Harley Davidson Softail 2000-2005. Service manual

ENGINE

149

OIL TANK AND LINES

1. Bolt
2. Grommet
3. Spacer
4. Filler cap/dipstick
5. O-ring
6. Flange nut
7. Oil tank
8. Mounting bracket
9. Hose line clip

10. Drain hose
11. Elbow
12. Drain plug
13. Oil feed hose
14. Oil feed line
15. Oil line clip
16. Oil line retainer

assembly

17. Oil return line
18. Oil tank vent line
19. Connector
20. Connector assembly
21. Oil tank vent line

connector assembly

22. Connector

210

211

209

b. Push the oil vent and return lines

straight

into the

fittings on the oil tank and crankcase until they lock
into place. After the lines have locked into place
into the fittings, pull straight out on the lines to
make sure they are secure within the fittings.

c. Be sure to correctly route the battery positive cable

behind the oil tank and the frame.

d. Refill the engine with oil as described in Chapter

Three.

e. Start the engine and check for oil leaks.
f. Turn off the engine and check the oil level; readjust

if necessary.

Oil Line Retainers and Fittings Replacement

The Oil Line Remover and Replacement tool (part No.

HD-4445) is required to remove and install the oil line re-
tainers at the oil tank and engine. Do not remove the re-
tainers from the engine fittings or oil tank fittings unless
the retainers, O-rings and/or spacers are damaged.

There are two sizes of oil line retainers and fittings and

the correct size tool for all service procedures. The large
tool is used on the crankcase fittings for the oil feed and
return lines, the remaining fittings on the crankcase and
oil tank use the small tool.

NOTE

This procedure is shown with the crankcase
disassembled to better illustrate the steps.

1. Remove the oil line from the fitting on the oil tank and
crankcase as previously described in this chapter.
2. Insert the correct size tool into the retainer on the fit-
ting.
3. Squeeze the tabs on the oil line retainer and withdraw
the tool, the retainer, both O-rings and the spacer from the
fitting (Figure 217).
4. Discard the old retainer assembly.

150

CHAPTER FOUR

216

213

214

215

212

5. Unscrew and remove the fittings from the crankcase
(Figure 218, typical).
6. Install a

new

O-ring (Figure 219) onto the fittings and

apply a light coat of clean engine oil to the O-ring. Install
the fittings into the crankcase and tighten securely.
7. Insert the correct size O-ring tool into the

new

retainer

assembly.

CAUTION

Do not damage the O-rings (

Figure 220

)

during retainer installation.

8. Insert the new retainer assembly and special tool into
the fitting until the tabs on the retainer lock into place.
9. Carefully withdraw the O-ring tool from the retainer
assembly leaving the retainer assembly in place.
10. Apply Loctite pipe sealant to the crankcase fittings
and tighten securely.

CAMSHAFT SUPPORT PLATE

A camshaft and crankshaft sprocket lock (JIMS part

No. 1285), and a camshaft chain tensioner tool (JIMS part
No. 1283) are required to remove and install the camshaft
support plate. Refer to Figure 221.

Removal

1. Remove the exhaust system as described in Chapter
Seven.
2. Drain the engine oil as described in Chapter Three.
3. Remove the pushrods, lifters and lifter covers as de-
scribed in this chapter.

CAUTION

On 2000 models only, the cam position sen-
sor wiring is routed through the camshaft
cover. Move the cover out of the way and se-
cure it to the frame with a piece of wire. Do
not hang the cover by the wiring.

4. Using a crisscross pattern, loosen then remove the
bolts securing the camshaft cover (Figure 222), and re-
move the cover and gasket.
5. To ensure the camshaft primary drive chain is rein-
stalled in the same direction of travel, mark one of the link
plates with a permanent marking pen or a scribe.
6. Relieve the tension on the camshaft primary drive
chain as follows:

a. Install the camshaft chain tensioner tool (A, Figure

223) onto the primary chain tensioner (A, Figure
224).

ENGINE

151

220

219

217

218

152

CHAPTER FOUR

221

CAMSHAFTS AND COVER

1. Oil screen
2. O-ring
3. Camshaft—rear cylinder
4. Oil pump feed rotors
5. Separator plate
6. Wave washer
7. Oil pump scavenger rotors
8. O-ring
9. Oil pump housing

10. O-ring
11. O-ring
12. Camshaft—front cylinder
13. Camshaft primary drive

chain

14. Relief valve spring
15. Relief valve
16. Bolt and washer
17. Rear camshaft

drive sprocket and spacer

18. Chain guide
19. Cleaning plug
20. O-ring
21. Secondary drive chain

tensioner

22. Snap ring
23. Primary drive chain

tensioner

24. Crankshaft sprocket
25. Bushing
26. Roll pin
27. Camshaft support plate
28. Bearing assembly
29. Screw
30. Snap ring
31. Ball bearing
32. Bearing retainer plate
33. Camshaft secondary

drive chain

34. Screw
35. Cover
36. Camshaft cover
37. Bolt
38. Gasket

b. Using a wrench, rotate the tool

counterclockwise

and insert the hold pin (B, Figure 223) through the
hole in the tensioner and into the hole in the support
plate. Push the hold pin in until it bottoms (B, Fig-
ure 224).

c. Remove the wrench and tensioner tool from the

tensioner.

7. Install and mesh the camshaft and crankshaft sprocket
lock (C, Figure 223) between the camshaft and crankshaft
sprockets (C, Figure 224).
8. Loosen the bolt securing the crankshaft sprocket (D,
Figure 224).

CAUTION

The rear camshaft sprocket bolt is secured
with a threadlocking compound. Attempt to
loosen the bolt with an impact driver or air
impact wrench. If this is not successful,
evenly heat the bolt head with a propane
torch. Use caution, as excessive heat may
damage tensioner assembly. Do

not

use ex-

cessive force to remove the bolt. If neces-
sary, have a Harley-Davidson dealership
remove the bolt.

9. Loosen the bolt (E, Figure 224) securing the rear cam-
shaft sprocket .
10. Remove the special tool installed in Step 6.
11. Remove camshaft sprocket bolt and the crankshaft
sprocket bolt and washer.

NOTE

If it is difficult to loosen either sprocket from
its respective shaft, use a small pry bar and
gently loosen the sprocket(s) from the
shaft(s).

12. Remove the rear camshaft drive sprocket (A, Figure
225), the crankshaft sprocket (B) and the primary cam-
shaft drive chain (C) as an assembly. Pull the assembly
straight off the shafts.
13. Remove the sprocket spacer (Figure 226) from the
rear camshaft.
14. Squeeze the tabs and remove the camshaft chain
guide (Figure 227).
15. Loosen the camshaft support plate Allen bolts in the
following sequence:

a. Using a crisscross pattern, loosen and remove the

four Allen bolts (A, Figure 228) securing the sup-
port plate to the oil pump assembly.

b. Using a crisscross pattern, loosen and remove the

remaining six Allen bolts securing the support plate
(B, Figure 228) to the crankcase.

ENGINE

153

222

223

224

225

16. Withdraw the camshaft support plate assembly from
the crankcase. If necessary, carefully pry the plate loose
from the crankcase in the areas where the locating dowels
are located (Figure 229).
17. Remove the O-ring (A, Figure 230) from the oil
pump assembly and the lower O-ring (B).
18. Remove the upper O-ring (C, Figure 230) and the oil
screen (Figure 231). Account for the two dowels (D, Fig-
ure 230).
19. If necessary, disassemble and remove the camshafts
as described in this chapter.

Installation

NOTE

Release the secondary chain tension to in-
stall the camshaft inner ends into the crank-
case bearings (E,

Figure 230

). If the tension

is not released, the inner ends of the cam-
shafts will be pulled together and out of
alignment with the bearings, making instal-
lation difficult if not impossible.

1. Release the tension on the camshaft secondary chain
tension as follows:

a. Install the camshaft chain tensioner tool (A, Figure

223) onto the camshaft secondary chain tensioner.

b. Using a wrench, rotate the tool

counterclockwise

(Figure 232) and insert the hold pin (A, Figure
233) through the hole in the outer surface of the sup-
port plate and into the hole in the tensioner. Push the
hold pin in until it bottoms.

c. Remove the wrench and tensioner tool from the

tensioner.

2. Push in on the oil pump assembly to make sure it is cor-
rectly seated against the crankcase.
3. Install a

new

O-ring (A, Figure 230) onto the oil pump

assembly and a

new

O-ring (B) onto the lower location.

Apply a light coat of clean engine oil to the O-rings.

154

CHAPTER FOUR

226

227

228

229

230

4. Install the oil screen (Figure 231) and a

new

upper

O-ring (C, Figure 230). Apply a light coat of clean engine
oil to the O-ring.

5. Lubricate the camshaft needle bearings (E, Figure
230) in the crankcase and the camshaft bearing surfaces
(B, Figure 233) with clean engine oil.

6. If the camshafts were removed from the support plate,
make sure the timing marks (Figure 234) on each cam-
shaft are aligned with each other. If the marks are not
aligned, reposition the camshafts prior to installing the as-
sembly into the crankcase.

CAUTION

Do not force the camshaft support plate as-
sembly into the crankcase. During installa-
tion, the camshaft ends may not be correctly
aligned with the needle bearings. If force is
applied, the needle bearing(s) will be dam-
aged.

7. If removed, install the two locating dowels (D, Figure
230) onto the crankcase.

8. Slowly install the camshaft support plate assembly (A,
Figure 235) into the crankcase. Guide the camshaft ends
into the crankcase needle bearings (B, Figure 235). If
necessary, slightly rotate and/or wiggle the end of the rear
cylinder camshaft to assist in the alignment.

CAUTION

When properly aligned, the camshaft sup-
port plate assembly fits snugly against the
crankcase mating surface. If they do not
meet correctly, do not attempt to pull the
parts together with the mounting bolts. Sep-
arate the camshaft support plate assembly
and determine the cause of the interference.

9. Push the camshaft support plate assembly onto the
crankcase until it bottoms on the two locating dowels and
the crankcase mating surface.

ENGINE

155

231

232

233

234

235

10. Make sure the timing marks on each camshaft are still
aligned (Figure 236). If they are not aligned, correct the
problem at this time.
11. Tighten the six camshaft support plate-to-crankcase
Allen bolts in the following sequence:

a. Install and loosely tighten the six Allen bolts (B,

Figure 228).

b. Tighten the Allen bolts in a crisscross pattern to

90-120 in.-lb. (10-14 N•m).

12. Tighten the camshaft four support plate-to-oil pump
Allen bolts in the following sequence:

a. Install the Allen bolts (A, Figure 228). Tighten the

bolts until they just contact the support plate, then
back them out 1/4 turn.

b. Rotate the engine until the oil pump is in neutral

center with no load on it.

c. Tighten the bolts until they are snug against the sup-

port plate. Then tighten the Allen bolts in a criss-
cross pattern to 10-14 ft.-lb. (14-19 N•m).

13. After all ten Allen bolts are tightened, check the per-
imeter of the support plate to make sure it is seated against
the crankcase mating surface.
14. Install an angled pick into the crankcase opening and
against the secondary camshaft chain tensioner shoe (A,
Figure 237).

Slowly

release the hold pin (B) and allow the

tensioner shoe to gradually contact the chain surface. If it
is released too fast, the shoe surface will slam against the
chain and be damaged.
15. Squeeze the camshaft chain guide tabs and install it
(Figure 227) onto the two posts.

NOTE

Step 16 is not necessary if the original cam-
shaft support plate, both camshafts, rear
camshaft

sprocket,

crankshaft

drive

sprocket and the crankshaft assembly are
reused. If any of these components have
been replaced, Step 16 is necessary to en-
sure correct alignment between the rear
camshaft sprocket and the crankshaft drive
sprocket. If the alignment is incorrect, the
primary drive chain and both sprockets will
bind and cause premature wear.

16. If new parts have been installed, perform the align-
ment procedure described under

Rear Camshaft Sprocket

and Crankshaft Drive Sprocket Alignment

. If all original

parts have been installed, proceed to Step 17.
17. Relieve the tension on the camshaft primary drive
chain as follows:

a. Install the camshaft chain tensioner tool (A, Figure

238) onto the camshaft primary chain tensioner.

156

CHAPTER FOUR

236

237

238

239

b. Using a wrench, rotate the tool counterclockwise

and insert the hold pin (B, Figure 238) through the
hole in the tensioner and into the hole in the support
plate. Push the hold pin in until it bottoms.

c. Remove the wrench and tensioner tool from the

tensioner.

18. Install the sprocket spacer (Figure 226) onto the rear
camshaft with the manufacturer’s marks facing the crank-
case.

NOTE

Refer to the mark made prior to removal and
position the camshaft primary drive chain
so it will travel in the same direction. If it is
installed incorrectly, the drive chain will
wear prematurely.

19. Assemble the rear camshaft sprocket, the crankshaft
drive sprocket and the primary drive chain as an assembly.
Align the index mark on both sprockets so they face each
other as shown in Figure 239.
20. On models so equipped, install the Woodruff key
onto the rear camshaft.
21. Install the rear camshaft drive sprocket (A, Figure
225), the crankshaft sprocket (B), and the primary cam-
shaft drive chain (C) as an assembly onto the crankshaft
and rear camshaft. Align the flat on the crankshaft
sprocket with the flat on the crankshaft (A, Figure 240).
Check the alignment of the index mark on both sprockets,
and make sure they face each other as shown in B, Figure
240. Realign the sprocket index marks if necessary.
22. Apply clean engine oil to the underside of both

new

sprocket bolts prior to installation.
23. Apply a small amount of ThreeBond TB1360 (red),
or an equivalent, threadlocking compound to the threads
of the

new

rear camshaft sprocket bolt. Do not apply the

locking agent to the crankshaft bolt.
24. Install a

new

camshaft sprocket bolt and

new

crank-

shaft sprocket bolt and washer. Tighten the bolts fin-
ger-tight at this time.
25. Install and mesh the camshaft and crankshaft
sprocket lock (Figure 241) between the camshaft and
crankshaft sprockets.
26. Place a flat blade screwdriver (A, Figure 242) be-
tween the primary camshaft drive chain and the tensioner.
Slowly release the hold pin (B, Figure 242), then slowly
withdraw the screwdriver (Figure 243) and allow the
tensioner to gradually contact the chain surface. If it is re-
leased too fast, the shoe surface will slam against the
chain and be damaged.
27. Tighten both bolts as follows:

a. Tighten both bolts to 15 ft.-lb. (20 N•m).
b. Loosen both bolts one complete revolution (360°).

ENGINE

157

240

241

242

243

c. Tighten the rear camshaft bolt (Figure 244) to 34

ft.-lb. (46 N•m).

d. Tighten the crankshaft bolt to (Figure 245) 24 ft.-lb.

(33 N•m).

28. Remove the tool (Figure 241) installed in Step 25.
29. Install a

new

camshaft cover gasket (Figure 246)

onto the crankcase.
30. On 2000 models only, install the camshaft cover (Fig-
ure 222) onto the crankcase. Make sure the cam position
sensor wiring is correctly positioned. Install the bolts and
tighten them securely in a crisscross pattern.
31. Install the lifter covers, lifters and pushrods as de-
scribed in this chapter.
32. Install the exhaust system as described in Chapter
Seven.

Rear Camshaft Sprocket and Crankshaft Drive
Sprocket Alignment

This procedure is required if the camshaft support plate,

either or both camshafts, the rear camshaft sprocket, the
crankshaft drive sprocket and/or the crankshaft assembly
have been replaced.

If alignment between the rear camshaft sprocket and the

crankshaft drive sprocket is incorrect, the primary drive
chain and both sprockets will bind and cause premature
wear.
1. Install the sprocket spacer (Figure 247) onto the rear
camshaft with the manufacturer’s marks facing the crank-
case.
2. On models so equipped, install the Woodruff key onto
the rear camshaft.
3. Apply clean engine oil to the camshaft splines and to
the rear camshaft sprocket splines.
4. Install the rear camshaft sprocket onto the camshaft.
Install the

used

mounting bolt and flat washer (A, Figure

248). Tighten the bolt finger-tight at this time.

NOTE

Use a smaller outer diameter washer in Step
5 to allow room for the straightedge to be
placed against the flat surface of the crank-
shaft sprocket face.

5. Install the crankshaft sprocket (B, Figure 248) onto
the crankshaft. Install the

used

mounting bolt and a

washer with a smaller outer diameter

. Tighten the bolt fin-

ger-tight at this time.
6. Install and mesh the camshaft and crankshaft sprocket
lock (Figure 241) between the camshaft and crankshaft
sprockets.
7. Tighten both bolts as follows:

158

CHAPTER FOUR

244

245

246

247

a. Tighten both bolts to 15 ft.-lb. (20 N•m).

b. Loosen both bolts one complete revolution (360°).

c. Tighten the rear camshaft bolt (Figure 244) to 34

ft.-lb. (46 N•m).

d. Tighten the crankshaft bolt to (Figure 245) 24 ft.-lb.

(33 N•m).

8. Remove the special tool from the sprockets.

9. Place a straightedge (A, Figure 249) against the face
of both sprockets. Push the straightedge against the

crank-

shaft sprocket

and hold it there.

10. Try to insert a 0.005 in. (0.127 mm) feeler gauge (B,
Figure 249) between the straightedge and the camshaft
sprocket face.
11A. If the 0.005 in. (0.127 mm) feeler gauge can be in-
serted, the sprockets are correctly aligned. Remove both
sprockets and proceed with Step 17 of

Camshaft Support

Plate Installation

in the previous procedure.

11B. If a different thickness feeler gauge can be inserted,
indicating a height difference other than 0.005 in. (0.127
mm), the rear camshaft spacer must be changed. Continue
to insert feeler gauges of different thickness’ until the di-
mension is determined. Record this dimension as it will be
used to choose a new spacer.
12. Remove the rear camshaft sprocket bolt, washer and
sprocket.
13. Remove the existing sprocket spacer (Figure 247)
from the rear camshaft. Compare the part number
stamped on the spacer with the part numbers in Table 5 to
determine the thickness.
14A. If the crankshaft sprocket is more than 0.005 in.
(0.127 mm) above the camshaft sprocket, install the next

thicker

size spacer under the camshaft sprocket.

14B. If the crankshaft sprocket is less than 0.005 in.
(0.127 mm) above the camshaft sprocket, install the next

thinner

size spacer under the camshaft sprocket.

15. Install a new spacer and repeat this procedure until
the height difference is 0.005 in. (0.127 mm).
16. After the correct spacer thickness is established, re-
move the sprockets from the rear camshaft and crank-
shaft, then proceed with Step 17 of

Camshaft Support

Plate Installation

in the previous procedure.

Camshaft Support Plate and Camshafts

A hydraulic press, camshaft chain tensioner tool (JIMS

part No. 1283) and camshaft remover and installer (JIMS
part No. 1277) are required to perform the following pro-
cedure.

Disassembly

1. Remove the camshaft support plate as described in this
chapter.
2. Remove the snap ring (Figure 250) from the front cyl-
inder camshaft.
3. Release the tension on the camshaft secondary chain
tension as follows:

a. Install the camshaft chain tensioner tool onto the

camshaft secondary chain tensioner.

b. Using a wrench, rotate the tool counterclockwise

and insert the hold pin (Figure 251) through the

ENGINE

159

248

249

250

hole in the outer surface of the support plate and
into the hole in the tensioner. Push the hold pin in
until it bottoms.

c. Remove the wrench and tensioner tool from the

tensioner.

4. Loosen and remove the four T20 Torx screws (Figure
252) securing the bearing retainer plate. Remove the bear-
ing retainer plate (Figure 253).
5. Press the camshafts and secondary drive chain out of
the camshaft support plate as follows:

a. Turn the camshaft support cover face up on two

support blocks in a press bed. Make sure the support
blocks are tall enough to allow the complete re-
moval of the camshafts from the cover.

b. Install the cups of the camshaft remover and in-

staller onto the top of the camshafts (Figure 254)
following the manufacturer’s instructions.

c. Center the press ram over the center of the tool (Fig-

ure 255).

d. Slowly press the assembly out of the support cover.
e. Remove the assembly, cover and special tool from

the press bed.

6. To ensure the camshaft secondary drive chain is rein-
stalled in the same direction of travel, mark one of the link
plates on the bearing side with a permanent marking pen
(Figure 256) or scribe.
7. Separate the camshafts from the secondary drive
chain.

Inspection

There are no manufacturer’s specifications available

for the camshaft. The following procedure is a visual in-
spection to determine if the camshafts require replace-
ment.
1. Check the camshaft lobes (Figure 257) for wear. The
lobes should not be scored and the edges should be square.

160

CHAPTER FOUR

251

253

254

255

252

2. Inspect the drive chain sprocket (Figure 258) for bro-
ken or chipped teeth. Also check the teeth for cracking or
rounding. If the sprocket is damaged or severely worn, re-
place the camshaft.
3. If the camshaft sprockets are worn, check the camshaft
secondary drive chain (Figure 259) for damage.
4. Inspect the external splines (A, Figure 260) on the rear
cylinder’s camshaft and the internal splines (B) on the
sprocket. Check for worn or damaged splines and replace
either or both parts if necessary. The sprocket must be a
tight fit on the camshaft.
5. Check the snap ring groove (Figure 261) on the front
cylinder’s camshaft for wear or damage.
6. Inspect and rotate the ball bearing (Figure 262) on
each camshaft. They should rotate smoothly with no
roughness. If they are damaged, replace the ball bearings
as described in this section.
7. Inspect the crankshaft bushing (Figure 263) for wear
or damage.

Assembly

NOTE

This procedure is shown with the ball bear-
ings in place on the camshafts.

ENGINE

161

259

260

258

257

256

261

1. Prior to installing the camshaft assembly, relieve the
tension on the secondary cam chain tensioner as follows:

a. Install the camshaft chain tensioner tool (Figure

264) onto the camshaft secondary chain tensioner.

b. Using a wrench, rotate the tool

counterclockwise

(Figure 265) and insert the hold pin through the
hole in the tensioner and into the hole in the support
plate. Push the hold pin in until it bottoms (Figure
266).

c. Remove the wrench and tensioner tool from the

tensioner.

2. Assemble the camshafts and the secondary drive chain
as follows:

a. Locate the index marks on the front of the cam-

shafts (Figure 267). Transfer these marks to the
backside of the sprockets, in the same location with
a permanent marking pen or scribe (Figure 268).
These marks will be used for proper alignment of
the camshaft as it is pressed into the camshaft sup-
port plate.

NOTE

Refer to the mark made on one of the link
plates in

Disassembly

Step 6 and position

the camshaft secondary drive chain so it
travels in the same direction as noted prior
to removal. If it is installed incorrectly, the
drive chain will wear prematurely.

b. Position the camshafts with the index marks facing

directly opposite each other (Figure 269).

c. Position the secondary chain with the marked link

plate facing up (Figure 256) and install the second-
ary chain onto both camshafts.

d. Rotate the camshafts in either direction several

times and recheck the alignment of the index marks.
If necessary, readjust one of the camshafts to
achieve correct alignment (Figure 269).

3. Apply a light coat of clean engine oil, or press lube, to
the camshaft ends and to the bearing receptacles in the
camshaft support plate.

162

CHAPTER FOUR

262

263

264

265

266

4. Place the camshaft support plate on the press bed with
the bearing receptacles facing up (Figure 270).

5. Position the camshaft assembly on the camshaft sup-
port plate with the rear cylinder camshaft (Figure 271) lo-
cated toward the back of the support plate. Align the
bearings with the support plate receptacles and hold the
assembly in place.

NOTE

Prior to pressing the camshaft assembly
into place, check the alignment of the cam-
shaft index marks on the backside of the
sprockets (

Figure 272

). If they are out of

alignment, remove the assembly and correct
this alignment.

6. Install the cups of the camshaft remover and installer
onto the top of the camshafts (Figure 273) following the
manufacturer’s instructions.

7. Center the press ram over the center of the tool (Figure
274).

8. Slowly press the assembly into the support cover until
it bottoms.

9. Remove the assembly and special tool from the press
bed.

ENGINE

163

268

269

270

271

272

267

10. Turn the assembly over and make sure the camshaft
index marks are still correctly aligned as shown in Figure
275.
11. Rotate the camshafts several complete revolutions
and check for binding.
12. Install the retainer plate (Figure 253).
13. Apply a small amount of ThreeBond TB1342 or an
equivalent threadlocking compound to the Torx screw
threads. Install the four T20 Torx screws (Figure 252) and
tighten them securely.
14. Place a flat blade screwdriver between the secondary
camshaft drive chain and the tensioner. Slowly release the
hold pin (Figure 251), then slowly withdraw the screw-
driver and allow the tensioner to gradually contact the
chain surface. If it is released too fast, the shoe surface
will slam against the chain and be damaged.
15. Install the snap ring (Figure 276) onto the front cylin-
der camshaft. Make sure the snap ring is correctly seated
in the camshaft groove.
16. Install the camshaft support plate as described in this
chapter.

Crankshaft bushing replacement

A crankshaft bushing tool (JIMS part No. 1281) is re-

quired to remove and install the crankshaft bushing (Fig-
ure 263).
1. Place the bushing support tool on the press bed.

NOTE

The crankshaft bushing edge is knurled on
the side that faces the primary chain side.

2. Position the camshaft support plate with the primary
chain side facing up. Place the camshaft support plate
onto the bushing support tool and center the bushing over
the tool (Figure 277).
3. Install the

remove side

of the driver (Figure 278)

through the bushing and into the support tool until the
shoulder of the driver contacts the edge of the bushing.
4. Press the bushing out of the support plate until the
driver collar contacts the support plate.
5. If the bushing support tool was removed, place it on
the press bed.
6. Position the camshaft support plate with the secondary
chain side facing up. Place the camshaft support plate
onto the bushing support tool.
7. Apply a light coat of clean engine oil, or press lube, to
the outer surface of the bushing and to the support plate
bushing receptacle.
8. Position the bushing into the receptacle with the
knurled side facing up.

164

CHAPTER FOUR

273

274

275

276

Harley Davidson Softail 2000-2005. Service manual - page 15