SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT
J047942009-07-09
GENERAL
Kit Number
27505-09
Models
For model fitment information, 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) which is 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.
NOTE
Crankcase Boring Tool Kit (94419-06) includes a modified top center screw (1093) to verify 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.
See appropriate sections in service manual for the special tools required to install this kit.
Proper installation of this kit also 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.
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. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||
| 2. | Disconnect battery cables, negative (-) battery cable first. | |
| 3. | 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) | ||
| 4. | Remove fuel tank according to the instructions in the 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.
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)
| 1 | O-ring counterbore |
| 2 | Spigot bore |
Figure 1. Spigot Bore and O-Ring Counterbore Dimensions
Table 1. Spigot Bore and O-Ring Counterbore Dimensions
Description | Bore | Depth |
|---|---|---|
Spigot Bore | 4.205 +/- 0.010 in. (107 +/- 0.25 mm) | 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) |
O-Ring Counterbore | 4.415 +/- 0.002 in. (112 +/- 0.05 mm) | 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) |
Figure 2. Cylinder Wall
MACHINE CRANKCASE
Crankcase Boring Preparation
NOTE
During final assembly of the engine, Harley-Davidson recommends replacing the OE 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.
- See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual.
- Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm).
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.
NOTE
To aid in crankcase boring, a Screamin' Eagle Crankcase Boring Tool Kit (94419-06) is available. Modified top center screw (1093) is included in this kit. Refer to Harley-Davidson Genuine Motor Accessories and Genuine Motor Parts catalog or Screamin' Eagle Pro catalog.
Modify Crankcase
NOTE
To prevent severe engine damage, thoroughly clean and remove all chips and debris from the engine crankcase after boring.
- Disassemble crankcase and wash (or clean) chips and debris from engine crankcase halves as necessary.
- See Figure 3. Using a 11/32 in. (8.7 mm) drill bit, drill out the existing threads of the top center screw hole. Drill to a depth of 0.79 in. (20 mm) from the gasket surface.
- Using a size "F" in. (6.6 mm) drill bit, extend the top center screw hole 1.00 in. (25.4 mm) maximum to a depth of 1.79 in. (45.5 mm) from the gasket surface.
- Using a bottoming tap (purchased separately) size 5/16-18 UNC-2B, tap the screw hole to a minimum depth of 1.59 in. (40.4 mm) from the gasket surface.
- Refer to the service manual and assemble the engine with the following changes:
- See Figure 6. Install the top center engine crankcase screw (15) supplied in kit but do not tighten.
- Tighten all of the engine crankcase screws to the specified torque, except the top center engine crankcase screw.
NOTE
Note that the cylinder spigot seal is a rectangular o-ring which should be seated at base of
cylinder prior to the cylinder being assembled to the crankcase. Using the crankcase to seat the rectangular o-ring to the base of the cylinder can roll (spiral ) the o-ring during assembly. A rolled (spiraled) o-ring will create a leak path at the cylinder/crankcase interface.
- After the cylinders and heads have been installed and the hardware tightened to specification, tighten top center engine crankcase screw to 5.6–10.2 N·m (50–90 in-lbs)
INSTALLATION
Install Engine and Clutch Components
- See Figure 6. 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.
- See Figure 7. Install exhaust head pipe assembly (1) from kit and mufflers previously removed. Refer to EXHAUST SYSTEM INSTALLATION in service manual.
- See Figure 4. Install Air Cleaner Kit (29592-05) according to the instructions in the Instruction Sheet.
Install ACR Overlay Wire Harness
See Figure 7. Install the ACR Overlay Wire Harness Kit (70623-06) according to the instruction sheet for that kit.
Final Assembly
WARNINGConnect 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)
NOTICE You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b) NOTICE Installation of this kit requires a calibration update using Digital Technician. Failure to download calibration update before starting motorcycle will result in ACR failure. (00567b) | ||
| 1. | Connect battery cables, positive cable first. |
| 2. | Calibrate the ECM before connecting the ACR overlay harness connectors to the ACR solenoids in the cylinder heads. | |
| 3. | Install fuel tank 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) | ||
| 4. | Install seat according to the instructions in the service manual. | |
| 5. | Install left side cover and left saddlebag. Refer to service manual. | |
| 6. | Start and run engine. Repeat several times to verify proper operation. |
Operation
Refer to BREAK-IN RIDING RULES in the owner's manual for instructions to break-in the motorcycle.
| 1 | Tap hole with 5/16-18 UNC-2B bottoming tap |
| 2 | Extend full thread depth - 0.80 in. (20 mm) |
| 3 | Distance - 0.48 in. (12 mm) |
| 4 | Distance - 0.48 in. (12 mm) |
| 5 | Drilled hole diameter - 0.34 in. (8.6 mm) |
| 6 | Extend hole depth - 1.00 in. (25.4 mm) maximum |
| 7 | Unthreaded screw hole depth - 0.79 in. (20 mm) |
| 8 | Distance to center of crank - 5.90 in. (150 mm) |
| 9 | Distance to center of crank - 6.00 in. (152 mm) |
| 10 | Radius - 0.31 in. (7.94 mm) - use 5/8 in. (16 mm) ball end mill |
Figure 3. Top Center Engine Crankcase Screw Hole Modification
SERVICE PARTS
Figure 4. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Conversion Kit
Table 2. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Conversion Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Cylinder assembly (Black) (2) | 17285-07 | 7 | O-ring, cylinder spigot (2) | Not Sold Separately | |
2 | Piston (2) | Not Sold Separately | 8 | Cylinder head, front (black) | 17251-07B | |
3 | Piston Ring Set (2) | 22285-07 | 9 | Cylinder head, rear (black) | 17252-07A | |
4 | Piston pin (2) | 22269-07 | 10 | Automatic Compression Release (ACR) | 28861-07A | |
5 | Piston pin circlip (4) | 22097-99 | 11 | Air Cleaner Kit (Not Shown) | 29592-05 | |
6 | Gasket, cylinder head (2) | 16801-07B | Notes: Piston Kit (22284-07) includes 2 through 5. Items 5 through 7 are included in Engine Overhaul Gasket Kit (17350-07). Refer to 2009 FXDFSE Parts Catalog (99430-09A) for cylinder head assembly (8, 9) components. Items 7 and 13 (table 4) are available in seal kit (11907). | |||
Figure 5. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Conversion Kit
Table 3. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Conversion Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, rocker cover base (2) | 16719-99B | 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 | Spring, clutch diaphragm (Not Shown) | 37951-98 | |
6 | O-ring, upper push rod cover (4) | 11293 | ||||
7 | O-ring, rocker arm support (2) | 11270 | ||||
8 | Gasket, breather (2) | Not Sold Separately | Notes: Breather Gasket Kit (17162-03) includes 8 through 11. Items 1 through 12 are included in Engine Overhaul Kit (17350-07). | |||
Figure 6. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Conversion Kit
Table 4. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Conversion Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, cam cover | 25244-99A |
2 | Washer | Not Sold Separately |
3 | Capscrew, flanged | Not Sold Separately |
4 | Retaining ring | 11461 |
5 | Camshaft, front | Not Sold Separately |
6 | Camshaft, rear | Not Sold Separately |
7 | Bearing, needle (2) (must be purchased separately, if needed) | 9215 |
8 | O-ring, oil pump to cam plate | 11293 |
9 | O-ring, cam plate to crankcase (2) | 11301 |
10 | O-ring, crankcase ring dowel (2) | 26432-76A |
11 | O-ring, piston cooling (2) | 11140 |
12 | Retaining ring, internal | 35114-02 |
13 | O-ring, crankcase dowel (2) | Not Sold Separately |
14 | Seal, main bearing oil | 12068 |
15 | Screw, top center crankcase, long | 1090A |
16 | O-ring, CPS | 11289 |
17 | Screw, modified, crankcase boring (Not Shown) (must be purchased separately) | 1093 |
18 | Flywheel bearing, sprocket shaft (Not Shown) | 24004-03A |
Notes: Cam Drive Retention Kit (25566-06) includes 2 and 3. Items 5 and 6 are available in Cam Kit (25638-07) Items 8 through 16 are included in Engine Overhaul Gasket Kit (17350-07) Items 13 and 7 (table 2) are available in Seal Kit (11907). | ||
Figure 7. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Conversion Kit
Table 5. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Conversion Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Head pipe assembly | 66884-09 |
2 | ACR Overlay Wire Harness Kit (Refer to Instruction Sheet J04210) | 70623-06 |