User manual | screamin&#39

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REV. 2006-08-01
SCREAMIN' EAGLE PRO AIR CLEANER KIT
1.
GENERAL
Remove seat according to the instructions in the Service
Manual.
Kit Number
29441-99A
Models
This kit fits 1999-2001 Twin Cam 88 model motorcycles
equipped with Electronic Fuel Injection (EFI).
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)
NOTE
This kit is intended for high performance applications only.
When included as part of a "street-legal" kit, this engine related
performance part is legal for sale or use in California on pollution controlled motor vehicles. Engine related performance
parts are intended for the experienced rider only.
Installation of this kit by an authorized Harley-Davidson dealer
will not impact your limited vehicle warranty.
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. (00049a)
2.
Disconnect battery cables, negative (-) cable first.
3.
Remove existing air cleaner assembly. Save air cleaner
cover and button head screw that secures cover.
Remaining parts can be discarded.
Additional Parts Required
Proper installation of this kit requires the use of the following
items:
•
Air Cleaner/Degreaser (99883-88T)
•
Air Cleaner Oil (99882-88T)
•
Digital Technician™ or Screamin' Eagle EFI Race Tuner
(See Harley-Davidson dealer)
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. (00333a)
INSTALLATION
The element in this kit is specifically designed for use with
the OE (original equipment) cover. Using this kit with an
air cleaner cover other than the OE cover could lead to
failure of the element faceplate. The kit may be used in
conjunction with other H-D accessory covers provided the
appropriate adapter recommended in those kits is used.
If the element faceplate fails the cover could detach possibly distracting the rider which could result in death or
serious injury. (00400b)
NOTES
NOTE
When servicing the air cleaner, apply Loctite 243 (blue) to
threads of all fasteners.
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.
Backplate appearance and some components may vary slightly
from illustrations, however the hardware assembly is the same
for all kits.
Kit Contents
Install Air Cleaner Hoses
See Figure 5 and Table 1.
1.
See Figure 5. Install one end of hose (1) to nipple of
breather bushing (2). Push until hose butts up against
breather bushing.
2.
See Figure 1. Lubricate hose with soapy water and carefully insert into rear of backplate (1). Continue to push until
the first bend is clearly through hole in backplate (2).
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)
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is03559
6
2
4
1
2
5
1
1. Rear of backplate
2. Backing plate hole
1.
2.
3.
4.
5.
6.
Figure 1. Install Hoses into Rear of Backplate
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2
1
3
Banjo bolt
Mounting bracket
Large I.D. washer
Large I.D. washer
Breather bushing
Small I.D. washer
Figure 3. Secure Mounting Bracket to Cylinder Head (Right
Side Shown)
4.
See Figure 4. Align gasket with backplate. Install studs
(1) through backplate and gasket, then thread into induction module. Do not tighten completely.
5.
Apply Loctite 243 (blue) to threads of screw (2) and secure
backplate to mounting bracket (3). Tighten screws to 5560 in-lbs (6.2-6.8).
6.
Tighten studs to 55-60 in-lbs (6.2-6.8 Nm).
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1. Hose
2. Breather bushing
2
Figure 2. Position Hoses for Installation
3.
4.
See Figure 2. Position hose (1) so that end is pointing
inward horizontally and breather bushing (2) is positioned
as shown.
4
3
1
Repeat Steps 1-3 for other hose.
Install Air Cleaner
1.
See Figure 5. Install washers (3) onto banjo bolts (4).
Apply Loctite 243 (blue) to threads of banjo bolts.
2.
Place gasket (5) (peel off and stick on) onto backplate (6).
3.
See Figure 3. Install banjo bolts (1) through bracket (2),
large I.D, washers (3 and 4), breather bushings (5), and
small I.D. washers (6). Then thread into tapped hole in
cylinder head. Do not tighten completely.
1.
2.
3.
4.
Stud (4)
Flathead screw (2)
Mounting bracket
Banjo bolt (2)
Figure 4. Secure Backplate to Mounting Bracket
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7.
Position breather hoses and breather fittings to provide
adequate clearance for the intake mechanisms behind
backplate. When banjo bolts (4) are tightened, the barbed
portion of the breather bushings should be near horizontal,
and hoses in front of backplate should be facing inward.
8.
Tighten banjo bolts to 10-12 ft-lbs (14-16 Nm).
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NOTE
Crankcase ventilation is critical for proper oil system operation.
If the hoses appear kinked, reposition as needed. If necessary,
loosen banjo bolt to reposition hose.
2.
Install Air Cleaner Element and Cover
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)
NOTE
When servicing the air cleaner, apply Loctite 243 (blue) to
threads of all fasteners.
Install seat according to the instructions in the Service
Manual.
1.
See Figure 5. Secure air filter element (12) to air cleaner
studs (9) using screws (11). Tighten screws to 55-60 inlbs (6.2-6.8 Nm).
Recalibrate ECM
2.
Carefully remove and discard the original air cleaner cover
insert from air cleaner cover (A). Remove any residual
adhesive on the cover with mineral spirits.
You must recalibrate the ECM when installing this kit.
Failure to properly recalibrate the ECM can result in severe
engine damage. (00399b)
3.
To ensure surface cleanliness, clean the insert area with
a mixture of 50 to 70% isopropyl alcohol and 30 to 50%
distilled water. Allow to dry thoroughly.
Download the new ECM calibration using the Digital Technician™ or Screamin' Eagle EFI Race Tuner at a HarleyDavidson dealer.
4.
Peel liner from adhesive backing of air cleaner cover (A)
without touching adhesive on cover surface. Line up top
of insert with top of oval air cleaner cover.
MAINTENANCE
5.
Press air cleaner cover insert (13) firmly against the cover
all around, and hold pressure for 30 seconds. After
releasing pressure, avoid direct contact with the insert for
about 20 minutes.
NOTE
Allow at least 24 hours after applying the insert before exposing
the area to vigorous washing, strong water spray, or extreme
weather. The adhesive bond will increase to maximum strength
after about 72 hours at normal room temperatures.
6.
Apply Loctite 243 (blue) to threads of air cleaner cover
screw (B). Secure air cleaner cover (A) to air filter element
(12) with screw.
7.
Align air cleaner cover horizontally for best appearance,
then tighten screw securely. Tighten to 36-60 in-lbs (4.16.8 Nm).
Air Cleaner Element Maintenance
NOTE
When servicing the air cleaner, apply Loctite 243 (blue) to
threads of all fasteners.
1.
See Figure 1. Remove air cleaner cover (A) and inspect
the filter element (12) every 5000 mi (8000 km), or more
often under dusty conditions.
2.
Clean filter element as follows:
a.
Remove and wash element by immersing it, on edge,
in a shallow pan containing enough Air
Cleaner/Degreaser to cover no more than 3/4 the
depth of the filter pleats. Do not let dirty solution get
inside the element. Carefully "roll" the element in the
solution around its perimeter until the entire outer
surface of the filter pleats has been soaked.
b.
Remove filter element from cleaner/degreaser and
allow five minutes for the cleaner to dissolve the dirt.
c.
From the inside out, rinse the element with cold water.
Shake off excess water, and allow the element to air
dry. Do not dry with compressed air.
d.
Red filter elements: Oil element using Air Cleaner Oil.
Apply along the full length of each pleat and allow to
set until the element is a uniform color. Allow excess
oil to drain.
Final Assembly
Connect positive (+) 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. (00068a)
1.
Connect battery cables, positive (+) cable first.
3.
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Install air cleaner element and cover.
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SERVICE PARTS
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8
7
1
5
2
3
10
3
12
4
9
6
11
B
A
13
Figure 5. Service Parts: Screamin' Eagle Pro Air Cleaner Kit
Table 1. Service Parts: Screamin' Eagle Pro Air Cleaner Kit
Item
Description (Quantity)
Part Number
1
Hose, rubber (2)
29476-99
2
Bushing, breather (2)
29445-02
3
Washer, large I.D. (4)
45596-93
4
Bolt, banjo (2)
45507-99
5
Gasket, backplate
29617-99
6
Backplate
29444-99A
7
Bracket, mounting
29452-99
8
Washer, small I.D. (2)
46465-99
9
Stud, air cleaner (4)
29447-99A
10
Screw, flathead 1/4-20 x 5/8 in. (2)
3793A
11
Screw, air cleaner element (4)
3652
12
Element, filter
29446-99C
13
Insert, air cleaner
29450-99
14
Loctite 243 (blue), 0.5 ml packet (Not Shown)
Not Sold Separately
Original equipment mentioned in text, but not included in kit:
A
Air cleaner cover
B
Screw
Note: Loctite (Item 14) is only available in 6 ml tube, part number 99642-97.
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