HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL 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) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

2006-up Harley-Davidson Single Bore Induction System Installation Instructions

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Filed Under (Harley Davidson) by admin on 10-11-2010

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Remove the stock fuel induction system, including the manifold and disconnecting all wire connections. It is up to the technician as to whether the gas tank should be removed or just raised up in the rear. Picture 1 2- You will need to disassemble the stock induction system to remove the pre-listed parts for re-use. 3- Verify the new manifold size is appropriate for your motorcycle by sliding it in place. Picture 2 Picture 3 4 5- Slide the MAP sensor in place, being sure not to pinch the orange rubber seal—some clean engine oil may make this easier. Install the cable guide and verify it is aligned with the throttle cable actuator. Once alignment is satisfactory, apply Loctite® 222 to the 10-24 x 1/4″ screws and tighten to 18-22 in-lbs. 4- Install the new O-ring into the throttle body. A light film of clean engine oil can be used to help hold the O-ring in place. Align the manifold to the throttle body, use purple 222 Loctite® on the 10-24 x 1″ socket-head assembly screws (with flat washers) and tighten them to 35-40 in-lbs. 6- Using the new S&S® supplied gasket, slide the S&S supplied intake air temperature (IAT) sensor in place. Use Loctite 222 on the T10 Torx button head M3 x .5 x 10mm screws and tighten to 6-8 in-lbs. Picture 4 Picture 5 Picture 6 5 7- For the stock throttle position sensor attach the “C” shaped spacer to the end of the throttle shaft, put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, apply some Loctite® 222 and torque screws to 18-23 in-lbs. 8- Install the new O-ring on the IAC motor. Lubricate the OD of the O-ring with a light film of clean engine oil. Put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, coat the threads with Loctite 222. Install the IAC motor and tighten the screws to 18-23 in-lbs. 9- Partially install the fuel injectors in the fuel rail. Be sure to orient the black O-rings to the rail and align the clocking tabs with their holes. It may be helpful to lubricate the O-rings with clean engine oil. See Picture 9. NOTE : These are special O-rings that seal pressurized gasoline. If you see one with damage or an abrasion—replace it immediately. Picture 7 Picture 8 Picture 9 6 10- Connect the Injectors to the manifold with a light squeezing action. Lubricate the O-rings with clean engine oil. Once in place, use Loctite® 222 on the threads of two 8-32 x 5/8″ slotted panhead screws and tighten to 15-20 in-lbs. 11- Install the backing washer and O-ring on the fuel supply tube. Lubricate the O-ring with clean engine oil. When the tube is in place, position the Y-shaped clip on the fuel rail and tighten the Loctite 222 coated T20 Torx button head M4 x 7 x 12mm screw to 18-23 in-lbs – Gently push the injectors downward toward the manifold to increase clearance for connecting the wire connectors. Cut the existing injector connectors from the motorcycle harness. Slide the sleeveing onto the injector harness. Slide heat shrink tubing on to each wire of the injector harness wires. Crimp the butt splices to the motorcycle harness. Move the heat shrinks over the splices and shrink with a heat gun. Slide the sleeve into place. Picture 10 Picture 11a Picture 11b Picture 12 Picture 12a 7 13- Put the stock manifold flanges on the manifold. YOU MUST USE THE S&S® RUBBER GASKETS ON THEM. Be sure to orient the tapered end towards the manifold and the flat end to the heads. 14- Hold the manifold up in its basic mounting position and connect all of the wiring harness connectors at this time. Install the manifold using the stock mounting flange bolts (from the primary side of the motorcycle) coated with Loctite® 242 and the new S&S cam side screws (1/4″ socket head, 5/16-18 x 3/4″). If a screw longer than 3/4″ is used, damage to the heads will result. Lightly snug all four manifold mounting bolts but DO NOT TIGHTEN AT THIS TIME. Connect the throttle cables and cruise control bracket (if applicable) at this time. NOTE: The Harley-Davidson® service manual for your model motorcycle will be helpful during this step. 15- Install the breather system now. On 4.00-inch bore or smaller engines the breather uses banjo fittings with hollow bolts and connects across the heads to the intake with a T-hose. This hose will need to be trimmed and have spring clamps attached as shown in photo. Torque the hollow bolts to 10-12 ft-lbs. On 41/8-inch bore or larger engines, install the sharp bent hose on the rear head and install the check valve with the white end towards the head. Mount the other hose on the black end of the check valve and connect it to the throttle body using spring clamps to secure the connections. Picture 13 Picture 14 Picture 15 8 16- Once the breathers are secure, install the fuel line per the factory service manual you are working with. Connect the battery and verify the fuel pump turns on to pressurize the system and there are no gas leaks, but DO NOT START THE ENGINE. At this time, PC software may also be used to verify sensor readings and adjust the throttle position sensor voltage if necessary. 17- Install two 242 Loctite® coated pipe plugs (included in kit) in the air cleaner backplate as shown in Picture 16. Torque to 35-45 in-lbs. Also, two pan screws coated with Loctite® 222 must be installed in the backplate in place of the enrichment device. See Picture 16a. Torque them to 12-18 in-lbs. Failure to install these screws could allow dirt and debris into the intake system. 18- Use a new gasket on the backplate and put it in place noting the number of shims required. Once you select the appropriate shims (included) mount the backing plate to the engine but DO NOT INSTALL THE SCREWS YET

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