SCREAMIN' EAGLE® PRO BIG BORE STAGE 2 KIT FOR EFI MODELS
J040802006-05-02
GENERAL
Kit Number
29893-07, 29894-07
Models
These kits fits all 2007 Twin Cam model motorcycles
Additional Parts Required
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.
NOTICE
You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b)
INSTALLATION
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNINGDisconnect negative (-) 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. (00049a)
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)
Installation of this kit is divided into six steps:
- Big-Bore Cylinder and Piston Conversion
- High Performance Camshafts
- High Performance Clutch Diaphragm Spring
- High Performance Air Cleaner
- Calibrate the ECM
NOTE
This Big-Bore Stage 2 kit is intended for High Performance applications only. Engine-related performance parts are intended for the experienced rider only.
The air cleaner contained in these kits is designed to perform with these kits only.
NOTICE
Head gaskets provided in the Big Bore kit eliminate the need for original equipment (O.E.) O-rings. Do not install the two O-rings from the kit on the top cylinder dowels or severe engine damage can occur. (00484d)
1. Big-Bore Cylinder and Piston Conversion
NOTE
Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to Section 3, ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL of the applicable Service Manual for instructions.
2. High Performance Camshafts
NOTE
Installation of this kit requires removal and re-installation of the cam support plate. Refer to Section 3, ENGINE: BOTTOM END Cam Support Plate, Removal and Disassembly/Assembly (Camshaft, Camshaft Bearings) of the applicable Service Manual for instructions.
Measuring Piston-to-Valve Clearance
After installing non-stock cams, check piston-to-valve clearance.
- Apply 1/8 inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons.
- Refer to the appropriate Service Manual and assemble the heads and valve train, and tighten cylinder studs to torque specified.
- Turn engine through two complete revolutions by hand.
- Remove heads and measure clay at its thinnest point.
NOTE
Clay must measure 0.080 inch (2.03 mm) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 0.135 inch (3.43 mm).
Measuring Valve-to-Valve Clearance
NOTE
Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents you from bending push rods or valves.
| 1. | Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust and intake valve heads cross, where both valves are off their seats by an equal amount. NOTE See Figure 1. If it is necessary after inspection to grind the intake and exhaust valves in order to meet the 0.040 inch (1.016 mm) clearance between the two valve heads, the margins (3) must be measured as follows: 0.031 inch (0.787 mm) minimum margin on exhaust valves and 0.015 inch (0.381 mm) minimum margin on intake valves. | 
Figure 1. Beveling Valve Heads | ||||||
| 2. | A 0.040 inch (1.016 mm) clearance is required between the two valve heads. Use a 0.040 inch wire gauge (1) to measure this. To adjust the clearance, grind the edges of the intake and exhaust valves at a 45 degree angle (2). | |||||||
| 3. | Repeat steps 1 and 2 for the rear cylinder. |
Install New Pistons, Cylinders, and Cylinder Heads
- Assembly - Refer to the ENGINE section of the appropriate Service Manual for installing pistons, cylinders and cylinder heads.
3. High Performance Clutch Diaphragm Spring
- Disassembly - Refer to the DRIVE section of the appropriate Service Manual to remove primary chain case, chain, diaphragm spring retainer and diaphragm spring.
- Assembly - Refer to the DRIVE section of the appropriate Service Manual for installing diaphragm spring retainer, diaphragm spring, chain and primary chain case.
4. High Performance Air Cleaner
Follow the instructions included with the High Performance air cleaner in this kit for installation.
5. Calibrate the ECM
Have dealer recalibrate the ECM prior to starting vehicle.
6. Exhaust
Refer to the appropriate Service Manual for exhaust installation procedure, if required.
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)
- Connect the battery cables, positive (+) cable first.
- Refer to the Service Manual, and follow instructions to install the seat.
SERVICE PARTS
Figure 2. Service Parts: Screamin' Big-Bore EFI Stage 2 Kit
Table 1. Service Parts: Screamin' Eagle Big-Bore EFI Stage 2 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | O-ring, middle push rod cover (4) | 11132 | 11 | Ring set, piston, 1690 standard (2) | 21918-99 | |
2 | O-ring, lower push rod cover (4) | 11145 | 12 | Lock wire, piston pin (4) | 22097-99 | |
3 | O-ring, cylinder spigot (2) | 11256 | 13 | Kit, Piston, 1690 standard (2) | 21966-07 | |
4 | O-ring, rocker arm support (2) | 11270 | 14 | Kit, breather gasket | 17162-03 | |
5 | O-ring, cylinder deck ring dowel (2) | 11273 | 15 | Pin, piston (2) | 22132-99 | |
6 | O-ring, upper push rod cover (4) | 11293 | Kit, exhaust gasket (not shown) | 17048-98 | ||
7 | Assembly, 1690 cylinder, black (2) | 16547-99 | Seal, intake manifold (not shown) (2) | 26995-86B | ||
Assembly, 1690 cylinder, silver (2) | 16548-99 | Kit, performance A/C CARB/EFI (not shown) | 29440-99D | |||
8 | Gasket, rocker cover base (2) | 16719-99A | Clutch diaphragm spring, high performance (not shown) | 37951-98 | ||
9 | Kit, head gasket (2) | 16787-99A | Loctite 262, red, 0.5 ml tube (not shown) | 94673-99 | ||
10 | Gasket, rocker cover top (2) | 17386-99A | Lable, EO (not shown) (Street Legal Kits only) | 29440-99D |
Figure 3. Service Parts: Screamin' Big-Bore EFI Stage 2 Kit
Table 2. Service Parts: Screamin' Eagle Big-Bore EFI Stage 2 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Capscrew, flanged (crank) | 898A | 6 | O-ring, cam plate-to-crankcase (2) | 11301 | |
2 | Capscrew, flanged (cam) | 996 | 7 | Gasket, cam cover | 25244-99A | |
3 | Washer (crank) | 6278A | 8 | Camshaft, front, SE255 | 25417-07 | |
4 | Washer (cam) | 6294 | 9 | Camshaft, rear, SE255 | 25427-07 | |
5 | O-ring, oil pump-to-cam plate | 11286 | ||||