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SCREAMIN' EAGLE PRO TC 103 (1690 CC) HIGH COMPRESSION KIT WITH CAMS - AIR COOLED
J060702025-01-23
GENERAL
Kit Number
92500023A
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
Installing this kit requires separate purchase of the following items from a Harley-Davidson dealer (see Table 1 ):
Table 1. Additional Parts Required
Item
Part Number
High Flow Air Cleaner Kit
See Screamin' Eagle Pro
Racing Parts catalog.
Cam Service Gasket Kit
17045-99C
Cam Drive Gear Retention Kit
91800088
Separate purchase of a Cam Spacer Kit (Part No. 25928-06) is recommended. This kit contains five different spacers to achieve proper sprocket alignment.
See service manual for special tools required to install this kit.
Use of a compression release system is recommended on 103 CI and larger engines. See the SE Pro Catalog for related assemblies and tools.
WARNING
Rider 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
See Figure 1 and Table 2.
NOTE
This kit is intended for Racing applications only. It is not legal for sale or use on pollution controlled motor vehicles. This kit could reduce or void the limited vehicle warranty. Engine-related performance parts are intended FOR THE EXPERIENCED RIDER ONLY.
PREPARATION
1. Raise the motorcycle.
WARNING
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a)
2. Remove seat. Retain the seat and all mounting hardware.
3. Purge and disconnect fuel supply line.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
NOTE
  • WITH security siren: With security fob present, turn ignition switch ON. See the service manual. After system is disarmed, turn ignition switch OFF. IMMEDIATELY remove the main fuse.
  • WITHOUT security siren: See the service manual. Remove the main fuse or main circuit breaker.
REMOVAL
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)
  1. See the service manual to:
    1. Remove the instrument console (if present) from the fuel tank.
    2. Remove the fuel tank.
    3. Remove the air cleaner assembly.
    4. Remove the exhaust system.
    5. Disassemble engine top end and cam plate assembly.
    6. Remove clutch diaphragm spring (14).
INSTALLATION
Install Engine and Clutch Components
  1. See Figure 1. Inspect camshaft needle bearings (C) and replace if necessary.
  2. Assemble new cams (15) to cam plate, performance valve springs (6) to cylinder heads and engine top end using parts from kit. See service manual.
    3. NOTE
    It is assumed cylinders are new or low mileage. Measure cylinders per service manual. Check piston fit following instructions in new piston kit (1) instruction sheet. If proper fit cannot be attained (out-of-round, tapered, or so forth) for standard pistons supplied, purchase new cylinders.
  3. Install new clutch diaphragm spring (14) from kit. See service manual.
  4. Install exhaust system.
  5. Install air cleaner assembly.
COMPLETION
Final Assembly
1. Install main fuse. See service manual.
2. Install fuel tank. See 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)
3. Install seat per the service manual.
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
Refer to BREAK-IN RIDING RULES in the owner's manual for break-in instructions.
SERVICE PARTS
Figure 1. Service Parts, Screamin' Eagle Pro TC 103 (1690 cc) High Compression Kit
SERVICE PARTS
Table 2. Service Parts
Item
Description (Quantity)
Part Number
1
Piston Kit, standard, 3.875 in (98.425 mm) bore (includes items 2-5)
22144-08B
2
  • Piston (2)
Not sold separately
3
  • Piston ring set (2)
22457-10
4
  • Piston pin (2)
22455-03
5
  • Retaining ring, piston pin (Circlip) (4)
22097-99
6
Performance Valve Spring Kit (includes items 7-10)
(see Instruction Sheet J03548 for installation)
18013-03A
7
  • Collar, upper valve spring (4)
Not sold separately
8
  • Collar, lower valve spring, with seal (4)
18016-03
9
  • Valve keeper (8)
18260-02
10
  • Valve spring (4)
Not sold separately
11
Pushrod Kit, Perfect Fit, +0.030 in (0.762 mm) (includes items 12-13)
(see Instruction Sheet J02977 for installation)
18401-03
12
  • Pushrod, intake, +0.030 in (0.762 mm) (2)
18407-03
13
  • Pushrod, exhaust, +0.030 in (0.762 mm) (2)
Not sold separately
14
Spring, clutch (not shown)
37951-98
15
Camshaft Kit, SE-585 (includes front and rear camshaft)
25400117
17
Upper End Overhaul Gasket Kit (includes items 18-36)
17052-99C
18
  • Gasket, cylinder head (2)
16775-99B
19
  • O-ring, cylinder base (2)
11256
20
  • Breather assembly (2) (includes items 21-25)
17025-03A
21
  • --- Breather sub-assembly (includes items 22-23)
Not sold separately
22
  • --- --- Breather valve, umbrella
26858-99
23
  • --- --- Baffle assembly, breather
Not sold separately
24
  • --- Breather valve, coalescing pad
29400147
25
  • --- Screw, hex flange head (4)
4400
26
  • Gasket, rocker housing (2)
16719-99B
27
  • Gasket, rocker cover (2) (also part of item B, Cam Service Gasket Kit)
17386-99A
28
  • Gasket, tappet cover (2) (also part of item B, Cam Service Gasket Kit)
18635-99B
29
  • O-ring, rocker arm support (2) (also part of item B, Cam Service Gasket Kit)
11270
30
  • O-ring, pushrod cover, lower (4) (also part of item B, Cam Service Gasket Kit)
11145A
31
  • O-ring, pushrod cover, upper (4)
11293
32
  • O-ring, pushrod cover, middle (4)
11132A
33
  • Seal, EFI intake (2) (not shown)
26995-86B
34
  • Service Kit, Valve Seal (includes items 35-36)
18094-02A
35
  • --- Integral valve seal/lower spring collar (4)
Not sold separately
36
  • --- Cap, valve stem
Not sold separately
37
Gasket, cam cover (also part of item B, Cam Service Gasket Kit)
25244-99A
38
Retaining ring (also part of item B, Cam Service Gasket Kit)
11461
39
O-ring, oil pump to cam plate (also part of item B, Cam Service Gasket Kit)
11293
40
O-ring, cam plate to crankcase (2) (also part of item B, Cam Service Gasket Kit)
11301
Items mentioned in text, but not included in kit:
A
Cam Drive Gear Retention Kit (Part No. 91800088)
B
Cam Service Gasket Kit (Part No. 17045-99C) (includes items 27-30, 37-40, C)
C
  • Needle bearing (2) (Part No. 9215)