SCREAMIN' EAGLE STAGE 1 BIG BORE CYLINDER CONVERSION KIT FOR EFI MODELS
J053592011-06-22
GENERAL
Kit Number
27535-08, 27536-08, 27539-08A, 27540-08A, 29903-07A, 29904-07A
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Proper installation of this kit requires the use of Digital Technician™ at a Harley-Davidson dealer.
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
NOTE
Installation of this kit by an authorized Harley-Davidson dealer will not impact your limited vehicle warranty.
This Big Bore Stage 1 kit is intended for High Performance applications only. This engine related performance part is legal for sale or use in California on pollution-controlled motor vehicles. Engine-related performance parts are intended for the experienced rider only.
The Product Information Label contained in this kit is a requirement of the California Air Resource Board (CARB) emission regulation for all 2007 Touring models and 2007-2008 Dyna and Softail models. Place the label on the right side of the frame directly beneath the VIN sticker. This label is not required outside the state of California.
The air cleaner contained in this kit is designed to perform with this kit only. Any other combination of components is not confirmed to be legal for street use.
REMOVAL
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
1.
Remove main fuse following the instructions in the service manual.
2.
Remove the seat (if necessary) following the instructions in the service manual. Save all hardware for installation.
NOTE
Head gaskets provided in the 1690 conversion kit eliminate the need for original equipment (OE) O-rings. Do not install the two O-rings from the kit on the top cylinder dowels or severe engine damage can occur.
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)
3.
Remove existing cylinder heads, cylinders and pistons following the instructions in the service manual.
4.
Remove existing primary chaincase cover, diaphragm spring retainer and clutch diaphragm spring following the instructions in the service manual.
INSTALLATION
Install Pistons, Cylinders and Clutch Components
  1. Install pistons, cylinders and cylinder heads from kit following the instructions in the service manual.
  2. Install diaphragm spring retainer, clutch diaphragm spring ( Table 2 , item 13) and primary chaincase cover following the instructions in the service manual.
Install High Performance Air Cleaner
Refer to instructions included with Air Cleaner Kit (29440-99D, 29260-08 or 29406-08 depending on your model motorcycle).
Final Assembly
1.
Install main fuse following the instructions in the service manual.
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)
2.
Install the seat (if removed) following the instructions in the service manual.
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)
Download the new ECM calibration using the Digital Technician™ at a Harley-Davidson dealer.
SERVICE PARTS
Figure 1. Service Parts: Screamin' Eagle Big Bore Stage 1 Kit
Table 1. Service Parts: Screamin' Eagle Big Bore Stage 1 Kit
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Cylinder assembly (Silver) (2)
16548-99A
5
Piston pin circlip (4)
22097-99
Cylinder assembly (Black) (2)
16547-99A
6
Head gasket (2)
16787-99A
2
Piston, 1690 standard (2)
Not Sold Separately
(Available in Piston Kit 21966-07)
7
O-ring, cylinder deck ring dowel (2)
11273
3
Piston ring set (2)
21918-99
8
O-ring, cylinder spigot (2)
11256
4
Piston pin (2)
22131-05
Note: Do not install O-ring (item 7) to top cylinder dowels.
Figure 2. Service Parts: Screamin' Eagle Big Bore Stage 1 Kit
Table 2. Service Parts: Screamin' Eagle Big Bore Stage 1 Kit
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Gasket, rocker cover base (2)
16719-99B
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
Seal, exhaust (not shown)
17048-98
4
O-ring, middle push rod cover (4)
11132A
12
Seal, EFI intake (2) (not shown)
26995-86B
5
O-ring, lower push rod cover (4)
11145A
13
Spring, clutch diaphragm (not shown)
37951-98
6
O-ring, upper push rod cover (4)
11293
14
Air cleaner kits (not shown)
7
O-ring, rocker arm support (2)
11270
  • Softail
  • Dyna
  • Touring
29440-99D
29260-08
29406-08
8
Bolt (4)
4400
15
Product information label (not shown)
Not sold separately