SCREAMIN' EAGLE 110 (1800 CC) BOLT-ON Stage V KIT
J061792025-01-23
GENERAL
Kit Number
92500038
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
Separate purchase and installation of extra parts or accessories may be required for proper installation of this kit. See the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Proper installation of this kit also requires the use of Digital Technician™ at a Harley-Davidson dealer or a separate purchase or use of Screamin' Eagle Street Performance Tuner Kit.
NOTE
Do not use stock CVO pistons with the 4 in Bolt-on Cylinders or interference occurs between the pistons and crankcase.
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 kit is intended for High Performance applications only. This engine-related performance kit is legal for sale or use in select countries or regions on pollution controlled motor vehicles. Check with your local Harley-Davidson dealer for compliance requirements in your area.
A partial emissions tune-up label and a product information label are included with this kit as a requirement of the California Air Resource Board (CARB)/EPA emissions regulation. Locate the emissions label on the frame tube below the handlebars. Place the new partial label from this kit over the top portion of the emissions label on the frame tube.
Locate the VIN label on the frame tube below the handlebars. Place the new product information label below the VIN label on the frame tube.
REMOVAL
Prepare for Service
| 1. | Disarm security system. | |
| 2. | Raise the motorcycle. | |
| 3. | Remove seat. See service manual. | |
| 4. | Remove main fuse. 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) | ||
| 5. | Remove fuel tank. See service manual. |
Remove Engine Components
- Remove existing air cleaner assembly. See service manual.
- Remove existing exhaust system. See service manual.
- Disassemble engine top end and cam plate assembly. See service manual.
- Remove existing clutch diaphragm spring. See service manual.
INSTALLATION
Install Engine and Clutch Components
- See Figure 4. Install new inner cam bearings included with this kit.
- Assemble throttle body and injectors from kit using ordinal equipment fuel line and fuel rail. Follow instructions in supplied throttle body.
- Install throttle body assembly to engine using intake flanges and seals supplied in the throttle body kit. Follow instructions in the supplied throttle body kit.
- Install clutch diaphragm spring from kit. See the CLUTCH INSTALLATION section in the service manual.
- Install valve spring kit and seals. Follow instructions in valve spring and seal kit.
- Install exhaust system. See service manual.
- Install air cleaner assembly. Follow instructions in air cleaner kit.
Final Assembly
| 1. | Install fuel tank. See service manual. | |
| 2. | Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual. | |
| 3. | Install main fuse. 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. | Download the new ECM calibration using the Digital Technician™ at a Harley-Davidson dealer or using Screamin' Eagle Street Performance Tuner Kit. | |
| 5. | 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 Twin Cam 110 (1800 cc) Stage V Race Kit
Table 1. Service Parts: Screamin' Eagle Twin Cam 110 (1800 CC) Stage V Race Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Cylinder assembly (Black) (2) | 16800102 | 6 | Gasket, cylinder head (2) | 16801-07B | |
7 | O-ring, cylinder spigot (2) | 11256 | ||||
2 | Piston (2) | Not Sold Separately | 8 | Gasket, exhaust port (2) | 65324-9A | |
3 | Piston Ring Set (2) | 21951-11 | 9 | Seal, intake manifold (2) | 26995-86B | |
4 | Piston pin (2) | 22100001 | 10 | Cylinder head, front (black) | 16500014A | |
5 | Piston pin circlip (4) | 22097-99 | 11 | Cylinder head, rear (black) | 16500015A | |
Notes: Piston Kit (21900020) includes 2 through 5. Item 6 through 9 are also included in Top End and Cam Gasket Kit (16500385). For cyliner head assembly (10, 11) components, refer to instruction sheet J05340. | ||||||
Figure 2. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race Kit
Table 2. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stave V Race Kit
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Gasket, rocker cover base (2) | 16719-99B | 8 | Breather bolt (4) | 4400 | |
2 | Gasket, rocker cover top (2) | 17386-99A | 9 | Breather assembly (2) | 17025-03A | |
3 | Gasket, tappet cover (2) | 18635-99B | 10 | Baffle assembly (2) [includes gaskets (2)] | 26500002 | |
4 | O-ring, middle push rod cover (4) | 11132A | 11 | Spring, clutch diaphragm (2) (Not Shown) | 37951-98 | |
5 | O-ring, lower push rod cover (4) | 11145A | 12 | High capacity tappet kit | 18572-13 | |
6 | O-ring, upper push rod cover (4) | 11293 | 13 | Perfect fit pushrod kit | 18400-03 | |
7 | O-ring, rocker arm support (2) | 11270 | Notes: Items 1 through 10 are included in Top End and Cam Gasket Kit (16500385). | |||
Figure 3. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race Kit
Table 3. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race 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 kit, needle, left side (2) | 24018-10 |
6 | O-ring, oil pump to cam plate | 11293 |
7 | O-ring, cam plate to crankcase (2) | 11301 |
8 | Roll pin | 601 |
9 | O-ring, crankcase dowel (2) | 11273 |
10 | Hi-flow injectors kit (not shown) | 27796-08 |
11 | 58 mm ETC throttle body kit (not shown) | 27713-08 |
12 | Partial Emissions Tune-up Label (not shown) | Not Sold Separately |
13 | Product Information Label (not shown) | Not Sold Separately |
Items mentioned in text, but not included in kit: | ||
A | Cam drive retention kit (includes screw and washer) | 91800088 |
Items 3 and 4 are available in Cam Kit (25482-10) Items 1, 2, and 5 through 9 are included in Top End and Cam Gasket Kit (16500385) | ||
Figure 4. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stave V Race Kit
Table 4. Service Parts: Screamin' Eagle Twin Cam 110 (1800 cc) Stage V Race Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, cylinder head (2) | 16801-07B |
2 | Breather assembly (2) | 17025-03A |
3 | Bearing kit, needle, left side, camshaft (2) | 24018-10 |
4 | roll pin, cam plate pressure relief | 601 |
5 | O-ring, cylinder spigot (2) | 11256 |
6 | O-ring, rocker arm support (2) | 11270 |
7 | O-ring, crankcase dowel (2) | 11273 |
8 | O-ring, upper push rod cover (4), oil pump to cam plate (1) | 11293 |
9 | O-ring, cam plate to crankcase (2) | 11301 |
10 | Retaining ring | 11461 |
11 | Gasket, rocker cover base (2) | 16719-99B |
12 | Gasket, rocker cover top (2) | 17386-99A |
13 | Gasket, Tappet cover (2) | 18635-99B |
14 | Gasket, cam cover | 25244-99A |
15 | Seal, intake manifold (2) | 26995-86B |
16 | Gasket, exhaust port (2) | 65324-83B |
17 | O-ring, middle push rod cover (4) | 11132A |
18 | O-ring, lower push rod cover (4) | 11145A |
Items mentioned in text, but not included in kit: | ||
A | Valve seal (4) (not shown) (not required) | 18094-02A |
Items 1, through 18 are included in 4 in Bolt-on Air Cooled Top End and Cam Gasket Kit (Part no. 16500385). | ||