SCREAMIN EAGLE® EXTREME FLOW 68MM INTAKE MANIFOLD

941005432024-07-02

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
27300217, 27300218	Safety Glasses, Torque Wrench

(1) Tightening to torque value or other moderate tools and techniques required

KIT CONTENTS

Figure 1. Kit Contents: Screamin Eagle® Extreme Flow 68mm Intake Manifold

Table 2. Kit Contents: Screamin Eagle® Extreme Flow 68mm Intake Manifold

	Verify that all contents are present in the kit before installing or removing items from vehicle.
	Item	Qty	Description	Part No.	Notes
	1	1	Intake manifold, 68mm	Not sold separately
Items mentioned in text, but not included in kit
	A	1	Fuel rail
	B	2	Screw (fuel rail)
	C	1	O-ring (fuel line)
	D	1	Screw (fuel line to fuel rail)
	E	1	Cap (fuel line)
	F	1	Fuel line
	G	2	Fuel injector
	H	1	Sensor, T-MAP
	I	1	Seal (throttle body to intake manifold)
	J	1	Throttle body, 68mm
	K	2	Screw, socket head (Right)
	L	2	Screw, socket head (Left)
	M	2	Flange adapter
	N	2	Seal (intake manifold)
Hardware kit not included in kit
	O	4	Hardware kit		Part No. 91800058 Includes: O-rings (4), M6 Allen head screw (3), M5 TORX screw (1)

GENERAL

Models

For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.

Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets

Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.

Installation Requirements

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 the year and model motorcycle is required for this installation and is available from:

A Harley-Davidson dealer.
H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.

These items are available at your local Harley-Davidson dealership:

Screamin' Eagle® (SE) High Flow 68MM Throttle Body (Part No. 27300194) is required for this installation.
SE High Flow Injector kit (Part No. 27400067) are recommended for this installation.
Digital Technician II (DT II) is required for proper installation of this kit. Contact a Harley-Davidson dealer.

PREPARE

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)

1.	Purge, disconnect and remove fuel supply line. See service manual.
2.	Remove seat. See service manual.
	WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
3.	Remove main fuse. See service manual.
4.	Remove fuel tank. See service manual.

REMOVE

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)

1.	See Figure 1. Remove Original Equipment (OE) throttle body (J), seal (I) and intake manifold. See service manual.
2.	Remove OE fuel rail assembly (A-F). See service manual. a. Save components for later use.
3.	Remove fuel injectors (G) and T-MAP sensor (H). See service manual. a. Save components for transfer to new intake manifold (1). b. Inspect T-MAP sensor O-ring. If damaged, replace sensor.

INSTALL

1.	See Figure 1. Apply threadlocker to threads of fuel rail screws (B).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97)
2.	Install fuel injectors (G), fuel rail and screws (B) to intake manifold (1). Tighten. Torque: 4–6 N·m (35–53 in-lbs)
3.	Install T-MAP sensor (H) on new intake manifold (1). a. Apply threadlocker to threads of screw (O).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) b. Tighten screw (O). Torque: 3.4–3.6 N·m (30–32 in-lbs)
4.	Install throttle body (J) to intake manifold. See Installation Requirements. a. Follow instructions in throttle body kit.
5.	With counterbore facing outward, install flange adapters (M) to intake manifold (1).
6.	Install new seal (N) in each flange adapter with beveled side against counter-bore.
7.	Install induction module assembly to engine. a. Partially install left side screws (L) in cylinder head. b. Slide induction module assembly into position until slots of flange adapter engage left side screws (L). c. Partially install right side screws (K) through flange adapter into cylinder head. d. Adjust induction module and flanges as needed.
8.	Finger tighten screws (K and L) as close as possible to adapter flange.
9.	Tighten left side screws (L). Torque: 11–17.6 N·m (97–156 in-lbs)
10.	Tighten right side screws (K). Torque: 11–17.6 N·m (97–156 in-lbs)
11.	Install fuel line to induction module. a. Install o-ring (C) to fuel line (F). b. Install fuel line (F) to fuel rail (A). c. Install screw (D). Tighten. Torque: 2.5–4.5 N·m (22–40 in-lbs)

RECALIBRATE ECM

NOTICE

You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b)

Use special tool to calibrate Electronic Control Module (ECM).

Special Tool: DIGITAL TECHNICIAN II (HD-48650)

COMPLETE

1.	Install fuel tank. See service manual.
2.	Connect quick-connect fitting to fuel tank. While pushing up on bottom of fitting, pull down on chrome sleeve. Tug on fuel supply tube fitting to make sure that it is locked in position. See service manual.
3.	Install main fuse. See service manual.
4.	Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual.
5.	Energize fuel pump and do a visual check for leaks.