sprocket fasteners to 23 Nm (17 ft-lbs).
a. See Figure 12. For the front cylinder, orient the spacer boss of the drive sprocket to the SE intake camshaft to the outside.
b. See Figure 13. For the rear cylinder, orient the spacer boss of the drive sprocket to the inside.
9. Follow Service Manual ENGINE: CYLINDER HEAD SERVICE, Head Assembly procedures. Search forward to installing the valve shims and tappets and continue to install the cams and cam journal caps on the SE cylinder heads. Tighten to specification.
10. Continue to follow the procedure and measure valve lash. If required, use a copy of the Valve Lash Calculation Worksheet found in the Appendix of the Service Manual. Adjust the valve lash following Service Manual MAINTENANCE: VALVE LASH, Lash Measurement and Lash Adjustment.
11. Follow Service Manual ENGINE: CYLINDER HEADS, Installation procedure to install the SE cylinder heads.
12. Follow Service Manual ENGINE: INSTALLING AND TIMING THE CAMS procedure to install and time the cams to the cam drive.
Figure 12. Drive Sprocket Orientation to Front Cylinder Intake Camshaft
1Spacer boss (outlined in white)
Figure 13. Spacer Boss on Inside of Rear Cylinder Cam Drive Sprocket
13. Follow Service Manual MAINTENANCE: VALVE LASH, Lash Measurement to verify the valve lash.
14. If required, use a copy of the Valve Lash Calculation Worksheet found in the Appendix of the Service Manual. Adjust the valve lash following Service Manual MAINTENANCE: VALVE LASH, Verify Cam Timing, and Lash Adjustment.
15. After verifying lash adjustment, install and tighten spark plugs to 23 Nm (17 ft-lbs).
16. With light grease, lightly lubricate the rubber O-ring and groove of the brass cam cavity breather tube and press into the cam drive breather hole in the front cylinder.
17. Continue the Service Manual ENGINE: INSTALLING AND TIMING THE CAMS procedure to install the gaskets and cam covers.
18. Follow the procedure to install the ball gear, needle roller bearing, thrust washer, starter limiter gear.
19. Follow the procedure to install the rotor shell with the integral ball clutch.
20. Follow the ELECTRICAL: ALTERNATOR procedure to install the alternator cover.
21. Follow the Service Manual ENGINE: OIL PUMP Replacement procedure to install the oil pump.
22. Follow the Service Manual ENGINE: CLUTCH, Installation procedure to install the clutch and the clutch side crankcase cover.
23. Follow the Service Manual ENGINE: THROTTLE BODY, Installation procedure to install the throttle body.
24. Install the engine label bracket and the Screamin' Eagle® engine label insert.
Step 8. Install the Engine in the Chassis
WARNING
Coolant mixture contains toxic chemicals, which may be fatal if swallowed. If swallowed, do not induce vomiting; call a physician immediately. Use in a well ventilated area. Irritation to skin or eyes can occur from vapors or direct contact. In case of skin or eye contact, flush thoroughly with water and go to hospital, if necessary. Dispose of used coolant according to federal, state and local regulations. (00092a)
NOTICE
You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b)
1. Follow Service Manual CHASSIS: ENGINE REPLACEMENT, Installation procedure to install the engine in the chassis.
NOTE
The remapping will be supplied through any authorized Harley-Davidson dealer.
NOTICE
You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM for this exhaust system can result in severe engine damage. (00349a)
2. Before starting the engine, recalibrate the ECM.
NOTE
The product information label contained in this kit is required in the state of California only. This Executive Order Label is required to aid in passing the California Smog Check Program. Place the 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.
3. Install the Executive Order (EO) label on your motorcycle.
Return the Motorcycle to Service
WARNING
Connect 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)
1. Install the maxi-fuse and the right side cover.
2. Reconnect the battery, positive (+) cable first.
NOTICE
When closing the seat, make sure the ignition switch is in the FUEL position. If the ignition switch is in any other position when the seat is closed, the seat latch mechanism could be damaged. (00196a)
3. Close the seat.
Test Run Motorcycle
WARNING
Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)
WARNING
Travel at speeds appropriate for road and conditions and never travel faster than posted speed limit. Excessive speed can cause loss of vehicle control, which could result in death or serious injury. (00008a)
  1. Test start engine. If the oil pressure indicator lamp illuminates, follow the Service Manual ENGINE: OIL PRESSURE, Checking Oil Pressure procedure to troubleshoot the problem.
  2. If there is a rattle heard during engine start-up, follow Service Manual MAINTENANCE: SECONDARY CAM CHAIN procedure to adjust the secondary cam chain.
  3. Test ride motorcycle and adjust controls, belt tension, wheel alignment, headlamp alignment, etc. as required.
SERVICE PARTS
See Figure 14 and Table 1.
Figure 14. Service Parts: V-Rod SE Bore Stage 1 Kit
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Front ported cylinder head assembly
17121-05K
2
  • Screw, SHCS, M5-.8 x 10
1043MA
3
  • Stud bolt (2)
16448-01KA
4
  • Valve spring, inner (4)
18052-01K
5
  • Valve spring, outer (4)
18055-01K
6
  • Valve collar (8)
18057-01K
7
  • Valve spring retainer, lower (4)
18661-01K
8
  • Valve spring retainer, upper (4)
18662-01K
9
  • Exhaust valve (2)
18663-01K
10
  • Intake valve (2)
18664-01K
11
  • Valve stem seal (4)
18687-01K
12
  • Expansion plug (2)
769M
13
  • Front cylinder head gasket
17691-05K
14
Piston liner assembly
22928-05K
15
  • O-ring (2)
11314K
16
  • Cylinder liner
Not sold separately
17
  • Retaining ring (2)
22121-01K
18
  • Piston pin
22126-05K
19
  • Piston
Not sold separately
20
  • Ring, top compression
22930-05K
21
  • Ring, 2nd compression
22931-05K
22
  • Ring, oil control
22932-05K
23
  • Intake camshaft (2)
17431-05K
24
SE engine label insert (2)
29530-05K
25
Screw, counter sunk hex socket, M3-.5 x 8 (4)
4496M
26
Engine label bracket (2)
69280-05K
27
Engine overhaul gasket kit
17011-1K
The following items are not shown:
Rear ported cylinder head assembly
17124-05K
  • Screw, SHCS, M5-.8 x 10
104MA
  • Stud bolt (2)
16448-01KA
  • Cam chainjet
Not sold separately
  • Valve spring, inner (4)
18052-01K
  • Valve spring, outer (4)
18055-01K
  • Valve collar (8)
18057-01K
  • Valve spring retainer, lower (4)
18661-01K
  • Valve spring retainer, upper (4)
18662-01K
  • Exhaust valve (2)
18663-01K
  • Intake valve (2)
18664-01K
  • Valve stem seal (4)
18687-01K
  • Expansion plug (2)
769M
Rear cylinder head gasket
17692-05K
EO label
Not sold separately