Street Performance TC 103 (1690 CC)Stage IV Kit
J057942014-12-23
GENERAL
Kit Number
92500019 (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 is intended for vehicles that are already 103 cid displacement with a stock 3.875 bore. If the cylinders are damaged or wore, order replacement cylinders assembly 16547-99A (two 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 Service Kit (17045-99D) which is 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 and 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.
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 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 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 plate 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 fuel line, fuel rail and injectors. 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 instructions from purchased air cleaner kit.
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 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) | 16547-99A | 6 | Gasket, cylinder head (2) | 16500066 | |
2 | Piston (2) | Not Sold Separately | 7 | O-ring, cylinder base | 11256 | |
3 | Piston ring set (2) | 22457-03 | 8 | Cylinder head assembly, front (black) | 16500209 | |
4 | Piston pin (2) | 22455-03 | 9 | Cylinder head assembly, rear (black) | 16500210 | |
5 | Piston pin circlip (4) | 22097-99 | Notes: Piston Kit (22942-00A) includes items 2 through 5. For cylinder head assembly (8, 9) components, refer to instruction sheet J05754. | |||
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 (16500244) 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 Pro TC 103 (1690 cc) Stage 4 Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Gasket, cam cover | 25244-99A |
2 | Washer | Not Sold Separately |
3 | Capscrew, flanged | Not Sold Separately |
4 | Retaining ring | 11461 |
5 | Camshaft, front, SE-259E | Not Sold Separately |
6 | Camshaft, rear, SE-259E | Not Sold Separately |
7 | Bearing, needle (2) (must be purchased separately, if needed) | 9215 |
8 | O-ring, oil pump to cam plate | 11293 |
9 | O-ring, cam plate to crankcase (2) | 11301 |
10 | 58 mm ETC throttle body kit (not shown) | 27713-08 |
Notes: Cam Drive Retention Kit (25566-06) includes 2 and 3. 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). | ||