SCREAMIN' EAGLE 4.625 INCH STROKE BIG BORE 135 PISTON KITS
941003492023-03-01
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
21900164 | Safety glasses, pencil or marker, micrometer, dial bore gauge |  |
(1) Special tools or techniques required for installation
KIT CONTENTS
Figure 1. Service parts: Screamin' Eagle Big Bore 135 Piston Kits
Table 2. Kit Contents: Screamin' Eagle 4.625 Inch Stroke Big Bore 135 Piston Kit Components
 | Item | Qty | Description | Part No. | Notes |
|---|---|---|---|---|---|
 | 1 | 2 | Piston | Not sold separately | |
| 2 | 2 | Piston pin | 22558-07 | |
| 3 | 4 | Circlip | 22097-99 | |
| 4 | 2 | Ring set, standard | 22000126 |
NOTE
Verify all contents are present in the kit before installing or removing items from vehicle.
GENERAL
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Verify that the most current version of the instruction sheet is used. It is available at: www.harley-davidson.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
NOTE
Disarm security system.
| 1. | Remove seat. See service manual. | |
| 2. | Remove main fuse. See service manual. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) | ||
| 3. | Disconnect negative battery cable. See service manual. | |
| 4. | Remove fuel tank. See service manual. | |
| 5. | Remove cylinder head, cylinder, and piston. See service manual. | |
| 6. | Follow procedures in service manual for inspection of parts. |
Figure 2. 0.5 in. (12.7 mm)
Measuring Pistons
| 1. | Allow piston to cool to room temperature. | |
| 2. | With a pencil or marker, mark piston on each side of skirt across thrust faces (perpendicular to piston pin bore) 0.5 in (12.7 mm) from bottom edge of chamfer on piston skirt. | |
| 3. | Using a micrometer at parks, measure nominal diameter of piston. | |
| 4. | Use a dial bore gauge to measure piston ring travel zone in cylinder bore. |
Installing Pistons
| 1. | The pistons in this kit are not front and rear cylinder specific. Install pistons in front and rear cylinders with arrow pointing toward front of engine. |
NOTE
Install rings with marking facing up. Rings with no markings can be installed either side up.
Always check piston-to-valve clearance with non-stock camshafts.
For ring compression tool, see Service Tool Instructions J06234.
Table 3. Piston Specifications
Piston | IN | MM | |
|---|---|---|---|
Fit in cylinder | 0.0007-0.0020 | 0.017-0.050 | |
Piston pin fit (loose) | 0.0006-0.0010 | 0.015-0.025 | |
Ring end gap | Top compression | 0.015-0.025 | 0.381-0.635 |
2nd compression | 0.015-0.025 | 0.381-0.635 | |
Oil control ring | 0.015+/-0.009 | 0.38+/-0.23 | |
Ring side clearance | Top compression | 0.0006-0.0024 | 0.015-0.060 |
2nd compression | 0.0008-0.0022 | 0.020-0.055 | |
Oil control rails | 0.0004-0.0059 | 0.010-0.150 | |
Table 4. Piston Service Wear Limits
Replace if Wear Exceeds | ||
|---|---|---|
Item | IN | MM |
Fit in cylinder (loose) | 0.0045 | 0.1143 |
Piston pin fit (loose) | 0.0015 | 0.0381 |
Top ring end gap | 0.031 | 0.79 |
2nd ring end gap | 0.032 | 0.81 |
Oil control ring rail gap | 0.031 | 0.79 |
Ring side clearance | 0.0035 | 0.089 |
2nd ring side clearance | 0.0037 | 0.094 |
Oil control ring side clearance | 0.0068 | 0.173 |
Piston Pin Circlip Installation
| 1. | See Figure 3. Position circlip opening (1) at 12 o'clock on special tool. Special Tool: PISTON PIN RETAINING RING INSTALLER (HD-51069-2) | |||||||||||||
| 2. | See Figure 4. Align and insert special tool (2) with circllip into piston. | |||||||||||||
| 3. | See Figure 5. Make sure that circlip (2) is fully seated in groove. a. Circlip opening (1) must be at 12 o'clock position. | 
Figure 3. Position Circlip 
Figure 4. Install Circlip 
Figure 5. Circlip Position on Piston | ||||||||||||
| 4. | Repeat procedure for remaining circlips. |
COMPLETE
| 1. | Install cylinder heads, cylinders, and high compression pistons and rings from kit. See service manual. | |
| 2. | Install fuel tank. See service manual. | |
| 3. | Connect negative battery cable. See service manual. | |
| 4. | Install main fuse. See service manual. | |
| 5. | Install seat. After installing seat, pull up on the seat to verify that it is secure. See service manual. | |
| 6. | Download the new ECM calibration using Screamin' Eagle Pro Street Performance Tuner Kit. | |
| 7. | Run engine. Repeat several times to verify proper operation. |
BREAK-IN RIDING RULES
Refer to the Owner's Manual to break in the motorcycle.