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EPA-Legal Harley-Davidson 103ci Hop-Up

Screamin' Eagle Big Bore Stage II Kit

By Ernie Lopez, Photography by Ernie Lopez
  • Harley Davidson Screamin Eagle Big Bore Kit
    Then the cam cover and camplate were removed. Brian needed to pull the stock cams and tensioner off the camplate and check and change out the oil pump O-rings before installing the new cams.
    Harley Davidson Screamin Eagle Big Bore Kit
    Then the cam cover and camplate were removed. Brian needed to pull the stock cams and tens
  • Harley Davidson Screamin Eagle Big Bore Kit
    Brian pulled all the Screamin' Eagle Big Bore Stage II Kit parts for EFI models from the box. There were a set of SE-255 cams, two Big Bore cylinders, two Big Bore flat top pistons, clips, a Stage I Air Cleaner Kit with one-piece backing plate, integral breathers, all mounting hardware, gaskets, a high-performance clutch spring, and catalyst mufflers.
    Harley Davidson Screamin Eagle Big Bore Kit
    Brian pulled all the Screamin' Eagle Big Bore Stage II Kit parts for EFI models from the b
  • Harley Davidson Screamin Eagle Big Bore Kit
    To get started on the install, Brian removed the stock cams from the camplate.
  • Harley Davidson Screamin Eagle Big Bore Kit
    The new cams were lined up by the timing marks from the front, then Brian took a black marker and drew a line across the two on the back of the cams to help ensure that the timing marks were lined up as he installed them back into the plate.
    Harley Davidson Screamin Eagle Big Bore Kit
    The new cams were lined up by the timing marks from the front, then Brian took a black mar
  • Harley Davidson Screamin Eagle Big Bore Kit
    Afterwards, he checked that the timing marks were right as he spun the cam by hand to see that they lined up.
    Harley Davidson Screamin Eagle Big Bore Kit
    Afterwards, he checked that the timing marks were right as he spun the cam by hand to see
  • Harley Davidson Screamin Eagle Big Bore Kit
    Next, the chain tensioner was reinstalled. Here is a photo of the old style with the pressure spring on the left and the oil-filled hydraulic tensioner on the right. It had an oil cavity to hold the pressure spring that filled with oil as the oil pump was running, keeping the chain tight (you cannot compress a liquid).
    Harley Davidson Screamin Eagle Big Bore Kit
    Next, the chain tensioner was reinstalled. Here is a photo of the old style with the press
  • Harley Davidson Screamin Eagle Big Bore Kit
    When the chain tensioner was bolted to the camplate, the oil pressure was fed through a small port on the bottom, shown here.
    Harley Davidson Screamin Eagle Big Bore Kit
    When the chain tensioner was bolted to the camplate, the oil pressure was fed through a sm
  • Harley Davidson Screamin Eagle Big Bore Kit
    Before the cam plate was reinstalled, Brian removed the stock oil pump from the motor to change out the pump's O-ring and inspected the oil pump for wear.
    Harley Davidson Screamin Eagle Big Bore Kit
    Before the cam plate was reinstalled, Brian removed the stock oil pump from the motor to c
  • Harley Davidson Screamin Eagle Big Bore Kit
    The camplate (with the SE-255 cams) was reinstalled and torqued to factory specs. You can see the new-style tensioner as it holds the chain.
    Harley Davidson Screamin Eagle Big Bore Kit
    The camplate (with the SE-255 cams) was reinstalled and torqued to factory specs. You can
  • Harley Davidson Screamin Eagle Big Bore Kit
    Brian moved onto the install of the new 3-7/8 flat top pistons into the new Big Bore cylinders. This increases the displacement of your Twin Cam-equipped model from 96 cubic inches (1584cc) to 103 cubic inches (1690cc).
    Harley Davidson Screamin Eagle Big Bore Kit
    Brian moved onto the install of the new 3-7/8 flat top pistons into the new Big Bore cylin
  • Harley Davidson Screamin Eagle Big Bore Kit
    The first thing he did was check the ring gap. They were within spec.
  • Harley Davidson Screamin Eagle Big Bore Kit
    Next, he installed the rings, starting with the upper compression ring, then the lower, and lastly the oil ring set.
    Harley Davidson Screamin Eagle Big Bore Kit
    Next, he installed the rings, starting with the upper compression ring, then the lower, an
By Ernie Lopez
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