SCREAMIN' EAGLE STAGE 2 BIG BORE KITS FOR EFI MODELS
J053652025-01-23
GENERAL
Kit Number
27543-08, 27545-08, 27557-08
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
Separate purchase of Cam Spacer Kit (25928-06) is recommended. This kit contains five different spacers to achieve proper sprocket alignment.
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 your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
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.
INSTALLATION
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)
NOTE
This Big-Bore Stage 2 kit is intended for High Performance applications only. Engine-related performance parts are intended for the experienced rider only.
The air cleaner contained in these kits is designed to perform with these kits only. Any other combination of components is not confirmed to be legal for street use.
Gaskets provided in the 1690 conversion kit eliminate the need for original head gasket O-rings. For this reason, DO NOT install the Original Equipment (OE) O-rings (11273) to the top of cylinder dowels, or severe engine damage may occur.
Big-Bore Cylinder and Piston Conversion
NOTE
Installation of this kit requires removal of the cylinder heads, cylinders and pistons. See the service manual for instructions.
High Performance Camshafts
NOTE
Installation of this kit requires removal and installation of the cam support plate. See the service manual for instructions.
Measuring Piston-to-Valve Clearance
After installing non-stock cams, check piston-to-valve clearance.
- Apply 1/8-inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons.
- Refer to the service manual and assemble the heads and valve train, and tighten cylinder studs to torque specified.
- Turn engine through two complete revolutions by hand.
- Remove heads and measure clay at its thinnest point.
NOTE
Clay must measure 0.080 inch (2.03 mm) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 0.135 inch (3.43 mm).
Measuring Valve-to-Valve Clearance
NOTE
Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents bending the push rods or valves.
- Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust and intake valve heads cross, where both valves are off their seats by an equal amount.
- A 0.040-inch (1.016 mm) clearance is required between the two valve heads. Use a 0.040-inch wire gauge (1) to measure this. To adjust the clearance, grind the edges of the intake and exhaust valves at a 45-degree angle (2).
- Repeat steps 1 and 2 for the rear cylinder.
NOTE
See Figure 1. If it is necessary after inspection to grind the intake and exhaust valves in order to meet the 0.040-inch (1.016 mm) clearance between the two valve heads, the margins (3) must be measured as follows: 0.031-inch (0.787 mm) minimum margin on exhaust valves and 0.015-inch (0.381 mm) minimum margin on intake valves.
Install new Pistons, Cylinders, and Cylinder Heads
- Assembly - Install pistons, cylinders and cylinder heads. See service manual.
High Performance Clutch Diaphragm Spring
- Disassembly - Remove primary chain case, chain, diaphragm spring retainer and diaphragm spring. See service manual.
- Assembly - Install diaphragm spring retainer, diaphragm spring, chain and primary chain case. See service manual.
High Performance Air Cleaner
Follow the instructions included with the High Performance air cleaner in this kit for installation.
| 1 | 0.040-in. wire gauge |
| 2 | 45-degree angle |
| 3 | Valve margins |
Figure 1. Beveling Valve Heads
Final Assembly
| 1. | Install main fuse. See service manual. | |
| 2. | Install seat (if removed). After installing seat, pull up on seat to verify that it is secure. See 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 2. Service Parts: Screamin' Eagle Big Bore EFI Stage 2 Kit
Table 1. Service Parts: Screamin' Eagle Big Bore EFI Stage 2 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | O-ring, middle push rod cover (4) | 11132A |
2 | O-ring, lower push rod cover (4) | 11145A |
3 | O-ring, cylinder spigot (2) | 11256 |
4 | O-ring, rocker arm support (2) | 11270 |
5 | O-ring, cylinder deck ring dowel (2) | 11273 |
6 | O-ring, upper push rod cover (4) | 11293 |
7 | Assembly, 1690 cylinder, black (2) | 16547-99A |
8 | Gasket, rocker cover base (2) | 16719-99B |
9 | Kit, head gasket (2) | 16787-99A |
10 | Gasket, rocker cover top (2) | 17386-99A |
11 | Ring set, piston, 1690 standard (2) | 21918-99 |
12 | Circlip, piston pin (4) | 22097-99 |
13 | Piston, 1690 standard (2) | Not Sold Separately |
14 | Pin, piston (2) | 22131-05 |
15 | Breather bolt (4) | 4400 |
16 | Breather assembly | 17025-03A |
17 | Baffle assembly (2) | 26500002 |
18 | Filter element, breather (2) | 63815-99 |
19 | Seal, intake manifold (not shown) (2) | 26995-86B |
20 | Stage 1 Air cleaner (not shown) | |
| 29406-08 29260-08 29440-99D | |
21 | Clutch diaphragm spring, high performance (not shown) | 37951-98 |
22 | Loctite 262, red, 0.5 ml tube (not shown) | 94673-99 |
23 | Product information label (not shown) | Not Sold Separately |
Piston Kit (21966-07) includes Items 11 through 14. Breather
Gasket Kit (17162-03) includes Items 15 through 18. | ||
Figure 3. Service Parts: Screamin' Eagle Big Bore EFI Stage 2 Kit
Table 2. Service Parts: Screamin' Eagle Big-Bore EFI Stage 2 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, cam cover | 25244-99A |
2 | Retaining ring | 11461 |
3 | Camshaft, front, SE-255 | Not Sold Separately |
4 | Camshaft, rear, SE-255 | Not Sold Separately |
5 | Bearing, needle (2) (must be purchased separately, if needed) | 9215 |
6 | O-ring, oil pump to cam plate | 11286 |
7 | O-ring, cam plate to crankcase (2) | 11301 |
Items mentioned in text, but not included in kit: | ||
A | Cam drive retention kit (includes screw and washer) | 91800088 |
Notes: Items 3 and 4 available in Cam Kit (25638-07). | ||