SCREAMIN' EAGLE PRO TC 103 CI (1690 CC) STAGE 4 KIT
J054562025-01-23
GENERAL
Kit Number
92500010B
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
Installation Requirements
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 the year and model motorcycle is required for this installation and is available from:
- A Harley-Davidson dealer.
- H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.
These items are available at your local Harley-Davidson dealership:
- Separate purchase of Camshaft Drive Retention Kit (Part No. 91800088) is required.
- Separate purchase of Camshaft Service Kit (17045-99D) is required.
- Separate purchase of Camshaft Spacer Kit (25928-06) is recommended. This kit contains five different spacers to achieve proper sprocket alignment.
- Separate purchase of Screamin' Eagle® (SE) air cleaner kit. Kit must be compatible with the supplied 58mm throttle body. See SE Pro catalog for available kits.
- Special tools are required to install this kit. See appropriate sections in service manual.
- Proper installation of this kit also requires Electronic Control Module (ECM) recalibration. Contact a Harley-Davidson dealer for details.
This kit is intended for vehicles that are 103 CI displacement with a stock 3.875 inch bore. If the cylinders are damaged or worn, replace the cylinder assemblies (Part No. 16547-99A)(QTY 2 required).
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. | 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. See service manual.
- Remove existing exhaust system. See service manual.
- Disassemble engine top end and camshaft plate assembly. See service manual.
- Remove existing clutch diaphragm spring. See service manual.
INSTALLATION
Install Engine and Clutch Components
- See Figure 3. Inspect camshaft needle bearings (5) and replace if necessary.
- Assemble throttle body and injectors from kit using original equipment fuel line and fuel rail. Refer to instructions in the supplied throttle body kit.
- Install throttle body assembly to engine using intake flanges and seals supplied in the throttle body kit. Refer to instructions from the supplied throttle body kit.
- Install clutch diaphragm spring from kit. See service manual.
- Install exhaust system. See service manual.
- Install air cleaner assembly. See 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. | Recalibrate 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 instructions to break-in the motorcycle.
SERVICE PARTS
Figure 1. Service Parts: Screamin' Eagle TC 103 (1690 cc) Stage 4 Kit
Table 1. Service Parts Table: Screamin' Eagle PRO TC 103 (1690 cc) Stage 4 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | 3.875 cylinder assembly (black) (2) | 16547-99A | 7 | O-ring, cylinder base | 11256 | |
2 | Piston (2) | Not Sold Separately | 8 | Cylinder head assembly, front (black) | 16500014A | |
3 | Piston ring set (2) | 22457-10 | 9 | Cylinder head assembly, rear (black) | 16500015A | |
4 | Piston pin (2) | 22455-03 | 10 | Automatic compression release (ACR) plug | 16648-08A | |
5 | Piston pin circlip (4) | 22097-99 | Notes: Piston Kit (22144-08B) includes items 2 through 5. For cylinder head assembly (8, 9) components, refer to instruction sheet J04792. | |||
6 | Gasket, cylinder head (2) | 16787-99A | ||||
Figure 2. Service Parts: Screamin' Eagle TC 103 (1690 cc) Stage 4 Kit
Table 2. Service Parts: Screamin' Eagle TC 103 cubic inch (1690 cc) Stage 4 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, rocker cover base (2) | 16719-99A | 10 | Baffle assembly (2) | 26500002 | |
2 | Gasket, rocker cover top (2) | 17386-99A | 11 | Seal, EFI intake (2) (Not Shown) | 29995-86B | |
3 | Gasket, tappet cover (2) | 18635-99B | 12 | Seal, map sensor (2) (Not Shown) | 11291 | |
4 | O-ring, middle push rod cover (4) | 11132A | 13 | Perfect fit pushrods kit | 18400-03 | |
5 | O-ring, lower push rod cover (4) | 11145A | 14 | Tappet (4) | 18572-13 | |
6 | O-ring, upper push rod cover (4) | 11293 | Notes: Breather assembly 17025-03A includes 8 through 10. Items 1 through 11 are included in Upper End Overhaul Kit (17052-99C) and items 6 and 7, Figure 1. | |||
7 | O-ring, rocker arm support (2) | 11270 | ||||
8 | Breather bolt (4) | 4400 | ||||
9 | Breather assembly (2) | 17025-03A | ||||
Figure 3. Service Parts: Screamin' Eagle Pro TC 103 (1690 cc) Stage 4 Kit
Table 3. Service Parts: Screamin' Eagle TC 103 (1690 cc) Stage 4 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, cam cover | 25244-99A |
2 | Retaining ring | 11461 |
3 | Camshaft, front, SE-259E | Not Sold Separately |
4 | Camshaft, rear, SE-259E | Not Sold Separately |
5 | Bearing, needle (2) (must be purchased separately, if needed) | 9215 |
6 | O-ring, oil pump to cam plate | 11293 |
7 | O-ring, cam plate to crankcase (2) | 11301 |
8 | Hi-flow injectors kit (not shown) | 27797-07 |
9 | 58 mm ETC throttle body kit (not shown) | 27639-07A |
10 | Manifold, 58 mm throttle body kit (not shown) | 29667-07 |
11 | Performance Clutch Diaphragm Spring (not shown) | 37951-98 |
Items mentioned in text, but not included in kit: | ||
A | Cam drive retention kit (includes screw and washer) | 91800088 |
Notes: Items 1, 2, 6 and 7 are included in Cam Service Gasket Kit (17045-99D). Items 3 and 4 available in Cam Kit (25482-10). | ||