SCREAMIN' EAGLE PRO TC 103 (1690 CC) STAGE 2 KIT
J052352010-11-09
GENERAL
Kit Number
92500003
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
This kit requires the separate purchase of a SE high flow air cleaner kit. See SE Pro catalog for available kits.
Separate purchase of Cam Spacer Kit (25928-06) is recommended. This kit contains five different spacers to achieve proper sprocket alignment.
See appropriate sections in service manual for the special tools required to install this kit.
Proper installation of this kit also requires ECM recalibration using EFI Race Tuner Kit. Refer to Screamin' Eagle Pro Catalog or contact a Harley-Davidson dealer.
WARNINGRider and passenger safety depend 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. (00333b)
NOTE
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.
Kit Contents
NOTE
This kit is intended for High Performance or Racing applications only and is not legal for sale or use on pollution controlled motor vehicles. This kit may may reduce or void the limited vehicle warranty. Engine related performance parts are intended for the experienced rider only.
REMOVAL
Prepare for Service
| 1. | Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner's manual for instructions to disarm the system. | |
| 2. | Remove seat according to the instructions in the service manual. | |
| 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) | ||
| 3. | Remove fuel tank according to the instructions in the service manual. | |
| 4. | Remove main fuse. Refer to service manual for your motorcycle. |
Remove Engine Components
- Remove existing air cleaner assembly. Refer to AIR CLEANER REMOVAL in service manual.
- Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual.
- Remove stock pushrods using a bolt cutter.
- Remove cam plate assembly. Refer to appropriate ENGINE sections in service manual.
- Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual.
NOTE
When removing the stock pushrods do not cut pushrods using a method that creates metal debris, which may end up in the engine (such as using a hacksaw or die grinder) and cause severe damage.
INSTALLATION
Install Engine and Clutch Components
- See Figure 2. Inspect camshaft needle bearings (7) and replace if necessary.
- Assemble cams to cam plate. Refer to appropriate ENGINE sections in service manual.
- Install clutch diaphragm spring from kit. Refer to CLUTCH INSTALLATION in service manual.
- Install exhaust system. Refer to EXHAUST SYSTEM INSTALLATION in service manual.
- Install air cleaner assembly. Refer to AIR CLEANER INSTALLATION in service manual.
Final Assembly
| 1. | Install main fuse. Refer to service manual for your motorcycle. | |
| 2. | Install fuel tank according to the instructions in the service manual. | |
| 3. | Install seat according to the instructions in the service manual. | |
| 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 EFI Race Tuner Kit and Interface Box supplied with kit. Refer to Screamin' Eagle Pro Catalog or contact a Harley-Davidson dealer. | |
| 5. | Start and run engine. Repeat several times to verify proper operation. |
Operation
Refer to BREAK-IN RIDING RULES in the owner's manual for instructions to break-in the motorcycle.
SERVICE PARTS
Figure 1. Service Parts: Screamin' Eagle Pro TC 103 (1690 cc) Stage 2 Kit
Table 1. Service Parts Table: Screamin' Eagle PRO TC 103 (1690 cc) Stage 2 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | O-ring, middle push rod cover (4) | 11132A | 4 | Spring, clutch diaphragm (not shown) | 37951-98 | |
2 | O-ring, lower push rod cover (4) | 11145A | 5 | Pushrods kit | 17997-99A | |
3 | O-ring, upper push rod cover (4) | 11293 | Notes: Items 1 through 3 are included in the Quick Install Pushrod Kit, 17997-99A. | |||
Figure 2. Service Parts: Screamin' Eagle Pro TC 110 (1800 cc) Stage 2 Upgrade Kit
Table 2. Service Parts: Screamin' Eagle Pro TC 110 (1800 cc) Stage 2 Upgrade Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, cam cover | 25244-99A |
2 | Washer | Not Sold Separately |
3 | Capscrew, flanged | Not Sold Separately |
4 | Retaining ring | 11461 |
5 | Camshaft, front, SE-254E | Not Sold Separately |
6 | Camshaft, rear, SE-254E | Not Sold Separately |
7 | Bearing, needle (2) (must be purchased separately, if needed) | 9215 |
8 | O-ring, oil pump to cam plate | 11293 |
9 | O-ring, cam plate to crankcase (2) | 11301 |
10 | Interface box, (VCI), Super Tuner (not shown) | 32109-08B |
Notes: Cam Drive Retention Kit (25566-06) includes 2 and 3. Items 1, 4, 8 and 9 are included in Cam Service Gasket Kit (17045-99D). Items 5 and 6 available in Cam Kit (25503-10). | ||