Harley Davidson 2013 Sportster Models. Service Manual

Table 3-29. Valve Stem Clearance/Service Wear Limits

SERVICE WEAR

LIMIT

CLEARANCE

VALVE

0.0965

0.0035

0.0254-0.0762

0.001-0.003

Intake

0.0965

0.0035

0.0254-0.0762

0.001-0.003

Exhaust

Table 3-30. Valve Guide Remover/Installer Components

ITEM

PART NO

Valve guide remover/installer

with installer sleeve

B-45524

Cylinder head support stand

HD-39782-A

Intake seat adapter, 883

HD-39782-2

Exhaust seat adapter, 883

HD-39782-3

Intake seat adapter, 1200

HD-39782-6

Exhaust seat adapter, 1200

HD-39782-7

sm01522

1. Valve guide remover/installer
2. Installer sleeve
3. Cylinder head support stand
4. Intake seat adapter, 883
5. Exhaust seat adapter, 883
6. Intake seat adapter, 1200
7. Exhaust seat adapter, 1200

Figure 3-59. Valve Guide Replacement Tools

sm01523a

1. Valve guide remover/installer
2. Cylinder head support stand
3. Ram

Figure 3-60. Removing Shoulderless Valve Guide

HOME

2013 Sportster Service: Engine 3-61

Installation

Check valve guide to valve guide bore clearance.

Measure outer diameter of a new standard valve
guide.

Measure the cylinder head valve guide bore. The
valve guide diameter should be 0.0020-0.0033 in
(0.0508-0.0838 mm) larger than cylinder head valve
guide bore.

If interference fit is within specification, a replacement
valve guide will be used. If interference fit is not within
specification, the cylinder head must be replaced.

Measure cylinder head bore and outside diameter of
replacement valve guide to verify correct interference fit.

NOTE

Always use cylinder head support stand. Misalignment during
valve guide replacement will cause damage to cylinder head
valve guide bore.

Prepare cylinder head for valve guide replacement.

See

Figure 3-59

. Insert sleeve of intake (4 or 6) or

exhaust (5 or 7) seat adapter into tube at top of cyl-
inder head support stand (3). Position cylinder head
so that valve seat is centered on seat adapter.

Apply petroleum jelly to lightly lubricate external sur-
faces of valve guide. Spread lubricant so that thin film
covers entire surface area.

At top of cylinder head, start valve guide into bore.

Place installer sleeve (2) over valve guide and then
insert VALVE GUIDE REMOVER/INSTALLER (1) into
installer sleeve.

See

Figure

3-61

Center

VALVE

GUIDE

REMOVER/INSTALLER (1) under ram of press and
apply pressure only until valve guide is started in bore
and then back off ram slightly to allow valve guide to
center itself.

NOTE

Always back off ram to allow the valve guide to find center.
Pressing valve guide into cylinder head in one stroke can
bend remover/installer, break valve guide, distort cylinder
head casting and/or damage cylinder head valve guide
bore.

Verify that cylinder head support stand (3) and VALVE
GUIDE REMOVER/INSTALLER are square. Center
VALVE GUIDE REMOVER/INSTALLER under ram
and press valve guide further into bore, then back off
ram again to allow valve guide to find center.

Repeat previous step and then apply pressure to
VALVE GUIDE REMOVER/INSTALLER until installer
sleeve (2) contacts machined area of cylinder head
surrounding valve guide.

XR 1200X:

Install

new

lock ring into valve guide

groove. Make sure that lock ring is square and fully
seated in the groove.

sm01524a

1. Valve guide remover/installer
2. Installer sleeve
3. Cylinder head support stand

Figure 3-61. Installing Shoulderless Valve Guide

Secure cylinder head for service.

See

Figure 3-62

. Thread 12 mm end of CYLINDER

HEAD HOLDING FIXTURE (Part No. HD-39786) into
cylinder head spark plug hole.

Clamp tool in vise at a 45 degree angle or one that
offers a comfortable working position.

NOTE

Valve guides must be reamed to within 0.0005-0.0001 in
(0.013-0.0025 mm) of finished size.

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3-62 2013 Sportster Service: Engine

sm01525a

1. T-handle
2. Valve guide reamer
3. Holding fixture

Figure 3-62. Reaming Valve Guide Bore

NOTES

•

Avoid damage to valve guide bore. Never back reamer
out of valve guide.

•

For best results, do not push on reamer or apply pressure
to the reamer handle. While excessive pressure results in
a rough cut, bore will be tapered if pressure is not centrally
applied.

Obtain the VALVE GUIDE REAMER (Part No. B-45523)
(2) and REAMER T-HANDLE (Part No. HD-39847) (1).

Install T-handle on reamer.

Start bit of reamer into bore at top of cylinder head.

Placing thumb on drive socket of REAMER T-
HANDLE, apply slight pressure rotating clockwise.

Continue rotating REAMER T-HANDLE until entire
bit has passed through valve guide bore and shank
of reamer rotates freely.

Remove T-handle from reamer. Carefully pulling on
bit, draw shaft of reamer out combustion chamber
side of valve guide.

NOTE

Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure.

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)

Direct compressed air into the valve guide bore to remove
any metal shavings or debris.

See

Figure 3-63

. Clean valve guide bore with the VALVE

GUIDE CLEANING BRUSH (Part No. HD-34751) (1).

See

Figure 3-64

. Obtain the VALVE GUIDE HONE (Part

No. B-45525) and REAMER LUBRICANT (Part No. HD-
39964).

Install hone in a high speed electric drill.

Apply REAMER LUBRICANT to finishing stones of
hone and valve guide bore.

Start finishing stones of hone into bore.

Complete 10 to 12 complete strokes using entire
length of finishing stone arrangement and drill. Work
for a crosshatch pattern of approximately 60 degrees.

NOTE

The hone is not intended for the removal of material.

sm01526a

1. Valve guide brush
2. Cylinder head holding fixture

Figure 3-63. Scrubbing Valve Guide Bore

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2013 Sportster Service: Engine 3-63

sm01527

1. Valve guide hone
2. Cylinder head holding fixture

Figure 3-64. Honing Valve Guide Bore

NOTE

Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure.

Direct low pressure compressed air into the valve guide
bore to remove any debris.

10. See

Figure 3-63

. Clean bore with the VALVE GUIDE

CLEANING BRUSH (1).

NOTE

Always verify valve stem to valve guide clearance after honing,
since a worn reamer may cut the bore undersize.

11. Check valve stem to valve guide clearance.

Measure the inside diameter of the valve guide with
an inside ball micrometer.

Measure the outside diameter of the valve stem with
an outside micrometer.

If valve stem to valve guide clearance is not within
specification, the valve stem may be excessively worn
or the valve guide bore undercut. Refer to

Table 3-29

12. Clean cylinder head assembly again.

Using cleaning solvent, thoroughly clean cylinder head
and valve guide bore.

Scrub valve guide bore with the VALVE GUIDE
CLEANING BRUSH. For best results, use a thin
engine oil and clean valve guide bore with the type
of swabs or patches found in gun cleaning kits.

Continue to wipe bore until clean cloth shows no
evidence of dirt or debris. Follow up with a thorough
wash in hot soapy water.

13. Blow parts dry with low pressure compressed air.

REFACING VALVE SEATS

TOOL NAME

PART NUMBER

CUTTER PILOT

B-35758-52A

VALVE GUIDE CLEANING BRUSH

HD-34751

NEWAY VALVE SEAT CUTTER SET

HD-35758-C

CYLINDER HEAD HOLDING FIXTURE

HD-39786

NOTES

•

Check that valve stem to valve guide clearance is correct
before refacing. Refer to

Table 3-29

. If new valve guides

must be installed, see

3.14 CYLINDER HEAD, Replacing

Valve Guides

and complete that task before refacing valve

seats.

•

This procedure is not based on the lapping of valves. The
end result is an interference fit between the 45 degree
valve face and the 46 degree valve seat.

•

Obtain a new valve if grinding leaves the margin less than
0.0313 in (0.795 mm). A valve in this condition does not
seat normally, burns easily and may crack or cause pre-
ignition.

Secure cylinder head for servicing.

Thread 12 mm end of CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) into cylinder head
spark plug hole.

Clamp fixture in vise. Tighten cylinder head onto the
fixture to prevent any movement during operation.

Place cylinder head at a 45 degree angle or one that
offers a comfortable working position.

To determine the correct location of the 46 degree valve
seat in the head, measure the width of the valve. Subtract
0.080 in (2.032 mm) from that number.

Set your dial caliper to the lesser measurement and lock
it down for quick reference. This is the location of your
valve seat.

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3-64 2013 Sportster Service: Engine

Use a permanent magic marker to highlight the valve seat
area to be cut. Highlight all three angles. Allow marker to
dry.

NOTES

•

Clean the cutter blades and cutter pilot. The correct
cleaning brush is supplied with the Neway tool set.

•

Clean the inside of the valve guide with the VALVE GUIDE
BRUSH.

sm01528

Figure 3-65. Neway Valve Seat Cutter Set (Part no.

HD-35758-C)

See

Figure 3-65

. Obtain the NEWAY VALVE SEAT

CUTTER SET (Part No. HD-35758-C). Select the correct
CUTTER PILOT (Part No. B-35758-52A). Securely seat
the pilot by pushing down and turning using the installation
tool supplied in the tool set.

Choose the proper 46 degree cutter (intake or exhaust)
and gently slide the cutter onto the pilot. Do not drop the
cutter onto the valve seat.

NOTE

Do not remove any more metal than is necessary.

Apply constant pressure. Cut the seat to a uniform finish
and to remove pitting.

NOTES

•

If the width of the clean-up angle is greater on one side
of the valve seat than the other, replace the valve guide.

•

After making the 46 degree cut, a groove cut completely
around the valve seat indicates worn cutter blades. This
condition can be corrected by staggering the blades.
Loosen all blades. Move each blade slightly in opposite
directions on the cutter. The tool needed to loosen the
blades is supplied in the tool set. A permanent magic
marker mark every 90 degree will help in determining
where new angles are.

Lock a dial caliper to the predetermined setting. Measure
the 46 degree cut at the outermost edge at the widest
point of the circle to determine the next cut.

If the 46 degree cut is too high (towards the combus-
tion chamber), use the 31 degree cutter to lower the
valve seat closer to the port.

If the 46 degree cut is too low, use the 60 degree
cutter to raise the valve seat or move it away from
the port.

NOTES

•

Because you are using the top measurement of the valve
seat as a reference point, it will usually be necessary to
use the 31 degree cutter following the initial 46 degree
cut.

•

Always highlight the valve seat with the permanent magic
marker in order to verify the location of the 46 degree valve
seat.

If the location of the valve seat is not correct, repeat pre-
vious two steps.

10. When you accomplish a complete clean-up of the 46

degree angle and the width is at least 0.062 in (1.575 mm),
proceed to the next step.

11. Select the proper 60 degree cutter and gently slide the

cutter down the cutter pilot to the valve seat.

12. Remove just enough material to provide an even valve

seat width of 0.040-0.062 in (1.016-1.575 mm).

13. Remove cutter and cutter pilot.

14. Repeat the process on any valve seat that needs service.

15. Insert valve in the valve guide and bottom on the valve

seat. Position the cylinder head port upwards with slight
thumb pressure against the valve. Fill the port with solvent
to seal the valve to the seat.

NOTE

Hold pressure against the valve for a minimum of 10 seconds.
If any leakage occurs, examine the valve seat for irregularities
or defects and if necessary repeat the above cutting process.

16. Clean valves, cylinder head and valve seats in solvent.

Follow up with a thorough wash in hot soapy water.

17. Scrub valve guide bores with VALVE GUIDE CLEANING

BRUSH (Part No. HD-34751) and hot, soapy water.

18. Blow parts dry with low pressure compressed air.

HOME

2013 Sportster Service: Engine 3-65

sm01530

1. Valve seat
2. Valve
3. Margin: not less than 0.0313 in (0.795 mm)
4. Valve seat width: 0.040-0.062 in (1.016-1.575 mm)

Figure 3-66. Intake and Exhaust Valve and Seat Dimensions

Replacing Valve Seats

Replacing a valve seat is a complex operation requiring special
equipment. If the valve seat is loose or not fully seated, transfer
of heat from the valve will be impaired. The valve seat surface
must be flush with or below the head surface. See

3.2 SPE-

CIFICATIONS

ASSEMBLY

TOOL NAME

PART NUMBER

VALVE SPRING COMPRESSOR

HD-34736-B

Apply a liberal amount of SCREAMIN' EAGLE ASSEMBLY
LUBE to the valve stem.

See

Figure 3-71

. Insert valve (1) into valve guide (3) and

bottom valve on valve seat (2).

See

Figure 3-67

. Place a protective sleeve over the valve

stem keeper groove. Coat the protective sleeve with
SCREAMIN' EAGLE ASSEMBLY LUBE.

NOTES

•

Always use a protective sleeve on the valve stem keeper
groove when installing valve stem seal. Installation without
the protective sleeve will damage the seal. This will cause
leaking around the valve stem, excessive oil consumption
and valve sticking.

•

See

Figure 3-68

. The valve seal is incorporated into the

lower valve collar and is installed by hand. NO SPECIAL
TOOLS ARE REQUIRED.

•

The valve seal is completely installed when the lower valve
collar contacts the machined surface of the head.

See

Figure 3-69

. Place a

new

seal and lower valve collar

assembly over valve stem and onto valve guide.

NOTES

•

Do not remove valve after seal is installed. Otherwise,
sharp edges on keeper groove will damage seal.

•

A single valve spring is used for each valve.

sm01531a

Figure 3-67. Valve Guide Seal Protector Sleeve

sm01534d

Figure 3-68. Valve Seal and Lower Valve Collar Assembly

(seal and lower collar replaced as assembly only)

sm01536a

Figure 3-69. Valve Seal and Lower Valve Collar Assembly

Installation

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3-66 2013 Sportster Service: Engine

See

Figure 3-71

. Install valve spring (5) and upper collar

(6).

See

Figure 3-70

. Compress valve spring with VALVE

SPRING COMPRESSOR (Part No. HD-34736-B).

See

Figure 3-71

. Insert valve collar retainers (7) into upper

collar, making sure they engage groove in valve stem.
The retainer gaps should be equal.

Release and remove VALVE SPRING COMPRESSOR.

Repeat previous steps for remaining valve(s).

sm00134

Figure 3-70. Valve Spring Compressor

sm06922

1. Valve
2. Valve seat
3. Valve guide
4. Valve seal and lower spring collar
5. Spring
6. Upper valve spring collar
7. Collar retainer

Figure 3-71. Cylinder Head

HOME

2013 Sportster Service: Engine 3-67

3.15

CYLINDER AND PISTON

CLEANING, INSPECTION AND REPAIR

TOOL NAME

PART NUMBER

TORQUE PLATE BOLTS

HD-33446-86

CYLINDER TORQUE PLATES

HD-33446-B

Soak cylinder and piston in an aluminum-compatible
cleaner/solvent until deposits are soft. Clean with a brush.
Blow off loosened carbon and dirt particles. Wash in
solvent.

Clean oil passage in cylinder with low pressure com-
pressed air.

Clean piston ring grooves with a piece of compression
ring ground to a chisel shape.

Inspect piston pin to see that it is not pitted or scored.

Check piston pin bushing to see that it is not loose in
connecting rod, grooved, pitted or scored.

A piston pin properly fitted to upper connecting rod
bushing has a 0.00125-0.00175 in (0.0317-0.0444
mm) clearance in bushing.

If piston pin-to-bushing clearance exceeds 0.002 in
(0.0508 mm), replace worn parts. See

3.15 CYL-

INDER AND PISTON, Connecting Rod Bushings

Clean piston pin lock ring grooves.

Inspect piston and cylinder for cracks, burnt spots, grooves
and gouges.

NOTE

Check connecting rod for up and down play in lower bearings.
When up and down play is detected, replace flywheel and
connecting rod assembly.

Checking Gasket Surface

NOTE

Replace the cylinder and piston if either cylinder gasket surface
does not meet specification.

See

Figure 3-72

. Check that cylinder top (head) gasket

surface is flat within 0.006 in (0.15 mm).

Lay a straight edge across the surface.

Insert a feeler gauge between the straightedge and
the gasket surface.

Check that the cylinder base gasket surface is flat within
0.008 in (0.20 mm).

Lay a straightedge across the surface.

Insert a feeler gauge between the straightedge and
the gasket surface.

sm01539a

Figure 3-72. Checking Gasket Surfaces

Measuring Cylinder Bore

See

Figure 3-73

. Remove any burrs from the cylinder

gasket surfaces.

Install a head and base gasket and CYLINDER TORQUE
PLATES (Part No. HD-33446-B) and TORQUE PLATE
BOLTS (Part No. HD-33446-86). Tighten in the cylinder
head torque sequence. See

3.16 TOP END OVERHAUL:

ASSEMBLY, Cylinder Head

NOTE

Torque plates simulate operating conditions. Without torque
plates, measurements vary as much as 0.001 in (0.025 mm).

Take cylinder bore measurement in ring path, starting
about 1/2 in (13 mm) from top of cylinder, measuring from
front to rear, and then side to side. Record readings.

Measure at top, center and bottom of the ring path. Record
readings. Determine if the cylinder is out-of-round, tapered
or bulged. Refer to

Table 3-31

HOME

3-68 2013 Sportster Service: Engine

Table 3-31. Cylinder Bore Service Wear Limits

XL 1200*

XL 883

BORE SIZE

88.920

3.5008

76.289

3.0035

Standard bore

89.027

3.5050

76.398

3.0078

0.005 in (0.13 mm) Oversize

89.154

3.5100

76.525

3.0128

0.010 in (0.25 mm) OS bore

*XR 1200X:

Oversized pistons are not available. Replace piston and/or cylinder if exceeds wear limits.

NOTE

If piston clearance exceeds service limit, cylinders should be
bored and honed to next standard oversize. Fit the cylinder
with the oversized piston and rings. Do not fit piston tighter
than 0.0007 in (0.018 mm). See

3.2 SPECIFICATIONS

sm01540

Figure 3-73. Measuring Cylinder Bore

Measuring Piston to Cylinder Fit

NOTES

•

This measurement is heat sensitive. Both piston and cyl-
inder must be at room temperature. Holding the piston in
your hand for too long can cause measurements to vary
by as much as 0.002 in (0.051 mm).

•

See

Figure 3-74

. The measurement is taken on bare alu-

minum to avoid measuring errors. An oval-shaped opening
in the coating is present on each side of the piston for
placement of the micrometer.

•

See

Figure 3-75

. The oval openings are too small for a

standard flat anvil micrometer. Use a 3-4 inch blade or
ball anvil style micrometer, or a 4-5 inch micrometer with
spherical ball anvil adapters.

Measure the piston skirt at the oval openings. Transfer
that measurement to a dial bore gauge.

NOTE

Install the torque plates on the cylinder.

Mark the top, middle and bottom of the piston ring travel
zone with a marker. Measure at markings in cylinder par-
allel and perpendicular to crankshaft.

Replace piston and/or cylinder if running clearance
exceeds 0.003 in (0.076 mm).

sm01543

Figure 3-74. Measurement Area

sm01545

1. 4-5 inch micrometer
2. Spherical ball anvil adapter (2)

Figure 3-75. Micrometer with Anvil Adapters

Boring and Honing Cylinder

The cylinder must be bored with gaskets and torque plates
attached. Bore the cylinder to 0.003 in (0.08 mm) under
the desired finished size.

HOME

2013 Sportster Service: Engine 3-69

NOTE

With the torque plates installed, hone the cylinder from the
crankcase end of the cylinder.

Use a 280 grit rigid hone followed by a 240 grit flexible
ball hone to hone the cylinder. Work for a 60 degree
crosshatch pattern.

Final cylinder bore sizes are measured after honing. Refer to

Table 3-32

NOTES

•

When cylinder requires boring over 0.010 in (0.25 mm),
replace the cylinder.

•

Replace the cylinder if it is scuffed or grooved.

•

Use the original piston if cylinder bore was not changed,
Replace the rings. Hone the cylinder walls with a No. 240
grit flexible ball hone.

Failure to remove all abrasive particles may result in pre-
mature cylinder, piston and ring wear and engine failure.
(00537c)

Thoroughly wash the cylinder bore with liquid dishwashing
soap and warm water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth shows
no remaining dirt or debris.

Hot rinse the cylinder. Dry with moisture free low pressure
compressed air.

Immediately apply a thin film of clean engine oil to a clean
white paper towel and thoroughly wipe the inside of the
cylinder.

NOTE

After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.

With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run.

Table 3-32. Cylinder Final Bore Sizes

XL 1200**

XL 883

BORE SIZE

88.844

3.4978

76.213

3.0005

Standard bore*

88.95

3.502

76.323

3.0048

0.005 in (0.13 mm) OS bore

89.08

3.507

76.449

3.0098

0.010 in (0.25 mm) OS bore

*All bore sizes + 0.0002 in (0.00508 mm)

**XR 1200X:

Oversized pistons are not available. Replace piston and/or cylinder if exceeds wear limits.

Fitting Piston Rings

See

Figure 3-76

. Piston rings are of two types: compression

and oil control. The two compression rings are positioned in
the two upper piston ring grooves. The dot on the second
compression ring must face upward. Ring sets are available
to fit standard and oversize pistons.

Piston ring sets must be properly fitted to piston and cylinder:

See

Figure 3-77

. Place piston in cylinder about 1/2 in (13

mm) from top. Set ring to be checked inside cylinder,
squarely against piston. Remove piston and check ring
end gap with thickness gauge. See

3.2 SPECIFICATIONS

NOTES

•

Always deglaze or hone the cylinder before installing new
rings.

•

Always use new piston rings. Piston rings take a set and
must not be reused.

•

Replace a ring if the end gap exceeds specification. See

3.2 SPECIFICATIONS

•

If end gap is under specification, file the ring gap. Insuffi-
cient ring gap can cause ring breakage, cylinder scuffing
or piston seizure.

•

Ring end gap specifications are applicable to rings for
oversized pistons.

HOME

3-70 2013 Sportster Service: Engine

sm01598

1. Top ring: install either side up
2. Second ring: install dot toward top
3. Oil control rings

Figure 3-76. Piston Rings

sm01548a

Figure 3-77. Measuring Ring End Gap

Blow debris from piston oil drain holes and ring grooves
with low pressure compressed air. Apply clean engine oil
to piston ring grooves.

See

Figure 3-78

. Install oil control ring expander spring.

Make sure ends of spring point upward. Spiral bottom oil
control ring into space in ring groove below expander
spring. Position oil control ring gap 90 degrees from gap
in expander spring. Spiral top oil control ring into space in
ring groove above expander spring. Position oil control
ring gap 180 degrees from gap in bottom oil control ring.

sm01553

Figure 3-78. Installing Oil Control Ring Expander Spring

(typical)

See

Figure 3-79

. Use a piston ring expander tool to slip

compression rings over piston into their respective
grooves. Install second compression ring first, then top
compression ring. Be extremely careful not to over expand
or twist rings, or damage piston surface when installing
rings.

NOTE

Install second compression ring with dot towards top of piston.

sm01554

Figure 3-79. Installing Piston Rings

See

Figure 3-80

. Position rings so end gaps of adjacent

rings are a minimum of 90 degrees apart. Ring gaps are
not to be within 10 degrees of the thrust face centerline.

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2013 Sportster Service: Engine 3-71

See

Figure 3-81

. Check for proper side clearance with

thickness gauge, as shown. See

3.2 SPECIFICATIONS

NOTE

If the ring grooves are clean and the side play is still not correct,
replace the rings, the piston or both.

sm01555

1. Front
2. Rear
3. Piston pin

Figure 3-80. Position Ring End Gaps at Arrows

sm1556a

Figure 3-81. Measuring Ring Clearance in Groove

CONNECTING ROD BUSHINGS

TOOL NAME

PART NUMBER

WRIST PIN BUSHING HONE

HD-35102

REAMER LUBRICANT

HD-39964

CONNECTING ROD BUSHING
REAMER

HD-94800-26A

CONNECTING ROD CLAMPING TOOL

HD-95952-33C

CONNECTING ROD BUSHING
REMOVER/INSTALLER

HD-95970-32D

Removing Upper Connecting Rod Bushings

NOTES

•

Replace the upper connecting rod bushing if the piston
pin to rod bushing clearance exceeds 0.002 in (0.051 mm).

•

Place clean shop towels in and around the crankcase
bore. This prevents prevents chips and shavings from
falling into the crankcase.

•

If CONNECTING ROD CLAMPING TOOL (Part No. HD-
95952-33C) holes are too small, enlarge the holes in the
tool.

See

Figure 3-82

. Obtain the CONNECTING ROD

CLAMPING TOOL and install as follows:

Slide clamp (2) over connecting rod so that slots
engage cylinder head studs. Exercise caution to avoid
scratching or bending studs.

With the knurled side up, screw threaded cylinders
(1) onto studs to secure position of clamp.

Alternately turn each clamp thumbscrew (3) a few
turns to gradually fix position of connecting rod.
Turning only one thumbscrew will move rod off-center,
while tightening second thumbscrew can cause rod
to flex or bend.

Install rubber hoses over remaining two cylinder studs.

See

Figure 3-83

. Obtain the CONNECTING ROD

BUSHING REMOVER/INSTALLER (Part No. HD-95970-
32D).

Sparingly apply graphite lubricant to threads of bolt
(6) to prolong service life and provide smooth opera-
tion.

Slide receiver cup (5) onto bolt with the closed side
facing bolt head.

Insert bolt through upper connecting rod bushing.

HOME

3-72 2013 Sportster Service: Engine

sm01557

1. Threaded cylinder (2)
2. Clamp
3. Thumb screw (2)

Figure 3-82. Connecting Rod Clamping Tool (Part No.

HD-95952-33C)

sm01558

1. Nut
2. Flat washer
3. Bearing
4. Remover/Installer
5. Receiver cup
6. Bolt

Figure 3-83. Connecting Rod Bushing Remover/Installer

(Part No. HD-95970-32D)

Remove bushing as follows:

See

Figure

3-84

Slide

remover

side

remover/installer onto bolt. The driver is stamped to
verify proper orientation.

See

Figure 3-83

. Slide bearing (3) and flat washer (2)

onto bolt (6) until they contact remover/installer (4).

Thread nut (1) onto bolt until assembly is snug.

Using two box end wrenches, tighten nut on bolt until
bushing is free.

Remove nut from bolt. Remove flat washer, bearing
and remover/installer. Remove bolt from bushing bore.

Remove bushing from receiver cup and discard.

NOTE

Leave CONNECTING ROD CLAMPING TOOL installed during
bushing installation procedure which follows.

sm01559

Figure 3-84. Remover Stackup. Use Remover Side Of

Remover/Installer

Installing Upper Connecting Rod Bushings

See

Figure 3-83

. Obtain the CONNECTING ROD

BUSHING REMOVER/INSTALLER (Part No. HD-95970-
32D).

Sparingly apply graphite lubricant to threads of bolt
(6) to prolong service life and provide smooth opera-
tion.

Slide receiver cup (5) onto bolt with the closed side
facing bolt head.

Insert bolt through upper connecting rod bushing bore.

See

Figure 3-85

. Slide

new

bushing onto bolt. Start

bushing into bore. Be sure that bushing is square in
bore and not cocked.

Slide installer side of remover/installer onto bolt until
shoulder contacts bushing. The remover/installer is
stamped to verify proper orientation.

Slide bearing and flat washer onto bolt until they
contact remover/installer.

Thread nut onto bolt until assembly is snug.

See

Figure 3-86

. Using two box end wrenches, tighten

nut on bolt until collar on remover/installer bottoms
against connecting rod.

Remove nut from bolt and remove flat washer, bearing
and remover/installer. Remove bolt from bushing bore,
but exercise caution to avoid scratching or gouging
bushing.

NOTE

Leave CONNECTING ROD CLAMPING TOOL installed during
bushing reaming procedure which follows.

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2013 Sportster Service: Engine 3-73

sm01573a

Figure 3-85. Installer Stackup

sm01575a

1. Piston bushing tool
2. Rod clamping fixture

Figure 3-86. Installing New Piston Pin Bushing

Reaming Upper Connecting Rod Bushings

NOTE

Sizing bushing with less than 0.00125 in (0.0317 mm) clearance
can result in a bushing loosening and/or seized pin in rod.

Clean up and size bushing to 0.0010-0.0005 in (0.025-
0.013 mm) undersize using the CONNECTING ROD
BUSHING REAMER (Part No. HD-94800-26A).

Carefully insert bit of reamer into upper connecting
rod bushing. Do not apply lubricant to reamer or
bushing. Ream the bushing dry or cut will not be
accurate.

Install a 11/16 12-pt socket and T-handle on reamer
lug.

Placing thumb on drive socket, apply slight pressure
on reamer while rotating handle/drive socket clock-
wise.

NOTE

For best results, do not push on reamer or apply pressure
to the reamer handle. While excessive pressure results in

a rough cut, bushing bore will be tapered if pressure is not
centrally applied.

Continue rotating handle/drive socket until entire bit
has passed through bushing and shank of reamer
rotates freely in the bore.

NOTE

Never back reamer out of connecting rod or bushing will be
damaged.

Remove T-handle and socket, and carefully pulling on bit,
draw shaft of reamer out of connecting rod bushing.

NOTE

Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure.

Using contact cleaner or cleaning solvent, thoroughly wipe
upper connecting rod and bushing of any metal shavings
or debris.

NOTE

Leave CONNECTING ROD CLAMPING TOOL installed during
bushing honing procedure which follows.

Honing Upper Connecting Rod Bushings

Obtain the WRIST PIN BUSHING HONE (Part No. HD-
35102) and REAMER LUBRICANT (Part No. HD-39964)
to hone bushing to final size. Use a liberal amount of
honing oil to prevent damage to hone or bushing. Use
care to prevent foreign material from falling into the
crankcase.

Install hone in a high speed electric drill.

Apply reamer lubricant to finishing stones of hone and
inside of upper connecting rod bushing.

Start finishing stones of hone into bushing.

Activating the drill, move the entire length of the fin-
ishing stone arrangement forward and backward
through the bushing bore for 10 to 12 complete
strokes. Work for a crosshatch pattern of approxim-
ately 60 degrees.

NOTE

Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine failure.

Using contact cleaner or cleaning solvent, thoroughly wipe
upper connecting rod and bushing of any metal shavings
or debris. Continue wiping until a clean cloth shows no
evidence of dirt or debris.

Lightly oil a good piston pin and insert it into the upper
connecting rod bushing bore to feel for the proper interfer-
ence fit. The pin should slide in and out of the bushing
without binding, but also without pivoting or rocking.

Remove the connecting rod clamping tool.

Remove shop towels exercising caution that shavings,
chips and other debris do not fall into crankcase.

Repair

If connecting rod is bent, do not attempt to straighten. Flywheel
and connecting rod assembly must be replaced. Straightening

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3-74 2013 Sportster Service: Engine

3.16

TOP END OVERHAUL: ASSEMBLY

GENERAL

This section describes assembling the top end of the engine,
from the cylinder deck up. If the engine crankcase has been
disassembled for repair, it must be assembled before assem-
bling the top end of the engine. See

3.22 BOTTOM END

OVERHAUL: ASSEMBLY

PISTON AND CYLINDER

TOOL NAME

PART NUMBER

PISTON PIN LOCK RING
REMOVER/INSTALLER

HD-34623-C

PISTON SUPPORT PLATE

HD-42322

PISTON RING COMPRESSOR

HD-96333-51E

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

NOTE

See

Figure 3-87

. Install XL pistons with the arrow on the top

and the side of the piston point toward the front.

Install piston assembly over connecting rod.

Install piston pin.

NOTE

You may wish to place clean shop towels over cylinder and
lifter bores prior to the next step, to prevent the piston pin lock
ring from falling into the crankcase.

See

Figure 3-88

. Install

new

piston pin lock rings with the

PISTON PIN LOCK RING REMOVER/INSTALLER (Part
No. HD-34623-C). Make sure the ring groove is clean and
that the ring is fully seated in the groove with the gap away
from the slot at the bottom.

NOTE

Avoid damage to cylinder and piston. Always use new lock
ring. Clean lock ring groove and seat lock ring firmly in groove.
If it does not, discard the lock ring. Do not install a used lock
ring or a new one that has been installed and removed. A
loosely installed ring will come out of the piston groove and
damage cylinder and piston beyond repair.

sm01577

Figure 3-87. Arrows on Piston Must Point Toward Front of

Engine

sm06556

Figure 3-88. Installing Piston Lock Rings

See

Figure 3-89

. Make sure the piston ring end gaps are

properly positioned as shown.

Lubricate cylinder wall, piston, pin and rod bushing with
engine oil.

Remove cylinder stud sleeves. Install a

new

cylinder base

gasket. Make sure the piston does not bump the studs or
crankcase.

HOME

3-76 2013 Sportster Service: Engine

Harley Davidson 2013 Sportster Models. Service Manual - page 37