SCREAMIN' EAGLE PRO TC 120 (1962 CC) CONVERSION KIT

J054632025-01-23

GENERAL

Kit Number

92500009

Models

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

NOTE

Installation of this kit requires jetting changes or recalibration for proper function. Failure to do so may cause a lean fuel condition which could lead to engine damage.

Additional Parts Required

NOTICE

Installation of this kit requires jetting changes or recalibration for proper function. Failure to do so may cause a lean fuel condition, which may result in engine damage. (00623b)

Separate purchase of LOCTITE^® 246 Medium Strength/High Temperature Threadlocker and Sealant is required for installation of this kit.
The cylinder heads in this kit are machined for use with symmetric intake flanges (original equipment since 2006). 1999-2005 models require separate purchase of symmetric intake seal flanges (Part No. 26993-06), quantity 2.
Installation of compression releases is required. See the Screamin' Eagle Pro catalog or contact a Harley-Davidson dealer.
Separate purchase of Screamin' Eagle Crankcases is recommended. See Screamin' Eagle Pro Catalog or contact a Harley-Davidson dealer.
Each head requires one 12 mm spark plug. We recommend Screamin' Eagle Performance Spark Plugs. See Screamin' Eagle Pro catalog.
If using stock camplate, separate purchase of Cam Spacer Kit (Part No. 25938-00) is recommended. This kit contains five different spacers to achieve proper sprocket alignment.
Separate purchase of a clutch kit that will support 140 ft-lbs of torque.
If using stock crankcases, separate purchase of Crankcase Boring Tool Kit (Part No. 94419-06) is recommended for installing this high performance engine conversion kit.
Separate purchase of SE Exhaust Gasket Kit (Part No. 17048-98) is recommended.

NOTE

Crankcase Boring Tool Kit (Part No. 94419-06) includes a modified top center screw (Part No. 1093) to verify the crankcase boring tool does not get damaged when installing the conversion kit. This screw can also be purchased separately from a Harley-Davidson dealer for those who wish to use their own boring fixture.

See appropriate sections in service manual for the special tools required to install this kit.

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 your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.

Kit Contents

See Figure 1 to Figure 3 , and Table 1 to Table 3.

NOTE

This conversion kit is intended for High Performance or Racing applications only and is not legal for sale or use on pollution controlled motor vehicles. This kit may may reduce or void the limited vehicle warranty. Engine related performance parts are intended for the experienced rider only.

REMOVAL

Prepare for Service

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. See service manual.
	WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
3.	Remove main fuse or disconnect the battery cables, negative cable first. Refer to the service manual.
	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)
4.	Remove fuel tank. See service manual.

Remove Engine Components

Remove existing air cleaner assembly. See service manual.
Remove existing exhaust system. See service manual.
Remove engine from chassis. See service manual.
Disassemble engine top end and bottom end. See service manual.
Remove existing clutch diaphragm spring. See service manual.

MACHINE CRANKCASE - STOCK CRANKCASE ONLY

NOTICE

The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b)

Crankcase Boring Preparation

NOTE

During final reassembly of the engine, Harley-Davidson recommends replacing the Original Equipment cylinder studs with Screamin' Eagle High Tensile Studs (Part No. 16505-01).

Remove cylinder studs from the engine crankcase.
Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas.
Inspect and clean engine case mating surfaces.
Refer to Instruction Sheet included with the Bigger Bore (4.060 inch) Cylinder Kit for crankcase boring and modifications to install.

NOTE

To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (Part No. 1093). This screw is included in the Crankcase Boring Tool Kit (Part No. 94419-06) and can be purchased separately from a Harley-Davidson dealer.

INSTALLATION

Assemble and Install Engine

NOTE

If using Screamin' Eagle crankcases, skip to Step 3.

1.	See Figure 3. Replace camshaft needle bearings (5), left main bearing (18) and retaining ring (11) from kit. Refer to the Engine section in the service manual.
2.	Install lowered piston cooling jets included with this kit. See service manual.
3.	Install flywheel assembly (22) from the kit. Refer to Instruction Sheet and the service manual.
4.	See Figure 1 through Figure 3. Assemble engine top end and bottom end using parts from kit. Refer to Instruction Sheets for the cams and pistons and refer to the service manual.
5.	Install engine in chassis following the instructions in the service manual.
6.	Install induction system using appropriate intake flanges.
7.	See Figure 5. Remove CNC ported medallion from the front cylinder head.
8.	Apply threadlocker and Sealer (purchased separately) to screws (13) and install Screamin' Eagle 120R medallion (12). Tighten. Torque: 1.1–1.4 N·m (10–12 in-lbs) screws
9.	Install clutch kit. Separate purchase of a clutch kit that support 140 ft-lbs of torque is required.
10.	Install exhaust system.
11.	Install the separately purchased air cleaner assembly. Refer to the service manual or instruction sheet from kit.

Final Assembly

1.	Install fuel tank. See service manual.
2.	Install main fuse or connect battery cables, negative cable first. See service manual.
3.	Install seat. After installing seat, pull up on seat to verify that it is secure. See 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.	For EFI Models: Recalibration can be performed using the EFI Race Tuner. Refer to Screamin' Eagle Catalog or contact a Harley-Davidson dealer. For Carbureted Models: Rejetting and retiming will be required.
5.	Start and run engine. Repeat several times to verify proper operation.

Operation

Refer to BREAK-IN RIDING RULES in the owner's manual for instructions to break-in the motorcycle.

SERVICE PARTS

Figure 1. Service Parts: Screamin' Eagle Pro TC 120 (1962 cc) Conversion Kit

Table 1. Service Parts Table: Screamin' Eagle Pro TC 120 cubic inch (1962 cc) Conversion Kit

Item	Description (Quantity)	Part Number
1	4.060 cylinder assembly, black (2) (used in Kit 16550-04C)	16562-04B (front) 16563-04B (rear)
2	Piston (2)	Not Sold Separately
3	Piston ring set (2)	22526-10
4	Piston pin (2)	22310-10
5	Piston pin circlip (4)	22097-99
6	Gasket, cylinder head (2)	16104-04
7	Gasket, cylinder base (2)	16736-04
8	Cylinder head assembly, front, black	16917-08
9	Cylinder head assembly, rear, black	16921-08
10	Automatic compression release (ACR) plug	16648-08
Notes: Cylinder kit (16550-04C) includes items 1, 6 and 7. Piston Kit (22574-10) includes items 2 through 5. Item 5 is also included in Engine Overhaul Gasket Kit (17053-99C). For cylinder heads (8, 9) assembly components refer to the Cylinder Head Information section.

Figure 2. Service Parts: Screamin' Eagle Twin Cam 120 (1962cc) Conversion Kit

Table 2. Service Parts: Screamin' Eagle Pro TC 120 cubic inch (1962 cc) Conversion Kit

Item	Description (Quantity)	Part Number	Item	Description (Quantity)	Part Number
1	Gasket, rocker cover base (2)	16719-99A	9	Breather assembly	17025-03A
2	Gasket, rocker cover top (2)	17386-99A	10	Baffle assembly	26500002
3	Gasket, tappet cover (2)	18635-99B	11	Perfect fit pushrods kit, (+0.030 inch)	18401-03
4	O-ring, middle push rod cover (4)	11132A	Notes: Items 1 through 11 are included in Engine Overhaul Gasket Kit (17053-99C). Item 11 is included in manifold kit (29667-07).
5	O-ring, lower push rod cover (4)	11145A
6	O-ring, upper push rod cover (4)	11293
7	O-ring, rocker arm support (2)	11270
8	Breather bolt	4400

Figure 3. Service Parts: Screamin' Eagle Pro TC 120 (1962 cc) Conversion Kit

Table 3. Service Parts: Screamin' Eagle Pro TC 120 (1962 cc) Conversion Kit

Item	Description (Quantity)	Part Number
1	Gasket, cam cover	25244-99A
2	Cam Drive Retention Kit w/6294, screws and washer	91800088
3	Retaining ring	11461
4	Camshaft, front, SE-266E	Not Sold Separately
5	Camshaft, rear, SE-266E	Not Sold Separately
6	Bearing kit, needle (kit contains 2)	24017-10
7	O-ring, oil pump to cam plate	11293
8	O-ring, cam plate to crankcase (2)	11301
9	O-ring, crankcase ring dowel (2)	26432-76A
10	O-ring, piston cooling (2)	10930
11	Retaining ring, internal	35114-02
12	O-ring, crankcase dowel (2)	11273
13	Seal, main bearing oil	12068
14	Screw, top center crankcase, long	1105
15	Washer, sealing	1086A
16	Piston cooling jet (2)	22315-06A
17	120R Cam cover medallion	25495-10
18	Bearing, main	24605-07
19	Thrust washer	8972
20	O-ring CPS (Not Shown)	11289A
21	Screw, modified, crankcase boring (not shown) (purchased separately)	1093
22	4.625 stroke flywheel assembly (not shown)	24100011
Notes: Items 1, 7-14, 20 are included in Engine Overhaul Gasket Kit (17053-99C). Items 4 and 5 available in Cam Kit (25400029). Cylinder kit includes items 14 and 15.

CYLINDER HEAD INFORMATION

NOTE

The valve springs in these cylinder head assemblies work with cams with up to 0.660 in. (16.74 mm) lift, and up to 7000 rpm.

Refer to the service manual for all removal/disassembly and assembly/installation procedures.

It is important to check valve-to-piston clearance as described in the following steps. We recommend that this inspection be performed by a Harley-Davidson dealer.

Valves must be properly adjusted to zero valve lash when claying pistons. Use adjustable pushrods and fully-bottom the hydraulic lifters for accurate measurements.

Apply 0.125 in. (3.2 mm) thick layer of clay to crowns of both pistons (in the areas where valves meet pistons).

Install new cylinder heads from this kit, using new gaskets from Top End Overhaul Gasket Kit (purchased separately). Assemble heads and valve train, and tighten headbolts to torque specifications listed in service manual.

Turn engine (by hand) through two complete revolutions.

Remove heads and measure the clay at its thinnest point.

NOTE

Clay must measure 0.080 in. (2.03 mm) at the thinnest point. If this measurement does not meet the minimum thickness, the depth of the valve notches must be increased; however, the depth of the notches must not exceed 0.135 in. (3.43 mm).
Since oversized valves are used, radial clearance should also be checked. Radial clearance of 0.050 in. (1.27 mm) is recommended.

NOTE

The valve springs on these cylinder heads have an installed spring height of 1.835 in. (46.61 mm) which equals 180 lbs (81.6 kg) of seat pressure.

Seat pressure can be increased by placing shims 18224-98 (0.015 in.) or 18225-98 (0.030 in.) under the lower spring collars. Every 0.015 in. (0.38 mm) reduction in spring height equals 7.5 lbs (3.4 kg) more of seat pressure. Shim to the desired seat pressure by placing shims under the lower collar, but maintain a minimum of 0.70 in. (17.78 mm) travel to coil bind.
Seat pressure can be decreased by machining the surface of the cylinder heads in the area under the valve spring lower collar. Every 0.015 in. (0.38 mm) increase in spring height equals 7.5 lbs (3.4 kg) less of seat pressure. Machine to the desired seat pressure by machining the spring pockets in the cylinder heads, but maintain a minimum of 0.70 in. (17.78 mm) travel to coil bind.

For constant operation at extreme RPMs, all four valve springs should be checked for matched, installed heights.

1	Upper collar
2	Lower collar
3	1.835 in. (46.61 mm) installed spring height/180 lbs (81.6 kg) spring pressure
4	Free travel should be at least 0.080 in. (2.03 mm) greater than maximum valve lift.

Figure 4. Valve Spring Travel

Change installed valve spring height (seat pressure) as follows:

a. Compress valve springs and remove valve collar retainers, upper collars, springs, valve seals, and lower collars on all four valves.

b. See Figure 4. Use shims or machine cylinder heads as required to obtain desired seat pressure (see notes above). Install lower valve spring collars, valve springs (do not install valve seals at this time), upper collars, and collar keys. Check installed spring height.

c. If spring heights still do not match, repeat Steps 8a and 8b above as necessary to reach the desired installed spring height, again without installing valve seals.

d. When all spring heights match, remove valve collar retainers, upper collars, springs, and lower collars. Install using new valve seals (18046-98) purchased separately. Assemble the cylinder head assemblies.

e. Because of the large diameter of the springs in this kit, there may be slight interference between the spring and the rocker box. If interference is detected, the clearance in the rocker box bolts may allow enough movement to gain clearance. If not, it may be necessary to remove a small amount of material from the rocker box.

Install the new cylinder head assemblies.

Check assembled engine for proper installation and operation.

NOTE

If mechanical compression release is desired, SE Compression Release Kit (32076-04) is available. The mechanical compression release can be machined using the SE Mechanical Compression Release Fixture (94638-08). The automatic compression release will need to be removed and plug 16648 can be installed.

SERVICE PARTS

Figure 5. Service Parts: Cylinder Head Service Parts

Table 4. Service Parts: Cylinder Head Service Parts List

Item	Description (Quantity)	Part Number
1a	Cylinder head assembly, rear (includes Items 2 through 11)	16921-08
1b	Cylinder head assembly, front (includes Items 2 through 13)	16917-08
2	Cylinder head (machined, with items B, C, D and E installed)	Not Sold Separately
3	Collar, valve spring, upper (4)	See Service Kits
4	Collar, valve spring, lower (4)	See Service Kits
5	Stud, exhaust port (4)	16715-83
6	Intake valve (2)	18190-08
7	Exhaust valve (2)	18183-03
8	seal, valve (4)	18046-98
9	Valve spring unit (4)	See Service Kits
10	Retainer, valve collar (8). Also included with Kit 18281-02A	18240-98
11	Plug	16648-08
12	Medallion, "120R" (for front cylinder head only) (loose)	17136-10
13	Screw, button head, TORX (2) (for front cylinder head only) (loose)	94634-99
Service Kits:
A	Valve Spring Kit, Screamin' Eagle	19281-02A
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)
	(+ 0.003 in.)	18158-05
	(+ 0.002 in.)	18156-05
	(+ 0.001 in.)	18154-05
E	Valve guide, exhaust (for service)
	(+ 0.003 in.)	18157-05
	(+ 0.002 in.)	18155-05
	(+ 0.001 in.)	18153-05