TABLE OF CONTENTS | |
---|---|
Page | Subject |
1 | SE120R ENGINE INSTALLATION |
3 | SE120R ENGINE SPECIFICATIONS |
3 | MANUFACTURING TOLERANCES |
5 | SERVICE WEAR LIMITS |
6 | SE120R CYLINDERS |
6 | SE120R PISTONS |
9 | REPLACING/SERVICING PUSHRODS |
10 | SERVICE PARTS |
1. | Position the motorcycle on a suitable lift. NOTE If vehicle is equipped with a 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. | |
![]() 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 the main fuse. Refer to service manual for your motorcycle. | |
4. | Remove the fuel tank according to the instructions in the service manual. | |
5. | Refer to ENGINE section of the appropriate service manual for removal of engine from chassis. |
6. | Install the fuel tank according to the instructions in the service manual. | |
7. | Refer to the service manual to install the main fuse. | |
8. | Install the seat according to the instructions in the service manual. | |
![]() 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) | ||
9. | Download the new ECM calibration when installing this kit. Refer to the Screamin' Eagle Pro Catalog or contact a Harley-Davidson dealer. | |
10. | Start and run the engine. Repeat several times to verify proper operation. |
Item | Specification | |
---|---|---|
Compression Ratio | 10.5 | |
Bore | 4.060 in. | 103.12 mm |
Stroke | 4.625 in. | 117.48 mm |
Displacement | 119.75 in. | 1962.39 cc |
Lubrication system | Pressurized dry sump with oil cooler | |
Maximum sustained engine speed | 6200 RPM |
ITEM | IN. | MM |
---|---|---|
Valve guide in head (tight) | 0.0020-0.0033 | 0.051-0.084 |
Intake valve seat in head (tight) | 0.004-0.0055 | 0.102-0.140 |
Exhaust valve seat in head (tight) | 0.004-0.0055 | 0.102-0.140 |
ITEM | IN. | MM |
---|---|---|
Fit in guide (intake and exhaust) | 0.0011-0.0029 | 0.028-0.074 |
Seat width | 0.034-0.062 | 0.86-1.57 |
Stem protrusion from cylinder head boss | 1.990-2.024 | 50.55-51.41 |
ITEM | PRESSURE | DIMENSION |
---|---|---|
Closed | 180 lbs (79 kg) | 1.800 in. (45.7 mm) |
Open | 500 lbs (196 kg) | 1.177 in. (29.9 mm) |
Free length | n/a | 2.210 in. (56.1 mm) |
Piston: | Clearance (in.) |
---|---|
Piston-to-cylinder fit (Loose) | 0.0026-0.0036 |
Piston pin fit (Loose) | 0.0003-0.0008 |
Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap | 0.012-0.020 0.016-0.024 0.008-0.0028 |
Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance | 0.0010-0.0022 0.0010-0.0022 0.0003-0.0072 |
Intake | Specification |
---|---|
Opens | 24 BTDC |
Closes | 58 ABDC |
Duration | 262o |
Max. Valve Lift | 0.658 in. |
Valve Lift @ TDC | 0.208 in. |
Exhaust | Specification |
Opens | 69 BBDC |
Closes | 17 ATDC |
Duration | 266o |
Max. Valve Lift | 0.658 in. |
Valve Lift @ TDC | 0.178 in. |
Cam Timing @ 0.053" of Tappet Lift in Crankshaft Degrees |
ITEM | REPLACE IF WEAR EXCEEDS | |
---|---|---|
IN. | MM | |
Taper | 0.002 | 0.051 |
Out of round | 0.002 | 0.051 |
Warpage of gasket or O-ring surfaces: top | 0.006 | 0.152 |
Warpage of gasket or O-ring surfaces: base | 0.004 | 0.102 |
ITEM | REPLACE IF WEAR EXCEEDS | |
---|---|---|
IN. | MM | |
Standard | 4.062 | 103.17 |
0.010 in. oversize | 4.072 | 103.43 |
Piston-to-cylinder fit (Loose) | Wear Limit (in.) |
---|---|
Fit in cylinder (Loose) | 0.0061 |
Piston Pin Fit (Loose) | 0.0011 |
Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap | 0.030 0.034 0.038 |
Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance | 0.0030 0.0030 0.0079 |
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. | |
![]() 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. |
1. | Refer to the appropriate service manual and assemble the engine with the following changes: a. Assemble the top end of the engine using the base gaskets and head gaskets provided in the kit. Refer to the appropriate engine section in the service manual. |
Figure 1. Cylinder Gaskets |
2. | Install the fuel tank according to the instructions in the service manual. | |
3. | Refer to the service manual to install the main fuse. | |
![]() 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 the seat according to the instructions in the service manual. |
1. | Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. | |||||
![]() 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) | ||||||
2. | Refer to the ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL, DISASSEMBLY sections of the service manual for cylinder head, cylinder and piston removal procedures. | |||||
3. | Follow the procedures in the ENGINE: SUBASSEMBLY SERVICE AND REPAIR, TOP END/ CYLINDER/ UPPER CONNECTING ROD sections of the service manual for inspection of parts. | |||||
4. | See the ENGINE: SUBASSEMBLY SERVICE AND REPAIR, CYLINDER section of the service manual for boring and honing instructions. NOTE Install the top ring (barrel-faced) and second ring (taper-faced Napier) with the "N" marking facing up. Oil ring rails can be installed either side up. The 4.060 inch cylinder base gaskets and cylinder head gaskets included in the kit eliminate the need for O-rings (11273). Do not use O-rings on cylinder dowels or cylinder spigots. When installing new base gasket, install with the embossed side down and the concave side up. NOTE Checking piston-to-cylinder fit at this location per table 11 is for reference. |
Figure 2. Piston Measurements | ||||
5. | See Figure 2. Measure the piston width (1), 90 degrees horizontally from both sides of the piston pin hole and 1.275 in. down from the deck surface (top) of the piston (2). See table 11 for piston-to-cylinder fit at this location. | |||||
6. | The pistons in this kit are front and rear specific. Install the piston marked "FRONT" in the front cylinder with the arrow pointing towards the front of the engine. Install the piston marked "REAR" in the rear cylinder with the arrow pointing towards the front of the engine. | |||||
7. | Refer to the ENGINE: TOP END OVERHAUL, ASSEMBLY section of the service manual for piston, cylinder and cylinder head installation procedures. |
Piston: | Clearance (in.) |
---|---|
Piston-to-cylinder fit (Loose) | 0.0026-0.0036 |
Piston pin fit (Loose) | 0.0003-0.0008 |
Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap | 0.012-0.020 0.016-0.024 0.008-0.0028 |
Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance | 0.0010-0.0022 0.0010-0.0022 0.0003-0.0072 |
Piston-to-cylinder fit (Loose) | Wear Limit (in.) |
---|---|
Fit in cylinder (Loose) | 0.0061 |
Piston Pin Fit (Loose) | 0.0011 |
Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap | 0.030 0.034 0.038 |
Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance | 0.0030 0.0030 0.0079 |
8. | See Figure 3. Insert the open end of the circlip (1) into the notch (2) on the groove (3) around the piston pin boss so that the gap is at the 12:00 or 6:00 o'clock position when installed. |
Figure 3. Circlip and Piston
Figure 4. Install Circlip | ||||||||||
9. | See Figure 4. Position your thumb (1) as shown, and press firmly until approximately 85% of the circlip (2) is seated in the groove. | |||||||||||
10. | Being careful not to scratch or mar the piston, use a small-bladed screwdriver to wedge the circlip into the remainder of the groove. Repeat for the remaining circlips. NOTE Make sure the piston circlip is fully seated, or ENGINE DAMAGE WILL OCCUR. | |||||||||||
11. | Refer to the ENGINE: ASSEMBLING MOTORCYCLE AFTER STRIPPING section of the service manual for final re-assembly procedures. | Figure 5. Piston Assembly |
Item | Description (Quantity) |
---|---|
1 | Piston (front, standard) |
2 | Piston (rear, standard) |
3 |
|
4 |
|
5 |
|
1 | Piston (front, +0.010) |
2 | Piston (rear, +0.010) |
3 |
|
4 |
|
5 |
|
1. | Refer to ENGINE section of service manual. NOTE Follow the appropriate service manual procedures for installing and removing the pushrods. The pushrods are marked Intake and Exhaust. The pushrods are directional. Be sure the larger end of the pushrods are installed down in the lifter sockets. |
Figure 6. Push Rods |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Engine assembly, complete | 19206-13 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Base gasket, cylinder (2) | 16736-04 |
2 | SE cylinder kit, 4.060 in., (black) (includes items 1, 3, 4, 1105 and 1086A) | 16550-04C |
3 | Dowel pin, ring (4) | 16595-99A |
4 | Gasket, cylinder head (2) | 16104-04 |
5 | Stud, cylinder (8) | 16834-99A |
6 | Gasket kit, engine overhaul (does not include cylinder head gasket, base gasket or valve stem seals) (Not Shown) | 17053-99C |
7 | Gasket kit, top-end, (does not include cylinder head gasket, base gasket or valve stem seals) (Not Shown) | 17052-99C |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Cylinder head assembly, rear (includes items 2 through 13) | 17444-10 |
Cylinder head assembly, front (includes items 2 through 13) | 17444-10 | |
2 |
| Not Sold Separately |
3 |
| See Service Kits |
4 |
| See Service Kits |
5 |
| 16715-83 |
6 |
| 18190-08 |
7 |
| 18183-03 |
8 |
| 18046-98 |
9 |
| See Service Kits |
10 |
| 18240-98 |
11 |
| 16648-08 |
12 | Medallion, "120R" (2) | 17136-10 |
13 | Screw, button head TORX (4) | 25800017 |
14 | Screw, internal thread, 3-3/16 inch (4) | 16478-85A |
15 | Screw, internal thread, 1-7/8 inch (4) | 16480-92A |
16 | Spark plugs (not shown) (2) | 32186-10 |
Service Kits: | ||
A | Valve Spring Kit, Screamin' Eagle | 18281-02A |
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) | |
| 18158-05 | |
| 18156-05 | |
| 18154-05 | |
E | Valve guide, exhaust (for service) | |
| 18157-05 | |
| 18155-05 | |
| 18153-05 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Screw 5/16-18 X 2-1/2 hex flange hd. (Grade 8) (8) | 1039 |
2 | Screw 5/16-18 X 1.0 hex hd., w/lockpatch (6) | 3692A |
3 | Screw 5/16-18 X 1-3/4 hex hd., w/lockpatch (10) | 3693A |
4 | Screw 5/16-18 X 1-1/4 hex flange hd., w/lockpatch (8) | 3736B |
5 | Screw 1/4-20 hex flange X 1-11/16 hex hd., w/lock patch, (Grade 8) (4) | 4400 |
6 | Screw 1/4-20 X 1 socket hd., w/lockpatch (8) | 4741A |
7 | Washer 11/16 X 29/32 X 1/32 (4) | 6762B |
8 | O-ring, push rod cover (4) | 11132A |
9 | O-ring, push rod cover (4) | 11145A |
10 | O-ring (2) | 11270 |
11 | O-ring (4) | 11293 |
12 | Gasket, rocker housing (2) | 16719-99B |
13 | Gasket kit, cam service | 17045-99D |
14 | Rocker arm, front intake, rear exhaust, with bushings (2) | 17360-83A |
15 | Rocker arm, rear intake, front exhaust, with bushings (2) | 17375-83A |
16 | Gasket, rocker cover (2) | 17386-99A |
17 | Bushing, rocker arm (8) | 17428-57 |
18 | Rocker cover, (chrome) (2) | 17572-99 |
19 | Rocker housing, (chrome) (2) | 17578-10 |
20 | Lifter cover, front (chrome) Lifter cover, rear (chrome) | 17964-99 17966-99 |
21 | Support, rocker arm (2) | 17594-99 |
22 | Breather assembly kit, (2) | 17025-03A |
23 | Shaft, rocker arm (4) | 17611-83 |
24 | Perfect Fit push rod kit (+0.030 inch) | 18401-03 |
25 | Cover, push rod, lower (4) | 17939-99 |
26 | Cap, cover spring (4) | 17945-36B |
27 | Spring, push rod cover (4) | 17947-36 |
28 | Cover, push rod upper (4) | 17948-99 |
29 | Retainer, spring cap (4) | 17968-99 |
30 | Pin, anti-rotation (2) | 18535-99 |
31 | Hydraulic lifter (4) | 17900022 |
32 | Gasket, lifter cover (2) | 18635-99B |
33 | Baffle assembly, breather (2) | 26500002 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Retaining ring | 11177A |
2 | Piston ring set, standard (2) Piston ring set, 0.010 inch over size (2) | 22526-10 22529-10 |
3 | Piston kit, front and rear, with ring sets, piston pin and lock rings, standard Piston kit, front and rear, with ring sets, piston pin and lock rings, 0.010 inch over size | 22574-10 22576-10 |
4 | Lock ring, piston pin (4) | 22097-99 |
5 | Piston pin (2) | 22310-10 |
6 | Flywheel assembly kit | 24100013 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Plug (3) | 765 |
2 2a 2b | Screw, 5/16-18 x 3.0 inch, hex flange head, (11) Screw, top center crankcase Washer, sealing | 895 1105 1086A |
3 | Washer 1-1/4 x 1-53/64 x 1/8 (2) | 8972 |
4 | Needle bearing kit, camshafts (2) (Kit includes 2) | 24018-10 |
5 | O-ring (2) | 10930 |
6 | Oil seal | 12068 |
7 | Dowel pin (2) | 16574-99A |
8 | Dowel pin (2) | 16589-99A |
9 | Dowel pin (4) | 16595-99A |
10 | Piston cooling jet, with 10930 (2) | 22315-06A |
11 | Bearing kit, left side with 8972, 24605-07, 35114-02, and inner race | 24004-03B |
12 | Spacer, sprocket shaft | 24009-06 |
13 | Crankcase set, (black) with bearings, cooling jets, and through bolts including bolt 21 | 24400001 |
14 | Spacer (4) | 24603-00 |
15 | Bearing, main (2) | 24605-07 |
16 | Adapter, oil filter | 26352-95A |
17 | Retaining ring | 35114-02 |
18 | Oil filter (chrome) | 63798-99A |
19 | Screw, TORX® head, 8-32 x 3/8 (4) | 68042-99 |
20 | Screw, TORX® button head, bearing retention, 1/4 - 20 x 7/16 inch (2) | 703B |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Screw (2) | 703B |
2 | Screw (6) | 956 |
3 | Bolt, balancer shift bolt (2) | 3110 |
4 | Washer, balancer shift bolt (2) | 6456 |
5 | Bearing, shell (2) | 8959 |
6 | Bearing, (2) | 8992A |
7 | Support assembly, chain guide, includes tensioner pistons | 14728-07 |
8 | Guide drive kit, w/14769-00, front and rear sprockets | 14761-00 |
9 | Guide kit, chain tensioner, includes lower front and rear guides | 14762-00 |
10 | Piston assembly kit, chain tensioner (2) | 14764-00 |
11 | Chain, balancer drive | 14769-00 |
12 | Spacer, .039 thick | 14784-07 |
13 | Balance shaft kit, w/8959, 8992A and balance shaft (2) | 14789-07 |
14 | Bushing, dowel (2) | 16583-00A |
15 | Retaining ring, balancer shift bearing (2) | 35240-07 |
16 | Seal, oil interconnect | 45359-00 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Roll pin | 601 |
2 | Screw, primary cam chain tensioner (2) | 942 |
3 | Screw, cam cover, 1/4-20 x 1-1/4, knurled with lockpatch (grade 8), (10) Screw, secondary cam tensioner, 1/4-20 x 1-1/4, knurled with lockpatch (grade 8), (2) | 4740A 4740A |
4 | Screw, 1/4-20 x 1, socket head, with lockpatch (8) | 4741A |
5 | Washer, 3/8 x 1-1/8 x 7/32 | 6294 |
6 | Bearing assembly w/bearing, inner race, washer and O-ring | 8983 |
7 | Needle bearing kit, camshafts (2) (Kit includes 2) | 24018-10 |
8 | O-ring | 11293 |
9 | O-ring (2) | 11301 |
10 | Retaining ring | 11494 |
11 | Gasket kit, cam service | 17045-99D |
12 | Cam drive sprocket retention kit, with 6294, screws and washer | 25566-06 |
13 | Plate, bearing retaining | 1200018 |
14 | Gasket, cam cover | 25244-99A |
15 | Cam support plate, with bypass valve | 25400018 |
16 | Cam cover, (chrome) | 25369-01B |
17 | Camshaft chain and fastener kit, with 25566-06, 25673-06, 25675-06 and 25728-06 | 25585-06 |
18 | Camshaft, front and rear kit, SE266E | 25400029 |
19 | Screw, 8-32 x 3/8 TORX® head (9) | 68042-99 |
20 | Sprocket, cam drive on crankshaft, 17 T | 25673-06 |
21 | Chain, primary cam drive | 25675-06 |
22 | Chain, secondary cam drive | 25607-99 |
23 | Sprocket, cam drive, 34 T | 25728-06 |
24 | Ball bearing | 8990A |
25 | Spacer, cam drive sprocket alignment 0.287 inch thick Spacer, cam drive sprocket alignment 0.297 inch thick Spacer, cam drive sprocket alignment 0.307 inch thick Spacer, cam drive sprocket alignment 0.317 inch thick Spacer, cam drive sprocket alignment 0.327 inch thick Spacer, cam drive sprocket alignment 0.337 inch thick Spacer, cam drive sprocket alignment 0.347 inch thick Spacer, cam drive sprocket alignment 0.357 inch thick | 25722-00 25723-00 25721-00 25719-00 25717-00 25725-00 11889 11890 |
26 | Oil pump assembly, with items 28-30, 35 and body | 62400001 |
27 | Spring, relief valve | 26210-99 |
28 | Gerotor assembly, scavenge | Not Sold Separately |
29 | Gerotor assembly, pressure | Not Sold Separately |
30 | Separator plate, gerotor (2) | Not Sold Separately |
31 | Relief valve, oil pump | 26400-82B |
32 | Cover, 120R | 25495-10 |
33 | Chain tensioner, primary cam drive chain | 39968-06 |
34 | Chain tensioner, secondary cam drive chain | 39969-06 |
35 | Spring, separator | 40323-00 |