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SCREAMIN' EAGLE MECHANICAL COMPRESSION RELEASE FIXTURE
J045092008-01-30
GENERAL
Kit Number
94638-08
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 Tools and Materials Required
The following items are required for proper the proper application of this tool:
  • Hand drill with 1/2 inch chuck
  • Tap handle or wrench
  • Hex key wrenches
  • Cutting fluid
  • Clean motor oil
  • Calipers
Kit Contents
See Figure 6 and Table 1.
Replacement parts for this kit are available directly from the vendor. If replacement parts are needed contact JIMS® at 805-482-6913 or www.jimsusa.com.
DRILLING AND TAPPING PROCEDURE
WARNING
Wear safety glasses or goggles while drilling. Flying debris could result in serious eye injury. (00565b)
NOTE
Perform the following procedure on both the front and rear cylinder heads.
Tool Setup
NOTE
Due to slight manufacturing differences, it may be necessary to tap the fixture into place with a rubber mallet. Do NOT use excessive force.
1. Align the fixture's locating pins with the 3/8 inch tooling holes in the head and install the fixture on the head.
2. See Figure 1 and Figure 6. Secure the fixture (1) to the head with two 5/16-18 socket head cap screws (2) and washers (9) included in the kit. Install the screws in the holes marked "F" when modifying the front head or in the holes marked "R" when modifying the rear head. Tighten screws to 9 N·m (80 in-lbs).
3. See Figure 3 and Figure 6. Install the drill bushing (3) in the bore marked "FRONT" when modifying the front head or in the bore marked "REAR" when modifying the rear head.
4. Tighten drill bushing set screw to 5.6 N·m (50 in-lbs).
5. See Figure 2 and Figure 6. Install collar stop (4) onto the 1/2 inch diameter shank of the step drill bit (5). Secure the collar stop with the set screw 9.9 cm (3.900 in) from the beginning of the 3/4 inch diameter step of the drill bit.
Figure 1. Install Drilling Fixture
Figure 2. Install Collar Stop on Drill Bit
Pre-Drill Setup
  1. Install step drill bit and stop collar into the drill motor chuck.
  2. With the drill stopped, insert the drill bit into the drill bushing in the fixture.
    3. NOTE
    Apply cutting fluid to the drill bit and hole as necessary.
  3. With the drill bit approximately 1/4 inch from the cylinder head surface, start the drill. Feed the drill bit slowly into the bushing, especially when the bit first makes contact with the cylinder head. Drill just deep enough to engage the full diameter of the drill bit tip (approximately 0.125 - 0.250 inch (3 - 6 mm)). Then stop the drill.
Verify Hole Diameter
  1. Remove the drill bit from the bushing.
  2. Measure the diameter of the hole. It should be within 8.91–9.14 mm (0.351–0.36 in) for effective tapping.
Figure 3. Install Drilling Bushing
Figure 4. Tap Drilled Hole
Drill and Spot-Face
NOTE
Apply cutting fluid to the drill bit and hole as necessary.
The collar depth setting is set as a starting point. It may be necessary to drill deeper due to cylinder head differences. Do not exceed a depth of 10.24 cm (4.03 in).
  1. Start the drill, then applying steady and even pressure, drill into the head until the collar stop is flush against the fixture. Ensure that full spot face of the cylinder head is achieved (approximately 1.9 cm (0.75 in) diameter).
Tap the Hole
1. Assemble the tap as follows:
a. See Figure 4 and Figure 6. Insert tap (6) into tap holder (7).
b. Secure the tap with the set screw of the tap holder. Ensure the tap is oriented so that the set screw engages the flat of the tap. Tighten the set screw to 5.6 N·m (50 in-lbs).
c. Install tap holder into a tap handle (not included).
2. Insert the tap holder into the drilling bushing and fixture.
NOTE
Apply cutting fluid to the tap and hole as necessary while tapping.
3. Start the tap by applying slight downward pressure while turning in a clockwise direction.
4. Continue to turn the tap clockwise until the tap has bottomed out, as indicated by increased resistance. Do NOT force the tap.
5. Back the tap out, by turning the tap counterclockwise, 3 - 4 turns, then blow out the debris using compressed air.
6. Turn the tap clockwise again, until the tap bottoms out (a minimum of 13 threads). Do NOT force the tap.
7. Turn the tap counterclockwise and remove the tap.
Figure 5. Combustion Chamber Release Hole
Drill Combustion Chamber Release Hole
  1. Remove two socket head cap screws, washers and the drilling fixture.
  2. Install the 1/16 inch drill bit (8) (included in kit) into the drill motor chuck.
    3. NOTE
    Apply cutting fluid to the drill bit and hole as necessary.
  3. Use the existing drill point at the bottom of the first drilled hole as a pilot. Slowly drill a 1/16 inch hole (See Figure 5.) into the combustion chamber. Be careful not to break the drill bit off in the head.
  4. Clean any loose debris out of the hole.
SERVICE PARTS
Figure 6. Kit Contents for Screamin' Eagle Mechanical Compression Release Tool
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Drilling fixture
Not Sold Separately
2
Socket head cap screw, 5/16-18 (2)
Not Sold Separately
3
Drilling bushing
Not Sold Separately
4
Collar stop
Not Sold Separately
5
Step drill bit*
Not Sold Separately
6
Tap*
Not Sold Separately
7
Tap holder*
Not Sold Separately
8
Drill bit, 1/16 inch*
Not Sold Separately
9
Washer (2)
Not Sold Separately
* If replacement parts are needed contact JIMS® at 805-482-6913 or www.jimsusa.com.