Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual

Table 2 TIRE INFLATION PRESSURE (COLD)

psi

kPa

Up to 300 lb. load

Front

1200 models

207

883 and 1100 models

1986-1990

179

1991-2003

207

Rear

1200 models

248

883 and 1100 models

1986-1990

207

1991-2003

248

Up to GVWR maximum load

Front

1200 models

207

883 and 1100 models

1986-1990

179

1991-2003

207

Rear

1200 models

276

883 and 1100 models

1986-1990

221

1991-2003

276

1. Tire inflation pressure is for original equipment tires. Aftermarket tires may require a different inflation pressure.
2. 300 lb. load includes rider, passenger and cargo.
3. The gross vehicle weight rating (GVWR) is listed on a decal mounted on the frame.

Table 3 ENGINE OIL SPECIFICTIONS

Ambient

Type

HD rating

Viscosity

operating temperature

H-D Multi-grade

HD360

SAE 10W/40

Below 40° F

H-D Multi-grade

HD360

SAE 20W/50

Above 40° F

H-D Regular heavy*

HD360

SAE 50

Above 60° F

H-D Extra heavy*

HD360

SAE 60

Above 80° F

*Not recommended for use when ambient temperature is below 50° F.

Table 4 ENGINE AND PRIMARY DRIVE/TRANSMISSION OIL CAPACITIES

Oil tank refill capacity with filter replacement

3.0 qt (2.8 L)

Transmission (includes primary chaincase)

1986-1992 models

24 oz (710 ml)

1993-2003 models

32 oz. (946 ml)

Table 5 RECOMMENDED LUBRICANTS AND FLUIDS

Brake fluid

DOT 5

Chain lubricant

Standard drive chain

H-D Chain Spray or HD High-Performance Chain Lube

O-ring drive chain

H-D High-Performance Chain Lube or automotive lubricant rated

API GL-5 with a viscosity index of SAE 80 or 90.

Front fork oil

H-D Type E or equivalent

Fuel

Type

Unleaded

Octane

1986-1990 models

Pump research octane of 89 or higher

1991-2003 models

Pump research octane of 87 or higher

Transmission

H-D Sport Trans Fluid or equivalent

LUBRICATION, MAINTENANCE AND TUNE-UP

149

Table 6 FRONT FORK OIL CAPACITY

Wet

Dry

1986-1987 models

5.4

160

6.4

189

1988-1991 models

9.0

266

10.2

302

1992-1998

883 Hugger models

10.7

316

12.1

358

All other models

9.0

266

10.2

302

1999-2003 models

9.0

266

10.2

302

Table 7 MAINTENANCE AND TUNE-UP SPECIFICATIONS

Item

Specification

Brake pad minimum thickness

0.062 in. (1.59 mm)

Clutch cable free play

1/16-1/8 in. (1.6-3.2 mm)

Drive belt deflection

1991-1999 models

9/16-11/16 in. (14.3-17.5 mm)

2000-2003 models

883, 1200, 1200S models

5/16-3/8 in. (7.9-9.6 mm)

883H and 883C models

1/4-5/16 in. (6.4-7.9 mm)

Drive chain

Drive chain free play*

1/4 in. (6.4 mm)

Engine compression (min.)

120 psi (828 kPa)

Idle speed

1986-1987 models

Slow idle

900-950 rpm

Fast idle

1500-1500 rpm

1988-2003 models

1000-1050 rpm

Primary chain free play

Cold engine

3/8-1/2 in. (9.6-12.7 mm)

Hot engine

1/4-3/8 in. (6.4-9.6 mm)

Spark plugs

HD-6R12

Gap

0.038-0.043 in. (0.97-1.09 mm)

Tire wear/maximum tread depth

1/16 in. (1.6 mm)

*Rider on seat.

Table 8 IGNITION TIMING SPECIFICATIONS

Year/Idle speed

VOES Connected

VOES Disconnected

1986-1994

Fast: 1650-1750 rpm

40° BTDC

Approximately 16°BTDC

Normal: 950-1050 rpm

30° BTDC

Approximately 7.5° BTDC

1995 U.S. models

1650-1950 rpm

35°BTDC

Approximately 16° BTDC

1995 HDI models

1000-1050 rpm

20°BTDC

Approximately 7.5° BTDC

1996-2003 models (except 1998-2003 1200S models)

1000-1050 rpm

20°BTDC

Approximately 7.5° BTDC

1998-2000 1200S models*

1000-1050 rpm

20° BTDC

2001-2003 1200S models*

1000-1050 rpm

15°BTDC

*Not equipped with VOES.

Table 9 MAINTENANCE AND TUNE UP TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Air filter cover

–

36-60

4-7

Front fork cap*

11-22

–

15-30

Primary chain adjuster locknut

1986-1990 models

–

98-144

11-16

1991-2003 models

20-25

–

27-34

Primary drive inspection cover retaining screws

–

84-108

10-12

Rear axle nut

60-65

–

81-88

Spark plug

11-18

–

15-24

Transmission/primary chaincase

drain plug

14-21

–

19-28

*1200S models. No specification available on other models.

150

CHAPTER THREE

No. 530 (3/8 in. wide) × 110 links

CHAPTER FOUR

ENGINE TOP END

This chapter covers the rocker covers, rocker arms, cylin-

der heads, valves, cylinder blocks, pistons, piston rings and
oil tank.

Tables 1-4 are located at the end of this chapter.

TOOLS

Engine service requires a number of special tools. These

tools and their part numbers are listed with the individual
procedures. For a complete list of the special tools men-
tioned in this manual, refer to Table 12 in Chapter One.

When purchasing tools from a dealership or parts sup-

plier, be sure to specify the tools required are for the
specific Sportster model being worked on. Many of the
tools are specific to the engine. Tools for other engine mod-
els may be slightly different.

The manufacturer’s part number is provided for many of

the tools mentioned in this manual. These part numbers are
correct at the time of original publication. The publisher
cannot guarantee the part number or the tools in this manual
will be available in the future.

ROCKER COVER ASSEMBLY

The rocker cover assembly (Figure 1) consists of the

outer rocker cover, middle rocker cover and inner rocker
cover, which contains the rocker arms and shafts.

The rocker covers can be removed from either cylinder

with the engine installed in the frame.

Rocker cover

Removal

Refer to Figure 1.

1. Remove the fuel tank as described in Chapter Ten or
Chapter Eleven.
2. Remove the air filter and backplate as described in
Chapter Ten or Chapter Eleven.
3. If removing the rocker cover on the front cylinder, re-
move the ignition coil as described in Chapter Twelve.

NOTE

Some rocker cover bolts have a captive
washer. Note their position so they can be in-
stalled in the correct location

4. Remove the upper rocker arm cover bolts (A, Figure 2),
steel washers (if used) and fiber washers. See Figure 3.
5. Remove the upper rocker arm cover (B, Figure 2).
6. Remove the gasket (A, Figure 4).
7. Remove the middle rocker arm cover (B, Figure 4).
8. Remove and discard the inner and outer gaskets (Figure 5).

NOTE

Steps 9A and 9B describe two methods for
turning the engine over by hand. When per-
forming Step 9A, the motorcycle must be sup-
ported with the rear wheel off the ground.

9A. Shift the transmission into fifth gear. While watching
the rocker arms, turn the rear wheel until both valves are
closed on the cylinder being serviced.
9B. Remove the primary cover as described in Chapter Six
or Chapter Seven. While watching the rocker arms, turn the
engine sprocket nut until both valves are closed on the cyl-
inder being serviced.
10. Loosen, then remove the two rocker arm mounting
bolts and washers next to the pushrods (Figure 6).
11. Remove the remaining lower rocker arm cover mount-
ing bolts and washers (Figure 7).
12. Remove the lower rocker arm cover (Figure 8). Dis-
card the gaskets.
13. Remove and discard the fiber washers, which may re-
main in the cover bolt recesses on the top of the rocker
cover.

Installation

NOTE

On 2003 models a one-piece gasket is used in
place of the two gaskets identified in Step 1A
or 1B.

NOTE

On 1986 models, record the crankcase number
on the right crankcase half. The number is lo-
cated above the point where the oil filter hoses
connect to the oil pump. Starting with crank-
case number 1786 127 043 (883 cc) or number
1886 127 001 (1100 cc), new style hydraulic
tappets were installed. If the center number is
126 or less, perform Step 1A. If the center
number is 127 or higher, perform Step 1B. On
all 1987-2003 models, perform Step 1B.

1A. Perform the following in order:

a. Install new lower rocker arm cover gaskets with the

bead facing up. Refer to Figure 9.

b. Install the lower rocker arm cover (Figure 10).
c. Refer to Figure 1. Install bolts 9, 13, 15 and 20.
d. Tighten bolts 9 and 15 (5/16 in.) in a crisscross pat-

tern to 15-18 ft.-lb. (20-24 N•m).

e. Tighten bolts 13 and 20 (1/4 in.) in a crisscross pat-

tern to 120-156 in.-lb. (14-18 N•m).

152

CHAPTER FOUR

ROCKER ARM COVER

1. Bolt
2. Washer
3. Fiber seal
4. Upper rocker

arm cover

5. Gasket
6. Middle rocker

arm cover

7. Gasket
8. Umbrella valve
9. Bolt

10. Washer
11. Gasket

12. Rocker arm
13. Bolt
14. Washer
15. Bolt
16. Lower rocker

arm cover

17. Rocker arm shafts
18. Bushing
19. Rocker arm
20. Bolt
21. Washer
22. Gasket
23. Gasket

f. Rotate the engine so that the tappets for the cylinder

being serviced are at the lowest position.

NOTE

If the pushrods were removed, refer to the cyl-
inder head installation section in this chapter
and install the pushrods.

NOTE

A piece of wire 13-14 in.(330-356 mm) long
with a diameter of 0.050-0.060 in. (1.3-1.5
mm)is required for the next step. Fine wire of
this type can be purchased at hobby shops or
hardware stores.

g. Remove the bolts (9, Figure 1).
h. Insert the wire through the pushrod and depress the

check valve in the tappet (Figure 11) while pushing
the pushrod down.

NOTE

The rocker arm shafts have cutouts in them.
The cutouts must align with the rocker cover
bolt holes.

i. Remove the wire while keeping the tappet depressed

with the pushrod and install the rocker arm (A, Fig-
ure 12) and shaft (B).

j. Install the bolts (9, Figure 1), and tighten to 15-18

ft..-lb. (20-24 N•m).

1B. Perform the following in order:

a. Rotate the engine so that the tappets for the cylinder

being serviced are at the lowest position.

NOTE

If the pushrods were removed, refer to the cyl-
inder head installation section in this chapter
and install the pushrods.

b. Install new lower rocker arm cover gaskets with the

bead facing up. See Figure 9.

NOTE

The rocker arm shafts have cutouts in them.
The cutouts must align with the rocker cover
bolt holes.

c. Install the rocker arms and rocker arm shafts into the

lower rocker arm cover.

d. Install the rocker arm cover assembly (Figure 8).
e. Align the pushrods with the rocker arm sockets.
f. Refer to Figure 1. Install bolts 9, 13, 15 and 20.
g. Tighten bolts 9 and 15 (5/16 in.) in a crisscross pat-

tern to 15-18 ft.-lb. (20-24 N•m).

h. Tighten bolts 13 and 20 (1/4 in.) in a crisscross pat-

tern to 120-156 in.-lb. (14-18 N•m).

CAUTION

On all models, make sure the pushrods can be
hand-turned before rotating the engine.

154

CHAPTER FOUR

Wire: 13-14 in. long
0.050-0.060 in. diameter

2. Install new center and outer gaskets (Figure 5) onto the
lower rocker arm cover.
3. Install the middle rocker cover (A, Figure 13) onto the
lower rocker cover.
4. Install a new gasket (B, Figure 13) onto the middle
rocker cover.
5. Install the upper rocker cover (Figure 14) onto the mid-
dle rocker cover.
6. Place a steel washer if used and fiber washer onto each
rocker cover mounting bolt (Figure 3).
7. Install the rocker cover mounting bolts and tighten to
120-156 in.-lb. (14-18 N•m).
8. Repeat the procedure for the remaining rocker cover as-
sembly.
9. If removed, install the ignition coil as described in
Chapter Twelve.
10. Install the air filter and backplate as described in Chap-
ter Ten or Chapter Eleven.
11. Install the fuel tank as described in Chapter Ten or
Chapter Eleven.

Removal/inspection/installation

Label all parts prior to disassembly so they may be in-

stalled in their original positions. Refer to Figure 1.
1. Before removing the rocker arms, measure rocker arm
end clearance as follows:

a. Insert a feeler gauge between the rocker arm and the

inside rocker arm cover boss as shown in Figure 15.

b. Record the measurement.
c. Repeat for each rocker arm.
d. Replace the rocker arm and/or the lower rocker cover if

the end clearance exceeds the service limit in Table 2.

2. Using a soft-faced punch, tap each rocker arm shaft (A,
Figure 16) out of the lower rocker arm cover.
3. Remove the rocker arms (B, Figure 16).
4. Clean the rocker covers, rocker arms and shafts in sol-
vent. Then clean with hot, soapy water and rinse with clear,
cold water. Dry with compressed air.
5. Blow compressed air through all the oil passages to
make sure they are clear.
6. Examine the rocker arm pads (area that contacts the
valve). See A, Figure 17. The pad on each rocker arm
should be shiny and convex—curving outward. Replace
the rocker arm if the pad shows signs of pitting, grooves or
excessive wear.
7. Examine the rocker arm socket (area that retains the
pushrod). See B, Figure 17. The socket will show wear but
it should be smooth without any sign of a step or lip. Re-
place the rocker arm if the socket is severely worn, cracked
or has a step or lip.
8. Examine the rocker arm shaft (Figure 18) for scoring,
ridge wear or other damage. If these conditions are present,
replace the rocker arm shaft. If the shaft does not show any
visual wear or damage, perform Step 9.

ENGINE TOP END

155

9. Measure the rocker arm shaft outside diameter (Figure
19) where it rides in the rocker arm and in the lower rocker
arm cover. Record both measurements.
10. Measure the rocker arm bushing inside diameter (Fig-
ure 20) and the lower rocker arm cover bore diameter
where the shaft rides (Figure 21). Record both measure-
ments.
11. Subtract the measurements taken in Step 9 from those
in Step 10 to obtain the following rocker arm shaft clear-
ance measurements:

a. Shaft fit in rocker cover.
b. Shaft fit in rocker arm bushing.

12. Replace the rocker arm bushings or the lower rocker
arm cover if the clearance exceeds the specifications in Ta-
ble 2. Also, replace any parts which are worn beyond the
service limit specification in Table 2. Rocker arm bushing
replacement is described in this section.

NOTE

On 1986 models specified in the NOTE under

Installation

in this section, the rocker arms

are not installed until the lower rocker cover
has been installed on the cylinder head. Dis-
regard the following steps.

13. Install the rocker arms into their original positions
(Figure 22).
14. Align the notch (A, Figure 23) in the rocker arm shaft
with the bolt hole (B) in the lower rocker arm cover and in-
stall the rocker arm shaft. Repeat for the opposite rocker
arm shaft. See Figure 24.

Bushing replacement

Each rocker arm is equipped with two bushings (Figure

20). Replacement bushings must be reamed using the
rocker arm bushing reamer (part No. HD-94804-57).

NOTE

Because new bushings must be reamed, re-
move only one bushing at a time. The oppo-
site bushing will be used as a guide when
reaming the first bushing.

1. Press or drive one of the bushings from the rocker arm
(Figure 20). Do not remove the second bushing. If the
bushing is difficult to remove, perform the following:

a. Thread a 9/16-18 in. tap into the bushing to be re-

moved.

b. Support the rocker arm in a press so that the tap is at

the bottom.

c. Insert a mandrel through the top of the rocker arm

and seat it on top of the tap.

d. Press on the mandrel to force the bushing/tap out of

the rocker arm. Don’t let the tap fall.

e. Remove the tap from the bushing and discard the

bushing.

156

CHAPTER FOUR

2. Position a new bushing so the split portion faces the top
of the rocker arm. Press in the new bushing until its outer
surface is flush with the rocker arm bore inside surface
(Figure 20).
3. Ream the new rocker arm bushing using the rocker arm
bushing reamer as follows:

a. Mount the rocker arm in a vise with soft jaws so that

the new bushing is at the bottom.

CAUTION

The reamer must be turned clockwise only.
Do not turn the reamer counterclockwise or
the reamer may be damaged.

b. Mount a tap handle on top of the reamer and insert the

reamer into the bushing. Turn the reamer clockwise
until it passes through the new bushing and remove it
from the bottom side. The old bushing left in the
rocker arm is used as a guide for the reamer.

4. Remove the rocker arm from the vise and repeat Steps
1-3 to replace the second bushing. The first bushing will
now act as a guide for the reamer.
5. When both bushings have been replaced and reamed,
clean the rocker arm and bushings in solvent. Clean with
hot, soapy water and rinse with clear and cold water. Dry
with compressed air.
6. Measure the inside diameter of each bushing with a snap
gauge. When properly reamed, the bushings should provide
0.0005-0.0020 in. (0.012-0.050 mm) shaft clearance.

CYLINDER HEAD

Removal

1. Remove the exhaust system as described in Chapter Ten
or Chapter Eleven.
2. Remove the air filter assembly and backplate as de-
scribed in Chapter Ten or Chapter Eleven.
3. On 1986-1994 models, disconnect the ignition switch
wires and remove the ignition switch as described in Chap-
ter Twelve. Remove the choke knob bracket (Figure 25) as
described in Chapter Ten.
4. Disconnect the spark plug wires and set them out of the
way.
5. Remove the ignition coil as described in Chapter Twelve.
6. On 1995-2003 models, remove the choke knob bracket
mounting screw. Secure the knob so it is out of the way.
7. On all models except 1998-2003 1200S models, re-
move the vacuum hose (Figure 26) from the VOES fitting
on the carburetor, and disconnect the VOES electrical
connector at the ignition module as described in Chapter
Twelve.
8. Remove the carburetor as described in Chapter Ten or
Chapter Eleven.
9. Remove the top center engine mount (Figure 27) as fol-
lows:

ENGINE TOP END

157

a. Remove the bolts, washers and lockplate securing the

top center engine mount to the frame. Check for a
shim (9, Figure 27) mounted between the top center
engine mount and frame; this shim is not used on all
models.

b. Remove the choke knob (Figure 28) if it was not re-

moved with the carburetor.

c. Loosen the Allen bolts securing the top center engine

mount to the cylinder heads.

d. Remove the Allen bolts (A, Figure 29), flat washers

and lockwashers.

e. On 1986-1993 models, remove the VOES ground

wire (Figure 30) when removing the rear cylinder

head bolt and set the wire aside. Check the VOES
wire for damage. Repair the wire or connector, if nec-
essary, before reinstalling the cylinder heads.

f. Remove the top center engine mount (B, Figure 29)

and shim (if used).

10. Remove the top front engine mount (Figure 31) as fol-
lows:

a. Pry off the side reflectors (Figure 32) from the front

frame tubes. See Figure 33.

b. Loosen then remove the bolts (A, Figure 34) and

washers securing the top front engine mount to the
frame mounting bracket. Remove the nut plate (5,
Figure 31) from the frame mounting bracket.

c. Loosen the bolt (B, Figure 34) and nut securing the

top front engine mount to the front cylinder block.

d. Remove the bolt, nut, lockwashers and flat washers.
e. Remove the top front engine mount (C, Figure 34).

11. Remove the spark plugs (Chapter Three).
12. On 1986-1990 models, remove the pushrod spring cap
retainer by prying outward (Figure 35).
13. Remove the rocker covers as described in this chapter.
14. Label and then remove both pushrods (A, Figure 36).
15. Remove the intake manifold as described in Chapter
Ten or Chapter Eleven.

CAUTION

Failure to loosen and remove the cylinder
head mounting bolts properly can damage
the cylinder head and cylinder studs.

16. Loosen the cylinder head mounting bolts 1/8 turn at a
time in the order shown in Figure 37. Continue loosening
the bolts 1/8 turn at a time until they are all loose. Then re-
move the bolts and washers.
17. Lift the cylinder head (B, Figure 36) off the cylinder. If
the head is tight, tap it with a soft-faced hammer, then re-
move it.
18. Remove and discard the cylinder head gasket (Figure
38).
19. Remove the O-rings around the cylinder dowel pins.
Discard the O-rings.
20. If necessary, service the pushrod assemblies as de-
scribed in this chapter.
21. To remove the valve tappets, refer to

Valve Tappets

Chapter Five.

Inspection

1. Remove the exhaust gasket from the cylinder head.
2. Remove and inspect the valves and valve seals as de-
scribed in

Valves and Valve Components

in this chapter.

Fabricate a cardboard or wooden holder to store the valves
as they are removed.
3. Clean the cylinder head. A thorough cleaning is required
to inspect the cylinder head accurately for wear and dam-
age. Because of cylinder head construction, materials and

ENGINE TOP END

159

operating conditions, different cleaning techniques and
procedures will be required.

a. First scrape the upper and lower gasket surfaces.

Work slowly and carefully, making sure not to
scratch or gouge these surfaces. Damage could cause
the head to leak when it is returned to service.

CAUTION

Use only solvent or cleaners that are compat-
ible with aluminum parts.

b. Soak the head in a solvent tank. This will help to

soften the carbon buildup in the combustion cham-
bers and exhaust port and to remove oil and grease

from the head surfaces. If a solvent tank is not
available, spray the head with an aerosol cleaner, fol-
lowing the manufacturer’s instructions. Then wash
the head in hot, soapy water and rinse with clear, cold
water. Dry with compressed air.

CAUTION

Do not use a power-driven wire brush to
clean the combustion chambers (

Figure 39

The bristles may leave scratches that could
become hot spots when the head is returned to
service.

c. Bead-blasting is the most efficient way of removing

deposits from the combustion chamber. If scraping

ENGINE TOP END

161

Front cylinder head

Rear cylinder head

the combustion chambers, work carefully around the
valve seats. A damaged or slightly scratched valve
seat will cause poor valve seating.

CAUTION

After bead-blasting a head, clean it thor-
oughly to remove all blasting residue. The
residue collects easily in corners and pockets
and is difficult to remove. A bead-blasted
head should be initially washed and soaked in
a solvent tank, cleaned with hot soapy water,
rinsed in cold water and then dried with a
thorough blasting of compressed air. Blasting
residue that is not removed will enter the lu-
brication system and cause rapid engine
wear.

4. Place a straightedge across the gasket surface at several
points (Figure 40). Measure warp by inserting a feeler
gauge between the straightedge and cylinder head at each
location. If the warp meets or exceeds the service limit in
Table 2, have the head resurfaced or replace it.

5. Examine the spark plug threads in the cylinder head for
damage. If damage is minor or if the threads are dirty or
clogged with carbon, use a spark plug thread tap (Figure
41) to clean the threads following the manufacturer’s in-
structions. If thread damage is severe and cannot be re-
paired with the thread tap, install the correct size steel insert
from a spark plug repair kit.

6. Check for cracks in the combustion chamber, exhaust
port (Figure 42) and valve guide (Figure 43). If a crack is
found, refer the repair to a dealership or replace the cylinder
head.

7. Measure the rocker arm shaft bore diameter as described
in

Rocker Cover Assembly

in this chapter.

8. Inspect the pushrods as described in

Pushrods and Cov-

ers

in this chapter.

9. Inspect the following components as described in

Valves

and Valve Components

in this chapter:

a. Valve guides.

b. Valve springs.

c. Valve seats.

d. Valves.

10. After the cylinder head has been thoroughly cleaned of
all carbon, valve grinding compound and bead-blasting res-
idue, install new valve guides (if necessary), valve seals,
valve springs and valves as described in

Valves and Valve

Components

in this chapter.

Installation

1. If removed, install the cylinder dowel pins (Figure 44).

2. Install new O-rings around the cylinder dowel pins (Fig-
ure 45).

162

CHAPTER FOUR

CAUTION

Be sure the head gasket fits around the dowel
pin O-rings (

Figure 45

). Otherwise, the

O-ring may leak.

3. If removed, install the pushrod cover assemblies. Install
a new O-ring at the top of each pushrod cover.

4. Lubricate the cylinder studs and cylinder head bolts as
follows:

a. Clean the cylinder studs and cylinder bolts.

b. Apply clean engine oil to the cylinder stud threads

and to the flat shoulder surface on the cylinder head
bolts (Figure 46).

c. Remove all excess oil from both parts with a lint-free

cloth or compressed air. An oil film is all that is nec-
essary on these surfaces.

CAUTION

Excessive oil left on the cylinder studs can
collect inside the top of cylinder head bolt,
causing an oil lock and preventing the bolt
from being correctly torqued. This will cause
a blown head gasket and oil leak.

CAUTION

An overhaul gasket set may include cylinder
head gaskets for more than one engine size. If
the gaskets are not identified, contact the
parts manufacturer. Be sure to install the cor-
rect gasket.

5. Remove the horn (Chapter Twelve).

6. Install a new cylinder head gasket (Figure 47).

CAUTION

Do not apply any type of sealer on original
equipment head gaskets. If using an after-
market head gasket, follow the manufac-
turer’s instructions for gasket installation.

NOTE

Cylinder heads can be identified by the
FRONT or REAR marks cast into the head;
see

Figure 48

ENGINE TOP END

163

7. Install the cylinder head onto the cylinder dowel pins
and studs. Position the head so the the head gasket is not
moved out of alignment.
8. Install the cylinder head bolts and install them fin-
ger-tight. Install the long bolts in the center bolt holes.
Install the short bolts in the outer bolt holes next to the
spark plug hole.

CAUTION

Failure to follow the torque pattern and se-
quence in Step 8 may cause cylinder head dis-
tortion and leaks.

9. Tighten the cylinder head bolts as follows:

a. Tighten bolt No. 1 to 84-108 in.-lb. (9-12 N•m). Then

continue and tighten bolts, 2, 3 and 4 in numerical or-
der. Figure 49 identifies the bolt numbers for the
front and rear cylinder heads.

b. Tighten bolt No. 1 to 144-168 in.-lb. (16-19 N•m).

Then continue and tighten bolts 2, 3 and 4 in numeri-
cal order.

c. On 1998-2003 models, loosen all the bolts and repeat

substeps a and b.

d. Make a mark on the No. 1 bolt head and a matching

mark on the cylinder head. Repeat for each bolt. See
Figure 50.

e. Following the tightening sequence in Figure 49, turn

each bolt head 1/4 turn (90

) clockwise (Figure 51),

using the match marks as a guide.

f. Repeat for the remaining cylinder head.

CAUTION

If a valve train component has been replaced
or if the cylinder head, valves and seats have
been reconditioned or replaced, the length of
each pushrod must be checked and adjusted.
This procedure should be referred to a deal-
ership as special tools are required. In addi-
tion, the pushrods must be installed in their
original positions by following the marks
made during disassembly. If the pushrods
were not marked, the length must be checked
by a dealership.

10A. On 1986-1990 models, install the pushrods in their
original positions if they were labeled during removal and
the cylinder head, valves or seats were not reconditioned or
replaced.
10B. On 1991-2003 models, install the pushrods in their
original positions if they were labeled during removal. If
the pushrods were not labeled, or new pushrods are being
installed, identify them as follows:

a. The exhaust pushrods are marked with three pink

bands (A, Figure 52) and are 10.800 in. (274.32 mm)
long.

b. The intake pushrods (B, Figure 52) are marked with

a single brown band and are 10.746 in. (272.94 mm)
long.

c. Confirm pushrod length.

164

CHAPTER FOUR

Front cylinder head

Rear cylinder head

Match marks

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 15