Screamin' Eagle Pro TC 103 (1690 CC) High Compression Kit with Cams - Twin-Cooled
J059892016-08-22
GENERAL
Kit Number
92500021A
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 requires the separate purchase of a SE high flow air cleaner kit. See SE Pro catalog for available kits.
This kit also requires the separate purchase of the Cam Drive Retention Kit (25566-06) and Cam Service Gasket Kit (17045-99D) which are available from a Harley-Davidson dealer.
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. 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. | Raise the motorcycle. | |
| 2. | Disarm security system. | |
| 3. | 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) | ||
| 4. | Remove fuel tank according to the instructions in the service manual. | |
| 5. | 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.
- Disassemble engine top end and cam plate assembly. Refer to appropriate ENGINE sections in service manual.
- Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual.
INSTALLATION
Install Engine and Clutch Components
- See Figure 3. Inspect camshaft needle bearings (7) and replace if necessary.
- 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.
NOTE
It is assumed cylinders are new or have low mileage. Measure cylinders per service manual and check piston fit following
instructions in supplied piston kit instruction sheet. If proper fitment cannot be attained (out-of-round, tapered, etc.) for standard
pistons supplied, new cylinders must be purchased.
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. | Recalibrate the ECM. Contact a Harley-Davidson dealer for details. | |
| 5. | Start and run engine. Repeat several times to verify proper operation. |
Operation
See the owner's manual for BREAK-IN RIDING RULES.
SERVICE PARTS
Figure 1. Service Parts: Screamin' Eagle Pro Twin-Cooled 103 (1690 CC) High Compression Kit
Table 1. Service Parts
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Piston (2) | Not Sold Separately | 5 | Gasket, cylinder head (2) | 16500066 | |
2 | Piston ring set (2) | 22457-10 | 6 | O-ring, cylinder base (2) | 11256 | |
3 | Piston pin (2) | 22455-03 | 7 | Performance valve spring kit | 18013-03A | |
4 | Piston pin circlip (4) | 22097-99 | Notes: Piston Kit (27000007) includes items 1 through 4. Items 4, 5 and 6 are also included in the Upper End Overhaul Gasket Kit (16500244). For valve spring components (Item 7) refer to instruction sheet J03548. | |||
Figure 2. Service Parts: Screamin' Eagle Pro Twin-Cooled 103 (1690 CC) High Compression Kit
Table 2. Service Parts
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, rocker cover base (2) | 16719-99A | 9 | Breather assembly (2) | 17025-03A | |
2 | Gasket, rocker cover top (2) | 17386-99A | 10 | Baffle assembly (2) | 26500002 | |
3 | Gasket, tappet cover (2) | 18635-99B | 11 | Seal, EFI intake (2) (Not Shown) | 29995-86B | |
4 | O-ring, middle push rod cover (4) | 11132A | 12 | Seal, map sensor (2) (Not Shown) | 11291 | |
5 | O-ring, lower push rod cover (4) | 11145A | 13 | Perfect fit pushrods kit, (+0.030 inch) | 18401-03 | |
6 | O-ring, upper push rod cover (4) | 11293 | 14 | Spring clutch diaphragm (Not Shown) | 37951-98 | |
7 | O-ring, rocker arm support (2) | 11270 | Notes: Breather assembly 17025-03A includes 8 through 10. Items 1 through 13 are included in Upper End Overhaul Gasket Kit (16500244) and items 6 and 7, Figure 1. | |||
8 | Breather bolt (4) | 4400 | ||||
Figure 3. Service Parts: Screamin' Eagle Pro Twin-Cooled 103 (1690 CC) High Compression Kit
Table 3. Service Parts
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-259E | Not Sold Separately |
6 | Camshaft, rear, SE-259E | 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 |
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 (25482-10). | ||