103" BB Install notes
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Road Captain
Joined: Jun 2007
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103" BB Install notes
Installed the SE 103" kit. Got it from Ebay for $350. Great deal.
Okay, a couple of notes:
1) The cylinder bores need major cleaning with BrakeKleen and shop towels, lots of machining residue left over.
2) The kit comes with everything you need except a primary cover gasket (and a cam cover gasket if you are doing cams).
3) Installing the SE Clutch spring is simple, takes all of 10 minutes after primary cover is off. No special tools needed, just a 10mm socket. The stock clutch spring thickness is pathetic.
4) Leaving your primary cover off during the cylinder install allows you the needed method to rotate the engine using the compensator nut.
5) You do not need to remove the gas tank at all. Just loosen the front bolt, remove the rear bolt and fuel line, and prop it up with a wooden 2x4.
6) Installing .030 Cometic MLS Head gaskets gets the quench area near perfect. I highly suggest this deviation to the SE kit. Jireh Cycles sells these under "1550 Big Bore MLS .030"
7) I am still using stock pushrods and all is well.
8) If you are installing a 103" kit, take my advice: INSTALL MANUAL COMPRESSION RELEASES!!. Jireh Cycles sells the exact same units as the Screamin Eagle ones (disregard the picture in the Jireh Catalog, the ones that show up are the SE type), for $15.00 each. Your local HD shop will have the SE or Jims tool to drill the 10mm holes.
I can tell you for sure the bike will not start easy without them. I tried, no way. Don't chance it, install them.
9) Buy two cans of BrakeKleen and two rolls of those blue shop paper towels, you will need it.
10) Use the Cometic gasket head torque instructions that come with the gasket.
11) The two air-cleaner side intake manifold hex-bolts are the hardest fasteners to deal with.
My $.02
Okay, a couple of notes:
1) The cylinder bores need major cleaning with BrakeKleen and shop towels, lots of machining residue left over.
2) The kit comes with everything you need except a primary cover gasket (and a cam cover gasket if you are doing cams).
3) Installing the SE Clutch spring is simple, takes all of 10 minutes after primary cover is off. No special tools needed, just a 10mm socket. The stock clutch spring thickness is pathetic.
4) Leaving your primary cover off during the cylinder install allows you the needed method to rotate the engine using the compensator nut.
5) You do not need to remove the gas tank at all. Just loosen the front bolt, remove the rear bolt and fuel line, and prop it up with a wooden 2x4.
6) Installing .030 Cometic MLS Head gaskets gets the quench area near perfect. I highly suggest this deviation to the SE kit. Jireh Cycles sells these under "1550 Big Bore MLS .030"
7) I am still using stock pushrods and all is well.
8) If you are installing a 103" kit, take my advice: INSTALL MANUAL COMPRESSION RELEASES!!. Jireh Cycles sells the exact same units as the Screamin Eagle ones (disregard the picture in the Jireh Catalog, the ones that show up are the SE type), for $15.00 each. Your local HD shop will have the SE or Jims tool to drill the 10mm holes.
I can tell you for sure the bike will not start easy without them. I tried, no way. Don't chance it, install them.
9) Buy two cans of BrakeKleen and two rolls of those blue shop paper towels, you will need it.
10) Use the Cometic gasket head torque instructions that come with the gasket.
11) The two air-cleaner side intake manifold hex-bolts are the hardest fasteners to deal with.
My $.02
Seasoned HDF Member
Joined: Jun 2007
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From: North of Hell, South of Heaven
Tourer
Joined: Dec 2007
Posts: 364
Likes: 0
From: Central DE
Echo to #8. My Service Mgr (103 kit was installed during accident rebuild) told me that Comp Releases were unnecessary.
He was wrong. Now if the bike doesn't start on the first try, it kills the battery and I am DITW.
Happened twice now, when the bike was put back together, in the shop, first time new motor, and when I finally got my tank from the painter and installed it.
It was to the point that I took the battery in for a load test, was found within specs and deep cycle charged.
I keep the Battery Tender on it whenever it's parked in the garage.
If you go with a 103 kit, do yourself favor and get the MCR or the ACR's installed while the engine is apart.
If it wasn't so sad I would have to laugh, when I told the SM about it he said,
well... we can put them in for you...
(insert face palm here)
He was wrong. Now if the bike doesn't start on the first try, it kills the battery and I am DITW.
Happened twice now, when the bike was put back together, in the shop, first time new motor, and when I finally got my tank from the painter and installed it.
It was to the point that I took the battery in for a load test, was found within specs and deep cycle charged.
I keep the Battery Tender on it whenever it's parked in the garage.
If you go with a 103 kit, do yourself favor and get the MCR or the ACR's installed while the engine is apart.
If it wasn't so sad I would have to laugh, when I told the SM about it he said,
well... we can put them in for you...
(insert face palm here)
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