SCREAMIN' EAGLE PRO BIGGER-BORE CYLINDER KITS
J049212014-05-12
GENERAL
Kit Number
16550-04C (Black) and 16551-04C (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).
NOTE
This kit cannot be installed on 110 CI CVO models or any Twin Cam models previously upgraded to a 110 CI motor.
Installation Requirements
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 crankcase screw (1093). This makes sure 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 using 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 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. One is available from a Harley-Davidson dealer.
Kit Contents
NOTE
This conversion kit is intended for High Performance or Racing applications. This kit is not legal for sale or use on pollution controlled motor vehicles. This kit may reduce or void the limited vehicle warranty. Engine-related performance parts are intended FOR THE EXPERIENCED RIDER ONLY.
REMOVAL
Prepare for Service
| 1. | Raise the motorcycle. NOTE Disarm security 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. | Remove main fuse. Refer to service manual for your motorcycle. |
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.
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).
| 1. | Remove cylinder studs from the engine crankcase. | |
| 2. | Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. | |
| 3. | Inspect and clean engine case mating surfaces. | |
| 4. | See Figure 5. Reassemble crankcase with original screws, except the top center screw between the cylinders. Tighten to specifications listed in service manual. 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). This screw can be purchased separately from a Harley-Davidson dealer. | |
| 5. | Install modified top center screw (1093) between the cylinders. Tighten to 50-90 in-lbs (5.6-10.2 Nm). | |
| 6. | See Figure 1 and Table 1. Machine crankcase cylinder spigot bore to the dimensions shown. |  Figure 1. Spigot Bore Dimensions |
Table 1. Spigot Bore Dimensions
Description | Bore | Depth |
|---|---|---|
Spigot Bore | 4.2625 +/- 0.0025 in. (108.3 +/- 0.006 mm) | 1.690 +/- 0.010 in. (42.9 +/- 0.25 mm) |
| 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 2. Top Center Engine Crankcase Screw Hole Modification
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 2. 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.
| 7. | See Figure 2 and Figure 3. Remove the thin material between the cylinders next to the top center screw as shown. Use a 5/8 in (16 mm) ball end mill and milling a 5/16 in (7.94 mm) radius at the two points shown. |  Figure 3. Cylinder Wall |
Install Engine Components
| 1. | Assemble bottom end of engine. Refer to ENGINE section in appropriate service manual. NOTE See Figure 4. The 4.060 in cylinder base gasket (1) and cylinder head gasket (2) eliminate the need for O-rings (11273). Do not use O-rings on cylinder dowels or cylinder spigots. When installing new base gasket (1), install with the embossed side down and the concave side up. | |
| 2. | Refer to the appropriate service manual and assemble the engine with the following changes: a. See Figure 5. Install the top center engine crankcase screw (4) and washer (5), supplied in the kit but do not tighten now. Install and tighten the rest of the crankcase screws to the specified torque. b. See Figure 5. Assemble top end of engine using the base gaskets (2) and head gaskets (3) provided in kit. Refer to ENGINE section in appropriate service manual. c. See Figure 5. After the cylinders and heads have been installed and the hardware tightened to specification, tighten the top center crankcase screw (4) supplied in kit to 5.6–10.2 N·m (50–90 in-lbs). |
| 1 | Gasket, cylinder base |
| 2 | Gasket, cylinder head |
Figure 4. Cylinder Gaskets
Final Assembly
| 1. | Install engine in chassis following the instructions in the service manual. | |
| 2. | Install exhaust system. Refer to EXHAUST SYSTEM INSTALLATION in service manual. | |
| 3. | Install air cleaner assembly. Refer to AIR CLEANER INSTALLATION in service manual. | |
| 4. | Install main fuse. Refer to service manual for your motorcycle. | |
| 5. | Install fuel tank according to the instructions in the service manual. | |
| 6. | 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) | ||
| 7. | Download the new ECM calibration using EFI Race Tuner Kit. Refer to Screamin' Eagle Pro Catalog or contact a Harley-Davidson dealer. | |
| 8. | Start and run engine. Repeat several times to verify proper operation. |
Operation
Refer to BREAK-IN RIDING RULES in the Owner's Manual to break in the motorcycle.
SERVICE PARTS
Figure 5. Service Parts: Screamin' Eagle Pro Bigger-Bore Cylinder Kits
Table 2. Service Parts: Screamin' Eagle Pro Bigger-Bore Cylinder Kits
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
16550-04C Conversion Kit, 4.060 in Bore, Black | 1 | Cylinder assembly, front, 4.060 in bore, black Cylinder assembly, rear, 4.060 in bore, black | 16562-04B 16563-04B |
2 | Gasket, cylinder base (2) | 16736-04A | |
3 | Gasket, cylinder head (2) | 16104-04 | |
4 | Screw, center crankcase | 1105 | |
5 | Washer, center crankcase | 1086A | |
16551-04C Conversion Kit, 4.060 in Bore, Silver | 1 | Cylinder assembly, front, 4.060 in bore, silver Cylinder assembly, rear, 4.060 in bore, silver | 16564-04B 16580-04B |
2 | Gasket, cylinder base (2) | 16736-04A | |
3 | Gasket, cylinder head (2) | 16104-04 | |
4 | Screw, center crankcase | 1105 | |
5 | Washer, center crankcase | 1086A |