street performance big bore stage iv kit - Harley
Contents
1. black 2 Sold Separately 7 O ring cylinder base 11256 2 Piston 2 Not Sold Separately 8 Cylinder head assembly front 16500014A black 3 Piston ring set 2 22457 10 9 Cylinder head assembly rear 16500015A black 4 Piston pin 2 22455 03 10 Automatic compression release 16648 08A ACR plug Piston pin circlip 4 22097 99 Notes Piston Kit 22144 08B includes items 2 through 5 For li h 2 16787 99A cylinder head assembly 8 9 components refer to instruction Gasket cylinder head 2 6787 99 sheet J05340 J05544 30f5 is03589c 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 9 Breather assembly 2 17025 03A 2 Gasket rocker cover top 2 17386 99A 10 Baffle assembly 2 26500002 3 Gasket tappet cover 2 18635 99B 11 Seal EFI intake 2 Not Shown 29995 86B 4 O ring middle push rod cover 4 11132A 12 Seal map sensor 2 Not Shown 11291 5 O ring lower push rod cover 4 11145A 13 Perfect fit pushrods kit 18400 03 6 O ring upper push rod cover 4 11293 Notes Breather assembly 17025 03A includes 8 through 10 7_ Oxing cer am support 11270 Co 8 Breather bolt 4 4400 J05544 4of5 is2. 05094a 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 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 11 Clutch diaphragm spring not shown 37951 98 99D 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 Items 5 and 6 available in Cam Kit 25482 10 J05544 5 of 5
3. ST SYSTEM INSTALLATION in service manual 7 Install air cleaner assembly Refer to AIR CLEANER 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 owner s manual J05544 IWIN NIN 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 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 for instructions to break in the motorcycle SERVICE PARTS is03918 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
4. and highly explosive which could result in death or serious injury 00330a 3 Remove fuel tank according to the instructions in the ser vice manual 4 Remove main fuse Refer to owner s manual for your motorcycle Remove Engine Components 1 Remove existing air cleaner assembly Refer to AIR CLEANER REMOVAL in service manual 2 Remove existing exhaust system Refer to EXHAUST SYSTEM REMOVAL in service manual 3 Disassemble engine top end and camplate assembly Refer to appropriate ENGINE sections in service manual 4 Remove existing clutch diaphragm spring Refer to CLUTCH REMOVAL in service manual INSTALLATION Install Engine and Clutch Components 1 See Figure 3 Inspect camshaft needle bearings 7 and replace if necessary 2 See Figure 1 through Figure 3 Assemble cams to camplate performance cylinder heads and engine top end 1of5 Please dispose of materials responsibly using parts from kit Refer to appropriate ENGINE sections in service manual 3 Assemble throttle body from kit using original equipment injectors fuel line and fuel rail Refer to instructions in the supplied throttle body kit 4 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 5 Install clutch diaphragm spring from kit Refer to CLUTCH INSTALLATION in service manual 6 Install exhaust system Refer to EXHAU
5. cMOTOR HARLEY DAVIDSON WY J05544 INSTRUCTIONS REV 2013 12 06 STREET PERFORMANCE BIG BORE STAGE IV KIT 103 CUBIC INCHES GENERAL Kit Number 92500011 Models For model fitment information see the P amp 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 103 Cl displacement with a stock 3 875 inch 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 25566 06 and Cam Service Kit 17045 99D which are available from a Harley Davidson dealer Separate purchase of Cam Spacer Kit 25928 06 is recom mended 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 PINT N IN The rider s safety depends 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 00333a NOTE This instruction shee
6. t 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 See Figure 1 to Figure 3 and Table 1 to Table 3 NOTES 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 J05544 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled 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 applica tions 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 experi enced 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 owner s manual WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable
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