SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT
J034062006-04-19
GENERAL
Kit Number
29842-04 (Black) and 29855-04 (Silver)
Models
These kits fit 2004 and 2005 Touring models equipped with Electronic Fuel Injection (EFI).
Additional Parts and Tools Required
This kit requires the separate purchase of the following parts and tools which are available from a Harley-Davidson dealer.
- Camshaft/Crankshaft Sprocket Locking Tool (HD-43614)
- Camshaft Remover/Installer (HD-43644)
- Muffler End Caps (See Parts Catalog)
- Loctite® 243 (blue) 99642-97
Proper installation of this kit requires the use of Digital Technician™ at a Harley-Davidson dealer.
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.
Kit Contents
NOTE
Installation of this kit by an authorized Harley-Davidson dealer will not impact your limited vehicle warranty.
This Conversion 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 Product Information Label contained in this kit is a requirement of the California Air Resource Board (CARB) emission regulation. Place the label on the right side of the frame directly beneath the VIN sticker. This label is not required outside the state of California.
REMOVAL
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)
- Remove maxi-fuse. Refer to MAXI-FUSE REMOVAL in Service Manual.
- Remove existing air cleaner assembly. Discard backplate and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual.
- Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual.
- Remove engine from chassis following the instructions in the Service Manual.
- Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual.
- Remove crankshaft following the instructions in the Service Manual.
INSTALLATION
Install Flywheel Assembly
See Figure 10. Install flywheel assembly (13) from kit following the instructions in the Service Manual.
Remove Existing Cam Bearings
NOTE
Both crank and primary cam sprocket flange screws are specially hardened while the flat washers are of a special diameter and have ground surfaces. Therefore, use only the parts provided in the Cam Drive Gear Retention Kit (25533-99A) when performing this upgrade. The crank and primary cam sprocket flange screws are not interchangeable.
- Remove existing crank and primary cam sprocket flange screws and washers according to instructions in Service Manual. Discard cam drive sprocket flange screws and washers.
- Remove existing cam drive sprocket according to instructions in Service Manual.
- Remove and discard existing cam bearings. Refer to ENGINE, BOTTOM END OVERHAUL Cam Support Plate, Disassembly/Assembly (Camshaft, Camshaft Bearings) section(s) of appropriate Service Manual.
Install New Cam Bearings
NOTICE
To center thrust washer, be sure O-ring is installed in relief groove. Damage to bearing cage and engine can occur if thrust washer is not centered. (00473d)
NOTE
If not enough of the splined shaft is exposed to install the sprocket, leave out the spacer and proceed to Step 1e. Once the bearing inner race has been started onto the machined area, remove the flange screw, washer, and sprocket, then assemble using the spacer. Repeat Step 1e to fully install bearing inner race.
| 1. | See Figure 1. Install rear cam roller bearing kit ( Figure 10 , item 8) onto rear camshaft. a. Install O-ring in grinding relief groove. Groove is on the splined end between the machined area and the secondary cam sprocket. Exercise caution to avoid stretching or breaking the O-ring. Since the O-ring is not sold separately, damage will require purchase of new roller bearing kit. b. Slide thrust washer down rear camshaft until centered over O-ring in grinding relief position. c. Slide bearing inner race down rear camshaft until contact is made with shoulder of machined area. d. Install primary cam sprocket spacer and sprocket on camshaft, and secure using thicker flat washer and long flange screw. e. See Figure 2. Wrap a shop rag (1) around camshaft to get a firm grip and also to protect hand from sharp edges of sprocket. Using a 9/16 in. box wrench (2), turn flange screw in a clockwise direction. Bearing inner race (3) is fully installed when it makes firm contact with the thrust washer (4). f. Verify thrust washer is locked in place and cannot be rotated. If necessary, install shaft in vise using brass jaw inserts, and further tighten flange screw until desired result is achieved. g. Remove flange screw, flat washer, sprocket, and spacer. NOTE Be aware that the front and rear cam bearings are not interchangeable. The rear cam utilizes a roller bearing while the front cam utilizes a ball bearing (See Figure 3 ). Bearing fit may be a light press or slightly loose fit. If deemed necessary, clean bearing O.D. and apply Loctite 243 (blue) before installation, but exercise caution to avoid getting compound on rollers or bearing I.D. | 
Figure 1. Rear Cam Roller Bearing Kit 
Figure 2. Install Bearing Inner Race (with O-Ring and Washer) | ||||||||||||||||
| 2. | Install new cam bearings into cam support plate according to the following: a. See Figure 4. Obtain the Camshaft Remover/Installer (HD-43644). b. With the secondary cam chain side facing upward, place cam support plate on support block, so that outer races of bearings are properly supported. Note that one corner of the support block is contoured to accommodate the chain guide blocks cast into the front of the support plate. c. Center new bearing over bearing bore with the lettered side up. Slide pilot shaft of bearing driver through bearing into hole of support block. d. See Figure 5. Center bearing driver under ram of arbor press. Press on driver until bearing makes firm contact with counterbore in cam support plate. Repeat Steps 2a through 2c to install second bearing. | 
Figure 3. Cam Bearings | ||||||||||||||||
| 3. | Apply Loctite 243 (blue) to threads of four bearing retainer plate screws. | |||||||||||||||||
| 4. | Using a T20 Torx® drive head, secure bearing retainer plate to cam support plate. | |||||||||||||||||
| 5. | Tighten four bearing retainer screws to 20-30 in-lbs (2.3-3.4 Nm) in a crosswise pattern. Verify that hole in retainer plate is properly aligned with secondary cam chain oiler. | 
Figure 4. Camshaft Remover/Installer 
Figure 5. Press Bearings into Cam Support Plate |
Install Camshafts
| 1. | Start camshafts into cam bearings. | |||||||
| 2. | Place cam support plate back on support block, if removed. The block properly supports inner races of bearings as camshafts are installed. | |||||||
| 3. | See Figure 6. Align punch marks on teeth of secondary cam sprockets (outboard faces). Using a colored marker, carefully mark the punch mark locations on the inboard side of the sprocket teeth. These marks are needed to observe proper orientation of the camshafts when they are pressed into the bearings. | 
Figure 6. Align Punch Marks on Teeth of Camshaft Sprockets | ||||||
| 4. | Place secondary cam chain around the sprockets of both the front and rear camshafts. To maintain the original direction of rotation, be sure that the colored mark placed on the chain link during disassembly is facing opposite the cam support plate during installation. | |||||||
| 5. | Orient the camshafts so that they are positioned on opposite ends of the chain, and then verify that the colored marks placed on the inboard side of the sprocket teeth are still in alignment. | |||||||
| 6. | Maintaining the position of the camshafts on the chain with the colored marks in alignment, place the sprocket ends of the camshafts into the bearings. NOTE Be sure not to mix camshafts during the press procedure. The rear camshaft, which can be identified by the splined shaft, must go into the roller bearing at the rear of the cam support plate. | |||||||
| 7. | Place cup of camshaft driver over end of front camshaft only. | |||||||
NOTICE During press procedure, keep tensioner shoe clear of chain to prevent damage to tensioner assembly. (00474b) | ||||||||
| 8. | Center end of front camshaft under ram and slowly apply pressure to driver just to start front camshaft into bearing I.D. | |||||||
NOTICE Be sure rear camshaft is aligned during press procedure. Misalignment can cause inner race to catch on bearing rollers resulting in bearing damage. (00475b) | ||||||||
| 9. | Slowly apply pressure to driver on front camshaft, while wiggling rear camshaft as necessary to guide inner race between bearing rollers. | |||||||
| 10. | When inner race on rear cam is started into roller bearing, apply pressure to driver until front camshaft is fully seated. If necessary, keep finger pressure at top of rear camshaft to ensure that assembly remains square and inner race moves to installed position in roller bearing. | |||||||
| 11. | After installing new cams, check for proper cam to cam timing using straightedge along punch marks as described in Service Manual. | |||||||
| 12. | Install retaining ring from kit in groove at end of front camshaft. NOTE |
Install Cam Support Plate
Install cam plate according to ENGINE, BOTTOM END OVERHAUL Cam Support Plate, Disassembly/Assembly instructions in applicable Service Manual.
Install Rear Cam Sprocket, Crank Sprocket, and Primary Cam Chain
| 1. | Apply a thin film of clean H-D 20W50 engine oil to the splines of the rear cam. | |
| 2. | Install splined sprocket onto rear camshaft. Refer to ENGINE, BOTTOM END OVERHAUL Cam Support Plate, Disassembly/Assembly (Camshaft, Camshaft Bearings) section(s) in appropriate Service Manual. Use spacers provided in kit in place of those listed in Service Manual. NOTE Verify alignment at crank and primary cam sprocket punch marks as described in Service Manual. Verify alignment at crank and primary cam sprocket faces. Use spacers provided in kit to maintain alignment at plus (+) or minus (-) 0.01 in. | |
| 3. | See Figure 10. Use cam flange screw (12), washer (11), crank flange screw (10), and washer (9) from kit. | |
| WARNING Apply threadlocker to maintain clamp load on flange bolt. A loose flange bolt can cause engine failure, which could result in death or serious injury. (00476c) | ||
| 4. | Install new flange screws and washers as follows: a. Ensure threads are clean and free from oil then apply Loctite Primer 7649. b. Apply Loctite® 262 (red) 94759-99 to threads of flange screws. c. Apply a thin film of clean H-D 20W50 engine oil to both sides of flat washers. d. Start flange screw with flat washer to secure crank sprocket to end of crankshaft. e. Start flange screw with flat washer to secure primary cam sprocket to end of camshaft. f. See Figure 7. Position Camshaft/Crankshaft Sprocket Locking Tool (HD-42314) between the crank and primary cam sprockets to prevent rotation. The handle of the tool is stamped "Cam" and "Crank" to ensure proper orientation. g. Tighten crank and primary cam sprocket flange screws to 15 ft-lbs (20.3 Nm). h. Loosen each flange screw one full turn. i. Tighten crank flange screw to 24 ft-lbs (32.5 Nm) final torque value. j. Tighten primary cam sprocket flange screw to 34 ft-lbs (46.0 Nm) final torque value. k. Remove sprocket locking tool and follow instructions in Service Manual for unloading primary cam chain tensioner. | |
| 5. | Install cam cover according to ENGINE, BOTTOM END OVERHAUL, Cam Support Plate, Disassembly/Assembly instructions in applicable Service Manual. NOTE Replace cam cover gasket ( Figure 10 , item 3). |
Figure 7. Camshaft/Crankshaft Sprocket Locking Tool
Install Engine and Clutch Diaphragm Spring
- Assemble remaining engine components. Refer to appropriate ENGINE sections in Service Manual.
- Install engine in chassis following the instructions in the Service Manual.
- Install clutch diaphragm spring ( Table 1 , item 15) following the instructions in the Service Manual.
Install Mufflers and Air Cleaner
- See Figure 10. Install exhaust system using mufflers (21) and retaining rings (22) from kit and muffler end caps purchased separately. Refer to EXHAUST SYSTEM INSTALLATION in Service Manual.
- See Figure 8. Install air cleaner assembly using backplate (9), filter element (10), and air cleaner cover insert (10) from kit. Refer to AIR CLEANER INSTALLATION in Service Manual.
Final Assembly
Install maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual.
Recalibrate ECM
NOTICE
You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b)
Download the new ECM calibration using the Digital Technician™ at a Harley-Davidson dealer.
SERVICE PARTS
Figure 8. Service Parts: Screamin' Eagle Twin Cam 103 (1690 CC) Conversion Kit
Table 1. Service Parts: Screamin' Eagle Twin Cam 103 (1690 CC) Conversion Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Cylinder assembly (Black) (2) (used in Kit 29842-04) | 16547-99 | 9 | Backplate assembly, air cleaner | 29697-02A | |
Cylinder assembly (Silver) (2) (used in Kit 29855-04) | 16548-99 | 10 | Element, filter | 29509-06 | ||
2 | Piston (2) | Not Sold Separately | 11 | Insert, air cleaner cover | 29480-03 | |
3 | Piston ring set (2) | 21918-99 | 12 | Cylinder head, front (black) | 16900-03A | |
4 | Piston pin (2) | 22132-99 | Cylinder head, front (silver) | 16960-03A | ||
5 | Piston pin circlip (4) | 22097-99 | 13 | Cylinder head, rear (black) | 16977-03A | |
6 | Head gasket (2) | 16787-99A | -- | Cylinder head, rear (silver) | 16966-03A | |
7 | O-ring, cylinder deck ring dowel (2) | 11273 | -- | Piston kit (includes items 2 through 5) | 22421-03 | |
8 | O-ring, cylinder spigot (2) | 11256 | Notes: Do not install O-ring (item 7) to top cylinder dowels. Refer to 2004 FLHRSEI2 Parts Catalog, part number 99428-04 for individual components of cylinder head assemblies (items 11 and 12). | |||
Figure 9. Service Parts: Screamin' Eagle Twin Cam 103 (1690 CC) Conversion Kit
Table 2. Service Parts: Screamin' Eagle Twin Cam 103 (1690 CC) Conversion Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, rock cover base (2) | 16719-99A | 10 | Umbrella valve (2) | 26858-99 | |
2 | Gasket, rocker cover top (2) | 17386-99A | 11 | Filter element, breather (2) | 63815-99 | |
3 | Gasket, tappet cover (2) | 18635-99B | 12 | Seal, exhaust (Not Shown) | 17048-98 | |
4 | O-ring, middle push rod cover (4) | 11132 | 13 | Seal, EFI intake (2) (Not Shown) | 26995-86B | |
5 | O-ring, lower push rod cover (4) | 11145 | 14 | Seal, map sensor (Not Shown) | 11291 | |
6 | O-ring, upper push rod cover (4) | 11293 | 15 | Spring, clutch diaphragm (Not Shown) | 37951-98 | |
7 | O-ring, rocker arm support (2) | 11270 | 16 | Product information label (Not Shown) | Not Sold Separately | |
8 | Gasket, breather (2) | Not Sold Separately | -- | Breather gasket kit (includes items 8 through 11) | 17162-03 | |
9 | Gasket, breather (2) | Not Sold Separately |
Figure 10. Service Parts: Screamin' Eagle Twin Cam 103 (1690 CC) Conversion Kit
Table 3. Service Parts: Screamin' Eagle Twin Cam 103 (1690 CC) Conversion Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Retaining ring, camshaft (2) | 11031 | 13 | Flywheel assembly | 23740-03B | |
2 | O-ring, oil pump to cam plate | 11286 | 14 | Seal, main bearing oil | 12068 | |
3 | Gasket, cam cover | 25244-99A | 15 | Washer, thrust sprocket shaft main bearing | 8972 | |
4 | Retaining ring, camshaft | 11494 | 16 | Bearing, main (2) | 24604-00D | |
5 | Ball bearing, front camshaft | 8990A | 17 | Retaining ring, internal | 35114-02 | |
6 | O-ring, cam plate to crankcase (2) | 11301 | 18 | O-ring, crankcase ring dowel (2) | 26432-76A | |
7 | Camshaft kit | 25376-03 | 19 | O-ring, piston cooling (2) | 11140 | |
8 | Roller bearing kit, rear camshaft | 8983 | 20 | O-ring, CPS | 11289A | |
9 | Washer, crank (2) | Not Sold Separately | 21 | Muffler (2) (Not Shown) | 65936-03 | |
10 | Screw, flange crank (2) | Not Sold Separately | 22 | Retaining ring, muffler end cap (2) (Not Shown) | 65332-00 | |
11 | Washer, rear cam | 6294 | 23 | Loctite 262 (red), 0.5 ml packet (Not Shown) | Not Sold Separately | |
12 | Screw, flange rear cam | 996 | Notes: Items 9 and 10 are only available as part of Cam Drive Gear Retention Kit 25533-99A. Loctite (item 23) is only available in 6 ml tube, part number 94759-99. | |||