Install Continued - Screamin’ Eagle 96-to-103 Kit

[26] The pistons were installed waiting for their respective cylinders.
[27] We installed a new O-ring on the bottom of each 103 cylinder. The O-rings are included in every kit.
[27] We installed a new O-ring on the bottom of each 103 cylinder. The O-rings are include
[28] We oiled up the wring compressor before using.

[29] We clamped the ring compressor in position over each piston as shown.
[30] We carefully slid the cylinder down over the piston pushing the wring compressor down after correctly orienting the cylinder with the push rod reliefs on the right side of the motor.
[30] We carefully slid the cylinder down over the piston pushing the wring compressor down
[31] We carefully unclamped the ring compressor and removed it.

[32] Before sliding the cylinder all the way down on the motor cases, we installed new O-rings on the oil drain tubes.
[32] Before sliding the cylinder all the way down on the motor cases, we installed new O-r
[33] We repeated the cylinder installation sequence on the rear cylinder. Note the green O-ring in position on the rear drain.
[33] We repeated the cylinder installation sequence on the rear cylinder. Note the green O
[34] Both cylinders were in position. The crosshatch was visible on the front cylinder. YES…this motor should be broken-in properly before being ridden hard.
[34] Both cylinders were in position. The crosshatch was visible on the front cylinder. YE

[35] We installed new head gaskets on each cylinder front and rear.
[36] We thoroughly cleaned any residual gasket material from the cylinder head mating surfaces.
[36] We thoroughly cleaned any residual gasket material from the cylinder head mating surf
[37] We did the same on all the gasket surfaces of the rocker boxes.

[38] We installed the cylinder head, throttle body assembly onto the new cylinders as a unit, the same way it was removed.
[38] We installed the cylinder head, throttle body assembly onto the new cylinders as a un
[39] We installed the cylinder head bolts into all the holes. Don’t forget any!
[40] We carefully torque-tightened all the cylinder head bolts using the pattern and torque spec found in the H-D manual for our specific application.
[40] We carefully torque-tightened all the cylinder head bolts using the pattern and torqu

[41] We installed new rocker box gaskets front and rear.
[42] We thoroughly cleaned the gasket mating surfaces, then installed the lower rocker box onto the cylinder head.
[42] We thoroughly cleaned the gasket mating surfaces, then installed the lower rocker box
[43] Using an inch-pound torque wrench, we tightened all the lower rocker box hardware to factory torque specifications.
[43] Using an inch-pound torque wrench, we tightened all the lower rocker box hardware to

[44] We installed new O-rings in the lifter covers as shown.
[45] We installed new internal O-rings where required in all four of the pushrod tubes.
[46] New O-rings are also required at the top of the push rod tube where it seats in the cylinder head.
[46] New O-rings are also required at the top of the push rod tube where it seats in the c

[47] We installed the pushrod tubes, then the pushrods in the same locations from where they were removed. We marked them, didn’t we?
[47] We installed the pushrod tubes, then the pushrods in the same locations from where th
[48] New and improved breather assemblies were included in the gasket set with the 103 kit. Old on top, new on the bottom.
[48] New and improved breather assemblies were included in the gasket set with the 103 kit
[49] We installed the rocker support assemblies onto each cylinder head including the new breather units.
[49] We installed the rocker support assemblies onto each cylinder head including the new

[50] We tightened the hardware holding the rocker blocks in place.
[51] We re-installed the exhaust system at this time.
[52] The rocker support was installed. Note the upgraded breathers.

[53]
[54] We finished tightening the exhaust system hardware. The green tape was holding the flanges in place.
[54] We finished tightening the exhaust system hardware. The green tape was holding the fl
[55] We plugged in both exhaust pipe O2 sensors.

[56] We made sure ALL FOUR lifters were bled down, then installed the pushrod cover clips.
[57] We installed and tightened the rear exhaust mount equipment.
[58] We tightened the breather bolts.

[59] We installed new rocker cover gaskets front and rear.
[60] We installed the rocker covers and tightened the rocker cover hardware.
[61] After ensuring the lifters had bled down, we installed the pushrod cover clips.

[62] We plugged in the throttle body control cable.
[63] We re-installed the top front motor mount (heim joint) and coil-coil bracket.
[64] We re-installed the air cleaner cover. It says 96, but we knew it was 103.

[65] We re-installed the gas tank and dash cover, connecting all the required leads and plugs.
[65] We re-installed the gas tank and dash cover, connecting all the required leads and pl
[66] We reconnected the positive terminal of the battery.
[67] We re-installed the seat and tightened that bolt.

[68] This Road King was ready for the road. It had new rubber installed front and rear before it left the lift. If you’re looking to convert your 96-inch Twin Cam to 103 cubic inches, one of the best places to have that done is your local Harley-Davidson dealer.

Sources

Harley-Davidson
harley-davidson.com