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

4. Inspect the sprocket shaft (A, Figure 136) and pinion
shaft (B) for severe wear or damage. If damaged, refer re-
placement to a dealership.

NOTE

If still in place, do not lose the shim (8,

Figure

128

) when performing Step 5.

5. Inspect the sprocket shaft bearing (Figure 137) for se-
vere wear or damage. If damaged, replace the bearing and
races as described in the

Sprocket Shaft Main Bearing As-

sembly Replacement

section.

6. Inspect the pinion shaft needle bearing (Figure 138) for
severe wear or damage. If the bearing is worn or damaged,
refer replacement to a dealership.
7. Support the crankshaft on a truing stand or in a lathe and
check runout at the shaft with a dial indicator and compare
it to the runout limit in Table 1. If not within specification,
refer service to a dealership.
8. Remove the left crankcase oil seal as follows:

a. On 1991-2003 models, remove the spacer (Figure

139).

b. Pry the oil seal out of the crankcase with a wide-blade

screwdriver (Figure 140). Pad the screwdrive to
avoid damaging the case.

9. Remove the left sprocket bearing (Figure 141). If dam-
aged, replace the bearing and races as described in the

Sprocket Shaft Main Bearing Assembly Replacement

sec-

tion.

238

CHAPTER FIVE

135

136

137

138

139

140

10. Inspect the bearing races in the left crankcase half
(Figure 141). If damaged, replace the bearings and races as
described in the

Sprocket Shaft Main Bearing Assembly Re-

placement

section.

Sprocket Shaft Main Bearing Assembly
Replacement

Replace the sprocket shaft main bearing assembly as a

complete set even if only one bearing or race is damaged.

Tools

1. Hydraulic press.
2. Sprocket shaft bearing race tool (part No. 94547-80B).
3. Race and bearing installation tool handle (part No.
33416-80).
4. Retaining ring removal and installation tool (part No.
1710).
5. Sprocket bearing race installation tool (part No. 2246).

Inner and outer bearing race replacement

CAUTION

When replacing the bearing races in the fol-
lowing steps, do not remove the retaining ring
installed between the inner and outer bearing
races unless a removal tool is available. This
ring is under heavy tension and will damage
the crankcase bearing bore as it passes
through it.

1. Place the crankcase on the workbench with the inboard
surface facing up.
2. If still in place, remove the crankshaft spacer, if used,
and oil seal from the bearing bore.
3. Install half of the bearing race remover tool into the
crankcase and push it against the inner bearing race (A,
Figure 142).
4. Install the other half of the bearing race remover tool
into the crankcase and push it against the inner bearing race
(B, Figure 142).
5. Hold the bearing race remover tools in place.
6. Insert the tool handle into the center of both race re-
mover tools. Press it in until the ring (Figure 143) is locked
into both bearing race remover tools (Figure 144).
7. Support the left crankcase half on the press bed with
wooden blocks and with the tool handle facing up.
8. Center the press ram directly over the tool handle
and slowly press the inner bearing race out of the crank-
case.
9. Remove the crankcase and tools from the press bed.
10. Place the crankcase on the workbench with the out-
board surface facing up.
11. Install half of the bearing race remover tool (A, Figure 145)
into the crankcase and push it against the outer bearing race.

ENGINE LOWER END

239

141

142

143

144

12. Install the other half of the bearing race remover tool
(B, Figure 145) into the crankcase and push it against the
outer bearing race.

13. Hold the bearing race remover tools in place.

14. Insert the tool handle into the race remover tools. Press
it in until the ring (Figure 146) is locked into both bearing
race remover tools (Figure 147).

15. Support the left crankcase half on the press bed with
wooden blocks and with the tool handle facing up.

16. Center the press ram directly over the tool handle and
press the outer bearing race out of the crankcase.

17. Remove the crankcase and tools from the press bed.

18. Clean the crankcase half in solvent and dry it with
compressed air.

19. Check the retaining ring (A, Figure 148) for looseness
or damage. If the retaining ring is loose or damaged, per-
form the following:

a. Place the crankcase on a workbench with the out-

board side facing up.

b. With the gap of the retaining ring at the 12 o’clock

position, install the tool clamps onto each side of the
retaining ring at the 10 o’clock and 2 o’clock posi-
tions.

c. Securely tighten the 9/16 in. Allen screws securing

the clamps to the retaining ring.

d. Use snap ring pliers to compress the retaining ring

and withdraw it from the crankcase groove.

e. Remove the clamps from the old retaining ring and

install them onto the new retaining ring.

f. Squeeze the pliers (Figure 149) and insert the retain-

ing ring into the crankcase groove.

g. Make sure the retaining ring gap is centered on the

crankcase oil hole (B, Figure 148).

NOTE

Install both races with their larger diameter
sides facing out. Install the bearing races with
the same tool used to remove the old ones.

20. Apply clean engine oil, or press lube, to the bearing re-
ceptacles in the crankcase and to the outer surface of the in-
ner bearing races.

240

CHAPTER FIVE

145

146

147

148

149

NOTE

The large end of the installer base must con-
tact the crankcase outer surface as shown in

Figure 150

21. Place the installer base on the press bed with the large
end facing up.
22. Install the inboard outer race (Figure 151) onto the
crankcase receptacle.
23. Position the crankcase with the inboard surface facing up.
24. Install the crankcase onto the installer base so the
crankcase retaining ring rests on top of the installer base.
25. Apply clean engine oil, or press lube, to the shaft of the
pressing plug (Figure 152) and install the pressing plug
into the installer base. Push it down onto the bearing outer
race (Figure 153).
26. Center the press ram directly over the pressing plug and
press the outer bearing race into the outboard surface of the
crankcase until it touches the retaining ring (Figure 154).
27. Remove the crankcase and special tools from the press.
28. Turn the crankcase over and repeat Steps 20-27 for the
outboard outer bearing race.

Crankshaft inner sprocket shaft bearing replacement

A sprocket shaft bearing cone installer (part No. HD-37047A

for 1986-1997 models or HD-42759 for 1998-2003 models) is
required to install the sprocket shaft bearing.
1. Support the crankshaft with the bearing side facing up.
2. Install the bearing splitter under the bearing (Figure
155) and tighten it securely.

ENGINE LOWER END

241

150

151

152

153

154

155

3. Attach a bearing puller to the splitter (Figure 156).
4. Tighten the center screw and withdraw the bearing from
the crankshaft shoulder.
5. Remove the bearing remover, splitter and bearing from
the crankshaft.
6. Clean the sprocket shaft with contact cleaner. Check the
sprocket shaft for cracks or other damage. If damaged, refer
service to a dealership.
7. Slide the new bearing onto the sprocket shaft.
8A. On 1986-1990 models, install the new bearing as fol-
lows:

a. Place the appropriate sleeve of the sprocket shaft

bearing cone installer onto the sprocket shaft so the

rounded end of the sleeve contacts the bearing inner
race.

b. Apply clean graphite lubricant to the threads of the

tool nut driver (1, Figure 157).

c. Thread the nut driver onto the sprocket shaft it con-

tacts the sleeve (Figure 158).

d. Turn the nut driver to force the bearing onto the

sprocket shaft until it bottoms.

e. Remove the tools.

8B. On 1991-2003 models, refer to Figure 159 and install
the new bearing as follows:

242

CHAPTER FIVE

156

157

SPROCKET SHAFT

BEARING/SEAL

INSTALLATION TOOL

158

Nut driver

Spacer

Bearing

159

1. Nut driver
2. 0.75 in. (19 mm)

spacer

3. 1.2 in (30.5 mm)

spacer

4. 1.6 in. (40.6 mm)

spacer

5. 2.06 in. (52.3 mm)

spacer

6. 2.5 in. (63.5 mm)

spacer

7. Seal driver
8. Driver handle

a. Apply clean graphite lubricant to the threads of the

pilot shaft, the flat washer and the bearing.

b. Thread the pilot shaft (A, Figure 159) onto the crank-

shaft until it contacts the crankshaft shoulder.

c. Slide the sleeve (B, Figure 159) over the pilot shaft

until it contacts the bearing inner race.

d. Install the bearing (C, Figure 159) and washer (D)

over the pilot shaft and onto the top of the sleeve.

e. Thread the handle (E, Figure 159) onto the pilot shaft

(A).

f. Tighten the handle clockwise until the bearing bot-

toms on the crankshaft shoulder.

g. Unscrew and remove all parts of the bearing installer

tool.

Crankshaft Installation/ Crankcase Assembly

The sprocket shaft bearing installation tool (part No.

HD-37047A for 1986-1997 models or HD-42579 for
1998-2003 models) is required to install the sprocket shaft
bearing and oil seal.

Refer to Figure 128.

1. Be sure the crankshaft pinion shaft and inner sprocket
shaft main bearings are installed as described in this section.
2. Lubricate all parts with new engine oil prior to installation.
3. Position the crankshaft in a vise with soft jaws so that
the sprocket shaft (Figure 160) faces up.
4. Place the left crankcase half over the crankshaft (Figure
161).
5. Install the end play shim (8, Figure 128) onto the
sprocket shaft.
6. Install the left sprocket shaft bearing (13, Figure 128)
onto the sprocket shaft.
7A. On 1986-1997 models, pull the crankshaft into position
as follows:

a. Slide the 0.75 in. (19 mm) spacer (2, Figure 157)

over the sprocket shaft so that its flat side faces down.

b. Thread the nut driver (1, Figure 157) onto the

sprocket shaft threads. Tighten the driver until it bot-
toms out.

c. Remove the nut driver and spacer from the sprocket

shaft.

d. Install the following spacers onto the sprocket shaft

so that their flat sides face down: 1.2 in. (30.5 mm),
1.6 in. (40.6 mm) and 2.06 in.(52.3 mm).

e. Install the nut driver (1, Figure 157) onto the

sprocket shaft. Then tighten the nut driver until the
left and right bearings (7 and 13, Figure 128) and end
play shim (8) are drawn together. See Figure 161.

f. Remove the nut driver and the spacer assembly.

7B. On 1998-2003 models, pull the crankshaft into position
as follows:

a. Thread the pilot (1, Figure 162) onto the sprocket

shaft until the pilot bottoms.

b. Apply a small amount of graphite lubricant to the

threads of the pilot shaft.

ENGINE LOWER END

243

160

161

Spacer

Nut driver

162

1. Pilot
2. Sleeve
3. Nice bearing
4. Washer
5. Handle

c. Slide the sleeve (2, Figure 162) onto the pilot until

the sleeve contacts the inner bearing race.

d. Install the Nice bearing (3, Figure 162), washer (4)

and handle (5).

e. Turn the handle clockwise until the left and right

bearings (7 and 13, Figure 128) and end play shim
(8) are drawn together.

f. Remove the tool assembly.

8A. To install the left crankcase oil seal on 1986-1990 mod-
els:

a. Pack the oil seal lip with waterproof grease prior to

installation.

b. Install the oil seal over the sprocket shaft so the

closed side faces out. Rest the seal against the crank-
case.

c. Using a seal driver (8, Figure 157), press in the oil

seal until the driver bottoms or the seal outer surface
is flush with the crankcase surface.

8B. To install the left crankcase oil seal on 1991-2003 mod-
els three tools are available: (part No. 2324 for 1995-2003
models , HD-37047A with HD-42774 for 1991-1997 mod-
els, and HD-42579 with HD-42774 for 1998-2003 models.
The first two tools are drivers (Figure 157) while the last
tool uses the shaft threads to force the seal into place (Fig-
ure 162).

a. Pack the oil seal lip with a waterproof grease prior to

installation.

b. Install the spacer into the seal.
c. Install the oil seal around the sprocket shaft so that

the open side faces out. Rest the seal against the
crankcase.

d. Place the installation tool over the sprocket shaft so

that the smaller outer diameter of the driver fits be-
tween the seal wall and the garter spring.

e. Force the seal and spacer into the crankcase bore until

the spacer contacts the bearing. Remove the installa-
tion tool.

CAUTION

Do not remove the spacer after installing it.
Removal damages the oil seal, which will re-
quire seal replacement.

9. Support the left crankcase assembly on wood blocks as
shown in Figure 163.
10. Install the crankcase dowel pins (Figure 164).
11. Coat the crankcase mating surfaces with sealant (Dow
Corning Silastic, 3-M #800 sealant or equivalent).
12. Align the crankcase halves and install the right crank-
case half (Figure 165).
13. Install the crankcase bolts and washers (Figure 166
and Figure 167).
14. Tighten the 1/4 in. bolts to 70-110 in.-lb. (8-12 N•m).
15. Tighten the 5/16 in. bolts to 16-18 ft.-lb. (21-24 N•m).
16. If the pinion shaft bearing (4, Figure 128) was re-
moved, install it as follows:

a. Lubricate the pinion shaft bearing with new engine

oil.

b. Slide the bearing onto the pinion shaft and into the

outer bearing race in the right crankcase.

c. Install a

new

retaining ring (3, Figure 128) in the

groove in the pinion shaft bearing inner race (5, Fig-
ure 128).

17. Install the engine in the frame as described in this chap-
ter.
18. Install all of the engine sub-assemblies as described in
this chapter.
19. If new engine components were installed, perform the
engine break-in as described in this chapter.

244

CHAPTER FIVE

163

164

165

3. Clean the crankcase threads and the new stud with sol-
vent or contact cleaner. Blow dry.
4. Measuring from the top of the stud, paint a mark that is
4.850 in. (123.2 mm) down the stud (Figure 169).
5. Drop a small steel ball (part No. 8860) into a cylinder
head bolt and thread the bolt onto the top of the new stud.
6. Hand-thread the new stud into the crankcase, then install
it with an air driver until the paint mark on the stud aligns
with the crankcase base gasket surface.
7. Remove the cylinder head bolt and steel ball from the
cylinder stud.
8. Measure the stud installed height (Figure 170). The stud
installed height should be 4.770-4.870 in. (121.2-123.7 mm).
9. Place a protective hose over the stud.
10. Repeat Steps 2-9 for each stud.

1995-2003 models

1. If the engine is assembled, stuff some clean shop rags
into the crankcase opening to prevent debris from falling
into the engine.
2. Remove the damaged stud with a stud remover (Chapter
One).
3. Clean the crankcase threads and the new stud with sol-
vent or contact cleaner. Blow dry.

NOTE

The cylinder studs have a shoulder on the
lower end (

Figure 171

4. Drop a small steel ball (part No. 8860) into a cylinder
head bolt and thread the bolt onto the top of the new stud.

5. Hand-thread the new stud into the crankcase, then install
it with an air driver until the shoulder on the stud contacts
the crankcase base gasket surface.

6. Tighten the stud to 120 in.-lb. (14 N•m).

7. Remove the cylinder head bolt and steel ball from the
cylinder stud.

8. Place a protective hose around the stud.

9. Repeat Steps 2-8 for each stud.

ENGINE BREAK-IN

If the engine is new, or following cylinder service such as

boring, honing and installing new rings, or major lower end
work, engine break-in is required.

1. For the first 50 mi. (80 km), maintain engine speed be-
low 2500 rpm in any gear. However, do not lug the engine.
Do not exceed 50 mph during this period.

2. From 50-500 mi. (80-804 km), vary the engine speed.
Avoid prolonged steady running at one engine speed. Dur-
ing this period, increase engine speed to 3000 rpm. Do not
exceed 55 mph.

3. After the first 500 mi. (804 km), the engine break-in is
complete.

ENGINE LOWER END

247

168

169

4.850 in.

(123.2 mm)

Paint mark

170

171

Table 1 ENGINE SERVICE SPECIFICATIONS

New

Service limit

in. (mm)

Tappets

Guide clearance

0.0008-0.0023

0.003

(0.020-0.058)

(0.076)

Roller fit

0.0006-0.0013

–

(0.015-0.033)

Roller end clearance

0.008-0.022

0.026

(0.203-0.559)

(0.66)

Oil Pump

1986-1990 models

Feed and scavenge outer to
inner rotor clearance

0.003

0.004

(0.076)

(0.102)

Shaft-to-bushing clearance

0.0025
(0.0635)

Feed gear height above cover

0.001-0.011
(0.025-0.279)

1991-2003 models

Shaft-to-pump clearance

0.0025

–

(0.064)

Feed/scavenge inner/outer rotor clearance

0.003

0.004

(0.08)

(0.102)

Gearcase

Cam gear shaft bushing clearance

0.0007-0.0022

0.003

(0.018-0.056)

(0.076)

Cam gear shaft end play (minimum)

1986-1990 models

Rear intake cam gear

0.001-0.035

0.040

(0.025-0.127)

(0.127)

All other cam gears

0.0005-0.0215

0.025

(0.0127-0.5461)

(0.635)

1991-2003 models

Rear intake cam gear

0.006-0.024

0.040

(0.15-0.61)

(1.016)

All other cam gears

0.005-0.024

0.025

(0.13-0.61)

(0.635)

Cam gear needle bearing

journal diameter
1986-1990 models

0.6865-0.6860

0.6858

(17.437-17.424)

(17.419)

Connecting rods

Side play @ crankshaft

0.005-0.025

0.030

(0.13-0.64)

(0.762)

Piston pin fit (clearance)

0.00125-0.00175

0.002

(0.0318-0.0445)

(0.051)

Fit on crankpin

Early 1986 models

0.0003-0.0015

0.002

(0.0076-0.0381)

(0.051)

Late 1986-2003 models

0.0004-0.0017

0.0027

(0.010-0.043)

(0.0686)

Crankshaft

Runout @ flywheel rim

0.000-0.010

0.010

(0.00-0.25)

(0.25)

Runout @ shaft

0.000-0.002

0.002

(0.00-0.051)

(0.051)

End play

0.001-0.005

0.005

(0.025-0.127)

(0.127)

Sprocket shaft bearing

Outer race fit in

crankcase (interference)

0.0004-0.0024

–

(0.010-0.061)

Bearing inner race fit on

crankshaft (interference)

0.0002-0.0015

–

(0.005-0.038)

(continued)

248

CHAPTER FIVE

Table 1 ENGINE SERVICE SPECIFICATIONS (continued)

New

Service limit

in. (mm)

Pinion shaft bearing (1987-2003 models)

Outer race diameter in crankcase

1.5646-1.5652

1.5672

(39.741-39.756)

(39.807)

Fit in cover bushing

0.0023-0.0043

0.0050

(0.058-0.109)

(0.127)

Bearing running clearance

0.00012-0.00088

–

(0.0030-0.0224)

Pinion shaft journal diameter

1986 models

1.2485-1.2490

1.2483

(31.712-31.725)

(31.707)

1987-2003 models

1.2496-1.2500

1.2494

(31.740-31.750)

(31.735)

Table 2 FLYWHEEL END PLAY SHIM THICKNESS

Harley-Davidson part number

in.

9155

0.0975-0.0985

2.477-2.502

9142

0.0995-0.1005

2.527-2.553

9143

0.1015-0.1025

2.578-2.604

9144

0.1035-0.1045

2.629-2.654

9145

0.1055-0.1065

2.680-2.705

9146

0.1075-0.1085

2.731-2.756

9147

0.1095-0.1105

2.781-2.807

9148

0.1115-0.1125

2.832-2.856

9149

0.1135-0.1145

2.883-2.908

Table 3 ENGINE TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Crankcase bolts

1/4 in.

–

70-110

8-12

5/16 in.

16-18

–

21-24

Cylinder head mounting

bracket fasteners
Engine mount-to-engine

25-30

–

34-41

Engine mount-to-frame

30-35

–

41-47

Engine center mount-to-engine

28-35

–

38-47

Cylinder stud (1995-2003 models)

–

120

Engine mount brackets

Lower front

Engine bolts

25-30

–

34-41

Frame bolts

25-30

–

34-41

Rear mount

Frame to crankcase bolts

25-30

–

34-41

Upper front

Engine bolts

25-30

–

34-41

Frame bolts

30-35

–

41-47

Top center

Engine bolts

25-30

–

34-41

Frame bolts

30-35

–

41-47

Engine sprocket

1986-1998 models

150-160

–

203-224

1999-2003 models

190-210

–

258-285

Gearcase cover screws

–

80-110

9-12

Oil filter adapter

–

96-144

11-16

Oil pressure switch

–

60-70

7-8

(continued)

ENGINE LOWER END

249

Table 3 ENGINE TORQUE SPECIFICATIONS (continued)

ft.-lb.

in.-lb.

N•m

Oil pump assembly and

mounting screws
(1991-2003 models)

–

125-150

14-17

Oil pump cover screws

–

70-80

7-9

Oil pressure regulator plug

15-20

–

20-27

Oil pump mounting screws

(1986-1990 models)

–

90-110

10-12

Pinion shaft nut

35-45

–

47-61

Tappet anti-rotation bolts

(2000-2003 models)

–

55-65

6-7

Tappet guide bolts

(1986-1990 models)

–

96-168

11-19

Tappet plate screws

(1991-1999 models)

–

80-110

9-12

1. Apply pipe sealant to the threads.
2. On 1988-2003 models, apply threadlock (Loctite 272 or equivalent).

250

CHAPTER FIVE

CHAPTER SIX

PRIMARY DRIVE AND CLUTCH

(1986-1990 MODELS)

This chapter covers the primary drive cover, primary

drive, clutch assembly and clutch cable.

Table 1 and Table 2 are at the end of the chapter.

PRIMARY DRIVE COVER

Refer to Figure 1.

Removal

1. Disconnect the negative battery cable (Chapter Twelve).
2. Drain the transmission oil (Chapter Three).
3. Remove the gearshift pedal and the left footpeg (Chap-
ter Seventeen).
4. Loosen the locknut and unscrew the adjuster (A, Figure
2) to loosen the primary drive chain.
5. Remove the clutch inspection cover (B, Figure 2).
6. Remove the adjusting screw spring and lockplate (Fig-
ure 3).
7. Turn the clutch adjusting screw clockwise (Figure 4)
until the nut can be removed, then remove the nut (Figure
5).

NOTE

Different length screws secure the primary
drive cover. Note the location and length of
the screws.

8. Remove the primary drive cover (C, Figure 2) and gas-
ket.

9. If necessary, remove the dowel pins.

10. If necessary, service the following components as de-
scribed in this chapter:

a. Clutch mechanism adjuster

b. Primary chain adjuster

c. Shift shaft oil seal

Installation

1. Clean the primary drive cover and engine crankcase gas-
ket surfaces in solvent and dry thoroughly.

2. If removed, install the clutch assembly and connect the
clutch cable as described in this chapter.

3. Install the dowel pins, if removed.

4. Using a new gasket, install the primary drive cover onto
the crankcase. Install the mounting screws and tighten to
80-110 in.-lb. (9-12 N•m).

5. Thread the nut (Figure 5) onto the clutch adjusting
screw until the screw slot is accessible with a screwdriver.
Then align and install the hex portion on the nut into the
outer ramp recess. Turn the clutch adjusting screw (Figure
4) counterclockwise until the nut cannot be removed.

6. Adjust the clutch as described in Chapter Three. The
spring and lockplate shown in Figure 3 will be installed
during the clutch adjustment procedure.

7. Adjust the primary chain (Chapter Three).

8. Refill the transmission oil (Chapter Three).

9. Install the shift lever and tighten the pinch bolt to 90-110
in.-lb. (10-12 N•m).

10. Install the left footpeg. Tighten the mounting bolts to
24-36 ft.-lb. (33-49 N•m).

CLUTCH RELEASE MECHANISM

Refer to Figure 1.

Removal

1. Remove the primary drive cover as described in this
chapter.
2. Pry the lockplate tabs away from the mounting screws
and remove the lockplate (A, Figure 6) and screws.
3. Remove the clutch release mechanism from the cover
and disconnect the cable (B, Figure 6) from the ramp and
coupling (C, Figure 6).

Inspection

1. Wash the clutch release mechanism in solvent and dry
thoroughly.

252

CHAPTER SIX

CLUTCH ADJUSTER

1. O-ring
2. Clutch cable (1988-1990 models)
3. Clutch cable (1986-1987 models)
4. Nut
5. Seal
6. Copper washer
7. Inspection cover
8. O-ring
9. Spring

10. Lockplate
11. Nut

12. Clutch cover

13A. Coupling (early 1986 models)
13B. Coupling (late 1986-1990 models)
14A. Outer ramp (early 1986 models)
14B. Outer ramp (late 1986-1990 models)

15. Balls
16. Inner ramp
17. Lockplate
18. Screw
19. Clutch adjusting screw assembly
20. Primary drive cover

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 20