Page | Subject |
---|---|
2 | SCREAMIN EAGLE120R ENGINE INSTALLATION |
3 | SCREAMIN EAGLE120R ENGINE SPECIFICATIONS |
3 | MANUFACTURING TOLERANCES |
4 | SERVICE WEAR LIMITS |
5 | SCREAMIN EAGLE120R CYLINDERS |
6 | SCREAMIN EAGLE120R PISTONS |
8 | REPLACING/SERVICING PUSHRODS |
9 | SERVICE PARTS |
1. | Position the motorcycle on a suitable lift. | |
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) WARNING To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) | ||
2. | See the service manual to perform the following steps: a. Remove seat. b. Purge and disconnect fuel supply line. |
1. | Install fuel tank. See the service manual. | |
2. | See the service manual. Install main fuse. | |
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. See 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 when installing this kit. Refer to the Screamin' Eagle Pro catalog or contact a Harley-Davidson dealer. | |
5. | Start and run engine. Repeat several times to verify proper operation. |
Item | Specification | |
---|---|---|
Compression Ratio | 10.5:1 | |
Bore | 4.060 in | 103.12 mm |
Stroke | 4.625 in | 117.48 mm |
Displacement | 119.75 cu in | 1962.39 cc |
Lubrication system | Pressurized dry sump with oil cooler |
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 the motorcycle on a suitable lift. | |
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) WARNING To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) | ||
2. | See the service manual to perform the following steps: a. Remove seat. b. Purge and disconnect fuel supply line. |
1. | Refer to the service manual. Assemble the engine with the following change: a. Assemble the top end of the engine using the base gaskets and head gaskets from the kit. Refer to ENGINE section of service manual. |
Figure 1. Cylinder Gaskets |
2. | Install fuel tank. See the service manual. | |
3. | See the service manual. Install main fuse. | |
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) | ||
4. | Install seat. See the service manual. |
1. | See the service manual. Remove seat. Disconnect both battery cables, negative battery cable first. Retain all seat mounting hardware. | |||||
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) | ||||||
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: SUB-ASSEMBLY SERVICE AND REPAIR, TOP END/ CYLINDER/ UPPER CONNECTING ROD sections of the service manual for inspection of parts. | |||||
4. | See the ENGINE: SUB-ASSEMBLY SERVICE AND REPAIR, CYLINDER section of the service manual for boring and honing instructions. NOTE
NOTE Checking piston-to-cylinder fit at this location per Table 11 is for reference. |
Figure 2. Piston Measurements | ||||
5. | See Figure 2. Measure piston width (1), 90 degrees horizontally from both sides of the piston pin hole and 32.38 mm (1.275 in) down from the deck (top) surface 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 toward the front of the engine. Install the piston marked "REAR" in the rear cylinder with the arrow pointing toward 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 the gap is at the straight up or straight down position when installed. | |||||||||||
9. | See Figure 4. Position your thumb (1) as shown. Press firmly until approximately 85% of the circlip (2) is seated in the groove. | |||||||||||
10. | Do not scratch or mar the piston. Use a small-bladed screwdriver to wedge the circlip into the rest of the groove. Repeat for the remaining circlips. NOTE Make sure that 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 reassembly procedures. |
Figure 3. Circlip and Piston
Figure 4. Install Circlip 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 service manual procedures for installing or removing pushrods. Pushrods are marked "INT" (intake) and "EXH" (exhaust). The pushrods are directional. Verify that the larger ends of the pushrods are installed down in the lifter sockets. |
Figure 6. Push Rods |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Engine assembly, complete | 19220-16 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Screamin' Eagle cylinder kit, 103.1 mm (4.060 in) (black). Includes front and rear cylinders, items 2-4, flanged hex head screw (Part No. 1105) and sealing washer (Part No. 1086A). | 16550-04C |
2 |
| 16595-99A |
3 |
| 16736-04A |
4 |
| 16104-04 |
5 | Stud, cylinder (8) | 16834-99A |
6 | Gasket kit, engine overhaul (not shown). DOES NOT include cylinder head gasket, base gasket or valve stem seals. | 17053-99C |
7 | Gasket kit, top-end (not shown). DOES NOT include cylinder head gasket, base gasket or valve stem seals. | 17052-99C |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Cylinder head assembly, rear (includes Items 2-13) Cylinder head assembly, front (includes Items 2-13) | 17444-10 17443-10 |
2 |
| Not sold separately |
3 |
| Not sold separately |
4 |
| Not sold separately |
5 |
| 16715-83 |
6 |
| 18190-08 |
7 |
| 18183-03 |
8 |
| 18046-98 |
9 |
| Not sold separately |
10 |
| 18240-98 |
11 |
| 28861-07A |
12 |
| 17136-10 |
13 |
| 25800017 |
14 | Screw, internal thread, 81 mm (3 3/16 in) long (4) | 16478-85A |
15 | Screw, internal thread, 47.6 mm (1 ⅞ in) long (4) | 16480-92A |
16 | Pin housing, two-way | 72009-05 |
17 | Wire seal, 16-20 AWG (4) | 72011-05 |
18 | Spark plug, Screamin' Eagle (2) (not shown) | 32186-10 |
Service Kits: | ||
A | Valve Spring Kit, Screamin' Eagle | 18281-02A |
The following Screamin' Eagle parts are available
separately: | ||
B | Seat, intake valve | 18191-08 |
C | Seat, exhaust valve | 18048-98A |
D | Valve guide, intake (for service) | |
| 18158-05 | |
| 18154-05 | |
E | Valve guide, exhaust (for service) | |
| 18157-05 | |
| 18155-05 | |
| 18153-05 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Cap screw, hex flanged head, 5/16-18 x 63.5 mm (2.5 in), Grade 8 with lock patch (8) | 1039 |
2 | Screw, internal/external hex flanged head, 5/16-18 x 25.4 mm (1.0 in), with lock patch (6) | 3692A |
3 | Screw, internal/external hex flanged head, 5/16-18 x 44.4 mm (1.75 in), with lock patch (10) | 3693A |
4 | Screw, hex flanged head SEMS, 5/16-18 x 31.8 mm (1.25 in), with lock patch (8) | 3736B |
5 | Screw, hex flanged head, 1/4-20 x 42.9 mm (1.69 in), Grade 8, with lock patch, (4) | 4400 |
6 | Cap screw, hex socket head, heat treated washer, 1/4-20 x 25.4 mm (1.0 in), lock patch (6) | 4741A |
7 | Washer, 0.79 mm (0.031 in) thick (4) | 6762B |
8* | O-ring, push rod cover, 17 mm (0.674 in) ID, brown (4) | 11132A |
9* | O-ring, push rod cover, 22 mm (0.862 in) ID, brown (4) | 11145A |
10* | O-ring, 15.5mm (0.612 in) ID, black (2) | 11270 |
11* | O-ring, 17mm (0.371 in) ID, yellow (4) | 11293 |
12 | Gasket, rocker housing (2) | 16719-99B |
13 | Gasket kit, cam service (contains items marked "*") | 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) | 17429-91 |
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 (2). Includes Items 5 and 33. | 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 | Keeper, spring cover (4) | 17968-99 |
30 | Pin, anti-rotation (2) | 18535-99 |
31 | Tappet, roller (4) | 18572-13 |
32 | Gasket, tappet cover (2) | 18635-99B |
33 | Baffle assembly, breather, with breather valve and filter (2) | 26500002 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Retaining ring | 11177A |
2 | Piston ring set, standard (2) Piston ring set, 0.254 mm (0.010 in) 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, 0.254 mm (0.010 in) over size | 22574-10 22576-10 |
4 | Lock ring, piston pin (4) | 22097-99 |
5 | Piston pin (2) | 22310-10 |
6 | Flywheel assembly kit (4-5/8 in stroker) | 23893-10A |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Plug (3) | 765 |
2 | Screw, hex flange head, 5/16-18 x 76 mm (3.0 in) long (8) | 895 |
3 | Screw, crankcase top center | 1105 |
4 | Sealing washer | 1086A |
5 | Washer, 32 mm (1.2 in) ID, 46 mm (1.8 in) OD, 3.2 mm (0.12 in) thick (2). Also part of Item 13. | 8972 |
6 | Needle bearing kit, camshaft (2) (Each kit includes two bearing assemblies) | 24018-10 |
7 | O-ring (2). Also included with Item 12. | 10930 |
8 | Oil seal | 12068 |
9 | Dowel pin, 14.158 mm (0.557 in) D x 19 mm (0.75 in) long (2) | 16574-99A |
10 | Dowel pin, 9.525 mm (0.375 in) D x 10.16 mm (0.40 in) long (2) | 16589-99A |
11 | Dowel pin, 11.074 mm (0.436 in) D x 15.5 mm (0.61 in) long (4) | 16595-99A |
12 | Piston cooling jet (2) (includes Item 7) | 22315-06A |
13 | Bearing kit, left side (includes item 5, item 18, bearing 24605-07 and the bearing inner race) | 24004-03B |
14 | Spacer, sprocket shaft | 24009-06 |
15 | Crankcase set (black) (includes Items 1, 2, 3, 4, 6, 9, 10, 11, 12, 16, 18, 20, 21 and 22) | 24601-10B |
16 | Bearing, main (right side) | 24604-00D |
17 | Adapter, oil filter | 26352-95A |
18 | Retaining ring. Also part of Item 13. | 35114-02 |
19 | Oil filter (chrome) | 63798-99A |
20 | Screw, TORX® head, 8-32 x 9.525 mm (0.375 in) long (4) | 68042-99 |
21 | Screw, bearing retention, TORX® button head, 1/4-20 x 11.1 mm (0.44) long (2) | 703B |
22 | Screw, hex flange head, with washer, 3/8-16 x 40.4 mm (1.59 in), Grade 8, with lock patch (2) | 3983 |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Cam support plate assembly (includes items 2-5) | 25400019 |
2 |
| 601 |
3 |
| 8873 |
4 |
| 26210-99 |
5 |
| 26400-82B |
6 | Chain tensioner, primary cam drive chain | 39968-06 |
7 | Screw, primary cam chain tensioner (2) | 942 |
8 | Camshaft chain and fastener kit (includes items 9-13) | 25585-06 |
9 |
| 25728-06 |
10 |
| 25673-06 |
11 |
| 25566-06 |
12 |
| 6294 |
13 |
| 25675-06 |
14 | Bushing, crankshaft | Not sold separately |
15 | Spacer, cam drive sprocket alignment, 2.54 mm (0.100 in) thick | 25729-06 |
16 | Spacer, cam drive sprocket alignment, 2.54 mm (0.100 in) thick (use as required) Spacer, cam drive sprocket alignment, 2.79 mm (0.110 in) thick (use as required) Spacer, cam drive sprocket alignment, 3.05 mm (0.120 in) thick (use as required) Spacer, cam drive sprocket alignment, 3.3 mm (0.130 in) thick (use as required) Spacer, cam drive sprocket alignment, 3.56 mm (0.140 in) thick (use as required) Spacer, cam drive sprocket alignment, 3.81 mm (0.150 in) thick (use as required) | 25729-06 25731-06 25734-06 25736-06 25737-06 25738-06 |
17 | Retaining ring | 11461 |
18 | Chain tensioner, secondary cam drive chain | 39969-06 |
19 | Screw, secondary cam tensioner (2) Screw, cam cover (10) 1/4-20 x 31.8 mm (1.25 in)long, Grade 8, knurled, with lockpatch | 4740A 4740A |
20 | Screw, socket head, 1/4-20 x 25.4 mm (1.0 in) long, with lockpatch (10) | 4741A |
21 | Camshaft kit, front and rear, SE266E | 25494-10 |
22 | Needle bearing kit, camshaft (includes two of Item 23) | 24018-10 |
23 |
| Not sold separately |
24 | Chain, secondary cam drive | 25683-06 |
25 | Oil pump assembly (includes items 26-29) | 26037-06 |
26 |
| 26278-06 |
27 |
| 26281-06 |
28 |
| 26282-06 |
29 |
| 40323-00 |
30 | Gasket kit, cam service (contains Item 31 and items marked "*" in Table 16) | 17045-99D |
31 |
| 11293 |
32 | O-ring, 9.2 mm (0.362 in) ID, brown (2) | 11301 |
33 | Cam cover, (chrome) | 25369-01B |
34 | Gasket, cam cover | 25244-99A |
35 | Cover, timer, "120R" | 25495-10 |
36 | Screw, TORX head, 8-32 x 0.375 in long (5) | 68042-99 |