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SCREAMIN' EAGLE PRO TC 120 (1962 CC) CONVERSION KIT
J052152010-09-07
GENERAL
Kit Number
30086-10A
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 cubic inch CVO models or any Twin Cam models previously upgraded to a 110 cubic inch motor.
Additional Parts Required
  • For 2008-2010 Models: Installation of SE High Capacity Compensator Kit (40274-08) is required for installation of this kit. For 2011 Models: Separate purchase of an SE High Capacity Compensator Kit is not required.
  • Each head requires one 12 mm spark plug. We recommend Screamin' Eagle Performance Spark Plugs (see Screamin' Eagle Pro catalog).
  • This kit requires the separate purchase of a SE air cleaner kit and SE High Flow Fuel Injectors that are compatible with the supplied 58mm throttle body. See Screamin' Eagle Pro catalog for available kits.
  • Separate purchase of Cam Spacer Kit (25928-06) is recommended. This kit contains five different spacers to achieve proper sprocket alignment.
  • Separate purchase of a clutch kit that will support 140 ft-lbs of torque.
  • The separate purchase of Crankcase Boring Tool Kit (94419-06) is recommended for installing this high performance engine conversion 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.
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.
WARNING
Rider 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
See Figure 1 to Figure 3 , and Table 1 to Table 3.
NOTE
This conversion kit is intended for High Performance or Racing applications only and 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. 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 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 main fuse. Refer to service manual for your motorcycle.
4. Remove fuel tank according to the instructions in the service manual.
Remove Engine Components
  1. Remove existing air cleaner assembly. Refer to the service manual.
  2. Remove existing exhaust system. Refer to the service manual.
  3. Remove engine from chassis following the instructions in the service manual.
  4. Disassemble engine top end and bottom end. Refer to the service manual.
  5. Remove existing clutch diaphragm spring. Refer to the 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. Refer to Instruction Sheet for Bigger Bore (4.060 inch) Cylinder Kit for instructions for crankcase boring and modifications.
    5. 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.
INSTALLATION
Install Engine and Clutch Components
  1. See Figure 3. Replace camshaft needle bearings (7) from kit. Refer to the service manual.
  2. Install lowered piston cooling jets included with this kit. Refer to the service manual.
  3. Install flywheel assembly from the kit. Refer to Instruction Sheet and the service manual.
  4. See Figure 1 through Figure 3. Assemble engine top end and bottom end using parts from kit. Refer to Instruction Sheets for the cams and pistons and refer to the service manual.
  5. Install engine in chassis following the instructions in the service manual.
  6. For 2008-2010 Touring Models: Install SE High Capacity Compensator Kit (40274-08). Follow instructions included with compensator kit. For 2011 Touring Models: Install original equipment compensator following instructions in the service manual.
  7. Assemble throttle body from kit and separately purchased injectors using original equipment fuel line and fuel rail. Refer to instructions in the supplied throttle body kit.
  8. Install throttle body assembly to engine using intake flanges and seals supplied in the throttle body kit. Refer to instructions from the supplied throttle body kit.
  9. Install clutch kit. Separate purchase of a clutch kit that will support 140 ft-lbs of torque is required.
  10. Install exhaust system. Refer to the service manual.
  11. Install the separately purchased air cleaner assembly. Refer to the service manual or Instruction Sheet from kit.
Final Assembly
1. Install main fuse. Refer to service manual.
2. 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)
3. Install seat according to the instructions in the 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 EFI Race Tuner Kit and Interface Box supplied with kit. Refer to Screamin' Eagle Pro Catalog or contact 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 1. Service Parts: Screamin' Eagle Pro TC 120 (1962 cc) Conversion Kit
Table 1. Service Parts Table: Screamin' Eagle Pro TC 120 cubic inch (1962 cc) Conversion Kit
Item
Description (Quantity)
Part Number
1
4.060 cylinder assembly, black (2) (used in Kit 16550-04C)
16562-04B (front)
16563-04B (rear)
2
Piston (2)
Not Sold Separately
3
Piston ring set (2)
22526-10
4
Piston pin (2)
22310-10
5
Piston pin circlip (4)
22097-99
6
Gasket, cylinder head (2)
16104-04
7
Gasket, cylinder base (2)
16736-04
8
Cylinder head assembly, front, black
17443-10
9
Cylinder head assembly, rear, black
17444-10
10
Automatic compression release (ACR) solenoid
28861-04A
Notes: Cylinder kit (16550-04C) includes items 1, 6 and 7. Piston Kit (22574-10) includes items 2 through 5. Item 5 is also included in Engine Overhaul Gasket Kit (17053-99C). For cylinder heads (8, 9) assembly components refer to the Cylinder Head Information section.
Figure 2. Service Parts: Screamin' Eagle Pro TC 110 (1800 cc) Stage 3 Upgrade Kit
Table 2. Service Parts: Screamin' Eagle Pro TC 120 cubic inch (1962 cc) Conversion Kit
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Gasket, rocker cover base (2)
16719-99A
9
Breather assembly
17025-03A
2
Gasket, rocker cover top (2)
17386-99A
10
Baffle assembly
26500002
3
Gasket, tappet cover (2)
18635-99B
11
Seal, EFI intake (2) (Not Shown)
27035-05
4
O-ring, middle push rod cover (4)
11132A
12
Seal, map sensor (Not Shown)
11291
5
O-ring, lower push rod cover (4)
11145A
13
Perfect fit pushrods kit, (+0.030 inch)
18401-03
6
O-ring, upper push rod cover (4)
11293
7
O-ring, rocker arm support (2)
11270
8
Breather bolt (2)
4400
Notes: Breather Gasket Kit (17162-03) includes 8 through 11. Items 1 through 11 are included in Engine Overhaul Gasket Kit (17053-99C). Item 11 is included in Manifold Kit (29667-07).
Figure 3. Service Parts: Screamin' Eagle Pro TC 120 (1962 cc) Conversion Kit
Table 3. Service Parts: Screamin' Eagle Pro TC 120 (1962 cc) Conversion Kit
Item
Description (Quantity)
Part Number
1
Gasket, cam cover
25244-99A
2
Washer
6294
3
Cam Drive Retention Kit, w/6294, screws and washer
25566-06
4
Retaining ring
11461
5
Camshaft, front, SE-266E
Not Sold Separately
6
Camshaft, rear, SE-266E
Not Sold Separately
7
Bearing, needle (2) (must be purchased separately, if needed)
9298
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)
10930
12
Retaining ring, internal
35114-02
13
O-ring, crankcase dowel (2)
11273
14
Seal, main bearing oil
12068
15
O-ring CPS (Not Shown)
11289A
16
Screw, top center crankcase
1105
17
Washer, sealing
1086A
18
Piston cooling jet (2)
22315-06A
19
120R Cam cover medallion
25495-10
20
Screw, modified, crankcase boring (Not Shown), (must be purchased separately)
1093
21
58 mm ETC throttle body kit (not shown)
27713-08
22
Interface box, (VCI), Super Tuner (not shown)
32109-08A
23
4.625 stroke flywheel assembly (not shown)
23893-10
24
Bearing, main
24605-07
25
Thrust washer
8972
26
Bearing Kit, w/8972, 24605-07, 35114-02 and inner race 24004-03A
23893-10
Notes: Items 1, 8 through 15 are included in Engine Overhaul Gasket Kit (17053-99C). Items 5 and 6 available in Cam Kit (25494-10). Cylinder kit includes items 16 and 17.
CYLINDER HEAD INFORMATION
NOTE
The valve springs in these cylinder head assemblies work with cams with up to 0.660 in. (16.74 mm) lift, and up to 7000 rpm.
Refer to ENGINE section of service manual for all removal/disassembly and assembly/installation procedures.
It is important to check valve-to-piston clearance as described in the following steps. We recommend that this inspection be performed by a Harley-Davidson dealer.
Valves must be properly adjusted to zero valve lash when claying pistons. Use adjustable pushrods and fully-bottom the hydraulic lifters for accurate measurements.
1. Apply 1/8 in. (3.2 mm) thick layer of clay to crowns of both pistons (in the areas where valves meet pistons).
2. Install new cylinder heads from this kit, using new gaskets from Top End Overhaul Gasket Kit (purchased separately). Assemble heads and valve train, and tighten headbolts to torque specifications listed in service manual.
3. Turn engine (by hand) through two complete revolutions.
4. Remove heads and measure the clay at its thinnest point.
NOTE
  • Clay must measure 0.080 in. (2.03 mm) at the thinnest point. If this measurement does not meet the minimum thickness, the depth of the valve notches must be increased; however, the depth of the notches must not exceed 0.135 in. (3.43 mm).
  • Since oversized valves are used, radial clearance should also be checked. Radial clearance of 0.050 in. (1.27 mm) is recommended.
NOTE
The valve springs on these cylinder heads have an installed spring height of 1.835 in. (46.61 mm) which equals 180 lbs (81.6 kg) of seat pressure.
  • Seat pressure can be increased by placing shims 18224-98 (0.015 in.) or 18225-98 (0.030 in.) under the lower spring collars. Every 0.015 in. (0.38 mm) reduction in spring height equals 7.5 lbs (3.4 kg) more of seat pressure. Shim to the desired seat pressure by placing shims under the lower collar, but maintain a minimum of 0.70 in. (17.78 mm) travel to coil bind.
  • Seat pressure can be decreased by machining the surface of the cylinder heads in the area under the valve spring lower collar. Every 0.015 in. (0.38 mm) increase in spring height equals 7.5 lbs (3.4 kg) less of seat pressure. Machine to the desired seat pressure by machining the spring pockets in the cylinder heads, but maintain a minimum of 0.70 in. (17.78 mm) travel to coil bind.
For constant operation at extreme RPMs, all four valve springs should be checked for matched, installed heights.
1Upper collar
2Lower collar
31.835 in. (46.61 mm) installed spring height/180 lbs (81.6 kg) spring pressure
4Free travel should be at least 0.080 in. (2.03 mm) greater than maximum valve lift.
Figure 4. Valve Spring Travel
5. Change installed valve spring height (seat pressure) as follows:
a. Compress valve springs and remove valve collar retainers, upper collars, springs, valve seals, and lower collars on all four valves.
b. See Figure 4. Use shims or machine cylinder heads as required to obtain desired seat pressure (see notes above). Install lower valve spring collars, valve springs (do not install valve seals at this time), upper collars, and collar keys. Check installed spring height.
c. If spring heights still do not match, repeat Steps 8a and 8b above as necessary to reach the desired installed spring height, again without installing valve seals.
d. When all spring heights match, remove valve collar retainers, upper collars, springs, and lower collars. Install using new valve seals (18046-98) purchased separately. Assemble the cylinder head assemblies.
e. Because of the large diameter of the springs in this kit, there may be slight interference between the spring and the rocker box. If interference is detected, the clearance in the rocker box bolts may allow enough movement to gain clearance. If not, it may be necessary to remove a small amount of material from the rocker box.
6. Install the new cylinder head assemblies.
7. Check assembled engine for proper installation and operation.
NOTE
If mechanical compression release is desired, SE Compression Release Kit (32076-04) is available. The mechanical compression release can be machined using the SE Mechanical Compression Release Fixture (94638-08). The automatic compression release will need to be removed and plug 16648 can be installed.
SERVICE PARTS
Figure 5. Service Parts: Cylinder Head Service Parts
Table 4. Service Parts: Cylinder Head Service Parts List
Item
Description (Quantity)
Part Number
1a
Cylinder head assembly, rear (includes Items 2 through 11)
17444-10
1b
Cylinder head assembly, front (includes Items 2 through 13)
17443-10
2
  • Cylinder head (machined, with items B, C, D and E installed)
Not Sold Separately
3
  • Collar, valve spring, upper (4)
See Service Kits
4
  • Collar, valve spring, lower (4)
See Service Kits
5
  • Stud, exhaust port (4)
16715-83
6
  • Intake valve (2)
18190-08
7
  • Exhaust valve (2)
18183-03
8
  • seal, valve (4)
18046-98
9
  • Valve spring unit (4)
See Service Kits
10
  • Retainer, valve collar (8). Also included with Kit 18281-02A
18240-98
11
  • Automatic compression release (2)
28861-07A
12
  • Medallion, "120R" (for front cylinder head only)
17136-10
13
  • Screw, button head, TORX (2) (for front cylinder head only)
94634-99
Service Kits:
A
Valve Spring Kit, Screamin' Eagle
19281-02A
The following Screamin' Eagle parts are available separately:
B
Valve seat, intake
18191-08
C
Valve seat, exhaust
18048-98A
D
Valve guide, intake (for service)
  • (+ 0.003 in.)
18158-05
  • (+ 0.002 in.)
18156-05
  • (+ 0.001 in.)
18154-05
E
Valve guide, exhaust (for service)
  • (+ 0.003 in.)
18157-05
  • (+ 0.002 in.)
18155-05
  • (+ 0.001 in.)
18153-05