SCREAMIN' EAGLE PRO XL 1200 CC Stage IV Kit
J061402016-08-22
GENERAL
Kit Number
92500029A, 92500030A
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
This kit is intended for vehicles that are already 1200 cc displacement with a stock 3.500 in bore. If the cylinders are damaged or wore, order replacement cylinders assemblies.
This kit requires the separate purchase of a SE air cleaner kit that is compatible with the supplied 58 mm throttle body. See SE Pro catalog for available kits.
Use of SE spark plugs (part no. 32186-10) is recommended for this high compression engine configuration.
See appropriate sections in service manual for the special tools required to install this kit.
Proper installation of this kit also requires ECM recalibration. Contact a Harley-Davidson dealer for details.
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 this year/model motorcycle is required for this installation. One 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 reduce or void the limited vehicle warranty.
Engine-related performance parts are intended for the experienced rider only.
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. | |
| 6. | See the service manual. Remove existing air cleaner assembly. | |
| 7. | See the service manual. Remove existing exhaust system. | |
| 8. | See the service manual. a. Remove fuel line, fuel rail, injectors and bracket. Save parts for installation of NEW throttle body manifold. b. Remove throttle body. Save intake seal flanges for installation of NEW throttle body manifold. | |
| 9. | Disassemble engine top end and cam valve train assembly. Refer to appropriate ENGINE sections in service manual. |
INSTALLATION
Install Engine Components
- See Figure 6. Inspect camshaft bushings and replace if necessary. Refer to appropriate ENGINE sections in service manual and instructions in subkits.
Install Induction System
NOTE
Throttle body assembly requires use of a compatible air cleaner backplate to draw together.
| 1. | See Figure 1. Install new manifold (3) to engine using new intake seals (4) and OE flanges and related fasteners. Tighten fasteners snugly enough to allow slight rotation of manifold during remaining assembly. Tighten when assembly is finished (that is, throttle body fully seated in manifold). See the service manual for torque spec. | |
| 2. | Assemble seal ring (1) to manifold and apply assembly lube or oil to seal ring to prevent damage (tearing) during throttle body engagement. | |
| 3. | Peel the protective strip off the backplate/throttle body gasket (6). Place the adhesive side onto the backplate. Align to the screw holes, and position the gasket carefully before firmly pressing the gasket into place. | |
| 4. | Insert backplate button head screws (7) through the backplate (8) and screw into throttle body. Tighten snugly first. Torque when assembly is assembled (that is, throttle body fully seated in manifold). | |
| 5. | Install (use grease or similar to hold in place) two O-rings (9) from kit in grooves around breather screw holes on throttle body side of backplate (8). | |
| 6. | Insert OE breather screws through the backplate and related O-rings. | |
| 7. | Apply Loctite 243 (blue) to breather screw threads and mating tapped holes in cylinder head. | |
| 8. | Start threading breather screws into cylinder head but do not tighten. | |
| 9. | See Figure 4. Verify manifold (3) is aligned parallel to throttle body assembly (2). Adjust if necessary. NOTE To prevent tearing of the seal ring it is critical the manifold and throttle body remain parallel as they are drawn together. | |
| 10. | Alternately tighten both breather screws to draw evenly on the throttle body into manifold/seal ring. Tighten to 13.6–16.3 N·m (120–144 in-lbs). | |
| 11. | See Figure 1. Tighten backplate screws to 6.2–6.8 N·m (55–60 in-lbs). | |
| 12. | Lubricate the O-rings (10) with clean engine oil or white lithium grease. Install the O-rings onto the breather plugs (11). Press the breather plugs into the breather screw cavities. | |
| 13. | Align the holes in gasket (12) with the holes in mounting ring (14) and the notches in the intake tube (13). Apply Loctite 243 (blue) to flat head screws (15). Tighten screws to 6.2–6.8 N·m (55–60 in-lbs). | |
| 14. | See the service manual. Install OE fuel line, fuel rail, injectors and bracket. Secure with new screw (5), part number 27216-95, provided. Tighten screw to 6.8 N·m (60 in-lbs). NOTE Cut back main harness sheathing 2.5–5 cm (1–2 in) to enable more slack and ease of connection | |
| 15. | Connect fuel injector harness leads and TPS, IAC motor and T-MAP sensor leads. | |
| 16. | See the service manual. Install throttle cables and adjust per procedure. | |
| 17. | Install air cleaner assembly. Refer to instructions from purchased air cleaner kit. | |
| 18. | See the service manual. Install exhaust system. |
Figure 1. Induction System Assembly
| 1 | Seal ring |
| 2 | Throttle body assembly |
| 3 | Intake Manifold |
Figure 2. Intake Manifold, Seal Ring, Throttle Body Assembly
Final Assembly
| 1. | See the service manual. Install fuel tank. | |
| 2. | See the service manual. Install main fuse. | |
| 3. | See the service manual. Install seat. | |
| 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. | Recalibrate the ECM. Contact a Harley-Davidson dealer for details. | |
| 5. | 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 3. Service Parts: 58 mm EFI Throttle Body and Intake Manifold
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Seal ring, 58mm | 29911-07 |
2 | Seal, intake manifold (2) | 26995-86B |
3 | Screw | 27216-95 |
4 | Intake manifold | Not sold separately |
5 | 58 mm throttle body assembly | Not sold separately |
Items mentioned in text, but not included in kit: | ||
A | Fuel injectors and fuel rail assembly | |
B | Throttle position sensor (TPS) (Part no. 27629-01A) | |
C | Idle air control motor (Part no. 27628-01A) | |
D | T-MAP sensor (Part no. 32319-07A) | |
E | Intake seal flange | |
Figure 4. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Table 2. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket kit, engine overhaul | 17027-08 |
2 | Piston (2) | Not Sold Separately |
3 | Piston ring set (2) | 21925-04 |
4 | Piston pin (2) | Not Sold Separately |
5 | Piston pin circlip (4) | Not Sold Separately |
6 | Gasket, cylinder head (2) | 16770-84F |
7 | Gasket, cylinder base (2) | 16789-04 |
8 | Cylinder head assembly, front (black, high lighted) Cylinder head assembly, front (black, non-high lighted) | 16500348 16500109 |
8 | Cylinder head assembly, rear (black, high lighted) Cylinder head assembly, rear (black, non-high lighted) | 16500349 16500110 |
Notes: Piston kit (22711-04A) includes items 2, 3, 4 and 5. For cylinder head assembly items 8 and 9 refer to instruction sheet in cylinder head kit. | ||
Figure 5. Service Parts: Screamin' Eagle LX 1200 cc Stage 4 Kit
Table 3. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, rocker cover base (2) | 17362-07B |
2 | Gasket, rocker cover top (2) | 16800-84B |
3 | Gasket, tappet cover (2) | 17976-04 |
4 | Gasket, rocker cover, chimney (2) | 17695-07B |
5 | O-ring, lower push rod cover (4) | 11377 |
6 | O-ring, upper push rod cover (4) | 11190 |
7 | Breather seal (2) | 17393-07 |
Notes: Items 1 through 7 are included in Engine Overhaul Gasket Kit (17027-08). | ||
Figure 6. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Table 4. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, cam gear cover | 25263-90D |
2 | Camshaft, rear, exhaust | Not Sold Separately |
3 | Camshaft, rear, intake | Not Sold Separately |
4 | Camshaft, front, intake | Not Sold Separately |
5 | Camshaft, front, exhaust | Not Sold Separately |
Notes: Item 1 is included in Engine Overhaul Gasket Kit (17027-08). Items 2, 3, 4 and 5 available in Cam Kit (25400125). | ||