Removal
1. Thread a nut onto cylinder stud.
2. Thread a second nut onto stud until it contacts the first.
3. Placing wrench on first nut installed, remove stud.
Installation
1. Place a steel ball inside a head screw. Put the head screw on the end of the cylinder stud without the collar.
2. Start the stud in the cylinder deck with the collar side down.
Tighten using air gun until collar reaches crankcase.
3. Hand tighten stud to 120-240 in-lbs (13.6-27.1 Nm).
Removal
If reusing flywheel, remove bearing inner race and thrust washer as follows:
1. See Figure 3-128. Install brass jaws or shop towels around teeth of vise to prevent damage to tool. Obtain FLYWHEEL SUPPORT FIXTURE (Part No. HD-44358). Clamp tool in vise with the round hole topside.
2. Insert crankshaft end through hole resting flywheel assembly on fixture. Slide knurled locating pin down slot in tool to engage crank pin hole. Hand tighten locating pin.
3. Slide hold-down clamp down slot to engage inboard side of right flywheel half, and then hand tighten knurled nut at bottom to secure. Repeat step to secure hold-down clamp on opposite side of flywheel.
NOTE
For proper clamping force, hold-down clamp must not be tilted.
Rotate hex on outboard stud until clamp is level.
4. Position WEDGE ATTACHMENT (Part No. HD-95637-46B) on inboard side of thrust washer and turn hex nuts an equal number of turns to draw halves of wedge together.
5. Obtain two 3/8-16 inch bolts 7-1/2 inches long (with flat washers). Install flat washers on bolts. Obtain bridge and forcing screw from MAINSHAFT BEARING INNER RACE PULLER/INSTALLER (Part No. HD-34902-B). Also obtain a suitable hardened washer to use between the puller screw and the end of the shaft.
6. Slide one bolt into channel on each side of bridge so that flat washer is between bridge and bolt head. Thread bolts into wedge attachment an equal number of turns.
7. Sparingly apply graphite lubricant to threads of forcing screw to prolong service life and verify smooth operation.
Start forcing screw into center hole of bridge.
NOTE
Failure to use hardened washer may result in damage to forcing screw and/or sprocket shaft.
8. Place hardened washer against end of sprocket shaft. Thread forcing screw into bridge until the steel ball at the end of the screw makes firm contact with hardened washer.
9. Using the ROBINAIR HEAT GUN (Part No. HD-25070), uniformly heat the bearing inner race for about 30 seconds using a circular motion.
NOTE
To assist removal without heat, apply a light penetrating oil to shaft and leading edge of bearing inner race.
10. Turn forcing screw until thrust washer and bearing inner race move approximately 1/8 in. (3.2 mm).
11. Turn hex nuts an equal number of turns to separate halves of WEDGE ATTACHMENT (Part No. HD-95637-46B).
12. After bottoming thrust washer on shaft, reposition WEDGE ATTACHMENT (Part No. HD-95637-46B) on inboard side of bearing inner race. Turn hex nuts an equal number of turns to draw halves of wedge together.
Install wedge attachment only so far as necessary to ensure positive contact with bearing inner race. Installing tool with more contact than necessary will result in damage to the flywheel (00500b)
13. See Figure 3-129. Verify that the tool assembly is square, so that the bearing inner race is not cocked during removal.
14. Using the ROBINAIR HEAT GUN (Part No. HD-25070), uniformly heat the bearing inner race for about 30 seconds using a circular motion.
NOTE
To assist removal without heat, apply a light penetrating oil to shaft and leading edge of bearing inner race.
15. Turn forcing screw until bearing inner race is pulled free of sprocket shaft.
16. Remove thrust washer from sprocket shaft.
Installation
1. Place new thrust washer over sprocket shaft.
2. Place new bearing inner race on bench top. Using the ROBINAIR HEAT GUN (Part No. HD-25070), uniformly heat bearing inner race for about 60 seconds using a circular motion.
3. Wearing suitable gloves to protect hands from burns, place heated bearing inner race over sprocket shaft.
Do not use heating devices with penetrating oil. Penetrating oil is flammable which could result in death or serious injury. (00375a)
NOTE
To assist installation without heat, apply a light penetrating oil to shaft and leading edge of bearing inner race.
4. See Figure 3-130. Obtain the SPROCKET SHAFT BEARING INSTALLER (Part No. HD-97225-55C).
Assemble tool as described below.
a. See Figure 3-131. Thread pilot adapter into sprocket shaft.
b. Thread pilot shaft onto pilot adapter.
c. Slide long collar over pilot shaft until it contacts bearing inner race.
d. Slide short collar over pilot shaft until it contacts long collar.
e. Slide bearing and large flat washer over pilot shaft.
f. Sparingly apply graphite lubricant to threads of pilot shaft to prolong service life and verify smooth operation.
g. See Figure 3-132. Thread handle onto pilot shaft.
5. See Figure 3-133. Rotate handle of tool clockwise until bearing inner race makes firm contact with thrust washer.
Verify that thrust washer cannot be rotated by hand.
6. Remove handle, flat washer, bearing, short collar, long collar, pilot shaft and pilot adapter from sprocket shaft.
Main Bearing Removal
NOTE
Never move or lift the crankcase by grasping the cylinder studs.
The crankcase is too heavy to be carried in this manner and could be dropped.
1. Hold flywheel assembly to prevent it from falling out of left crankcase half. Rotate bottom end assembly in engine stand so assembly is upright and flywheel shafts are horizontal.
2. Carefully slide flywheel assembly out of left crankcase and place it in a clean safe place.
3. Remove thrust washer from outboard side of crankcase half by pulling it past oil seal. Set thrust washer aside for
inspection or reuse.
4. Remove oil seal from crankcase bore. Discard oil seal.
5. See Figure 3-124. Using a flat blade screwdriver, carefully lift edge of bearing retaining ring up out of its groove in crankcase.
6. Slide screwdriver tip around edge of bearing, lifting retaining ring up and out of groove. Do not damage lip of groove in crankcase.
NOTE
See Figure 3-125. If the ram of the press is wider than the head of pilot/driver (2), a suitable press plug will be needed in order to remove the main bearing.
7. Obtain CRANKCASE BEARING REMOVER/INSTALLER (Part No. B-45655) and REMOVER/INSTALLER SUPPORT TUBE (Part No. HD-42720-5).
8. See Figure 3-126. Place support tube (3) on press table with “A” end up. Note that support tube is stamped “A” and “B” to provide proper orientation.
9. With the outboard side of the left crankcase half facing upward, position main bearing bore over support tube.
10. Slide pilot/driver (2) through the main bearing into support tube (3).
11. Center pilot/driver under ram (1) of press. Apply pressure to pilot/driver until bearing is free.
12. Remove crankcase half, pilot/driver and bearing from support tube. Discard bearing.
Main Bearing Installation
NOTES
• Never move or lift the crankcase by grasping the cylinder studs. The crankcase is too heavy to be carried in this manner and could be dropped.
• Always replace sprocket shaft bearing inner race whenever left main bearing is replaced. See 3.28 CRANKCASE DISASSEMBLY AND REPAIR, Sprocket Shaft Bearing Inner Race.
1. See Figure 3-125. Obtain CRANKCASE BEARING REMOVER/INSTALLER (Part No. B-45655) and REMOVER/INSTALLER SUPPORT TUBE (Part No. HD-42720-5).
2. See Figure 3-127. Place a thin film of clean engine oil on outer diameter of new main bearing (4).
3. Place support tube (3) on hydraulic press table with the “A” end up.
4. With the inboard side of the left crankcase half facing upward, position main bearing bore over support tube.
5. Start new main bearing in bearing bore, letter side down.
6. Slide pilot/driver (2) through bearing into support tube.
7. Apply pressure to pilot/driver until bearing is lightly bottomed in main bearing bore.
8. Remove crankcase half and pilot/driver from support tube.
9. Install new retaining ring in bearing bore groove, being careful not to damage edges of groove. Make sure that retaining ring is fully seated in groove.
NOTE
If retaining ring will not fit into groove, the bearing may not be fully seated in the bore. Inspect bearing and bore. If necessary, remove bearing, clean bore and install bearing. Then install retaining ring.
Main Bearing Removal
NOTE
Never move or lift the crankcase by grasping the cylinder studs.
The crankcase is too heavy to be carried in this manner and may be dropped.
1. See Figure 3-123. Remove two main bearing retaining screws (5) from the cam compartment side.
2. See Figure 3-121. Obtain CRANKCASE BEARING REMOVER/INSTALLER (Part No. B-45655) and REMOVER/INSTALLER SUPPORT TUBE (Part No. HD-42720-5)
3. Place support tube (4) on hydraulic press table with the “A” end up. Note that the sides of the support tube are stamped to verify proper orientation.
4. With the cam compartment side facing downward, position main bearing bore over support tube.
5. Slide remover/installer (1) through bearing into support tube.
6. Center remover/installer under ram (3) of press. Apply pressure until bearing is free.
7. Remove crankcase, remover/installer and bearing from support tube. Discard bearing.
Main Bearing Installation
1. See Figure 3-122. Obtain CRANKCASE BEARING REMOVER/INSTALLER (Part No. B-45655), CRANKSHAFT BEARING DRIVER SHIM (Part No. HD-42720-4) and REMOVER/INSTALLER SUPPORT TUBE (Part No. HD-42720-5).
2. Spread a thin film of clean engine oil on OD of new bearing (5).
3. Place support tube (3) on press table with the “B” end is up. The ends of the support tube are stamped “A” and “B” to verify proper orientation.
4. Place CRANKSHAFT BEARING DRIVER SHIM (Part No. HD-42720-4) (2) on support tube (3).
5. With the cam compartment side facing upward, position main bearing bore over support tube.
6. Start the new bearing in bearing bore with the lettering facing into the cam compartment (up).
7. Slide remover/installer (1) through bearing into support tube.
8. Center remover/installer under ram (4) of press. Apply pressure until resistance is felt and bearing is bottomed on the support tube.
9. Remove remover/installer and crankcase half from support tube.
NOTES
• Verify that the bearing is flush or slightly below the surface of the crankcase. Never “push” the bearing into position using the retaining screws.
• If new retaining screws are not available, apply LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue) to threads of screws before installation.
10. See Figure 3-123. Install two new main bearing retaining screws (5) from the cam compartment side. Tighten screws to 40-70 in-lbs (4.5-7.9 Nm).
Piston Jets Removal
1. See Figure 3-123. Remove two screws (1) to free piston jet (2) from crankcase.
2. Remove O-ring (3) from groove in mounting flange of jet.
Discard O-ring.
Piston Jets Installation
NOTE
If piston jet is being reused, apply LOCTITE 222 LOW STRENGTH THREADLOCKER AND SEALANT (purple) to threads of screws before installation.
1. See Figure 3-123. Apply a very thin film of clean engine oil to new O-ring (3). Install new O-ring in groove of jet mounting flange.
2. With jet pointed upward, secure piston jet (2) with two screws (1). Tighten to 25-35 in-lbs (2.8-3.9 Nm).
1. Scrape old gasket material from the crankcase flanges. Old gasket material left on mating surfaces will cause leaks.
2. Clean all parts in a non-volatile cleaning solution or solvent.
3. Dry parts with moisture free compressed air.
4. Verify that all oil holes and passageways are clean and open.
5. Check ring dowels for looseness, wear or damage.
Replace as necessary.
6. Use a file to carefully remove any nicks or burrs from machined surfaces.
7. Clean out tapped holes and clean up damaged threads.
8. Check the top of the crankcase for flatness with a straightedge and feeler gauge. Replace if warped.
9. Spray all machined surfaces with clean engine oil.
10. Inspect crankshaft/flywheel assembly. See 3.29 FLYWHEEL AND CONNECTING RODS.
1. Remove oil pump from crankshaft.
NOTE
Do NOT rotate left crankcase half in the engine stand so the flywheel sprocket shaft is facing up. The flywheel assembly will fall out of the case.
2. Rotate crankcase in the engine stand so that the cam cover flange is facing straight upward.
3. See Figure 3-119. Remove the nine crankcase bolts in the sequence shown.
NOTE
Never move or lift the crankcase by grasping the cylinder studs.
The crankcase is too heavy to be carried in this manner and may be dropped.
4. Separate case halves. Lift right crankcase half off end of crankshaft.
5. See Figure 3-120. Remove two dowel pins in split line face of right case half.
6. Remove flywheel assembly from the crankcase. Inspect crankshaft/flywheel assembly. See 3.29 FLYWHEEL AND CONNECTING RODS.
NOTE
Lubricate parts with SCREAMIN’ EAGLE ASSEMBLY LUBE during assembly.
1. See Figure 3-117. Apply a very thin film of SCREAMIN’ EAGLE ASSEMBLY LUBE to new scavenge port stub O-ring (6). Install O-ring on scavenge port stub of oil pump housing.
2. Slide oil pump housing (5) onto crankshaft while fitting O- ring on scavenge port stub into crankcase bore.
a. Firmly push on scavenge port stub with thumb to verify that it is snug in bore.
b. Inspect O-ring to verify that it is not pinched or distorted.
3. Assemble the wide gerotor set (4). Install on the crankshaft until it bottoms in the oil pump housing.
4. Install inside separator plate (2) on the crankshaft until it contacts the wide gerotor set (4). Install wave washer (3) and outside separator plate (2).
5. Assemble the narrow gerotor set (1). Install on the crankshaft until it contacts the outside separator plate (2).
6. See Figure 3-118. Apply a very thin film of SCREAMIN’ EAGLE ASSEMBLY LUBE to new O-ring (3) for crankcase post. Install new O-ring in groove on crankcase post.
7. Complete engine assembly. See 3.26 CAM COMPARTMENT AND COMPONENTS and 3.25 TOP END OVERHAUL: ASSEMBLY.
1. Clean all parts in a non-volatile cleaning solution or solvent.
2. Dry parts using low pressure compressed air. Verify that all oil passages are clean and open.
3. Inspect for scoring, gouging or cracking caused by foreign material.
4. Inspect for grooves or scratches on the cam support plate.
5. Check for excessive wear or damage on lobes of outer and inner gerotor gears.
6. See Figure 3-116. Check gerotor wear.
a. Mesh rotors of one gerotor set together.
b. Use a feeler gauge to determine clearance between tips of lobes on inner and outer gerotors.
c. Replace gerotors as a set if clearance exceeds 0.004 in. (0.10 mm). Inspect second gerotor set in the same
manner.
7. Measure and compare thickness of each rotor in both gerotor sets. Replace the gerotor set if the difference
exceeds 0.001 in. (0.025 mm).
8. See Figure 3-117. Assemble the oil pump.
9. Verify that feed gerotors extend past the oil pump surface 0.015-0.025 in. (0.38-0.64 mm).
10. If measurement is less than 0.015 in. (0.38 mm), remove feed gerotor set and reassemble using new wave washer.
11. Repeat measurement and replace oil pump body if not within specification.
1. See 3.18 TOP END OVERHAUL: DISASSEMBLY.
a. Remove breather assembly.
b. Remove rocker arm support plate.
c. Remove pushrods and pushrod covers. Do not remove lifters or lifter covers.
d. Support hydraulic lifters from dropping into the cam compartment using SCREAMIN’ EAGLE MAGNETIC LIFTER HOLDERS (Part No. 93979-10). See 3.26 CAM COMPARTMENT AND COMPONENTS.
2. Remove cover and cam support plate. See 3.26 CAM COMPARTMENT AND COMPONENTS.
3. Carefully remove oil pump assembly from crankshaft.
4. See Figure 3-114. Remove and discard O-rings (1, 2).
5. See Figure 3-115. Disassemble and inspect oil pump components.
1. See Figure 3-106. Apply a very thin film of SCREAMIN’ EAGLE ASSEMBLY LUBE to new O-ring (1) and install in groove around oil feed hole.
2. Lubricate cam needle bearings with SCREAMIN’ EAGLE ASSEMBLY LUBE.
3. See Figure 3-107. Verify that the timing marks on the ends of the front and rear camshafts are in alignment.
4. Slide cam support plate over crankshaft and onto two ring dowels in crankcase flange. Use a rubber mallet to fully seat cam support plate on ring dowels.
5. See Figure 3-108. Install cam support plate screws.
Tighten to 100-120 in-lbs (11.3-13.6 Nm) in the sequence shown.
NOTES
• Rotating the crankshaft while tightening screws will allow the oil pump to find its natural center. For methods of crankshaft rotation, see 3.18 TOP END OVERHAUL: DISASSEMBLY, Rocker Arm Support Plate.
• Numbers cast adjacent to the bolt holes indicate the oil pump torque sequence.
6. See Figure 3-109. Secure oil pump.
a. Start four screws to secure oil pump.
b. While rotating the crankshaft, install screws (1 and 2) until snug.
c. Install screws (3 and 4) until snug.
d. Tighten all four screws to 40-45 in-lbs (4.5-5.1 Nm) in the sequence shown.
e. Final tighten all four screws to 90-120 in-lbs (10.2-13.6 Nm) in the sequence shown.
7. With the lettering facing inboard, install rear cam sprocket spacer onto the rear camshaft.
8. Engines with one or more of the following new parts: cam support plate, camshafts, primary cam sprocket, crankshaft sprocket or flywheel assembly.
a. Install primary cam sprocket without chain using the long flange bolt with thicker flat washer.
b. Install crankshaft sprocket without chain using the short flange bolt and a smaller diameter flat washer from bulk inventory.
c. Position the CRANKSHAFT/CAMSHAFT SPROCKET LOCKING TOOL (Part No. HD-47941) between the crankshaft and primary cam sprockets. Tighten both sprocket flange bolts to 15 ft-lbs (20.3 Nm). Remove the sprocket locking tool.
d. Rotate engine stand so cam compartment is pointing upward. Push on crankshaft and rear camshaft to eliminate endplay.
e. If engine was not removed from motorcycle, install compensating sprocket assembly to pull the crankshaft to the left side of the engine. Push on crankshaft and rear camshaft to eliminate endplay.
f. See Figure 3-110. Place a straightedge across the sprocket faces. Attempt to insert a 0.010 in. (0.254 mm) feeler gauge between the straightedge and each sprocket face. If the feeler gauge will not fit at either location, sprocket offset is within specification.
Remove both sprockets and discard temporary small washer.
g. If measurement is not within specification, replace the rear cam sprocket spacer using Table 3-38 as a guide.
h. Repeat alignment inspection with the new spacer installed. Remove both sprockets when measurement is within specification and discard temporary small washer.
9. See Figure 3-111. Apply a light film of SCREAMIN’ EAGLE ASSEMBLY LUBE to splines on rear cam. Install the primary cam chain and sprocket assembly.
a. Place both cam sprockets (2, 4) in the primary chain with the timing marks aligned. Verify that the colored mark placed on the chain link (7) is on the same side as the timing marks and is visible during installation.
b. With the timing marks in alignment, start the rear cam sprocket onto the end of the rear camshaft. Note that the sprocket has an integral key that must be aligned with the keyway in the camshaft.
c. Maintaining the position of the crankshaft sprocket on the chain, rotate the rear cam sprocket clockwise until the flat on the crankshaft sprocket is aligned with the flat on the crankshaft. Install the crankshaft sprocket.
10. Rotate the crankshaft clockwise until the timing marks on the sprockets are aligned and also aligned with alignment mark (5) on cam support plate.
NOTES
• Both crank and rear cam sprocket flange bolts are specially hardened and the flat washers are of a special diameter.
• Use only genuine Harley-Davidson parts when replacement is necessary.
• If new flange bolts are not available, thoroughly clean both internal and external threads.
• Apply a small amount of LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (red) before installation.
• Both sprocket bolts must install freely by hand.
• The crankshaft and rear cam sprocket flange bolts and flat washers are not interchangeable.
• Refer to Table 3-38.
11. Apply a film of oil to bottom of both sprocket bolt heads and washers. Loosely install to secure sprockets.
12. Position the CRANKSHAFT/CAMSHAFT SPROCKET LOCKING TOOL (Part No. HD-47941) between the crankshaft and rear cam sprockets to prevent rotation.
The handle of the tool is stamped “Crank” and “Cam” to verify proper orientation.
a. Tighten both sprocket bolts (1, 3) to 15 ft-lbs (20.3 Nm).
b. Loosen both bolts one revolution (360 degrees).
c. Final tighten the rear cam sprocket bolt (1) to 34 ft- lbs (46.1 Nm).
d. Final tighten the crankshaft sprocket bolt (3) to 24 ft- lbs (32.5 Nm).
e. Remove the sprocket locking tool.
13. Install primary cam chain tensioner. Tighten to 100-120 in-lbs (11.3-13.6 Nm).
14. Apply SCREAMIN’ EAGLE ASSEMBLY LUBE to both sprockets.
NOTE
Inserting a screw into a blind hole with debris can damage the crankcase.
15. Clean all blind holes in crankcase.
16. See Figure 3-112. Install cam cover and new cam cover gasket.
17. See Figure 3-113. Secure cover with socket head screws.
Following the sequence shown, tighten the screws to 125-155 in-lbs (14.1-17.5 Nm).
18. If removed, install timer cover with five screws. Tighten to 20-30 in-lbs (2.3-3.4 Nm).
19.Complete motorcycle assembly.
a. If engine was completely overhauled, see 3.25 TOP END OVERHAUL: ASSEMBLY. Perform all steps.
b. If only cam compartment components were serviced, install pushrod covers, pushrods, rocker arm support plate and breather assembly. See appropriate topics under 3.25 TOP END OVERHAUL: ASSEMBLY.
