Street Performance XL 1200 cc Stage IV Kit
J062172016-10-13
GENERAL
Kit Number
92500041, 92500042
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
NOTE
Installation of this kit allows re-use of the original equipment (OE) push rods. Perfect Fit Push Rods are not required.
This kit is intended for vehicles that are already 1200 cc displacement with a stock 3.500 in. bore. If the cylinders are damaged or wore, order replacement cylinders.
This kit requires the separate purchase of a Screamin Eagle® air cleaner kit that is compatible with the supplied 58 mm throttle body. See Screamin Eagle Pro catalog for available kits.
Use of Screamin Eagle spark plugs (part no. 32186-10) is recommended for this high compression engine configuration.
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 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. | Raise the motorcycle. NOTE Disarm security 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 owner's manual for your motorcycle. |
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 cam valve train assembly. Refer to appropriate ENGINE sections in service manual.
INSTALLATION
Install Engine Components
- See Figure 3. Inspect camshaft bushings and replace if necessary. Refer to appropriate ENGINE sections in service manual.
- Assemble throttle body manifold from kit using original equipment fuel rail, injectors and fuel line. Refer to instructions in the supplied throttle body and manifold kit.
- Install throttle body assembly and manifold to engine using stock/OE intake flanges and seals supplied in the throttle body kit. Refer to instructions from the supplied throttle body and manifold kit.
- Install air cleaner assembly. Refer to instructions from purchased air cleaner kit.
- Install exhaust system. Refer to EXHAUST SYSTEM INSTALLATION in service manual.
Final Assembly
| 1. | Install main fuse. Refer to owner's 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. | Have a Harley-Davidson dealer download the new ECM calibration using Digital Technician™. | |
| 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 Pro XL 1200 cc Stage 4 Kit
Table 1. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket kit, engine overhaul | 17027-08 |
2 | Piston (2) | Not Sold Separately |
3 | Piston ring set (2) | 21925-04 |
4 | Piston pin (2) | Not Sold Separately |
5 | Piston pin circlip (4) | Not Sold Separately |
6 | Gasket, cylinder head (2) | 16770-84F |
7 | Gasket, cylinder base (2) | 16789-04 |
8 | Cylinder head assembly, front (black, high lighted) Cylinder head assembly, front (black, non-high lighted) | 16500348 Not Sold Separately |
9 | Cylinder head assembly, rear (black, high lighted) Cylinder head assembly, rear (black, non-high lighted) | 16500349 Not Sold Separately |
Notes: Piston kit (22711-04A) includes items 2, 3, 4 and 5. For cylinder head assembly items 8 and 9 refer to instruction sheet in cylinder head kit. | ||
Figure 2. Service Parts: Screamin' Eagle LX 1200 cc Stage 4 Kit
Table 2. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, rocker cover base (2) | 17362-07B |
2 | Gasket, rocker cover top (2) | 16800-84B |
3 | Gasket, tappet cover (2) | 17976-04 |
4 | Gasket, rocker cover, chimney (2) | 17695-07B |
5 | O-ring, lower push rod cover (4) | 11377 |
6 | O-ring, upper push rod cover (4) | 11190 |
7 | Breather seal (2) | 17393-07 |
Notes: Items 1 through 7 are included in Engine Overhaul Gasket Kit (17027-08). | ||
Figure 3. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Table 3. Service Parts: Screamin' Eagle Pro XL 1200 cc Stage 4 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, cam gear cover | 25263-90D |
2 | Camshaft, rear, exhaust | Not Sold Separately |
3 | Camshaft, rear, intake | Not Sold Separately |
4 | Camshaft, front, intake | Not Sold Separately |
5 | Camshaft, front, exhaust | Not Sold Separately |
Notes: Item 1 is included in Engine Overhaul Gasket Kit (17027-08). Items 2, 3, 4 and 5 available in Cam Kit (25400125). | ||