Harley Davidson Softail 2000-2005. Service manual

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

board side facing up.

b. With the gap of the lock ring at the 12 o’clock posi-

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

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

the clamps to the lock ring.

d. Use snap ring pliers to compress the lock ring and

withdraw it from the crankcase groove.

e. Remove the clamps from the old lock ring and in-

stall them onto the new lock ring.

f. Squeeze the pliers (Figure 351) and insert the lock

ring into the crankcase groove.

g. Make sure the lock ring gap is centered with the

crankcase oil hole.

NOTE

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

20. Apply clean engine oil, or press lube, to the bearing
receptacles in the crankcase and to the outer surface of the
inner bearing races.

NOTE

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

Figure 352

21. Place the installer base on the press bed with the large
end facing up.
22. Install the inboard outer race onto the crankcase re-
ceptacle (Figure 353).
23. Position the crankcase with the inboard surface fac-
ing up.
24. Install the crankcase onto the installer base so the
crankcase retaining ring rests on top of the installer base.

ENGINE

181

350

351

352

353

349

25. Apply clean engine oil, or press lube, to the shaft of
the pressing plug and install the pressing plug into the in-
staller base (Figure 354). Push it down onto the bearing
outer race (Figure 355).

26. Center the press ram directly over the pressing plug
and slowly press the outer bearing race into the outboard
surface of the crankcase until it touches the retaining ring
(Figure 356).

27. Remove the crankcase and special tools from the
press.

28. Turn the crankcase over and repeat Steps 23-26 for
the outboard outer bearing race.

Crankshaft inner sprocket shaft bearing replacement

A sprocket shaft bearing cone installer (part No.

HD-997225-55B) is required to install the sprocket shaft
bearing (Figure 357).

1. Support the crankshaft with the bearing side facing up.

2. Install the bearing splitter under the bearing (Figure
358) and tighten it securely.

3. Attach a bearing puller to the splitter (Figure 359).

4. Slowly tighten the center screw and withdraw the bear-
ing from the crankshaft shoulder.

5. Remove the bearing remover, splitter and bearing from
the crankshaft.

6. Clean the sprocket shaft with contact cleaner. Check
the sprocket shaft for cracks or other damage. If it is dam-
aged, refer service to a Harley-Davidson dealership.

7. Slide the new bearing over the sprocket shaft.

8. Refer to Figure 360 and install the new bearing as fol-
lows:

a. Apply clean graphite lubricant to the threads of the

pilot shaft, the flat washer and the bearing.

b. Thread the pilot shaft (A) onto the crankshaft until it

contacts the crankshaft shoulder.

c. Slide the sleeve (B) over the pilot shaft until it con-

tacts the bearing inner race.

d. Install the bearing (C) and washer (D) over the pilot

shaft and onto the top of the sleeve.

e. Thread the handle (E) onto the pilot shaft (A).

f. Slowly tighten the handle

clockwise

until the bear-

ing bottoms on the crankshaft shoulder.

g. Unscrew and remove all parts of the special tool.

182

CHAPTER FOUR

354

355

356

357

Left Side Main Bearing Assembly
Replacement (2003 Model)

Tools

The following tools or their equivalents are required to

remove and install the left side main bearing (Figure
303):
1. Hydraulic press.
2. Crankshaft roller bearing pilot/driver (HD-997225-
55B).
3. Crankshaft roller bearing support tube (HD-42720-5).

NOTE

The support tube ends are marked with an A
and B. The A and B are referred to in the fol-
lowing procedure to indicate which side of
the support tube must face.

Bearing removal

1. Place the crankcase on the workbench with the inboard
surface facing up.
2. If still in place, remove the crankshaft spacer from the
bearing bore.
3. Carefully pull the thrust washer from the outer surface
of the crankcase past the oil seal.
4. Place the support tube on the workbench with the

side facing up.
5. Position the crankcase with the inner surface facing up
and place the bearing bore over the support tube.
6. Use a suitable size drift and tap the oil seal out of the
bearing bore. Discard the oil seal.
7. Turn the crankcase over with the inner surface facing
up.

CAUTION

Do not damage the crankcase retaining ring
groove with the screwdriver. The groove
must remain sharp to correctly seat the re-
taining ring.

8. The roller bearing (A, Figure 361) is secured in the
crankcase with a retaining ring (B) on the inner surface of
the bearing bore. Remove the retaining ring (C, Figure
361) as follows:

a. Use a flat tip screwdriver and place it under the re-

taining ring. Carefully lift the edge of the retaining
ring up and out of the crankcase groove.

b. Slide the tip of the screwdriver around the edge of

the bearing and continue to lift the retaining ring out
of the crankcase groove.

c. Remove the retaining ring.

ENGINE

183

359

360

358

9. Position the support tube (A, Figure 362) on the press
bed with the

side facing up.

10. Position the crankcase half with the outer side facing
up and position the crankshaft’s bearing bore over the sup-
port tube. Correctly align the two parts.
11. Slide the pilot/driver (B, Figure 362) through the
crankcase bearing and into the support.
12. Center the press ram (C, Figure 362) directly over the
pilot/driver (B) and slowly press the bearing out of the
crankcase.
13. Remove the crankcase and special tools from the
press bed.
14. Clean the crankcase half in solvent and dry it with
compressed air.

Bearing installation

1. Apply clean engine oil, or press lube, to the bearing re-
ceptacle in the crankcase and to the outer race of the

new

bearing.
2. Position the support tube (A, Figure 363) on the press
bed with the

side facing up.

3. Position the crankcase half with the inner side facing
up and position the crankshaft’s bearing bore over the sup-
port tube. Correctly align the two parts.
4. Correctly position the

new

bearing (B, Figure 363)

over the crankcase bore.
5. Slide the pilot/driver (C, Figure 363) through the new
bearing and the crankcase and into the support.
6. Center the press ram (D, Figure 363) directly over the
pilot/driver (C) and slowly press the bearing into the
crankcase until it

lightly

bottoms in the crankshaft bearing

bore.
7. Remove the crankcase and special tools from the press.
8. Make sure the bearing is has been pressed in past the
retaining ring groove. If the groove is not visible above
the bearing, repeat Steps 2-6 until the groove is visible.
9. Position the crankcase on the workbench with the in-
ner surface facing up.

CAUTION

Do not damage the crankcase retaining ring
groove with the screwdriver. The groove
must remain sharp to correctly seat the re-
taining ring.

NOTE

If the retaining ring will not correctly seat in
the crankcase groove, the bearing is not
correctly seated in the crankcase bore. Re-
peat Steps 2-6

10. Install the bearing’s

new

retainer ring as follows:

184

CHAPTER FOUR

361

362

a. Work the retaining ring into the crankcase groove

being careful not to damage the crankcase groove.

b. Use a flat tip screwdriver and push the retaining

ring. Continue to push the retaining ring into the
crankcase groove.

Crankshaft End Play Inspection (2000-2002 Models)

NOTE

The 2003 models are equipped with an as-
sembled roller bearing and this procedure is
not necessary.

The crankshaft end play

must

be between 0.001-0.005

in. (0.025-0.127 mm). End play is determined by the
thickness of the shim between the inner and outer bearings
on the left side. Table 6 lists the shim part numbers and
thickness.

If the end play was measured before disassembly and

was within specification, and if the same components are
reinstalled, then the same size shim can be reinstalled as a
starting point.

Carefully measure the end play as described in Step 11.

If there is

any

doubt about your abilities to properly set up

the crankshaft end play, refer this procedure to a
Harley-Davidson dealership.

Tools

The following tools or their equivalents are required to

assemble the crankcase halves:
1. Sprocket shaft bearing installation tool (JIMS part No.
97225-55).
2. Crankshaft guide (JIMS part No. 1288).
3. Engine base stand (JIMS part No. 1138) and engine
stand (JIMS part No. 1142).

Procedure

1. Position the crankshaft (Figure 364) with the left side
facing up.
2. Apply clean engine oil or assembly lube to the inner
bearing and to the left side crankcase inner bearing race.
3. Install the shim of the specified thickness onto the inner
bearing inner race.
4. Place the left crankcase half over the crankshaft
sprocket and onto the inner bearing.
5. Make sure the connecting rods are positioned within
the crankcase openings (Figure 365).
6. Make sure the crankcase is located correctly on the
crankshaft inner bearing.

ENGINE

185

363

364

365

7. Install the outer roller bearing onto the crankshaft
(Figure 366) and push it into the outer bearing race.
8. Install the sprocket shaft bearing installation tool (Fig-
ure 367) onto the crankshaft following the manufacturer’s
instructions.
9. Hold onto the handle of the installation tool (A, Figure
368) and tighten the large nut with a wrench (B). Tighten
the large nut until the outer bearing is seated correctly and
makes firm contact with the shim installed in Step 3.
10. Remove the special tools and make sure the outer
bearing is seated correctly.
11. Check crankshaft end play as follows:

a. Securely attach a dial indicator to the left crankcase

half (A, Figure 369).

b. Position the dial indicator contact pointer on the end

of the crankshaft (B, Figure 369).

c. Push down hard on the crankcase (C, Figure 369)

while turning it back and forth.

d. Hold the crankcase down and zero the dial gauge.
e. Pull up on the crankcase as far as it will go while turn-

ing it back and forth. Note the dial indicator reading.

f. Repeat this step several times and note the readings.

They should all be the same.

g. The end play should be within 0.001-0.005 in.

(0.025-0.127 mm). If the end play is incorrect, re-
place the shim with a shim of a different thickness.
Table 6 lists the various thickness shims and their
part numbers.

h. Remove the dial indicator.

Crankcase Assembly

One special tool, crankshaft guide (JIMS part No.

1288), is required to assemble the crankcase halves.
1. Perform Steps 1-9 of

Crankshaft End Play Inspection

(2000-2002 Models) in the proceeding procedure and in-
stall the crankshaft into the left side crankcase.
2. Turn the crankcase assembly over and place it on
wooden blocks thick enough so the left side of the crank-
shaft clears the workbench surface.
3. Install the

new

O-rings (Figure 370) onto both locating

dowels in both locations (Figure 371) in the right crank-
case half. Apply clean engine oil to the O-rings.
4. Install the crankshaft guide (Figure 372) over the
crankshaft.
5. Thoroughly clean and dry both crankcase gasket sur-
faces before applying gasket sealer in Step 6.
6. Apply a thin coat of a non-hardening gasket sealant to
the crankcase mating surfaces. Use one of the following
gasket sealants:

a. Harley-Davidson crankcase sealant (part No.

HD-99650-81).

186

CHAPTER FOUR

366

367

368

369

b. 3M #800 sealant.
c. ThreeBond Liquid Gasket 1104.

7. Align the crankcase halves and carefully lower the
right crankcase half onto the crankshaft and left crank-
case half. Press it down until it is seated correctly on the
locating dowels. If necessary, carefully tap the perime-
ter of the right crankcase half until it is seated around
the entire perimeter.

CAUTION

When properly aligned, the crankcase
halves will fit snugly against each other
around the entire perimeter. If they do not
meet correctly, do not attempt to pull the
case halves together with the mounting
bolts. Separate the crankcase assembly and
investigate the cause of the interference.

8. Remove the crankshaft guide (Figure 373) from the
crankshaft.
9. If available, place the crankcase assembly in an engine
stand. Secure the engine stand to the workbench.
10. Install the nine crankcase bolts into the left crankcase
half (Figure 374) and tighten them as follows:

a. Alternately tighten the nine bolts finger-tight.
b. Using the torque pattern shown in Figure 375,

tighten the bolts to 10 ft.-lb. (14 N•m).

c. Using the same sequence, tighten the bolts to 15-19

ft.-lb. (20-26 N•m).

11. Install the left crankcase oil seal as described in the
following procedure.
12. Apply clean engine oil to the outer surface of the
sprocket shaft spacer and install it onto the crankshaft and
into the oil seal (Figure 376).
13. Install the following components as described in this
chapter:

a. Alternator rotor and stator assembly (Chapter

Eight).

b. Oil pump.
c. Camshaft assembly.

ENGINE

187

371

372

373

374

370

d. Pushrods and valve lifters.
e. Pistons.
f. Cylinder heads and cylinders.

14. Install the engine into the frame as described in this
chapter.

Crankcase Left Side Oil Seal Replacement

Special Tools

The following tools or their equivalents are required to

install the oil seal:
1. Sprocket shaft seal installer tool (JIMS part No.
39361-69).
2. Sprocket shaft bearing installation tool (JIMS part No.
97225-55).

Procedure

1. Remove the sprocket shaft spacer (Figure 376) from
the crankshaft and the oil seal.
2. Carefully pry the old oil seal out of the bearing bore
and discard it.
3. Position the

new

oil seal with the open side facing out.

4. Install the oil seal onto the crankshaft (Figure 377) and
center it within the bearing bore.
5. Apply clean engine oil or press lube to the installer tool
threads, both washers and the radial bearing.
6. Install the main body onto the crankshaft and screw it
on until it stops (Figure 378).
7. Install the shaft seal installer tool following the manu-
facturer’s instructions.
8. Hold onto the handle (A, Figure 379) of the main body
and tighten the large nut (B) with a wrench. Tighten the
large nut slowly and make sure the oil seal (C, Figure
379) is entering straight into the bearing bore.
9. Tighten the large nut until the shaft seal installer tool
contacts the crankcase surface (Figure 380).
10. Remove the special tools.
11. Apply clean engine oil to the outer surface of the
sprocket shaft spacer and install it onto the crankshaft and
into the oil seal (Figure 376).

Cylinder Stud Replacement

Replace bent or damaged cylinder studs (A, Figure

381) to prevent cylinder block and cylinder head leaks.
1. If the engine lower end is assembled, block off the
lower crankcase opening with clean shop cloths.

188

CHAPTER FOUR

377

375

378

376

2A. If the stud has broken off with the top surface of the
crankcase, remove it with a stud remover. Refer to Chap-
ter One.

2B. If the stud is still in place, perform the following:

a. Thread a 3/8 in.-16 nut onto the top of the stud.

b. Thread an additional nut onto the stud and tighten it

against the first nut so they are locked.

c. Turn the bottom nut

counterclockwise

and unscrew

the stud.

3. Clean the stud threads in the crankcase with a spiral
brush, then clean them with an aerosol parts cleaner. If
necessary, clean the threads with an appropriate size tap.

NOTE

If the new studs have a threadlocking com-
pound patch already applied to the lower
stud threads, do not apply any additional
locking compound.

4. If the new stud does not have the threadlocking com-
pound patch, apply ThreeBond TB1360 (red) or an equiv-
alent to the studs lower threads.

NOTE

The cylinder studs have a shoulder on one
end. This end must be installed next to the
crankcase surface.

5A. Install the Motion Pro stud installation tool (part No.
08-0148) (B, Figure 381) onto the stud.

5B. Place a 0.313 in. diameter steel ball (H-D part No.
8860) into a cylinder head bolt, then thread the bolt onto
the end of the new stud without the collar.

6. Position the stud with the shoulder end going in first
and hand-thread the new stud into the crankcase.

CAUTION

Do not use a breaker bar, ratchet or similar
tool to install the studs. These tools may
bend the stud and cause the engine to leak
oil.

7. Hold the air impact wrench directly in-line with the
stud.

Slowly

tighten the new stud with an air impact

wrench until the stud shoulder just contacts the top surface
of the crankcase (Figure 382).

8. Tighten the stud to 10 ft.-lb. (14 N•m).

9. Remove the cylinder head bolt and steel ball or instal-
lation tool from the cylinder stud.

10. Repeat Steps 2-9 for any additional studs.

ENGINE

189

379

380

381

382

COUNTER BALANCER ASSEMBLY

Special Tools

The following special tools are required to service the

counter balancer assembly (Figure 383):

1. Balancer shaft retention pins (JIMS part No. 1163 or
part No. HD-44062).

2. Hydraulic tensioner compressor (part No. HD-44063).

3. Hydraulic tensioner retainers (part No. HD-44408).

Removal

1. Separate the crankcase halves as described in this
chapter.

2. Place the left side crankcase on the workbench sup-
ported by wooden blocks with the inner surface facing up.

3. If still in place, remove and discard the rubber oil inter-
connect seal (Figure 384).

190

CHAPTER FOUR

383

COUNTER BALANCER ASSEMBLY

1. Locating dowel
2. Balancer shaft support

(front and rear)

3. Balancer*
4. Ball bearing
5. Chain*
6. Chain guide (lower)
7. Seal (oil interconnect)
8. Chain guide (upper)

*Many of the components are arranged in kits that contain parts that
must be replaced as a set. Check with a Harley-Davidson dealership for
what is contained in the various kits.
**Spacers are available in nine different thicknesses.

9. Piston assembly

10. Bolt
11. Support assembly*
12. Nut
13. Washer
14. Sprocket*
15. Spacer**
16. Bearing

4. Rotate the crankshaft until the holes in the balance
shafts (A, Figure 385) align with the holes in the shaft
supports (B).

5. Insert a balancer shaft retaining pin (C, Figure 385)
into the front and the rear supports to lock the balancer
shafts (A) in place.

6. Install and clamp the tensioner compressor (A, Figure
386) over the balancer chain adjacent to the hydraulic
tensioner (B) and the bottom of the chain guide bracket
(C).

7. Pump the tensioner compressor handle and compress
the hydraulic tensioner (A, Figure 386).
8. Move the retainer (D, Figure 386) over the tip of the
tensioner (B).
9. Release the pressure on the tensioner compressor and
remove it.
10. Repeat Steps 6-9 for the remaining tensioner assem-
bly.
11. Loosen the self-locking hex nuts (E, Figure 386) on
the balancer shafts. If the nuts are difficult to loosen an in-
correct amount or type of threadlocking compound may
have been applied during prior installation of the nuts. If
necessary, heat the hex nuts to loosen the threadlocking
compound. Do not remove the hex nuts at this time.

CAUTION

Do not apply heat to the hex nuts with any
type of open flame (propane or welding
torch).

NOTE

If necessary, an industrial type heat gun, ca-
pable of 248

F (120

C) may be required to

loosen the hex nut on the balancer shafts.

12. Carefully pry on the tensioner guide to clear it from
the locking post.
13. Use a small screwdriver and pry the front chain
tensioner guide (1, Figure 387) upward from the locking
post.
14. Repeat Step 13 for the rear chain tensioner guide (2,
Figure 387).
15. Carefully pry the chain tensioner guide (3, Figure
387) away from the chain guide bracket assembly while
freeing the two tensioner tabs (4) on the lower chain run.
16. Remove both self-locking hex nuts and washers (5, 6
Figure 387), loosened in Step 11, from the front and rear
balance shafts.
17. Carefully pry the rear (7, Figure 387) and front (8)
sprockets away from the chain guide bracket assembly
and release the balancer chain (9). Remove the balancer
chain and both sprockets.
18. Remove the spacer from the front balance shaft.
19. Remove the six T40 Torx screws (10, Figure 387) se-
curing the chain guide support assembly to the balancer
shaft supports and crankcase.

CAUTION

After removing the balancer shaft retain-
ing pins, inspect the tip of each pin. If the
small ball at the end is missing, locate it
within the crankcase half and remove it. If
the ball worked loose and stays within the

ENGINE

191

384

385

386

crankcase, severe engine damage could
occur.

20. Remove both balancer shaft retaining pins (11, Fig-
ure 387), installed in Step 5, from the front and rear sup-
ports.

NOTE

The balancer shaft supports are marked
with a F (front) and R (rear) and they must

be installed in the correct location during
assembly. The balancer shafts are identical
with the same part number.

21. Withdraw the front and rear balancer shaft supports
and balancer shafts from the left side crankcase bearings
(Figure 388). Do not lose the two dowel pins at each sup-
port location.

22. Inspect all components as described in this chapter.

192

CHAPTER FOUR

387

388

SUPPORT ASSEMBLY

1. Front chain tensioner guide
2. Rear chain tensioner guide
3. Chain tensioner guide
4. Tensioner tab
5. Hex nut and washer—front
6. Hex nut and washer—rear
7. Rear sprocket
8. Front sprocket
9. Balancer chain

10. Torx screw
11. Retaining pins

BALANCER

1. Retaining ring
2. Inner bearing
3. Balancer shaft support
4. Dowel pins
5. Balancer
6. Outer bearing

Installation

1. Place the left side crankcase on the workbench sup-
ported by wooden blocks with the inner surface facing up.
2. Apply clean engine oil to the balancer shaft bearings in
the crankcase. Also apply oil to the balancer shafts where
they engage the bearings.
3. Position the balancer shaft with the smooth end facing
down and insert it into the crankcase bearing. Push the
balancer shaft down until it bottoms.
4. Repeat Step 3 for the other balancer shaft.
5. Make sure both locating dowels are in place in the
crankcase.
6. Install the front balancer shaft support marked with a

over the front balancer shaft into the crankcase front re-
ceptacle. Push the support down until it bottoms against
the crankcase mating surface.
7. Install the rear balancer shaft support marked with a

over the rear balancer shaft into the crankcase rear recep-
tacle. Push the support down until it bottoms against the
crankcase mating surface.

8. Compress both hydraulic tensioners and install the
chain guide support assembly over the front and rear bal-
ance shafts. Push the assembly down until it seats flush
with the crankcase mating surface.

9. Apply a high strength threadlocking compound to the
T40 Torx screws through the chain guide support assem-
bly, the balancer shaft housings and into the crankcase.
Tighten all six screws (10, Figure 387) finger tight and
make sure the assembly is seated flush with the crankcase
mating surface. Do not try to pull the assembly down with
the Torx screws.

10. Tighten the six Torx screws to 18-22 ft.-lb. (24-30
N•m) in the sequence shown in Figure 389.

11. Rotate the crankshaft until the sprocket timing mark
is at the 6 o’clock position (A, Figure 390) and the flat
portion (B) is directly below the crankshaft crankpin hole
(C).

12. Rotate the balance shafts until the holes in the balance
shafts (A, Figure 385) align with the shaft supports (B).

13. Insert balance shaft retaining pins (C, Figure 385)
into the front and rear supports and balancer shafts to lock
the balancer shafts (A) in place. This will lock the balance
shafts into correct timing with the crankshaft.

14. Install the spacer onto the

front

balance shaft.

15. Correctly position the chain sprockets with their
marks facing UP. Install the front (8, Figure 387) and rear
(7) sprockets onto the balance shafts.

16. Install the washer and an

old

hex nut onto each bal-

ance shaft and tighten the nuts sufficiently to hold the
sprockets in place.

17. Perform

Front Sprocket Alignment

procedure as de-

scribed in this section. This procedure must be done to en-
sure correct alignment between the sprockets and balance

ENGINE

193

389

390

chain. If this alignment is incorrect, there will be prema-
ture wear on the sprockets and balancer chain.
18. Apply a thin coat of clean engine oil to the balancer
chain.
19. Locate the balancer chain timing marks as shown in
Figure 391. Loosely place the balancer chain next to the
front and rear sprockets and crankshaft timing mark.
Align the colored chain links next to the sprockets.
20. Slide the balancer chain over the sprockets starting
with the rear sprocket. Align the colored chain link with
the alignment arrow on the rear sprocket and mesh the
chain onto the sprocket.
21. Pull the balancer chain taut and align the center col-
ored chain link with the alignment mark on the crankshaft
sprocket.
22. Pull the balancer chain taut, align the colored chain
link with the alignment arrow on the front sprocket, then
mesh the balancer chain onto the front sprocket.

CAUTION

All three balancer chain link alignment
marks must be correctly aligned with the
three sprockets. If alignment is incorrect,
the balancer system will not function cor-
rectly, resulting in excessive vibration.

23. Verify that all three colored chain links are aligned
with the marks on both front and rear sprockets and the
crankshaft sprocket (Figure 391). Readjust if necessary.

NOTE

If new self-locking hex nuts are not avail-
able, apply a high-strength threadlocking

compound to the old nuts prior to installa-
tion.

24. Remove the old nuts installed in Step 16. Install

new

self-locking hex nuts (5, 6 Figure 387) and tighten to
78-82 ft.-lb. (106-111 N•m).

25. After the nuts have been tightened, once again verify
that all three colored chain links are aligned with the
marks on both front and rear sprockets and the crankshaft
sprocket (Figure 391). Readjust if necessary.

26. Correctly position the front upper chain guide (A,
Figure 392) with the

facing out. Install the front guide

onto the post and push it down until it snaps into place.

27. Correctly position the rear upper chain guide (B, Fig-
ure 392) with the

facing out. Install the rear guide onto

the post and push it down until it snaps into place.

194

CHAPTER FOUR

391

Rear alignment

mark

Center alignment

mark

Front alignment

mark

392

28. Install the lower chain guide (C, Figure 392) into
place and snap the two retention tabs (D) into place lock-
ing the guide in place.

29. Install and clamp the tensioner compressor (A, Fig-
ure 393) over the balancer chain adjacent to the hydraulic
tensioner and the bottom of the chain guide bracket.

30. Pump the tensioner compressor handle and compress
the hydraulic tensioner (C, Figure 393).
31. Slide the hydraulic tensioner retainer (B, Figure 393)
away from the tip of the tensioner (C).
32. Slowly release pressure on the tensioner compressor
and remove it.

CAUTION

After removing the balancer shaft retaining
pins, inspect the tip of each pin. If the small
ball at the end is missing, locate it within the
crankcase half and remove it. If the ball
worked loose and stays within the crank-
case, severe engine damage could occur.

33. Repeat Steps 29-32 for the remaining tensioner.
34. Slowly remove the balancer shaft retaining pin (D,
Figure 393), installed in Step 13, from the balancer shaft
support and the balancer.
35. Install a

new

rubber interconnect (Figure 384).

Front Sprocket Alignment

The balancer sprocket alignment tool (JIMS part No.

1166 or part No. HD-44064) is required for this procedure
(Figure 394).

This procedure if for the front sprocket only. The rear

sprocket is not equipped with a spacer.
1. Slide the special tool (Figure 395) over the crankshaft
and the timing sprocket shoulder.
2. Hold down the special tool in place on the crankshaft
and move the tool over onto the

front

sprocket face.

3. Alignment is correct if the tool’s

outside step

clears the

top surface of the sprocket (Figure 396). Alignment clear-
ance between the tool and the sprocket surface is 0.014 in.
(0.356 mm). The tool’s inside step

must not

pass over the

sprocket face.
4. If alignment is incorrect, replace the spacer with a new
one that will bring the front sprocket alignment into speci-
fication. Refer to Table 7.

Inspection

1. Clean all parts in solvent and dry with compressed air.
2. Check the flatness of each sprocket with a straightedge
and flat feeler gauge. The sprocket must be flat within the
service limit specification in Table 2.
3. Inspect the crankshaft and balancer sprockets for un-
dercut or sharp teeth (Figure 397) or missing teeth.

NOTE

The balancer chain sprocket on the crank-
shaft is pressed into place. If severely dam-

ENGINE

195

393

394

395

aged, have the sprocket replaced by a
Harley-Davidson dealership.

4. If excessive wear or damage is evident, replace the bal-
ancer sprockets and balancer chain as a set. Rapid bal-
ancer chain wear occurs if the new chain is installed with
worn sprockets.
5. Check the sprocket surface where it mates with the bal-
ancer surface. Make sure the surface is clean without any
burrs or surface irregularities. Replace as necessary.
6. The balancer chain will darken to a brown color as the
result of wear and the exposure of engine oil. If the chain
has turned blue, it has overheated and should be replaced.
7. Inspect the inner plate chain links. They must be
slightly polished on both sides. If the chain shows consid-
erable uneven wear on one side, the sprockets are cor-
rectly aligned. Excessive wear requires the balancer chain
and sprockets to be replaced.
8. Inspect the upper and lower chain guides for wear or
damage. Replace any guide if a groove is worn to the wear
limit in Table 2.
9. Inspect the chain guide support assembly for wear or
distortion. Replace if necessary.

Balance Shaft Bearing Inspection/Replacement

Inspection

Refer to Figure 388.
Inspect the balancer bearing in the balance shaft support

and in the left side crankcase (Figure 398). Turn each in-
ner race by hand (Figure 399). The bearing must turn
smoothly. Some axial play is normal, but radial play must
be negligible. See Figure 400.

If the bearing(s) is damaged, replace it as described in

the following.

Inner crankcase bearing replacement

A balancer shaft bearing remover and installer (JIMS

part No. 1167) and a hydraulic press are required to ser-
vice the counterbalancer shaft bearing.
1. Separate the crankcase and remove the balancer sys-
tem as described in this chapter.
2. Thoroughly clean the crankcase half with solvent and
dry with compressed air.
3. Place the left side crankcase half on towels or shop
cloths to protect the exterior finish. Place the crankcase on
the workbench.
4. Apply a light coat of graphite lubricant to the threads
of the bearing puller and large nut.

196

CHAPTER FOUR

396

397

Correct sprocket height

High sprocket height

Low sprocket height

Normal wear

Excessive wear

Harley Davidson Softail 2000-2005. Service manual - page 17