SCREAMIN' EAGLE PRO TC 103 (96 CI TO 103 CI) STAGE 4 KIT
J048012025-01-23
GENERAL
Kit Number
27516-08F (Black)
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 air cleaner kit that is compatible with the supplied 58mm throttle body. See SE Pro catalog for available kits.
This kit also requires the separate purchase of the Cam Drive Retention Kit (91800088) and Cam Service Kit (17045-99C) which are available from a Harley-Davidson dealer.
Please 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 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 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. See 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. See service manual. |
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 camplate 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 (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. 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. See service manual. | |
| 2. | Install fuel tank. See service manual. | |
| 3. | Install seat. After installing seat, pull up on seat to verify that it is secure. See 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 instructions to break-in the motorcycle.
SERVICE PARTS
Figure 1. Service Parts: Screamin' Eagle Pro 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) | 16547-99 | 7 | O-ring, cylinder base | 11256 | |
2 | Piston (2) | Not Sold Separately | 8 | Cylinder head assembly, front (black) | 17067-08A | |
3 | Piston ring set (2) | 22457-03 | 9 | Cylinder head assembly, rear (black) | 17065-08A | |
4 | Piston pin (2) | 22455-03 | 10 | Automatic compression release (ACR) plug | 16648-08A | |
5 | Piston pin circlip (4) | 22456-03 | Notes: Piston Kit (22137-08) includes items 2 through 5. For cylinder head assembly (8, 9) components, refer to instruction sheet J04792. | |||
6 | Gasket, cylinder head (2) | 16787-99 | ||||
Figure 2. Service Parts: Screamin' Eagle Pro TC 103 (1690 cc) Stage 4 Kit
Table 2. Service Parts: Screamin' Eagle Pro TC 103 (1690 cc) Stage 4 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, rocker cover base (2) | 16719-99A | 9 | Gasket, breather (2) | Not Sold Separately | |
2 | Gasket, rocker cover top (2) | 17386-99A | 10 | Umbrella valve (2) | 26858-99 | |
3 | Gasket, tappet cover (2) | 18635-99B | 11 | Filter element, breather (2) | 63815-99 | |
4 | O-ring, middle push rod cover (4) | 11132A | 12 | Seal, EFI intake (2) (Not Shown) | 29995-86B | |
5 | O-ring, lower push rod cover (4) | 11145A | 13 | Seal, map sensor (Not Shown) | 11291 | |
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 | 15 | Perfect fit pushrods kit, (+0.030 inch) | 18401-03 | |
8 | Gasket, breather (2) | Not Sold Separately | Notes: Breather Gasket Kit (17162-03) includes 8 through 11. Items 1 through 13 are included in Upper End Overhaul Kit (17052-99B) and items 6 and 7, Figure 1. | |||
Figure 3. Service Parts: Screamin' Eagle Pro TC 103 (1690 cc) Stage 4 Kit
Table 3. Service Parts: Screamin' Eagle Pro 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 | Not Sold Separately |
4 | Camshaft, rear | 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 cable drive throttle body kit (not shown) | 27639-07 |
10 | Manifold, 58 mm throttle body kit (not shown) | 29667-07 |
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 (17045-99C). Items 3 and 4 available in Cam Kit (25475-06). | ||