Harley Davidson 2009 Dyna Models. Service manual

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Expander ring

Bottom oil rail

Top oil rail

Second compression ring

Top compression ring

Front

Rear

Figure 3-106. Piston Ring Gap Alignment

INSTALLATION OVERVIEW

See

3.17 TOP END OVERHAUL: ASSEMBLY

Attach piston to connecting rod.

Install cylinder.

Install cylinder head.

Install push rod covers and push rods.

Install rocker arm support plate.

Install breather assembly.

Continue with vehicle assembly as directed.

HOME

3-84 2009 Dyna Service: Engine

3.26

CAM SUPPORT PLATE AND COVER

REMOVAL OVERVIEW

See

3.16 TOP END OVERHAUL: DISASSEMBLY

Remove breather assembly.

Remove rocker arm support plate.

Remove push rods and push rod covers. Do not
remove lifters or lifter covers.

See

Figure 3-107

. Fashion lifter holding tool to prevent

the hydraulic lifters from dropping into the cam compart-
ment during cam support plate removal.

Obtain a large binder clip (1) which is available at any
office supply store. Squeeze wireforms (2) to remove
from binder clip.

Compress wireform (2) slightly and insert free ends
into outer and inner lifter cover bores so that legs
engage walls of both hydraulic lifter sockets.

To remove cover and cam support plate, see

3.18 BOTTOM END OVERHAUL: DISASSEMBLY

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Binder clip

Wireform

Figure 3-107. Hydraulic Lifter Holding Tool

CAMSHAFTS

TOOL NAME

PART NUMBER

CAMSHAFT ASSEMBLY TOOL

HD-47956

Removal

See

Figure 3-108

. Remove screws (4) and remove sec-

ondary cam chain tensioner (3).

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

Remove retaining ring from groove at end of front cam-
shaft. Discard retaining ring.

Remove spacer from front camshaft. Do not mix front and
rear camshaft spacers. Front spacer is 0.100 in. (2.54 mm)
thick.

Using a colored marker, mark one of the links of the sec-
ondary cam chain. Maintaining the original direction of
rotation during assembly may prolong service life.

Slide camshafts and secondary cam chain out of cam
support plate.

Remove secondary cam chain from cam sprockets.

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Cam support plate

Front cam

Secondary cam chain tensioner

Secondary cam chain tensioner fasteners

Rear cam

Figure 3-108. Camshafts

Assembly

See

Figure 3-109

. Align timing marks on teeth of sec-

ondary cam sprockets (outboard faces).

NOTE

Do not mix camshafts during the installation procedure. The
rear camshaft, which can be identified by the splined shaft,
must go into the hole at the rear of the cam support plate.

HOME

2009 Dyna Service: Engine 3-85

Place the secondary cam chain around the sprockets of
both the front and rear camshafts while keeping the timing
marks (3) in alignment. To maintain the original direction
of rotation, be sure that the mark placed on the chain link
during disassembly is visible during installation.

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Rear camshaft

Front camshaft

Timing marks

Figure 3-109. Camshaft Timing Marks

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Rear camshaft

Small guide

Front camshaft

Large guide

Cam chain

Timing marks

Assembly tool base

Figure 3-110. Camshaft Assembly Tool

See

Figure 3-110

. Obtain CAMSHAFT ASSEMBLY

TOOL (Part No. HD-47956). Place crankcase side of

camshaft/cam chain assembly into assembly tool base (7)
while maintaining cam timing mark (6) alignment.

Place small guide (2) on rear camshaft (1). Place large
guide (4) on front camshaft (3).

Lubricate support plate camshaft cavities with clean H-D
20W50 engine oil.

Install cam support plate over guides.

Remove guides and base.

See

Figure 3-111

. Using a straightedge, verify that the

timing marks are in alignment. If they are not, then the
camshafts must be removed, realigned and reinstalled.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

Install 0.100 in. (2.54 mm) thick front camshaft spacer
over end of front camshaft.

10. With the sharp edge out, install new retaining ring in

groove at end of front camshaft.

11. Inspect primary and secondary cam chain tensioners.

Inspect tensioners for wear. Replace tensioners if
damaged or if chain contact portion of shoe material
is less than 0.060 in. (1.52 mm) thick.

See

Figure 3-112

. Be sure primary and secondary

cam chain tensioners are assembled as shown. If
assembled incorrectly, tensioners will not function
properly.

12. Install secondary cam chain tensioner. Tighten fasteners

to 100-120 in-lbs (11.3-13.6 Nm).

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Rear camshaft

Front camshaft

Timing marks

Figure 3-111. Verify Alignment of Timing Marks

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3-86 2009 Dyna Service: Engine

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Secondary cam chain tensioner

Primary cam chain tensioner

Piston

Spring

Shoe

Figure 3-112. Cam Chain Tensioner Assemblies

OIL PRESSURE RELIEF VALVE

Removal

Before removal, see

3.27 OIL PUMP, Cleaning and

Inspection

Secure the cam support plate in a vise with access to the
roll pin. Be sure to install a pair of brass jaw inserts in the
vise to avoid damage to the casting.

See

Figure 3-113

. Using a 1/8 in. punch with a small

hammer, carefully tap roll pin (1) from pin hole in cam
support plate. Discard roll pin.

Remove spring (2) and valve body (3) from bypass port.

Installation

Secure the cam support plate in a vise. Be sure to install
a pair of brass jaw inserts to avoid damage to the casting.

See

Figure 3-113

. Lubricate valve body (3) with clean H-

D 20W50 engine oil. Slide valve body into bypass port of
cam support plate with the open side facing outward.

Slide spring (2) into bypass port until seated in open side
of valve body.

Start new roll pin (1) into hole in cam support plate.
Compress spring in port using the blade of a small
screwdriver.

Holding spring compressed, tap roll pin into cam support
plate until it approaches pin hole on opposite side.

Remove screwdriver to release spring. Verify that spring
is straight and square in bore.

Using a 1/8 in. punch with a small hammer, carefully tap
roll pin until flush with casting.

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Roll pin

Spring

Valve body

Bypass port

Figure 3-113. Oil Pressure Relief Valve Assembly

Inspection

NOTE

If diagnosing low oil pressure, start with step 1. If diagnosing
high oil pressure, then begin with step 2.

Insert straight stiff wire into unplugged hole outboard of
roll pin until it bottoms. Mark wire and measure distance
from edge of cam support plate to inboard side of piston.
With piston fully seated in the bore, depth should be
approximately 2.25 in. (57.15 mm). If it is not, continue
with next step.

Remove oil pressure relief valve.

Inspect spring for stretching, kinks, or distortion.

Inspect piston and bore for burrs, scoring or other damage.
Look for steel particles or aluminum chips. Replace cam
support plate and piston if any of these conditions are
found.

Install piston in bore and measure running clearance. If
running clearance exceeds 0.003 in. (0.076 mm), install
new piston and measure again. Replace cam support
plate if running clearance still exceeds specification.

CAM NEEDLE BEARINGS

TOOL NAME

PART NUMBER

CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER

HD-42325-A

Removal

Obtain the CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER (Part No. HD-42325-A).

See

Figure 3-115

. Remove four thumb screws (1) from

threaded holes in support plate (2), if installed.

Sparingly apply graphite lubricant (9) to threads of collet
(3) to prolong service life and verify smooth operation.

HOME

2009 Dyna Service: Engine 3-87

Slide collet through support plate so that threaded end
exits stamped side of plate.

Aligning two large holes in support plate with needle
bearing bores, hang right side of plate on ring dowel in
crankcase flange.

Align four holes at corners of support plate with threaded
holes in crankcase flange. Install thumb screws in these
holes to secure support plate to crankcase.

Center expandable end of collet in bearing bore and slide
Nice bearing (7) and flat washer (5) on threaded end. Start
hex nut (8) on threaded end.

Push expandable end of collet through bearing bore into
flywheel compartment. Feel for inside edge of needle
bearing using end of collet and then back off slightly.

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Flat

Hex

Figure 3-114. Expanding Collet by Turning Hex Clockwise

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Installer (1 in., 25.4 mm)

Thumb screw

Support plate

Nice bearing

Hex nut

Removal collet (Threaded end: left, Expandable
end: right)

Graphite lubricant

Installer forcing screw

Flat washer

Figure 3-115. Camshaft Needle Bearing Remover/Installer (Part No. HD-42325-A)

Holding collet to prevent lateral movement, finger tighten
hex nut until Nice bearing contacts support plate.

10. See

Figure 3-114

. Using a 7/16 in. open end wrench, hold

flat on collet to prevent rotation. Using a second 7/16 in.
open end wrench, expand collet by turning hex at end of
shaft in a clockwise direction. Expandable end of collet
makes contact with needle bearing ID.

11. See

Figure 3-116

. Using a 15/16 in. open end wrench,

turn hex nut in a clockwise direction until bearing is free.
If necessary, hold flat on collet to prevent rotation.

12. Remove four thumb screws and pull support plate from

crankcase.

13. Holding flat on collet, turn hex at end of shaft in a counter-

clockwise direction to close collet. Remove and discard
needle bearing.

14. Remove hex nut, flat washer and Nice bearing from

threaded end of collet. Pull collet from support plate.

15. Repeat this procedure to remove second needle bearing.

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3-88 2009 Dyna Service: Engine

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Figure 3-116. Bearing Removal

Installation

Obtain the CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER (Part No. HD-42325-A).

NOTE

To avoid engine damage, care must be taken to install needle
bearings to the correct depth. The correct depth is achieved
only when the edge of the needle bearing is 3.10 in. (78.7 mm)
from the cam cover flange.

Since measuring from the top of the support plate is easier
and produces the most accurate and consistent results,
proceed as follows:

See

Figure 3-117

. Using a dial caliper, measure

thickness of support plate.

To determine the required distance from the top of
the support plate to the edge of the installed needle
bearing, add measurement obtained in the previous
step to 3.10 in. (78.7 mm).

NOTE

For example, if the support plate is 0.50 in. (12.7 mm) thick,
then the measurement from the top of the support plate to the
edge of the needle bearing should be 3.60 in. (91.4 mm).

See

Figure 3-115

. Sparingly apply graphite lubricant (9)

to threads of installer forcing screw (4) to prolong service
life and verify smooth operation.

Thread installer forcing screw into stamped side of support
plate (2) until threads begin to emerge from opposite side.

Place installer (6) at end of installer forcing screw.

Place new needle bearing on installer with lettered side
facing shoulder of installer.

See

Figure 3-118

. Aligning two large holes in support plate

with needle bearing bores, hang right side of plate on ring
dowel in crankcase flange.

Align four holes at corners of support plate with threaded
holes in crankcase flange. Install thumb screws in these
holes to secure support plate to crankcase.

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Figure 3-117. Measure Thickness of Support Plate

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Figure 3-118. Installer Forcing Screw Installation

HOME

2009 Dyna Service: Engine 3-89

Install first needle bearing as follows:

See

Figure 3-119

. Turn hex at end of installer forcing

screw in a clockwise direction to press needle bearing
into bore.

Back out forcing screw. Reaching into crankcase,
remove installer. Remove forcing screw from support
plate.

See

Figure 3-120

. Inserting dial caliper through forcing

screw bore, measure distance from top of support
plate to edge of needle bearing.

If bearing is not installed to the correct depth (as cal-
culated earlier), install forcing screw and installer and
repeat the three previous steps.

Install forcing screw back into support plate. Reaching
into crankcase, place installer at end of forcing screw.
Hand turn forcing screw until shoulder on installer
makes contact with edge of needle bearing.

NOTE

In the next step, a measurement will be taken of the distance
from the head of the installer forcing screw to the support plate.
This measurement will be used for installing the second needle
bearing. For an accurate measurement, be sure the shoulder
on the installer is in contact with the edge of the needle bearing.

10. See

Figure 3-121

. Using a dial caliper, measure from head

(top) of installer forcing screw to support plate. Record
this measurement.

11. Back out forcing screw. Reaching into crankcase, remove

installer. Remove forcing screw from support plate.

12. Install forcing screw in support plate over second needle

bearing bore. Reaching into crankcase, place installer at
end of forcing screw. Place new needle bearing on installer
with lettered side facing shoulder of installer.

13. Turn hex on forcing screw in a clockwise direction until

distance from head (top) of forcing screw to support plate
equals measurement obtained previously.

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Figure 3-119. 1 Inch (25.4 mm) Bearing Installation

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Figure 3-120. Measure from Top of Support Plate to Edge

of Needle Bearing

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Figure 3-121. Measure from Top of Forcing Screw to

Support Plate

CLEANING AND INSPECTION

Oil Pressure Valve

See

3.26 CAM SUPPORT PLATE AND COVER, Oil Pressure

Relief Valve

Cam Support Plate

Verify that all oil holes are clean and open.

NOTE

Exercise caution to avoid enlarging the oil holes or oil pressure
will be adversely affected.

INSTALLATION OVERVIEW

Begin with

3.19 BOTTOM END OVERHAUL: ASSEMBLY,

Cam Support Plate and Cover

Continue with

3.17 TOP END OVERHAUL: ASSEMBLY

HOME

3-90 2009 Dyna Service: Engine

3.27

OIL PUMP

REMOVAL OVERVIEW

See

3.16 TOP END OVERHAUL: DISASSEMBLY

Remove breather assembly.

Remove rocker arm support plate.

Remove push rods and push rod covers. Do not
remove lifters or lifter covers.

Fashion lifter holding tool to prevent the hydraulic lifters
from dropping into the cam compartment during cam
support plate removal. See

3.26 CAM SUPPORT PLATE

AND COVER

To remove cover and cam support plate, see

3.18 BOTTOM END OVERHAUL: DISASSEMBLY

Remove oil pump after removing cam support plate.

CLEANING AND INSPECTION

Clean all parts in a non-volatile cleaning solution or
solvent.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

Blow parts dry with low pressure compressed air. Verify
that all oil passages are clean and open.

Look for scoring, gouging or cracking caused by foreign
material that may have passed through the oil pump.

Look for grooves or scratches on the cam support plate,
which serves as the outboard side of the oil pump.

Check for excessive wear or damage on lobes of outer
gerotor gears and between lobes on inner gerotor gears.

See

Figure 3-122

. Check gerotor wear.

Mesh pieces of one gerotor set together.

Use a feeler gauge to determine clearance between
tips of lobes on inner and outer gerotors.

Replace gerotors as a set if clearance exceeds 0.004
in. (0.10 mm). Inspect second gerotor set in the same
manner.

Measure thickness of inner gerotor of one set with a
micrometer. Measure the outer gerotor of the same set.
Replace the gerotor set if the difference exceeds 0.001
in. (0.025 mm). Inspect second gerotor set in the same
manner.

See

Figure 3-123

. Assemble the oil pump. Verify that feed

gerotors stand proud of the oil pump surface 0.015-0.025
in. (0.38-0.64 mm). If measurement is less than 0.015 in.
(0.38 mm), remove feed gerotor set and reassemble using
new wave washer. Repeat measurement and replace oil
pump body if still not within specification.

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Outer gerotor

Inner gerotor

Wear limit

Figure 3-122. Measure Gerotor Sets for Wear

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Narrow gerotor set (feed)

Separator plate

Wave washer

Wide gerotor set (scavenge)

Oil pump housing

Scavenge port O-ring

Figure 3-123. Assembling Oil Pump

INSTALLATION OVERVIEW

See

3.26 CAM SUPPORT PLATE AND COVER, Installa-

tion Overview

Continue with

3.17 TOP END OVERHAUL: ASSEMBLY

HOME

2009 Dyna Service: Engine 3-91

3.28

CRANKCASE

REMOVAL OVERVIEW

Perform all steps under

3.16 TOP END OVERHAUL:

DISASSEMBLY

Perform all steps under

3.18 BOTTOM END OVERHAUL:

DISASSEMBLY

RIGHT CRANKCASE HALF

TOOL NAME

PART NUMBER

CRANKCASE BEARING
REMOVER/INSTALLER

B-45655

CRANKCASE BEARING
REMOVER/INSTALLER BASE

HD-42720-5

Main Bearing Removal

NOTE

Do not 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.

See

Figure 3-124

. Obtain CRANKCASE BEARING

REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER
BASE (Part No. HD-42720-5).

Place support tube (2) on hydraulic press table with the
"A" end up. Note that the sides of the support tube are
stamped to ensure proper orientation.

With the outboard side of the right crankcase half facing
upward, position main bearing bore over support tube.
During removal it is important that the curved edges on
the pilot/driver (1) match the curved edges of the crank-
case.

Slide pilot/driver (1) through bearing into support tube.

Center pilot/driver under ram (3) of press. Apply pressure
to pilot/driver until bearing is free.

Remove crankcase, pilot/driver and bearing from support
tube. Discard bearing.

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Pilot/driver

Support tube

Ram

Support tube (2) "A" end up

Figure 3-124. Right Main Bearing Removal

Main Bearing Installation

See

Figure 3-125

. Obtain CRANKCASE BEARING

REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER BASE
(Part No. HD-42720-5).

Obtain new main bearing (4). Spread a thin film of clean
engine oil on O.D. of new bearing.

Turn support tube (2) over so that the "B" end is up. The
sides of the support tube are stamped "A" and "B" to
ensure proper orientation.

With the outboard side of the right crankcase half facing
upward, position main bearing bore over support tube.

Lubricate leading edge (letter side) of new main bearing
with clean engine oil. Start leading edge of bearing in
bearing bore.

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3-92 2009 Dyna Service: Engine

Slide pilot/driver (1) through bearing into support tube.

Center pilot/driver under ram (3) of press. Apply pressure
to pilot/driver until resistance is felt and bearing is bot-
tomed on the support tube.

Remove pilot/driver and crankcase half from support tube.

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Pilot/driver

Support tube

Ram

Main bearing

Support tube (2) "B" end up

Figure 3-125. Right Main Bearing Installation

Piston Jets Removal

See

Figure 3-126

. Remove two T20 TORX screws (1) to

free piston jet (2) from crankcase.

Remove o-ring (3) from groove in mounting flange of jet.
Discard o-ring.

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T20 TORX screw

Piston jet

O-ring

Figure 3-126. Piston Jets

Piston Jets Installation

NOTES

•

If piston jet is being reused, apply LOCTITE THREAD-
LOCKER 222 (purple) to threads of TORX screws before
installation.

•

O-rings that are missing, distorted, pinched or otherwise
damaged 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 3-126

. Apply a very thin film of clean H-D

20W50 engine oil to new o-ring (3) for piston jet. Install
new o-ring in groove of jet mounting flange.

With jet pointed upward, start two T20 TORX screws (1)
to secure piston jet (2) to crankcase. Tighten to 25-35 in-
lbs (2.8-3.9 Nm).

LEFT CRANKCASE HALF

TOOL NAME

PART NUMBER

CRANKCASE BEARING
REMOVER/INSTALLER

B-45655

CRANKCASE BEARING
REMOVER/INSTALLER BASE

HD-42720-5

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.

HOME

2009 Dyna Service: Engine 3-93

Do not rotate left crankcase half in engine stand such that
flywheel sprocket shaft is facing up.The flywheel assembly
can fall out, resulting in parts damage or moderate injury.
(00552b)

While holding flywheel assembly so that it does not fall
out of left crankcase half, rotate bottom end assembly in
engine stand so assembly is upright and flywheel shafts
are horizontal.

Carefully slide flywheel assembly out of left crankcase and
place it in a clean safe place.

Unbolt left crankcase half from stand and move it to bench
area. Remove thrust washer from outboard side of crank-
case half by pulling it past oil seal. Set thrust washer aside
for inspection or reuse.

Remove oil seal from crankcase bore. Discard oil seal.

See

Figure 3-127

. The left main bearing (1) is press-fit

into the main bearing bore (2) in the left crankcase and
secured with a retaining ring (3) on the inboard side. See

Figure 3-128

. Using the tip of a flat blade screwdriver,

carefully lift the edge of the retaining ring up out of its
groove in the crankcase. Slide the screwdriver tip around
the edge of the bearing, lifting the retaining ring up and
out of the groove. Be careful not to damage the lip of the
groove in the crankcase.

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Main bearing

Main bearing bore

Retaining ring

Figure 3-127. Left Main Bearing Assembly

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Figure 3-128. Removing Retaining Ring

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Support tube

Pilot/driver

Figure 3-129. Left Main Bearing Remover and Installer

Tools

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3-94 2009 Dyna Service: Engine

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Ram

Pilot/driver

Support tube ("B" end up)

Figure 3-130. Left Main Bearing Removal

NOTE

See

Figure 3-129

. 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.

O b t a i n C R A N K C A S E B E A R I N G
REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER
BASE (Part No. HD-42720-5).

See

Figure 3-130

. Place support tube (3) on hydraulic

press table with "B" end up. Note that sides of support
tube are stamped "A" and "B" to verify proper orientation.

With the outboard side of the left crankcase half facing
upward, position main bearing bore over support tube.

Slide pilot/driver (2) through main bearing into support
tube (3).

10. If the ram of the press is wider than the head of pilot/driver

(2), place a suitable press plug on top of pilot/driver (2).

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

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.

See

Figure 3-129

. Obtain CRANKCASE BEARING

REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER BASE
(Part No. HD-42720-5).

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Ram

Pilot/driver

Support tube ("A" end up)

Main bearing

Figure 3-131. Left Main Bearing Installation

See

Figure 3-131

. Obtain new main bearing (4). Place a

thin film of clean engine oil on outer diameter of bearing.

Place support tube (3) on hydraulic press table with the
"A" end up.

With the inboard side of the left crankcase half facing
upward, position main bearing bore over support tube.

Lubricate leading edge of new main bearing before
placement. Start new main bearing in bearing bore, letter
side down.

Slide pilot/driver (2) through bearing into support tube.

Center pilot/driver (2) under ram (1) of press. Apply pres-
sure to pilot/driver until bearing is lightly bottomed in main
bearing bore.

Remove crankcase half and pilot/driver from support tube.

Obtain new retaining ring and install in bearing bore in
inboard side of crankcase half. Work retaining ring into
groove, being careful not to damage edges of groove.
Make sure retaining ring is fully seated in groove.

NOTE

If retaining ring will not fit into groove in bearing bore, it is a
sign that the bearing is not fully seated in the bore. Examine
the bearing and bore. If necessary, remove bearing, clean bore
and install bearing. Then install retaining ring.

HOME

2009 Dyna Service: Engine 3-95

SPROCKET SHAFT BEARING INNER RACE

TOOL NAME

PART NUMBER

ROBINAIR HEAT GUN

HD-25070

MAINSHAFT BEARING INNER RACE
PULLER/INSTALLER

HD-34902-B

FLYWHEEL SUPPORT FIXTURE

HD-44358

WEDGE ATTACHMENT

HD-95637-46B

SPROCKET SHAFT BEARING
INSTALLER

HD-97225-55C

Removal

If reusing flywheel, remove bearing inner race and thrust
washer as follows:

Obtain FLYWHEEL SUPPORT FIXTURE (Part No. HD-
44358). See

Figure 3-132

. Install brass jaws or shop

towels around teeth of vise to prevent damage to tool.
Clamp tool in vise with the round hole topside.

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.

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.

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Locating pin

Hold-down clamp

Figure 3-132. Flywheel Fixture (Part No. HD-44358)

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.

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)

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.

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.

Sparingly apply graphite lubricant to threads of forcing
screw to prolong service life and ensure 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.

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.

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 facilitate removal without heat, apply a light penetrating oil
to shaft and leading edge of bearing inner race.

Do not use heating devices with penetrating oil. Penet-
rating oil is flammable which could result in death or ser-
ious injury. (00375a)

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 3-133

. Verify that the tool assembly is square,

so that the bearing inner race is not cocked during
removal.

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3-96 2009 Dyna Service: Engine

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 facilitate 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.

sm03853

Forcing screw

3/8-16 in. bolt with flat washer

Bridge

Hardened washer

Wedge attachment

Bearing inner race

Sprocket shaft

Figure 3-133. Remove Inner Race from Sprocket Shaft

Installation

Place new thrust washer over sprocket shaft.

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 cir-
cular motion.

Wearing suitable gloves to protect hands from burns, place
heated bearing inner race over sprocket shaft.

NOTE

To facilitate installation without heat, apply a light penetrating
oil to shaft and leading edge of bearing inner race.

Do not use heating devices with penetrating oil. Penet-
rating oil is flammable which could result in death or ser-
ious injury. (00375a)

See

Figure 3-134

. Obtain the SPROCKET SHAFT

BEARING INSTALLER (Part No. HD-97225-55C).
Assemble tool as described below.

See

Figure 3-135

. Thread pilot adapter into sprocket

shaft.

Thread pilot shaft onto pilot adapter.

Slide long collar over pilot shaft until it contacts
bearing inner race.

Slide short collar over pilot shaft until it contacts long
collar.

Slide Nice bearing and large flat washer over pilot
shaft.

Sparingly apply graphite lubricant to threads of pilot
shaft to prolong service life and ensure smooth oper-
ation.

See

Figure 3-136

.Thread handle onto pilot shaft.

See

Figure 3-137

. Rotate handle of tool in a clockwise

direction until bearing inner race makes firm contact with
thrust washer. Verify that thrust washer cannot be rotated
by hand.

Remove handle, flat washer, Nice bearing, short collar,
long collar, pilot shaft and pilot adapter from sprocket shaft.

sm03854

Figure 3-134. Sprocket Shaft Bearing Installer (Part No.

HD-97225-55C)

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2009 Dyna Service: Engine 3-97

sm03855

Figure 3-135. Thread Pilot Adapter into Sprocket Shaft

sm03856

Pilot adapter

Pilot shaft

Handle

Flat washer

Nice bearing

Short collar

Long collar

Inner race

Thrust washer

Figure 3-136. Press Inner Race onto Sprocket Shaft: Setup

sm03857

Figure 3-137. Press Inner Race onto Sprocket Shaft:

Operation

CYLINDER STUDS

Removal

Thread a 3/8"-16 nut onto cylinder stud.

Thread a second nut onto stud until it contacts the first.

Placing wrench on first nut installed, remove stud.

Installation

Place a steel ball inside a head screw. Put the head screw
on the end of the cylinder stud without the collar.

Start the stud in the cylinder deck with the collar side down.
Tighten using air gun until collar reaches crankcase.

Hand tighten stud to 10-20 ft-lbs (3.6-27.1 Nm).

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3-98 2009 Dyna Service: Engine

PIPE PLUG AND OIL FITTINGS

Removal

See

Figure 3-138

. Turn pipe plug counterclockwise until free.

sm02309

Figure 3-138. Pipe Plug

Installation

Apply LOCTITE PIPE SEALANT 565 to threads.

Install pipe plug. Tighten pipe plug to 120-144 in-lbs (13.6-
16.3 Nm).

CLEANING AND INSPECTION

Scrape old gasket material from the crankcase flanges.
Old gasket material left on mating surfaces will cause
leaks.

Clean all parts in a non-volatile cleaning solution or
solvent.

Blow parts dry with low pressure compressed air.

Verify that all oil holes and passageways are clean and
open.

Check ring dowels for looseness, wear or damage.
Replace as necessary.

Use a file to carefully remove any nicks or burrs from
machined surfaces.

Clean out tapped holes and clean up damaged threads.

Check the top of the crankcase for flatness with a
straightedge and feeler gauge. Replace if warped.

Spray all machined surfaces with clean engine oil.

INSTALLATION OVERVIEW

Perform all steps under

3.19 BOTTOM END OVERHAUL:

ASSEMBLY

Perform all steps under

3.17 TOP END OVERHAUL:

ASSEMBLY

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2009 Dyna Service: Engine 3-99

Harley Davidson 2009 Dyna Models. Service manual - page 19