SCREAMIN' EAGLE 110 (1800 CC) BOLT-ON Stage V KIT
J061792015-04-30
GENERAL
Kit Number
92500038
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
Separate purchase and installation of extra parts or accessories may be required for proper installation of this kit. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Proper installation of this kit also requires the use of Digital Technician™ at a Harley-Davidson dealer or a separate purchase or use of Screamin' Eagle Street Performance Tuner Kit.
NOTE
Do not use stock CVO pistons with the 4 in Bolt-on Cylinders or interference occurs between the pistons and crankcase.
WARNING
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)
NOTE
This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
Kit Contents
See Figure 1 to Figure 4 , and Table 1 to Table 4.
NOTE
Installation of this kit by an authorized Harley-Davidson dealer will not impact your limited vehicle warranty.
The kit is intended for High Performance applications only. This engine-related performance kit is legal for sale or use in select countries or regions on pollution controlled motor vehicles. Check with your local Harley-Davidson dealer for compliance requirements in your area.
A partial emissions tune-up label and a product information label are included with this kit as a requirement of the California Air Resource Board (CARB)/EPA emissions regulation. Locate the emissions label on the frame tube below the handlebars. Place the new partial label from this kit over the top portion of the emissions label on the frame tube.
Locate the VIN label on the frame tube below the handlebars. Place the new product information label below the VIN label on the frame tube.
REMOVAL
Prepare for Service
1.
Disarm security system.
2.
Raise the motorcycle.
3.
See the service manual. Remove seat.
4.
See the service manual. Remove main fuse.
WARNING
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)
5.
See the service manual. Remove fuel tank.
Remove Engine Components
  1. See the service manual. Remove existing air cleaner assembly.
  2. See the service manual. Remove existing exhaust system.
  3. See the service manual. Disassemble engine top end and cam plate assembly.
  4. See the service manual. Remove existing clutch diaphragm spring.
INSTALLATION
Install Engine and Clutch Components
  1. See Figure 4. Install new inner cam bearings included with this kit.
  2. See Figure 1 through Figure 4. Assemble cams to cam plate and engine top end using parts from kit. Refer to appropriate ENGINE sections in service manual.
  3. Assemble throttle body and injectors from kit using ordinal equipment fuel line and fuel rail. Follow instructions in supplied throttle body.
  4. Install throttle body assembly to engine using intake flanges and seals supplied in the throttle body kit. Follow instructions in the supplied throttle body kit.
  5. Install clutch diaphragm spring from kit. See the CLUTCH INSTALLATION section in the service manual.
  6. Install valve spring kit and seals. Follow instructions in valve spring and seal kit.
  7. See the service manual. Install exhaust system.
  8. Install air cleaner assembly. Follow instructions in air cleaner kit.
Final Assembly
1.
See the service manual. Install fuel tank.
2.
See the service manual. Install seat.
3.
See the service manual. Install main fuse.
WARNING
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)
NOTICE
You must recalibrate the ECM when installing this kit. Failure to properly recalibrate the ECM can result in severe engine damage. (00399b)
4.
Download the new ECM calibration using the Digital Technician™ at a Harley-Davidson dealer or using Screamin Eagle Street Performance Tuner Kit.
5.
Start and run engine. Repeat several times to verify proper operation.
Operation
Refer to BREAK-IN RIDING RULES in the Owner's Manual to break in the motorcycle.
SERVICE PARTS
Figure 1. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race Kit
Table 1. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Stage V Race Kit
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Cylinder assembly (Black) (2)
16800102
6
Gasket, cylinder head (2)
16801-07B
7
O-ring, cylinder spigot (2)
11256
2
Piston (2)
Not Sold Separately
8
Gasket, exhaust port (2)
65324-9A
3
Piston Ring Set (2)
21951-11
9
Seal, intake manifold (2)
26995-86B
4
Piston pin (2)
22100001
10
Cylinder head, front (black)
16500014A
5
Piston pin circlip (4)
22097-99
11
Cylinder head, rear (black)
16500015A
Notes: Piston Kit (21900020) includes 2 through 5. Item 6 through 9 are also included in Top End and Cam Gasket Kit (16500385). For cyliner head assembly (10, 11) components, refer to instruction sheet J05340.
Figure 2. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race Kit
Table 2. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stave V Race Kit
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Gasket, rocker cover base (2)
16719-99B
8
Breather bolt (4)
4400
2
Gasket, rocker cover top (2)
17386-99A
9
Breather assembly (2)
17025-03A
3
Gasket, tappet cover (2)
18635-99B
10
Baffle assembly (2) [includes gaskets (2)]
26500002
4
O-ring, middle push rod cover (4)
11132A
11
Spring, clutch diaphragm (2) (Not Shown)
37951-98
5
O-ring, lower push rod cover (4)
11145A
12
High capacity tappet kit
18572-13
6
O-ring, upper push rod cover (4)
11293
13
Perfect fit pushrod kit
18400-03
7
O-ring, rocker arm support (2)
11270
Notes: Items 1 through 10 are included in Top End and Cam Gasket Kit (16500385).
Figure 3. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race Kit
Table 3. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race Kit
Item
Description (Quantity)
Part Number
1
Gasket, cam cover
25244-99A
2
Retaining ring
11461
3
Camshaft, front
Not Sold Separately
4
Camshaft, rear
Not Sold Separately
5
Bearing kit, needle, left side (2)
24018-10
6
O-ring, oil pump to cam plate
11293
7
O-ring, cam plate to crankcase (2)
11301
8
Roll pin
601
9
O-ring, crankcase dowel (2)
11273
10
Hi-flow injectors kit (not shown)
27796-08
11
58 mm ETC throttle body kit (not shown)
27713-08
12
Partial Emissions Tune-up Label (not shown)
Not Sold Separately
13
Product Information Label (not shown)
Not Sold Separately
Items mentioned in text, but not included in kit:
A
Washer
6294
B
Cam drive retention kit (includes screw and washer)
25566-06
Items 3 and 4 are available in Cam Kit (25482-10)
Items 1, 2, and 5 through 9 are included in Top End and Cam Gasket Kit (16500385)
Figure 4. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stave V Race Kit
Table 4. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race Kit
Item
Description (Quantity)
Part Number
1
Gasket, cylinder head (2)
16801-07B
2
Breather assembly (2)
17025-03A
3
Bearing kit, needle, left side, camshaft (2)
24018-10
4
roll pin, cam plate pressure relief
601
5
O-ring, cylinder spigot (2)
11256
6
O-ring, rocker arm support (2)
11270
7
O-ring, crankcase dowel (2)
11273
8
O-ring, upper push rod cover (4), oil pump to cam plate (1)
11293
9
O-ring, cam plate to crankcase (2)
11301
10
Retaining ring
11461
11
Gasket, rocker cover base (2)
16719-99B
12
Gasket, rocker cover top (2)
17386-99A
13
Gasket, Tappet cover (2)
18635-99B
14
Gasket, cam cover
25244-99A
15
Seal, intake manifold (2)
26995-86B
16
Gasket, exhaust port (2)
65324-83B
17
O-ring, middle push rod cover (4)
11132A
18
O-ring, lower push rod cover (4)
11145A
Items mentioned in text, but not included in kit:
A
Valve seal (4) (not shown) (not required)
18094-02A
Items 1, through 18 are included in 4 in Bolt-on Air Cooled Top End and Cam Gasket Kit (Part no. 16500385).