SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT
J047952011-04-27
GENERAL
Kit Number
27508-09A (Black) and 27506-09A (Silver)
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 not 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 the system. | |
| 2. | Remove the main fuse according to the instructions in service manual. | |
| 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. Discard mufflers but save remaining parts. 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.
- See Figure 6. Reassemble engine case with original 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.
| 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) |
Modify Crankcase
NOTE
To prevent severe engine damage, thoroughly clean and remove all chips and debris from the engine crankcase after boring.
| 1. | Disassemble crankcase and wash (or clean) chips and debris from engine crankcase halves as necessary. | |
| 2. | 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. | |
| 3. | 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. | |
| 4. | 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. | |
| 5. | See Figure 2 and Figure 3. Remove the thin material between the cylinders next to the top center screw as shown, by using a 5/8 in. (16 mm) ball end mill and milling a 5/16 in. (16 mm) radius at the two points shown. |  Figure 2. Cylinder Wall |
| 6. | Refer to the appropriate service manual and assemble the engine with the following changes: a. Tighten all of the engine crankcase screws to the specified torque, except the top center engine crankcase screw. b. See Figure 6. After the cylinders and heads have been installed and the hardware tightened to specification, install the top center engine crankcase screw (15) supplied in kit. Tighten screw to 50-90 in-lbs (5.6-10.2 Nm). |
| 1 | Tap hole with a 5/16-18 UNC-2B bottoming tap |
| 2 | Extended 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
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 system using mufflers (1) from kit. Refer to EXHAUST SYSTEM INSTALLATION in service manual.
- See Figure 4. Install Air Cleaner Kit (29592-05) following the instructions in the Instruction Sheet.
Install ACR Overlay Wire Harness
See Figure 7. Install ACR Overlay Wire Harness Kit (70623-06) following the instructions in the Instruction Sheet.
Final Assembly
| 1. | 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) | ||
| 2. | Install fuel tank according to the instructions in the service manual. | |
| 3. | Install main fuse according to the instructions in service manual. | |
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 the Digital Technician at a Harley-Davidson dealer. | |
| 5. | 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.
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) | 17285-07A | 8 | Cylinder head, front, w\ACR, (black) | 17251-07B | |
Cylinder assembly (Silver) (2) | 16815-07A | Cylinder head, front, w\ACR, (silver) | 17261-07B | |||
2 | Piston (2) | Not Sold Separately | 9 | Cylinder head, rear, w\ACR, (black) | 17252-07A | |
3 | Piston Ring Set (2) | 21951-11 | Cylinder head, rear, w/ACR, (silver) | 17262-07A | ||
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) | 16801-07C | Notes: Piston Kit (21991-11) includes 2 through 5. Item 5 is also included in Engine Overhaul Gasket Kit (17350-07B). Refer to 2009 FXSTSSE3 Parts Catalog (99458-09) for cylinder head assembly (8, 9) components. | |||
7 | O-ring, cylinder spigot (2) | Not Sold Separately | ||||
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 | Breather assembly (2) | 17025-03A | |
2 | Gasket, rocker cover top (2) | 17386-99A | 10 | Baffle assembly (2) | 26500002 | |
3 | Gasket, tappet cover (2) | 18635-99B | 11 | Seal, EFI intake (2) (not shown) | 26995-86B | |
4 | O-ring, middle push rod cover (4) | 11132A | 12 | Spring clutch diaphragm (not shown) | 37951-86B | |
5 | O-ring, lower push rod cover (4) | 11145A | ||||
6 | O-ring, upper push rod cover (4) | 11293 | Items 1 through 11 are included in Engine Overhaul Gasket Kit (17350-07B). | |||
7 | O-ring, rocker arm support (2) | 11270 | ||||
8 | Bolt 1/4-20 x 1-11/16 hex head w/Scotch grip (4) | 4400 | ||||
Figure 6. Service Parts: Screamin' Eagle Pro 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 | 6294 |
3 | Cam drive sprocket retention kit w/6294, screws and washers | 25566-06 |
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 (not shown) | 11289A |
17 | Seal, exhaust (2) (not shown) | 65324-83B |
18 | Seal, oil interconnect (not shown) (Softail models only) | 45359-00 |
19 | Valve seal (4) (not shown) (not required) | 18067-09 |
20 | Main bearing | 24605-07 |
21 | Thrust washer | 8972 |
22 | Bearing kit, w/ 8972, 24605-07, 35114-02 + inner race (not shown) | 24004-03B |
23 | Screw, modified, crankcase boring (not shown) (must be purchased separately) | 1093 |
Notes: Items 5 and 6 are available in Cam Kit (25638-07) Items 8 through 22 are included in Engine Overhaul Gasket Kit (17350-07B) Items 13 and 7 (table 2) are available in Seal Kit (11907) which is included in the Engine Overhaul Gasket Kit | ||
Figure 7. Service Parts: Screamin' Eagle Twin Cam (1800 CC) Conversion Kit
Table 5. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Conversion Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Muffler, catalytic (2) | 65872-09 |
2 | ACR Overlay Wire Harness Kit (Refer to Instruction Sheet J04210) | 70623-06 |