Kits | Suggested Tools | Skill Level(1) | Time |
---|---|---|---|
21900130 (122) 21900129 (119) | Safety glasses, pencil or marker, micrometer, dial bore gauge, small blade screwdriver | 1 hour |
Item | Qty | Description | Part No. | Notes | |
---|---|---|---|---|---|
1 | 2 | Piston | Not sold separately | ||
2 | 2 | Piston pin | 22558-07 | ||
3 | 4 | Cir-clip | 22097-99 | ||
4 | 2 | Ring set | 22000105 |
Item | Qty | Description | Part No. | Notes | |
---|---|---|---|---|---|
1 | 2 | Piston | Not sold separately | ||
2 | 2 | Piston pin | 22558-07 | ||
3 | 4 | Circlip | 22097-99 | ||
4 | 2 | Standard ring set | 22000105 |
1. | Raise the motorcycle. | |
2. | Remove seat according to the instructions in the service manual. | |
3. | Remove main fuse. | |
WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) | ||
4. | Disconnect negative battery cable. | |
5. | Remove cylinder head, cylinder, and piston. See service manual. | |
6. | Follow the procedures in the service manual for inspection of parts. |
1. | Allow the piston to cool to room temperature. | |
2. | With a pencil or marker, mark the piston on each side of the skirt across the thrust faces (perpendicular to the piston pin bore) 0.5 in (12.7 mm) from the bottom edge of the chamfer on the piston skirt. | |
3. | Using a micrometer at the parks, measure the nominal diameter of the piston. | |
4. | Use a dial bore gauge to measure the piston ring travel zone in the cylinder bore. |
1. | The pistons in this kit are not front and rear cylinder specific. Install the pistons in the front and rear cylinders with the arrow pointing toward the front of the engine. |
Piston | IN | MM | |
---|---|---|---|
Fit in cylinder | 0.0017-0.0028 | 0.0440-0.0707 | |
Piston pin fit (loose) | 0.0060-0.0081 | 0.152-0.207 | |
Ring end gap | Top compression | 0.0150-0.0250 | 0.381-0.635 |
2nd compression | 0.0150-0.0250 | 0.381-0.635 | |
Oil control ring | 0.0098-0.0295 | 0.25-0.75 | |
Ring side clearance | Top compression | 0.0007-0.0027 | 0.019-0.069 |
2nd compression | 0.0009-0.0029 | 0.024-0.074 | |
Oil control rails | 0.0004-0.0059 | 0.01-0.15 |
Replace if Wear Exceeds | ||
---|---|---|
Item | IN | MM |
Fit in cylinder (loose) | 0.0045 | 0.1143 |
Piston pin fit (loose) | 0.0015 | 0.0381 |
Top ring end gap | 0.031 | 0.79 |
2nd ring end gap | 0.032 | 0.81 |
Oil control ring rail gap | 0.031 | 0.79 |
Ring side clearance | 0.0035 | 0.089 |
2nd ring side clearance | 0.0037 | 0.094 |
Oil control ring side clearance | 0.0068 | 0.173 |
1. | See Figure 3. Insert the open end of circlip (1) into notch (2) on groove (3). | |||||||||||
2. | See Figure 4. Place thumb on piston (1). Press firmly until approximately 85% of circlip (2) is seated in groove. NOTE Make sure that the circlip is fully seated for proper installation. |
Figure 3. Circlip and piston
Figure 4. Install circlip | ||||||||||
3. | Use a small blade screwdriver to wedge circlip into remainder of groove. Do not scratch or mar piston. Repeat for remaining circlips. | |||||||||||
4. | Install cylinder heads, cylinders, and high compression pistons and rings from kit. See service manual. |
1. | Install fuel tank. See service manual. | |
2. | Install main fuse. See service manual. | |
3. | Install seat. After installing seat, pull up on the seat to verify that it is secure. See service manual. | |
4. | Download the new ECM calibration using Screamin' Eagle Pro Street Performance Tuner Kit. | |
5. | Run engine. Repeat several times to verify proper operation. |