SCREAMIN' EAGLE PRO TC 113 (1856 CC) CONVERSION KIT
J042982007-04-13
GENERAL
Kit Number
27526-07 (Silver) and 27525-07 (Black)
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
This kit requires the separate purchase of the Cam Drive Retention Kit (25566-06) and an ACR Overlay Wire Harness Kit (70623-06) which are available from a Harley-Davidson dealer.
The separate purchase of Crankcase Boring Tool Kit (94419-06) is recommended for installing this high performance engine conversion kit.
Instruction Sheets -J02635, -J03501, -J04210 and -J04418.
NOTE
Crankcase Boring Tool Kit (94419-06) includes a modified top center screw (1093) to ensure the crankcase boring tool does not get damaged when installing the conversion kit. This screw can also be purchased separately from a Harley-Davidson dealer for those who wish to use their own boring fixture.
Please see appropriate sections in Service Manual for the special tools required to install this kit.
Proper installation of this kit also requires ECM recalibration using EFI Race Tuner Kit. Refer to Screamin' Eagle Pro Catalog or contact 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
This conversion kit is intended for High Performance or Racing applications only and is not legal for sale or use on pollution controlled motor vehicles. This kit may may reduce or void the limited vehicle warranty. Engine related performance parts are intended for the experienced rider only.
REMOVAL
Prepare for Service
| 1. | Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see Owner's Manual for instructions to disarm the system. | |
| 2. | Remove seat according to the instructions in the Service Manual. | |
| 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) | ||
| 3. | Remove fuel tank according to the instructions in the Service Manual. | |
| 4. | Touring models: Remove left side saddlebag, left side cover, and maxi-fuse. Refer to SADDLEBAG REMOVAL and SYSTEM FUSES in Service Manual. Dyna models: Remove electrical caddy cover and Maxi® fuse. Refer to FUSES in Service Manual. Softail models: Remove maxi-fuse. Refer to METRI-PACK 800 in Service Manual. |
Remove Engine Components
- Remove existing air cleaner assembly. Refer to AIR CLEANER REMOVAL in Service Manual.
- Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in Service Manual.
- Remove engine from chassis following the instructions in the Service Manual.
- Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in Service Manual.
- Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in Service Manual.
MACHINE CRANKCASE
NOTICE
The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b)
Crankcase Boring Preparation
NOTE
During final reassembly of the engine, Harley-Davidson recommends replacing the Original Equipment cylinder studs with Screamin' Eagle High Tensile Studs (16505-01).
- Remove cylinder studs from the engine crankcase.
- Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas.
- Inspect and clean engine case mating surfaces.
- Refer to Instruction Sheet -J02635 for crankcase boring and modifications to install Bigger Bore (4.060 inch) Cylinder Kit.
NOTE
To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley-Davidson dealer.
INSTALLATION
Install Engine and Clutch Components
- See Figure 3. Inspect camshaft needle bearings (7) and replace if necessary.
- Install engine in chassis following the instructions in the Service Manual.
- Install clutch diaphragm spring from kit. Refer to CLUTCH INSTALLATION in Service Manual.
- Install exhaust system. Refer to EXHAUST SYSTEM INSTALLATION in Service Manual.
- Install air cleaner assembly. Refer to AIR CLEANER INSTALLATION in Service Manual.
Install ACR Overlay Wire Harness
Refer to Instruction Sheet -J04210 for instructions to install ACR Overlay Wire Harness Kit (70623-06).
Final Assembly
| 1. | Touring models: Install maxi-fuse, left side cover, and left side saddlebag. Refer to SADDLEBAG INSTALLATION and SYSTEM FUSES in Service Manual. Dyna models: Install Maxi fuse and electrical caddy cover. Refer to FUSES in Service Manual. Softail models: Install maxi-fuse. Refer to METRI-PACK 800 in Service Manual. | |
| 2. | Install fuel tank according to the instructions in the Service Manual. | |
| 3. | Install seat according to the instructions in the Service Manual. | |
| 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) NOTICE You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b) | ||
| 4. | Download the new ECM calibration using EFI Race Tuner Kit. Refer to Screamin' Eagle Pro Catalog or contact a Harley-Davidson dealer. | |
| 5. | Start and run engine. Repeat several times to ensure proper operation. |
Operation
Refer to BREAK-IN RIDING RULES in the Owner's Manual for instructions to break-in the motorcycle.
SERVICE PARTS
Figure 1. Service Parts: Screamin' Eagle Pro TC 113 (1856 cc) Conversion Kit
Table 1. Service Parts Table: Screamin' Eagle PRO TC 113 cubic inch (1856 cc) Conversion Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | 4.060 cylinder assembly (Black) (2) (used in Kit 16550-04) | 16562-04 (front) | 7 | Gasket, cylinder base (2) | 16736-04 | |
16563-04 (rear) | 8 | Cylinder head, front (black) | 16983-07 | |||
4.060 cylinder assembly (Silver) (2) (used in Kit 16551-04) | 16564-04 (front) | Cylinder head, front (silver) | 16997-07 | |||
16580-04 (rear) | 9 | Cylinder head, rear (black) | 16988-07 | |||
2 | Piston (2) | Not Sold Separately | Cylinder head, rear (silver) | 16999-07 | ||
3 | Piston ring set (2) | 22526-04 | 10 | Automatic compression release (ACR) | 28861-07 | |
4 | Piston pin (2) | 22455-03 | 11 | Medallion, cylinder head (2) | 16897-07 | |
5 | Piston pin circlip (4) | 22456-03 | 12 | Race valve spring kit | 18281-02 | |
6 | Gasket, cylinder head (2) | 16104-04 | ||||
Notes: Cylinder kits (16550-04 and 16551-04) include items 1, 6 and 7. Piston Kit (22571-07) includes items 2 through 5. Item 5 is also included in Engine Overhaul Gasket Kit (17053-99B). For cylinder head assembly (8, 9) components, refer to 2007 FLHTCUSE (99428-07), 2007 FXDSE (99430-07) and 2007 FXSTSSE (99458-07) Parts Catalog for service part numbers (machined with seats and guides). | ||||||
Figure 2. Service Parts: Screamin' Eagle Pro TC 113 (1856 cc) Conversion Kit
Table 2. Service Parts: Screamin' Eagle Pro TC 113 (1856 cc) Conversion Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, rocker cover base (2) | 16719-99A | 9 | Gasket, breather (2) | Not Sold Separately | |
2 | Gasket, rocker cover top (2) | 17386-99A | 10 | Umbrella valve (2) | 26858-99 | |
3 | Gasket, tappet cover (2) | 18635-99B | 11 | Filter element, breather (2) | 63815-99 | |
4 | O-ring, middle push rod cover (4) | 11132A | 12 | Seal, EFI intake (2) (Not Shown) | 29995-86B | |
5 | O-ring, lower push rod cover (4) | 11145A | 13 | Seal, map sensor (Not Shown) | 11291 | |
6 | O-ring, upper push rod cover (4) | 11293 | 14 | Spring, clutch diaphragm (Not Shown) | 37951-98 | |
7 | O-ring, rocker arm support (2) | 11270 | Notes: Breather Gasket Kit (17162-03) includes 8 through 11. Items 1 through 13 are included in Engine Overhaul Kit (17053-99B). | |||
8 | Gasket, breather (2) | Not Sold Separately | ||||
Figure 3. Service Parts: Screamin' Eagle Pro TC 113 (1856 cc) Conversion Kit
Table 3. Service Parts Table: Screamin' Eagle Pro TC 113 (1856 cc) Conversion Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, cam cover | 25244-99A | 10 | O-ring, crankcase ring dowel (2) | 26432-76A | |
2 | Washer | Not Sold Separately | 11 | O-ring, piston cooling (2) | 11140 | |
3 | Cap screw, flanged | Not Sold Separately | 12 | Retaining ring, internal | 35114-02 | |
4 | Retaining ring | 11461 | 13 | O-ring, crankcase dowel (2) | 11273 | |
5 | Camshaft, front | Not Sold Separately | 14 | Seal, main bearing oil | 12068 | |
6 | Camshaft, rear | Not Sold Separately | 15 | Screw, top center crankcase, long | 1085 | |
7 | Bearing, needle (2) (must be purchased separately, if needed) | 9215 | 16 | Screw, modified, crankcase boring (Not Shown) (purchased separately) | 1093 | |
8 | O-ring, oil pump to cam plate | 11293 | 17 | Washer, top center crankcase | 1086 | |
9 | O-ring, cam plate to crankcase (2) | 11301 | ||||
Notes: Cylinder kits (16550-04 and 16551-04) include items 15 and 17. Cam Drive Retention Kit (25566-06) includes 2 and 3. Items 8 through 14 are included in Engine Overhaul Gasket Kit (17053-99B). Cylinder Kit includes items 15 and 17. Items 5 and 6 available in Cam Kit (25476-06). | ||||||