SCREAMIN EAGLE MILWAUKEE EIGHT 135CI CRATE ENGINE
941003842024-07-09
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
16200784, 16200785, 16200786, 16200787 | Safety Glasses, Torque Wrench, Digital Technician II (DT II) |  |
(1) DTII and dealer installation required
KIT CONTENTS
Figure 1. Screamin Eagle Milwaukee Eight 135 Crate Engine
Table 2. Screamin Eagle Milwaukee Eight 135 Crate Engine
 | Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
 | 1 | 1 | Engine assembly complete | 16200784, 16200785, 16200786, 16200787 | |
| 2 | 2 | Screamin Eagle High Flow Injector Kit, 6.8 GPS | 27400067 | |
| 3 | 1 | Screamin Eagle 68mm Throttle Body | 27300194 | |
| 4 | 1 | Screamin Eagle 68mm Intake Manifold (with fuel rail) | 27300210 | |
Figure 2. Screamin Eagle Milwaukee Eight 135 Crate Engine Cylinders
Table 3. Screamin Eagle Milwaukee Eight 135 Crate Engine Cylinders
| Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
| 1 | 2 | Screamin Eagle cylinder kit, 4.310 in (black highlighted) | 16800407 | Includes front and rear cylinders, items 2-4 |
| 2 | 4 | Dowel pin, ring | 16589-99B | |
| 3 | 2 | Gasket, cylinder base | 16500332 | |
| 4 | 2 | Gasket, cylinder head | 16500657A | |
Figure 3. Screamin Eagle Milwaukee Eight 135 Crate Engine Cylinder Heads and Valves
Table 4. Screamin Eagle Milwaukee Eight 135 Crate Engine Cylinder Heads and Valves
| Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
| 1 | 2 | Automatic compression release | 18400073B | |
| 2 | 8 | Flange nut | 10200303 | |
| 3 | 16 | Keeper, valve | Not sold separately | |
| 4 | 8 | Collar, valve spring | Not sold separately | |
| 5 | 8 | Valve spring | Not sold separately | |
| 6 | 8 | Seal, valve | Not sold separately | |
| 7 | 1 | Cylinder head assembly, rear | 16500779 | Oil cooled |
16500815 | Water cooled | ||||
| 1 | Cylinder head assembly, front | 16500778 | Oil cooled | |
16500814 | Water cooled | ||||
| 8 | 2 | Exhaust valve, 33 mm | 18000047 | |
| 9 | 2 | Intake valve, 41 mm | 18000046 | |
| 10 | 4 | Screw, button head, TORX | 68120-00 | |
| 11 | 2 | Medallion, 135 | 14101814 | |
| 12 | 4 | Stud, exhaust port | 10900015A | |
| A | Valve spring kit, Screamin' Eagle | 18100080A | Includes items 3-6 | |
Figure 4. Screamin Eagle Milwaukee Eight 135 Crate Engine Pistons
Table 5. Screamin Eagle Milwaukee Eight 135 Crate Engine Pistons
| Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
| 1 | 1 | Piston kit, front and rear, with ring sets, piston pin and lock rings, standard | 21900164A | |
| 2 | 2 | Piston ring set, standard | 22000126 | |
| 3 | 4 | Lock ring, piston pin | 22097-99 | |
| 4 | 2 | Piston pin | 22558-07 | |
Figure 5. Screamin Eagle Milwaukee Eight 135 Crate Engine Camshaft and Camshaft Cover
Table 6. Screamin Eagle Milwaukee Eight 135 Crate Engine Camshaft and Camshaft Cover
| Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
| 1 | 1 | Camshaft kit, SE8-517 | 25400353 | |
| 2 | 1 | Needle bearing kit, camshaft | 9298A | Included in gasket kit, item 9 |
| 3 | 1 | Oil pump assembly | 62400279 | Oil cooled, includes items 4-7 |
| 62400278 | Water cooled, includes items 4-7 | |||
| 4 | 1 | Spring, relief valve | 26210-99 | |
| 5 | 1 | Relief valve, oil pump bypass | 26400-82B | |
| 6 | 1 | Roll pin | 601 | Included in gasket kit, item 9 |
| 7 | 1 | Gerotor assembly | 62400006 | Oil cooled |
| 62400274 | Water cooled | |||
| 8 | 4 | Hydraulic lifter | 18572-13 | |
| 9 | 1 | Gasket kit | 25700731 | |
| 10 | 1 | Spacer, cam drive sprocket alignment 2.54 mm (0.100 in) | 25729-06 | Use as required |
| 1 | Spacer, cam drive sprocket alignment 2.79 mm (0.110 in) thick | 25731-06 | Use as required | |
| 1 | Spacer, cam drive sprocket alignment 3.05 mm (0.120 in) thick | 25734-06 | Use as required | |
| 1 | Spacer, cam drive sprocket alignment 3.3 mm (0.130 in) thick | 25736-06 | Use as required | |
| 1 | Spacer, cam drive sprocket alignment 3.54 mm (0.139 in) thick | 25737-06 | Use as required | |
| 1 | Spacer, cam drive sprocket alignment 3.81 mm (0.150 in) thick | 25738-06 | Use as required | |
| 11 | 1 | Cam drive sprocket retention kit | 25566-06 | |
| 12 | 1 | Washer | 6294 | |
| 13 | 1 | Gasket, cam shaft cover | 25700730 | Included in gasket kit, item 9 |
| 14 | 1 | Cover, timer | 25600116 | |
| 15 | 1 | Cover, timer, insert, 135 Stage IV | 25600162 | |
| 16 | 1 | Camshaft plate assembly | 25400419 | |
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
WARNINGRider 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.
PREPARE
WARNINGWhen 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)
WARNINGTo 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. | Position vehicle on a suitable lift. See service manual. | |
| 2. | Remove main fuse. See service manual. | |
| 3. | Remove seat. See service manual. | |
| 4. | Purge fuel and disconnect fuel supply line. See service manual. | |
| 5. | Remove fuel tank. See service manual. | |
| 6. | Raise vehicle. |
REMOVE
| 1. | Remove engine from chassis. See service manual. |
INSTALL
| 1. | Before installing engine: a. Make sure that there is no debris or contaminates in lubrication system. b. Have the oil pan flushed out by a Harley-Davidson dealer or qualified technician. c. If the engine that was removed had internal damage, replace oil pan. | |
| 2. | Remove oil passage caps or plugs at engine to transmission interface. | |
| 3. | Install engine into chassis. See service manual. | |
| 4. | Install throttle body, intake manifold, and high flow injectors from this kit. |
COMPLETE
| 1. | Install fuel tank. See service manual. | |
| 2. | Connect fuel supply line. See service manual. | |
| 3. | Install seat. See service manual. | |
| 4. | Install main fuse. See service manual. | |
| 5. | Refer to BREAK-IN RIDING RULES in the vehicle owner's manual to break in the new engine. |
MAINTENANCE
| 1. | Refer to MAINTENANCE SCHEDULE in vehicle's service manual or owner's manual. | |
| 2. | Refer to ENGINE section of service manual for proper service procedures. |
135 ENGINE SPECIFICATIONS
NOTE
The following sections provide unique information not available in the Touring service manual ENGINE section for the Milwaukee-Eight engine.
Table 7. Screamin Eagle Milwaukee Eight 135 Crate Engine
Item | Specification | |
|---|---|---|
Compression Ratio | 10.7:1 | |
Bore | 4.310 in | 109.5 mm |
Stroke | 4.625 in | 117.5 mm |
Displacement | 135.3 cu in | 2217 cc |
Lubrication system | Pressurized dry sump with oil cooler | |
MANUFACTURING TOLERANCES
Refer to the engine specifications in the service manual for any specification not shown in the following tables.
Table 8. Valve Spring Specifications
ITEM | PRESSURE | DIMENSION |
|---|---|---|
Height 1 | 100 lbs (45 kg) | 1.470 in. (37.4 mm) |
Height 2 | 262 lbs (119 kg) | 0.97 in. (24.6 mm) |
Free length | n/a | 1.779 in. (45.2 mm) |
Table 9. Pistons
Piston: | Clearance (in.) |
|---|---|
Piston-to-cylinder fit (Loose) | 0.0045 |
Piston pin fit (Loose) | 0.0606-0.0010 |
Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap | 0.015-0.025 0.015-0.025 0.015±0.009 |
Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance | 0.0017-0.0027 0.0009-0.0029 0.0004-0.0059 |
Table 10. Cam Specifications-SE8-517
Intake | Specification |
|---|---|
Opens | F-7° B; R-7° B |
Closes | F-40° A; R-40°A |
Duration | F-227° |
Maximum Valve Lift | I -515 in. |
Valve Lift @ TDC | F-.112 in.; R-.112 in. |
Exhaust | Specification |
Opens | F-62° BBDC: R-61°BBDC |
Closes | F-7° A; R-1° A |
Duration | F-249°; R-242° |
Maximum Valve Lift | 0.513 in. |
Valve Lift @ TDC | F-0.066 in.; R-0.052 in. |
Cam Timing @ 0.050 in. Tappet Lift in Crankshaft Degrees | |
SERVICE WEAR LIMITS
NOTE
Refer to engine specifications in service manual for any specification not shown in following tables.
Use wear limits as guide to part replacement.
Table 11. Pistons
Piston-to-cylinder fit (Loose) | Wear Limit (in.) |
|---|---|
Fit in cylinder (Loose) | 0.0045 |
Piston Pin Fit (Loose) | 0.0010 |
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 | 0.0035 0.0035 0.0067 |