Harley Davidson 2009 Dyna Models. Service manual - page 16

3.15

INSTALLING ENGINE IN CHASSIS

PROCEDURE

Using a suitable hoist, position engine in chassis and align
four transmission mounting holes. A pry bar wrapped in a
shop rag may be needed to position engine so two lower
locating dowel pins engage holes in crankcase.

Install new engine to transmission case gasket.

Install four bolts and washers to mate transmission and
engine. Tighten bolts finger tight.

Align two front engine mount bracket holes with engine
and install bolts and washers. Tighten bolts finger tight.

See

Figure 3-11

. Tighten the four transmission mounting

bolts in the sequence shown as follows:

Tighten to 15 ft-lbs (20.3 Nm).

Tighten to 34-39 ft-lbs (46.1-52.9 Nm).

Tighten two crankcase to front engine mounting bracket
bolts to 25-30 ft-lbs (33.9-40.7 Nm).

Remove ratchet strap securing transmission to chassis.

Install engine oil dipstick.

Remove jack and block of wood from under transmission.

10. Remove wire loom or protective material from front

downtubes.

11. Route clutch cable back to left side of motorcycle and

install to clutch lever. See

2.25 CLUTCH CONTROL

Secure clutch cable to left downtube with clip.

12. Install MAP sensor connector [80] to MAP sensor.

NOTE

If the stabilizer link bolt cannot be installed without pushing the
engine to the right or left, perform the vehicle alignment pro-
cedure. See

2.12 VEHICLE ALIGNMENT

13. Install horn bracket/stabilizer link assembly to frame tab

and cylinder heads. Place spacer between frame tab and
stabilizer link. Make sure horn ground wire is installed
beneath bracket on front cylinder.

Tighten the stabilizer link bolt to 18-22 ft-lbs (24.4-
29.8 Nm).

Tighten two cylinder head bracket bolts to 35-40 ft-
lbs (47.5-54.2 Nm).

14. Install spark plugs to cylinder heads. Connect spark plug

cables to spark plugs. See

1.20 SPARK PLUGS

15. Install new gasket between engine and primary chaincase.

Install primary chaincase. See

5.5 PRIMARY CHAINCASE

HOUSING

NOTE

Make sure spring washer is in position on shifter shaft between
engine and primary chaincase.

16. Adjust clutch. See

1.12 CLUTCH

sm02180

Figure 3-11. Transmission Housing to Crankcase Torque

Sequence

17. Adjust primary chain. See

1.10 PRIMARY CHAIN

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

18. Install primary chaincase cover and magnetic drain plug.

See

5.5 PRIMARY CHAINCASE HOUSING

19. Fill primary chaincase with primary chaincase lubricant.

See

1.10 PRIMARY CHAIN

20. Install left side footpeg and bracket with two screws.

Tighten to 25-35 ft-lbs (33.9-47.5 Nm).

21. Install shifter foot lever to primary chaincase. Tighten pinch

bolt to 18-22 ft-lbs (24.4-29.8 Nm). Connect shifter linkage.

22. Move to right side of motorcycle. Connect the following

connectors.

Crank position sensor connector [79].

Stator/voltage regulator connector [46].

Oil pressure sending unit connector [140].

23. Install rear brake pedal and right footpeg bracket with two

screws. Tighten to 25-35 ft-lbs (33.9-47.5 Nm). Install
actuator lever to pedal with clevis pin and new cotter pin.
See

2.15 REAR BRAKE MASTER CYLINDER

24. Install exhaust and heat shields. See

4.17 EXHAUST

SYSTEM

25. Install throttle control cables to induction module. See

4.10 INDUCTION MODULE

HOME

2009 Dyna Service: Engine 3-27

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)

26. Install fuel tank and connect crossover tube, fuel gauge

connector and clip vapor valve to downtube. See

4.6 FUEL

TANK

27. Install backplate and air cleaner cover. See

4.5 AIR

CLEANER ASSEMBLY

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

28. Connect battery cables, positive cable first.

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)

29. Install seat.

30. Install new oil filter. Fill engine to either wet or dry capacity

depending upon service status. See

1.5 ENGINE OIL AND

FILTER

NOTE

Use wet capacity for engines that have just had the oil drained.
Use dry capacity for engines that have been disassembled,
cleaned in solvent and dried.

31. Remove motorcycle from lift.

32. Perform vehicle alignment. See

2.12 VEHICLE ALIGN-

MENT

33. Check rear brakes, clutch and throttle for proper operation.

34. Check engine oil level with both cold check and hot check

procedures. See

1.5 ENGINE OIL AND FILTER

HOME

3-28 2009 Dyna Service: Engine

3.16

TOP END OVERHAUL: DISASSEMBLY

GENERAL

It is assumed that each step performed on one cylinder is
automatically repeated on the other.

To perform a complete top end overhaul, follow all steps listed
in this section including inspection and repair procedures.

ROCKER COVERS

TOOL NAME

PART NUMBER

LOWER ROCKER BOX WRENCH

HD-47248

UPPER ROCKER BOX WRENCH

HD-47258

NOTE

Dirt caked on cooling fins and other areas can fall into crank-
case bore or stick to subassemblies as parts are removed.
Abrasive particles can damage machined surfaces or plug oil
passageways. Remove all dirt and particles before disassembly
to prevent component damage.

Use low pressure spray to thoroughly clean exterior sur-
faces of engine prior to disassembly.

NOTE

See

Figure 3-12

. If the engine is left in the chassis for service,

use the UPPER ROCKER BOX WRENCH (Part No. HD-47258)
and LOWER ROCKER BOX WRENCH (Part No. HD-47248)
to remove the rocker cover and rocker housing bolts, respect-
ively. These tools are especially useful when removing the
bolts on the left side of the engine (particularly the rear) where
there is close proximity to the frame. With both an external and
internal hex, the bolts also can be removed with either a 7/16
inch socket or open end/box wrench (open spaces), or a short
3/16 inch allen wrench (tight spaces).

See

Figure 3-13

. Following the sequence shown, altern-

ately loosen the six rocker cover bolts. Remove the rocker
cover bolts and their captive washers.

Remove the rocker cover and gasket. Discard gasket.

sm02324

Internal hex

External hex

Lock patch

Figure 3-12. Rocker Cover Bolt (Rocker Housing Bolt

Similar)

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Figure 3-13. Rocker Cover Bolt Removal Sequence

ROCKER ARM SUPPORT PLATE

TOOL NAME

PART NUMBER

CRANKSHAFT ROTATING WRENCH

HD-48283

See

Figure 3-14

. Insert the blade of a small screwdriver

into cast loop (1) of spring cap retainer (at top of upper
push rod cover). While pushing down on spring cap (2),
rotate bottom of screwdriver toward outboard side to
remove. Repeat step on second push rod cover.

HOME

2009 Dyna Service: Engine 3-29

sm02329

Cast loop

Spring cap

Figure 3-14. Removing Spring Cap Retainer

Collapse upper and lower push rod covers.

To remove the rocker arm support plate, both lifters of the
cylinder being serviced must be on the base circle (lowest
position) of the cam. To find the base circle, it is first
necessary to rotate the engine. Based on the level of dis-
assembly required, three methods of engine rotation are
presented below.

With primary cover installed - Remove spark plugs.
With the rear wheel raised, place the transmission in
6th gear and rotate rear wheel in a clockwise direction
(as viewed from right side) until the base circle is
found. Continue with next numbered step.

With primary cover removed - Remove spark plugs.
Place the transmission in neutral. Fit a socket on the
compensating sprocket shaft nut. Rotate nut in a
counterclockwise direction until the base circle is
found. Continue with step 4.

NOTE

Do not attempt to rotate engine by removing cam cover
and placing socket on crank or primary cam sprocket
flange bolt. Head of flange bolt can break off possibly
resulting in damage to flywheel or camshaft.

See

Figure 3-15

. With engine mounted in engine

stand - Install CRANKSHAFT ROTATING
WRENCH (Part No. HD-48283) on sprocket shaft and
rotate in a counterclockwise direction until the base
circle is found.

sm02377

Figure 3-15. Crankshaft Rotating Wrench

Using one of the methods above, rotate engine until piston
is at top dead center (TDC) of compression stroke.

To accomplish this, first raise lower push rod cover
to access intake lifter (inside hole of lifter cover).

Place index finger on top of the intake lifter. While
rotating engine, feel lifter rise (valve open) and fall
(valve closed).

Now place finger tightly over spark plug hole and
rotate engine again. In the compression stroke, air
will be forced out against your finger until the piston
reaches the TDC position. Stop engine rotation when
the flow of air through the spark plug hole stops.

Direct the beam of a small flashlight into spark plug
hole to verify piston is at TDC. Both intake and
exhaust valves are now closed and the push rods are
in the unloaded (loose) position.

See

Figure 3-16

. Remove two bolts to release breather

assembly (arrow) and filter element from the rocker arm
support plate. For inspection and repair information, see

3.20 BREATHER ASSEMBLY

Alternately loosen each of the four rocker arm support
plate bolts 1/4 turn in the pattern shown the figure. Con-
tinue turning the bolts in these increments until loose.
Remove the rocker arm support plate bolts with flat
washers.

Remove the rocker arm support plate assembly from the
rocker housing. For inspection and repair information, see

3.21 ROCKER ARM SUPPORT PLATE

NOTE

Always service each cylinder separately. After the first cylinder
is serviced the engine must be rotated to find the base circle
on the second cam. Service on the remaining cylinder can then
proceed.

HOME

3-30 2009 Dyna Service: Engine

sm02386

Figure 3-16. 1/4 Turn Rocker Arm Bolts in Sequence

PUSH RODS, LIFTERS AND COVERS

See

Figure 3-17

. Remove the intake and exhaust push

rods and push rod covers.

Tag the push rods for location (front/rear cylinder),
and orientation (top/bottom) as they are removed.
This will simplify installation.

Remove push rod covers from cylinder head and lifter
cover bores.

Remove three o-rings from push rod covers and dis-
card. If o-ring is missing from upper push rod cover,
be sure to dislodge it from the cylinder head bore.

See

Figure 3-18

. Remove lifter covers.

Using a crosswise pattern, remove four screws with
captive washers (1) to release the lifter cover (2).

Remove the lifter cover and gasket. Discard gasket.

Remove lifters.

Remove the anti-rotational pin to free the hydraulic
lifters.

Tag the lifters for location (front/rear cylinder) and
function (intake/exhaust) as they are removed. This
will simplify installation.

Place the lifters in clean plastic bags to keep out dust,
dirt and debris.

See

Figure 3-19

. Remove and discard o-ring from groove

around breather baffle hole in rocker housing.

For inspection and repair information, see

3.22 PUSH

RODS, LIFTERS AND COVERS

sm02181

Front cylinder exhaust push rod

Front cylinder intake push rod

Rear cylinder intake push rod

Rear cylinder exhaust push rod

Figure 3-17. Push Rod Locations

sm02378

Screw with captive washer (4)

Lifter cover

Figure 3-18. Lifter Cover

HOME

2009 Dyna Service: Engine 3-31

sm02680

Figure 3-19. Breather Baffle Hole O-Ring

CYLINDER HEAD

TOOL NAME

PART NUMBER

CYLINDER TORQUE PLATES

HD-42324-A

See

Figure 3-20

. Following the sequence shown, altern-

ately loosen the six rocker housing bolts. Remove rocker
housing bolts and their captive washers.

Remove rocker housing and gasket. Discard gasket.

NOTE

To prevent distortion of the cylinder head, cylinder and cylinder
studs, gradually loosen the cylinder head bolts in the specified
sequence.

See

Figure 3-21

. Remove cylinder head bolts.

Following the sequence shown, alternately loosen
each of the four cylinder head bolts just 1/4 turn.

Continue turning the bolts in these increments until
loose.

Remove the cylinder head bolts.

Remove cylinder head and head gasket.

NOTE

Save the cylinder head gasket (if salvageable) for use with the
CYLINDER TORQUE PLATES (Part No. HD-42324-A) when
measuring, boring or honing of the cylinder is required.

For inspection and repair information, see

3.23 CYLINDER

HEAD

sm02389

Figure 3-20. Rocker Housing Bolts Removal Sequence

HOME

3-32 2009 Dyna Service: Engine

sm02392

Figure 3-21. 1/4 Turn Head Bolts in Sequence

CYLINDER

Raise the cylinder just enough to place clean shop towels
under the piston. This will prevent any dirt or debris, such
as broken ring pieces, from falling into the crankcase bore.

NOTE

Exercise caution to avoid bending the cylinder studs. Even a
slight bend or nick can cause a stress riser leading to stud
failure.

Carefully remove the cylinder. Exercise caution to avoid
bending the cylinder studs. As the piston becomes free of
the cylinder, hold it upright to prevent it from striking the
studs or dragging across the stud thread area.

Mark cylinder FRONT or REAR as appropriate.

Slide approximately 6.0 in. (152 mm) of plastic tubing,
rubber hose or conduit over each cylinder stud. Use
material with I.D. of 0.5 in. (12.7 mm) to protect cylinder
studs and piston from damage.

See

Figure 3-22

. Remove o-ring seal (4) from the bottom

of the cylinder liner. Discard o-ring seal.

See

Figure 3-23

. Remove o-ring from dowel pin (4) on

base of cylinder deck. Discard o-ring.

For inspection and repair information, see

3.24 CYL-

INDER

sm02294

Dowel pin

Head gasket

Cylinder

O-ring seal

Figure 3-22. Cylinder Assembly

PISTON

TOOL NAME

PART NUMBER

PISTON PIN CIRCLIP
REMOVER/INSTALLER

HD-42317-A

PISTON PIN REMOVER

HD-42320-B

Verify that clean shop towels are properly positioned over
the crankcase bore to prevent the piston pin circlip from
falling into the crankcase.

Wear safety glasses or goggles when removing or
installing piston pin retaining rings. Piston pin retaining
rings are compressed in the ring groove and can fly out
when removed from the groove, which could result in
serious eye injury. (00293a)

HOME

2009 Dyna Service: Engine 3-33

See

Figure 3-23

. Remove the piston pin circlip.

I n s e r t t h e P I S TO N P I N C I R C L I P
REMOVER/INSTALLER (Part No. HD-42317-A) (1)
into the piston pin bore. Position claw on tool in slot
of piston (2) (directly under circlip).

Hold a shop towel over the piston pin bore in case a
circlip should fly out during removal. Squeeze the
handles of the tool together and pull from bore.
Remove circlip from claw and discard.

sm02336

Piston pin circlip remover/installer

Piston

Protective material over cylinder studs

Cylinder deck dowel (O-ring not shown)

Figure 3-23. Piston Pin Circlip Removal (Part No. HD-42317)

NOTE

It is not necessary to remove both piston pin circlips during
piston removal. Leave the second circlip in the pin bore.

See

Figure 3-24

. Remove the piston pin. If piston pin is

difficult to remove, use PISTON PIN REMOVER (Part
No. HD-42320-B).

Remove acorn nut and spacer from rod end of tool.

Slide rod end through piston pin. Install spacer and
acorn nut (1) on end of rod.

Position rubber-coated tips (2) of tool on flat each
side of pin bore.

Turn handle (3) in a clockwise direction until piston
pin is pulled free of bore.

Remove the piston. Be sure to hold the connecting rod
shank upright to prevent it from striking the crankcase.
Place a 3.0 in. (76.2 mm) long piece of foam-type water
pipe insulation around each connecting rod. Use material
with an O.D. of 2.25 in. (57.1 mm) and an I.D. of 1.0 in.
(25.4 mm) to prevent damage.

Turn the piston over. Mark the pin boss with the letters
F(ront) or R(ear) to identify location.

Service as needed. For inspection and repair information,
see

3.25 PISTON

Complete engine work.

If performing a top end overhaul only, see

3.17 TOP

END OVERHAUL: ASSEMBLY

If performing a complete engine overhaul, see

3.18 BOTTOM END OVERHAUL: DISASSEMBLY

sm02334

Spacer and acorn nut

Rubber coated tip

Handle

Figure 3-24. Piston Pin Remover (Part No. HD-42320-B)

HOME

3-34 2009 Dyna Service: Engine

3.17

TOP END OVERHAUL: ASSEMBLY

GENERAL

NOTES

•

It is assumed that each step performed on one cylinder is
automatically repeated on the other.

•

Do not mix 2007 and later pistons with earlier style pistons.
New style pistons have tapered wrist pin boss. The wrist
pin portion of the connecting rod is also tapered.

This section provides a sequential process for engine reas-
sembly after a complete

3.16 TOP END OVERHAUL: DISAS-

SEMBLY

. If you reached this section after an inspection or

repair procedure, start where necessary and continue to the
end of the section.

•

Piston installation-see

3.17 TOP END OVERHAUL:

ASSEMBLY, Piston

•

Cylinder installation-see

3.17 TOP END OVERHAUL:

ASSEMBLY, Cylinder

•

Cylinder head installation-see

3.17 TOP END OVERHAUL:

ASSEMBLY, Cylinder Head

•

Push rods, lifters and covers installation-see

3.17 TOP

END OVERHAUL: ASSEMBLY, Push Rods, Lifters and
Covers

•

Rocker arm support plate installation-see

3.16 TOP END

OVERHAUL: DISASSEMBLY, Rocker Arm Support Plate

•

Breather assembly installation-see

3.17 TOP END

OVERHAUL: ASSEMBLY, Breather Assembly

PISTON

TOOL NAME

PART NUMBER

PISTON PIN CIRCLIP
REMOVER/INSTALLER

HD-42317-A

Slide approximately 6.0 in. (152 mm) of plastic tubing,
rubber hose or conduit over each cylinder stud, if removed.
Use material with I.D. of 0.5 in. (12.7 mm) to protect cyl-
inder studs and piston from damage.

Apply clean H-D 20W50 engine oil to piston pin, piston
bosses and upper connecting rod bushing.

Remove water pipe insulation from connecting rod shank.

See

Figure 3-25

. Place piston over rod end so that the

arrow stamped at the top of the piston points toward the
front of the engine.

See

Figure 3-26

. Insert piston pin (1) through pin bore and

upper connecting rod bushing. Push pin until it contacts
circlip installed in opposite pin boss. Verify that end gap
(3) for circlip is 180 degrees from opening (2).

Place clean shop towels over the cylinder and lifter bores
to prevent the piston pin circlip from falling into the crank-
case. Verify that the circlip groove is clean and free of dirt
and grime.

sm02379

Figure 3-25. Piston Installation Arrow

sm02380

Piston pin

Circlip opening

End gap location

Figure 3-26. Preinstalled Circlip

NOTE

Do not reuse piston pin circlips. The circlips could weaken
during removal causing them to break or dislodge during engine
operation, a condition that will result in engine damage.

HOME

2009 Dyna Service: Engine 3-35

Install new piston pin circlip with the PISTON PIN CIRCLIP
REMOVER/INSTALLER (Part No. HD-42317-A).

See

Figure 3-27

. Slide circlip down nose of tool until

it contacts claw. Lightly squeeze handles of tool to
capture circlip in claw.

Releasing pressure on handles, rotate circlip so that
the end gap is centered at top of tool and then
recapture in claw.

Tilt the circlip forward until the end gap contacts nose
of tool.

See

Figure 3-28

. Insert the tool (1) into the piston pin

bore until claw is aligned with slot (2) in piston.

Firmly push the tool into the piston pin bore until it
bottoms. Release handles and remove tool.

Inspect the circlip to verify that it is fully seated in the
groove.

sm02339

Figure 3-27. Aligning Circlip

sm02341

Piston pin circlip remover/installer

Slot

Cylinder deck dowel (O-ring not shown)

Figure 3-28. Pin Circlip Remover/Installer (Part No.

HD-42317)

CYLINDER

TOOL NAME

PART NUMBER

PISTON SUPPORT PLATE

HD-42322

THREADED CYLINDERS

HD-95952-1

CONNECTING ROD CLAMPING TOOL

HD-95952-33C

PISTON RING COMPRESSOR

HD-96333-51F

NOTE

O-rings that are missing, distorted, pinched or otherwise dam-
aged will result in either oil leakage or low oil pressure. Use of
the wrong o-ring will have the same results. Since many o-rings
are similar in size and appearance, always use new o-rings,
keeping them packaged until use to avoid confusion.

See

Figure 3-28

. Apply a very thin film of clean H-D 20W50

engine oil to new o-rings for both lower cylinder deck
dowels. Install and verify that o-ring is properly seated in
groove.

See

Figure 3-29

. Apply a very thin film of clean H-D 20W50

engine oil to new o-ring seal for the bottom of the cylinder
liner. Install new o-ring seal.

NOTE

Excessive lubrication of cylinder sleeve o-ring seal will result
in oil weepage between cylinder and crankcase as engine is
run. This condition may be incorrectly diagnosed as an oil leak.

See

Figure 3-30

. Verify that the piston ring end gaps are

staggered. Rotate each ring to position the gap 90 to 180
degrees from the gap in the ring above it. Locate the top
piston ring (5) gap towards the intake port.

Apply clean H-D 20W50 engine oil to piston, piston rings
and cylinder bore.

Remove protective covers from cylinder studs. Rotate
engine until piston is at top dead center. If necessary, see

3.16 TOP END OVERHAUL: DISASSEMBLY, Rocker Arm
Support Plate

for three methods of engine rotation.

See

Figure 3-31

. Install the PISTON SUPPORT

PLATE (Part No. HD-42322).

Slide both adjustable knobs (2) on support plate (1)
down away from forked end. Tighten knobs when
contact is made with flats at end of slots.

With the forked end of the tool pointing towards the
center of the engine and the adjustable knobs facing
downward, capture shank of connecting rod in fork.
Lay tool on cylinder deck so that adjustable knobs
contact wall of cylinder bore.

Rotate engine until piston skirt is centered and firmly
seated on top of support plate.

HOME

3-36 2009 Dyna Service: Engine

See

Figure 3-32

. Install cylinder using PISTON RING

COMPRESSOR (Part No. HD-96333-51F).

Fit tabs on pliers (1) into slots of ring compressor band
(2). The arrow stamped on the band indicates the
side that faces up, so disregard the word "bottom".
Place band around piston. Press the lever on the right
side of the pliers to open the jaws for band expansion.

Orient tool so that the top of the band is positioned
between the top compression ring and the piston
crown. Tightly squeeze handles of tool to compress
piston rings. The ratcheting action of the tool allows
release of the handles after the rings are compressed.

With the indent in the cooling fins facing the right side
of the engine, gently slide cylinder over the cylinder
studs and the piston crown resting it on the top of the
ring compressor band.

Place the palms of both hands at the top of the cyl-
inder. Push down on the cylinder with a sharp, quick
motion to pass the piston ring area.

Rotate the engine slightly to raise piston off support
plate. Remove pliers from band and then remove
band from around shank of connecting rod. Remove
piston support plate

Remove shop towels from around the crankcase bore
exercising caution to keep out any dirt or debris.

Carefully set the cylinder over the two dowel pins in the
cylinder deck. Push down on the cylinder until it is fully
seated in the crankcase bore.

NOTE

See

Figure 3-33

. To hold the first cylinder in position while

installing the second, install THREADED CYLINDERS (Part
No. HD-95952-1) from CONNECTING ROD CLAMPING
TOOL (Part No. HD-95952-33C) onto cylinder studs with the
knurled side down. This will prevent the piston rings from raising
the cylinder as the engine is rotated to bring the other piston
into position for installation of the second cylinder.

sm02342

Figure 3-29. O-ring Seal For Cylinder

sm02182

Expander spring

Bottom oil rail

Top oil rail

Second compression ring

Top compression ring

Front

Rear

Figure 3-30. Piston Ring Alignment

HOME

2009 Dyna Service: Engine 3-37

Ease off crank sprocket with a slightly smaller pry bar (seal
remover). Remove the rear cam sprocket, primary cam
chain and crank sprocket.

sm02399

Link

Rear cam sprocket

Primary cam chain tensioner

Primary cam chain tensioner fasteners

Crank sprocket

Retention hole

Figure 3-47. Cam Support Plate Assembly

sm02401

Rear cam sprocket bolt (large) and flat washer

Rear cam sprocket

Camshaft locking tool (HD-47941)

Crank sprocket bolt (small) and flat washer

Crank sprocket

Figure 3-48. Cam Support Plate Assembly

Cam Support Plate

See

Figure 3-49

. Following the sequence shown, altern-

ately loosen and then remove the four allen head socket
screws with captive washers to release the cam support
plate from the oil pump flange.

See

Figure 3-50

. Following the sequence shown, altern-

ately loosen and then remove the six allen head socket
screws with captive washers to release the cam support
plate from the crankcase flange.

HOME

2009 Dyna Service: Engine 3-47

sm02185

Figure 3-49. Oil Pump Torque Sequence

sm02404

Figure 3-50. Cam Support Plate Torque Sequence

See

Figure 3-51

. Two ring dowels (2, 3) in crankcase

flange locate cam support plate.

Insert small pry bar (seal remover) between inboard
side of cam support plate and crankcase flange in
area adjacent to ring dowels.

Alternately work each side free and then carefully
ease cam support plate and camshafts from end of
crankshaft.

See

3.26 CAM SUPPORT PLATE AND COVER

for

inspection and repair information.

sm02407

Right crankcase half

Forward ring dowel

Rear ring dowel

Figure 3-51. Ring Dowels

CRANKCASE

Carefully pull oil pump from crankshaft.

See

Figure 3-52

. Remove o-rings (1, 2) from crankcase

housing. Discard o-rings. See

3.27 OIL PUMP

for inspec-

tion and repair information.

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.

Rotate crankcase in the engine stand so that the cam
cover flange is facing straight upward.

See

Figure 3-53

. 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.

Using pry points, loosen case halves. Lift right crankcase
half off end of crankshaft.

See

Figure 3-54

. Remove two dowel pins in split line face

of right case half.

For inspection and repair information, see

3.28 CRANK-

CASE

HOME

3-48 2009 Dyna Service: Engine

sm02408

Oil feed hole O-ring

O-ring on crankcase post

Figure 3-52. Oil Pump O-rings

sm02186

Figure 3-53. Crankcase Bolt Sequence

sm02296

Figure 3-54. Right Crankcase Forward Dowel Pin (Rear

Dowel Pin Not Shown)

HOME

2009 Dyna Service: Engine 3-49

3.19

BOTTOM END OVERHAUL: ASSEMBLY

GENERAL

This section lists a sequential process for engine reassembly
after a complete bottom end disassembly and overhaul. If you
reached this section after an inspection or repair procedure,
start where necessary and continue to the end of the section.

•

Crankcase installation: see

3.28 CRANKCASE

•

Cover and cam support plate installation: see

3.19 BOTTOM END OVERHAUL: ASSEMBLY, Cam
Support Plate and Cover

CRANKCASE

TOOL NAME

PART NUMBER

HIGH-PERFORMANCE SEALANT,
GRAY

99650-02

SPROCKET SHAFT OIL SEAL
INSTALLER

HD-39361-B

CRANKSHAFT GUIDE

HD-42326-B

SPROCKET SHAFT BEARING
INSTALLER

HD-97225-55C

NOTE

O-rings that are missing, distorted, pinched or otherwise dam-
aged will result in either oil leakage or low oil pressure. Use of
the wrong o-ring will have the same results. Since many o-rings
are similar in size and appearance, always use new o-rings
keeping them packaged until use to avoid confusion.

Bolt left crankcase half upright in engine stand.

To facilitate assembly and prevent damage to the crank-
shaft (roller) bearing in the left crankcase half, slide
CRANKSHAFT GUIDE (Part No. HD-42326-B) onto fly-
wheel sprocket shaft.

Slide flywheel assembly into left crankcase half. Remove
CRANKSHAFT GUIDE tool.

Tip crankcase assembly in engine stand so that flywheel
sprocket shaft is pointing straight up.

Verify that both dowel pins are installed in split line face
of right case half.

With the right crankcase half resting on the cam cover
flange, apply a bead of sealant approximately 0.056 in.
(1.42 mm) wide to the split line face and around the two
dowel pins. For best results, use HIGH-PERFORMANCE
SEALANT, GRAY (Part No. 99650-02).

See

Figure 3-55

. To facilitate assembly and prevent

damage to the crankshaft (roller) bearing in the right
crankcase half, place CRANKSHAFT GUIDE (1) (Part No.
HD-42326-B) over end of crankshaft until it contacts
shoulder on shaft.

Mate case halves sliding bearing roller in right crankcase
half over end of crankshaft. Remove CRANKSHAFT
GUIDE.

sm02297

Crankshaft guide

Water pipe insulation

Figure 3-55. Crankshaft Guide (Part No. HD-42326-A)

sm02186

Figure 3-56. Tightening Crankcase Bolts

See

Figure 3-56

. Start the nine crankcase bolts and tighten

in the following sequence.

Alternately turn each crankcase bolt until finger tight.

Tighten the crankcase bolts to 10 ft-lbs (13.6 Nm) in
the order shown.

Following the same sequence, tighten each bolt to to
15-19 ft-lbs (20.3-25.8 Nm).

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3-50 2009 Dyna Service: Engine

10. Tip crankcase assembly so that sprocket shaft is pointing

straight up.

11. Install thrust washer on sprocket shaft with "THIS SIDE

OUT" facing out (and the chamfer inboard). If using OE
part without markings, orient as required to preserve
existing wear pattern.

12. See

Figure 3-57

. Install new oil seal into bearing bore.

Obtain pilot adapter, pilot shaft, short collar, Nice bearing,
large flat washer and handle from SPROCKET SHAFT
BEARING INSTALLER (Part No. HD-97225-55C).

Thread pilot adapter into sprocket shaft.

Thread pilot shaft onto pilot adapter.

Verify that lip garter spring is in place on both sides
of oil seal.

Install sprocket shaft spacer in oil seal bore.

With the lettering on the oil seal facing outside, slide
sprocket shaft spacer and oil seal over pilot shaft until
it contacts bearing bore.

Slide SPROCKET SHAFT OIL SEAL
INSTALLER (Part No. HD-39361-B) over pilot shaft
until it contacts oil seal.

Slide short collar over pilot shaft until it contacts seal
installer.

Slide Nice bearing and large flat washer over pilot
shaft.

Sparingly apply graphite lubricant to threads of pilot
shaft to prolong service life and verify smooth opera-
tion.

Thread handle onto pilot shaft to complete assembly
of tool.

13. Rotate handle in a clockwise direction until oil seal installer

makes firm contact with crankcase stator mount.

14. Remove handle, flat washer, Nice bearing, short collar,

seal installer, pilot shaft and pilot adapter from sprocket
shaft.

15. Rotate crankcase in engine stand so that cam cover flange

is facing upward.

sm02348

Seal Installer

Figure 3-57. Sprocket Shaft Oil Seal Installer

NOTE

O-rings that are missing, distorted, pinched or otherwise dam-
aged will result in either oil leakage or low oil pressure. Use of
the wrong o-ring will have the same results. Since many o-rings
are similar in size and appearance, always use new o-rings
keeping them packaged until use to avoid confusion.

16. See

Figure 3-58

. Assemble and install oil pump. Lubricate

parts with clean H-D 20W50 engine oil during assembly.

Apply a very thin film of clean H-D 20W50 engine oil
to new scavenge port stub o-ring (6). Install new o-
ring on scavenge port stub of oil pump housing.

Slide oil pump housing (5) onto crankshaft fitting o-
ring on scavenge port stub into crankcase bore at
back of cam compartment. Firmly push on scavenge
port stub with thumb to be sure that it is snug in bore.
Inspect o-ring on stub to verify that it is not pinched
or distorted.

Separate the gerotor gears into two sets, one wide
(4) (scavenge) and the other narrow (1) (feed).

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2009 Dyna Service: Engine 3-51

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