STREET PERFORMANCE BIG BORE STAGE IV KIT - 103 CUBIC INCHES
J055442025-01-23
GENERAL
Kit Number
92500011
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 103 CI displacement with a stock 3.875 in bore. If the cylinders are damaged or worn, replace the cylinder assemblies (Part No. 16547-99A, 2 required).
This kit also requires the separate purchase of the Cam Drive Retention Kit (91800088) and Cam Service Kit (17045-99D). 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 the use of Digital Technician™ at a Harley-Davidson dealer.
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. One is available from a Harley-Davidson dealer.
Kit Contents
NOTE
Installation of this kit by an authorized Harley-Davidson dealer will not impact your limited vehicle warranty.
The Product Information Label contained in this kit is a requirement of the California Air Resource Board (CARB) emission regulation for all 2010 - 2012 Touring models. Place the label on the right side of the frame directly beneath the VIN sticker. This label is not required outside the state of California.
This conversion kit is intended for High Performance applications only. This engine-related performance part is legal for sale or use in California on pollution controlled motor vehicles.
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 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. See 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 (7) and replace if necessary.
- Assemble throttle body from kit using original equipment injectors, 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) NOTICE Installation of this kit requires a calibration update using Digital Technician. Failure to download calibration update before starting motorcycle will result in ACR failure. (00567b) | ||
| 4. | Start and 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 1. Service Parts: Screamin' Eagle TC 103 (1690 cc) Stage 4 Kit
Table 1. Service Parts Table: Screamin' Eagle TC 103 (1690 cc) Stage 4 Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | 3.875 cylinder assembly (black) (2) | Sold Separately | 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 J05340. | |||
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 kit (must be purchased separately, if needed) | 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 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 | 58 mm ETC throttle body kit (not shown) | 27713-08 |
9 | 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, 4, 8 and 9 are included in Cam Service Gasket Kit (17045-99D). Items 5 and 6 available in Cam Kit (25482-10). | ||