SE120R SCREAMIN' EAGLE PRO RACE-USE CRATE ENGINE

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Jeremy Randall
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1 -J007 REV SE0R SCREAMIN' EAGLE PRO RACE-USE CRATE ENGINE GENERAL Kit Number 90- Models For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of (English only). NOTE This engine is for race use only! You must remove the emissions label and license plate from the factory chassis. TABLE OF CONTENTS Page 9 0 Table. TABLE OF CONTENTS Subject SE0R ENGINE INSTALLATION SE0R ENGINE SPECIFICATIONS MANUFACTURING TOLERANCES SERVICE WEAR LIMITS SE0R CYLINDERS SE0R PISTONS REPLACING/SERVICING PUSHRODS SERVICE PARTS Additional Parts Required Recommended synthetic engine oil, Screamin' Eagle SYN 0W0 (p/n 998-0/00QT). 00 Dyna models (only) require the replacement of the stock top two engine-to-transmission mounting bolts with shorter bolts (H-D p/n 98). Clutch kit that will support a minimum of 0 ft-lbs of torque. SE 8 mm throttle body, Air Cleaner and High Flow injectors. Refer to the Screamin' Eagle Pro Catalog or contact a Harley- Davidson dealer. SE exhaust gaskets kit (p/n ). Oil cooler is recommended. See P&A Retail Catalog or the Parts and Accessories section of SE Pro Super Tuner. Refer to Screamin' Eagle Pro Catalog or contact a Harley-Davidson dealer. See appropriate sections in service manual for the special tools required to install this kit. The rider's safety depends 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. (00a) 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. REMOVAL Remove OEM Engine. Position the motorcycle on a suitable lift. NOTE If vehicle is equipped with a Harley-Davidson Smart Security System, see owner's manual for instructions to disarm the system.. Remove seat according to the instructions in the service manual. 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. (000a). Remove the main fuse. Refer to service manual for your motorcycle.. Remove the fuel tank according to the instructions in the service manual.. Refer to ENGINE section of the appropriate service manual for removal of engine from chassis. SE0R ENGINE INSTALLATION. Before installing the engine, make sure there is no debris or contaminates in the oiling system. The oil tank should be flushed-out. The tank flush-out should be performed by an authorized dealer or qualified technician.. Remove the oil passage caps/plugs at the engine to transmission interface.. Refer to the ENGINE section of the appropriate service manual for installation of the engine to the chassis. -J007 of 9

2 Final Assembly. Install the fuel tank according to the instructions in the service manual.. Refer to the service manual to install the main fuse.. Install the seat according to the instructions in the service manual. 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) 7. Download the new ECM calibration when installing this kit. Refer to the Screamin' Eagle Pro Catalog or contact a Harley-Davidson dealer. 8. Start and run the 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 new engine. MAINTENANCE. Refer to the MAINTENANCE SCHEDULE in the appropriate service manual or owner's manual.. For engine assembly/disassembly refer to the ENGINE section of the appropriate service manual. You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (0099b) -J007 of 9

3 SE0R ENGINE SPECIFICATIONS NOTE The following sections provide unique information not available in the service manual ENGINE section for the appropriate Twin Cam 9 alpha engines from Touring or Dyna platforms. Table. Engine: SE Twin Cam 0R Table. Valve Springs Specifications ITEM PRESSURE DIMENSION Closed 80 lbs (79 kg).800 in. (.7 mm) Open 00 lbs (9 kg).77 in. (9.9 mm) Free length n/a.0 in. (. mm) Compression Ratio Bore Stroke Displacement Lubrication system.00 in.. in. 9.7 in. Specification mm 7.8 mm 9.9 cc Pressurized dry sump with oil cooler MANUFACTURING TOLERANCES Refer to the Twin-Cam 9 specifications in the service manual for any specification not shown in the following tables. Table. Pistons Piston: Piston-to-cylinder fit (Loose) Piston pin fit (Loose) Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance Clearance (in.) ITEM Valve guide in head (tight) Intake valve seat in head (tight) Exhaust valve seat in head (tight) ITEM Fit in guide (intake and exhaust) Seat width Stem protrusion from cylinder head boss Table. Cylinder Heads IN Table. Valves IN MM MM Table 7. Cam Specifications - SEE Intake Specification Opens BTDC Closes 8 ABDC Duration o Max. Valve Lift 0.8 in. Valve TDC 0.08 in. Exhaust Specification Opens 9 BBDC Closes 7 ATDC Duration o Max. Valve Lift 0.8 in. Valve TDC 0.78 in. Cam 0.0" of Tappet Lift in Crankshaft Degrees -J007 of 9

4 SERVICE WEAR LIMITS Wear limits can be used as a guide when deciding whether to reuse engine parts. Replace used parts whenever the following wear limits are exceeded. NOTE Refer to the Twin-Cam 9 specifications in the service manual for any specification not shown in the following tables Table 9. Cylinder Bore ITEM REPLACE IF WEAR EXCEEDS IN. MM Standard in. oversize ITEM Taper Out of round Warpage of gasket or O-ring surfaces: top Warpage of gasket or O-ring surfaces: base Table 8. Cylinders REPLACE IF WEAR EXCEEDS IN MM Table 0. Pistons Piston-to-cylinder fit (Loose) Fit in cylinder (Loose) Piston Pin Fit (Loose) Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance Wear Limit (in.) J007 of 9

5 SE0R CYLINDERS. 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.. Remove seat according to the instructions in the service manual.. Refer to the appropriate service manual and assemble the engine with the following changes: a. Assemble the top end of the engine using the base gaskets and head gaskets provided in the kit. Refer to the appropriate engine section in the service manual. is08 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. (000a). Remove main fuse. Refer to service manual for your motorcycle.. Remove fuel tank according to the instructions in the service manual. Remove Engine Components. Refer to service manual to remove existing air cleaner assembly.. Remove the existing exhaust system following service manual procedures.. Disassemble the engine top end. Refer to the appropriate engine sections in the service manual. Install Engine Top End Components NOTES See Figure. The.00 in. cylinder base gasket () and cylinder head gasket () eliminate the need for O-rings. Do not use O-rings on cylinder dowels or cylinder spigots. When installing new base gasket (), install with the embossed side down and the concave side up.. Gasket, cylinder base. Gasket, cylinder head Final Assembly Figure. Cylinder Gaskets. Install the fuel tank according to the instructions in the service manual.. Refer to the service manual to install the main fuse.. Install the seat according to the instructions in the service manual. 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) -J007 of 9

6 SE0R PISTON is0. Refer to ENGINE section of service manual INSTALLATION.7 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (0007a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (0009a). Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 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. (000a). Refer to the ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL, DISASSEMBLY sections of the service manual for cylinder head, cylinder and piston removal procedures.. Follow the procedures in the ENGINE: SUBASSEMBLY SERVICE AND REPAIR, TOP END/ CYLINDER/ UPPER CONNECTING ROD sections of the service manual for inspection of parts.. See the ENGINE: SUBASSEMBLY SERVICE AND REPAIR, CYLINDER section of the service manual for boring and honing instructions. NOTES Install the top ring (barrel-faced) and second ring (taper-faced Napier) with the "N" marking facing up. Oil ring rails can be installed either side up. The.00 inch cylinder base gaskets and cylinder head gaskets included in the kit eliminate the need for O-rings (7). Do not use O-rings on cylinder dowels or cylinder spigots. When installing new base gasket, install with the embossed side down and the concave side up.. Piston width. Measurement area Figure. Piston Measurements NOTE Checking piston-to-cylinder fit at this location per table 0 is for reference.. See Figure. Measure the piston width (), 90 degrees horizontally from both sides of the piston pin hole and.7 in. down from the deck surface (top) of the piston (). See table 0 for piston-to-cylinder fit at this location.. The pistons in this kit are front and rear specific. Install the piston marked "FRONT" in the front cylinder with the arrow pointing towards the front of the engine. Install the piston marked "REAR" in the rear cylinder with the arrow pointing towards the front of the engine. 7. Refer to the ENGINE: TOP END OVERHAUL, ASSEMBLY section of the service manual for piston, cylinder and cylinder head installation procedures. Table. Specifications Piston: Piston-to-cylinder fit (Loose) Piston pin fit (Loose) Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance Table. Service Wear Limits Clearance (in.) Piston-to-cylinder fit (Loose) Fit in cylinder (Loose) Piston Pin Fit (Loose) Top Ring End Gap Second Ring End Gap Oil Control Ring Rail Gap Top Ring Side Clearance Second Ring Side Clearance Oil Control Ring Side Clearance Wear Limit (in.) J007 of 9

Being careful not to scratch or mar the piston, use a smallbladed screwdriver to wedge the circlip into the remainder of the groove. Repeat for the remaining circlips.

7 PISTON PIN RETAINING RING (CIRCLIP) INSTALLATION NOTE Circlip gap must be at :00 or :00 position when installed. 8. See Figure. Insert the open end of the circlip () into the notch () on the groove () around the piston pin boss so that the gap is at the :00 or :00 o'clock position when installed. 0. Being careful not to scratch or mar the piston, use a smallbladed screwdriver to wedge the circlip into the remainder of the groove. Repeat for the remaining circlips. NOTE Make sure the piston circlip is fully seated, or ENGINE DAMAGE WILL OCCUR.. Refer to the ENGINE: ASSEMBLING MOTORCYCLE AFTER STRIPPING section of the service manual for final re-assembly procedures. is0 is000b. Circlip. Notch. Groove Figure. Circlip and Piston is07. Thumb orientation. Circlip 8% seated Figure. Install Circlip 9. See Figure. Position your thumb () as shown, and press firmly until approximately 8% of the circlip () is seated in the groove. Figure. Piston Assembly Table. Piston Assembly Piston (front, standard) Piston (rear, standard) Ring set, standard () Piston pin () Circlip () Piston (front, +0.00) Piston (rear, +0.00) Ring set, () Piston pin () Circlip () -J007 7 of 9

8 REPLACING/SERVICING PUSHRODS. Refer to ENGINE section of service manual. NOTES Follow the appropriate service manual procedures for installing and removing the pushrods. The pushrods are marked Intake and Exhaust. The pushrods are directional. Be sure the larger end of the pushrods are installed down in the lifter sockets. is097. Rocker cover assembly. Rocker arm support plate assembly. Rear intake pushrod. Rear exhaust pushrod Figure. Push Rods -J007 8 of 9

9 SERVICE PARTS is077 Figure 7. Engine Assembly, SE 0R Complete Table. SE0R Screamin' Eagle Pro Race-Use Crate Engine Engine assembly, complete 90- -J007 9 of 9

10 is080a Figure 8. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine Table. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine 7 Base gasket, cylinder SE cylinder kit,.00 in., (black) (includes items,,, 0 and 08A) Dowel pin, ring () Gasket, cylinder head () Stud, cylinder (8) Gasket kit, engine overhaul (does not include cylinder head gasket, base gasket or valve stem seals) (Not Shown) Gasket kit, top-end, (does not include cylinder head gasket, base gasket or valve stem seals) (Not Shown) C 9-99A A 70-99C 70-99C -J007 0 of 9

11 is08 0 A a b 9 A 7 9 A 8 0 A A A A 8 A E D C B 7 Figure 9. Service Parts: SE0R Screamin' Eagle Pro Race-use Engine Crate a b Table. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine Cylinder head assembly, rear (includes s through ) Cylinder head assembly, front (includes s through ) J007 of 9

12 Table. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine Cylinder head (machined, with items B, C, D and E installed) Collar, valve spring, upper () Collar, valve spring, lower () Stud, exhaust port () Intake valve () 7 Exhaust valve () 8 seal, valve () 9 Valve spring unit () 0 Retainer, valve collar (8). Also included with Kit 88-0A Automatic compression release () Medallion, "0R" (for front cylinder head only) Screw, button head, TORX () (for front cylinder head only) Screw, internal thread, -/ inch () Screw, internal thread, -7/8 inch () Housing -way pin 7 Wire seal, -0 AWG () Service Kits: A Valve Spring Kit, Screamin' Eagle The following Screamin' Eagle parts are available separately: B Valve seat, intake C Valve seat, exhaust D Valve guide, intake (for service) ( in.) ( in.) ( in.) E Valve guide, exhaust (for service) ( in.) ( in.) ( in.) Not Sold Separately See Service Kits See Service Kits See Service Kits A A 80-9A A A J007 of 9

13 is08c Figure 0. SE0R Screamin' Eagle Pro Race-Use Crate Engine Table 7. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine Screw /-8 X -/ hex flange hd. (Grade 8) (8) Screw /-8 X.0 hex hd., w/lockpatch () 09 9A -J007 of 9

14 Table 7. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine Screw /-8 X -/ hex hd., w/lockpatch (0) Screw /-8 X -/ hex flange hd., w/lockpatch (8) Screw /-0 X -/ hex hd. (Grade 8), with lockpatch, () Screw /-0 X socket hd., w/lockpatch (8) Washer / X 9/ X / () O-ring, push rod cover () O-ring, push rod cover () O-ring () O-ring () Gasket, rocker housing () Gasket kit, cam service Rocker arm, front intake, rear exhaust, with bushings () Rocker arm, rear intake, front exhaust, with bushings () Gasket, rocker cover () Bushing, rocker arm (8) Rocker cover, (chrome) () Rocker housing, (chrome) () Lifter cover, front (chrome) Lifter cover, rear (chrome) Support, rocker arm () Breather assembly () Shaft, rocker arm () Perfect Fit push rod kit (+0.00 inch) Cover, push rod, lower () Cap, cover spring () Spring, push rod cover () Cover, push rod upper () Retainer, spring cap () Pin, anti-rotation () Hydraulic lifter () Gasket, lifter cover () Baffle assembly, breather () 9A 7B 00 7A 7B A A B 70-99D 70-8A 77-8A 78-99A A B B 8-99B J007 of 9

15 is08 Figure. Service Parts; SE0R Screamin' Eagle Pro Race-Use Crate Engine Table 8. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine Retaining ring Piston ring set, standard () Piston ring set, 0.00 inch over size () Piston kit, front and rear, with ring sets, piston pin and lock rings, standard Piston kit, front and rear, with ring sets, piston pin and lock rings, 0.00 inch over size Lock ring, piston pin () Piston pin () Flywheel assembly kit (requires purchase/installation of washer 897 and inner race 897) 77A J007 of 9

16 is087a 0 b a > > Figure. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine Table 9. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine a b Plug () Screw, /-8 x.0 inch, hex flange head, (8) Screw, top center crankcase Washer, sealing Washer -/ x -/ x /8 () Needle bearing, left side of camshafts () O-ring () O-ring () Oil seal Dowel pin () Dowel pin () Dowel pin () Piston cooling jet, with 090 () Bearing kit, left side with 897, 0-07, -0, and inner race Spacer, sprocket shaft Crankcase set, (black) with,,,, 8, 9, 0,,, 7, 9, 0 and 98 bolts (not shown) Bearing, main () Adapter, oil filter Retaining ring Oil filter (chrome) A A 89-99A 9-99A -0A 00-0A A A A -J007 of 9

17 Table 9. Service Parts: SE0R Screamin' Eagle Pro Race-Use Crate Engine 9 0 Screw, TORX head, 8- x /8 () Screw, TORX button head, bearing retention, / - 0 x 7/ inch () B -J007 7 of 9

18 is R Figure. Service Parts: SE0R Screamin' Eagle Pro Race-use Crate Engine Table 0. Service Parts: SE0R Screamin' Eagle Pro Race-use Crate Engine Roll pin 0 Screw, primary cam chain tensioner () 9 -J007 8 of 9

19 Table 0. Service Parts: SE0R Screamin' Eagle Pro Race-use Crate Engine Screw, cam cover, /-0 x -/, knurled with lockpatch (grade 8), (0) Screw, secondary cam tensioner, /-0 x -/, knurled with lockpatch (grade 8), () Screw, /-0 x, socket head, with lockpatch (8) Washer, /8 x -/8 x 7/ Ball () Needle bearing, camshaft () O-ring O-ring () Retaining ring Gasket kit, cam service Cam drive sprocket retention kit, with 9, screws and washer Bushing, crankshaft Gasket, cam cover Cam support plate, with bypass valve Cam cover, (chrome) Camshaft chain and fastener kit, with -0, 7-0, 7-0 and 78-0 Camshaft, front Camshaft, rear Sprocket, cam drive on crankshaft, 7 T Chain, primary cam drive Chain, secondary cam drive Sprocket, cam drive, T Spacer, cam drive sprocket alignment 0.00 inch thick Spacer, cam drive sporcket alignment 0.00 inch thick Spacer, cam drive sprocket alignment 0.0 inch thick Spacer, cam drive sprocket alignment 0.0 inch thick Spacer, cam drive sporcket alignment 0.0 inch thick Spacer, cam drive sporcket alignment 0.0 inch thick Spacer, cam drive sprocket alignment 0.0 inch thick Oil pump assembly, with 78-0, 8-0, 8-0, 0-00 and body Spring, relief valve Gerotor assembly, scavenge Gerotor assembly, pressure Separator plate, gerotor () Relief valve, oil pump Cover, 0R Chain tensioner, primary cam drive chain Chain tensioner, secondary cam drive chain Spring, separator Screw, 8- x /8 TORX head () 70A 70A 7A D A -0A 9-0B B J007 9 of 9

w w w. h d o n l i n e s h o p. d e SCREAMIN' EAGLE "HEAVY BREATHER" PERFORMANCE AIR CLEANER KIT GENERAL INSTALLATION -J04479 REV.

w w w. h d o n l i n e s h o p. d e SCREAMIN' EAGLE HEAVY BREATHER PERFORMANCE AIR CLEANER KIT GENERAL INSTALLATION -J04479 REV. -J04479 REV. 008-- SCREAMIN' EAGLE "HEAVY BREATHER" PERFORMANCE AIR CLEANER KIT GENERAL Kit Numbers 95-08A, 9006-09A Models For model fitment information, see the P&A Retail Catalog or the Parts and Accessories