Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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160

CHAPTER FOUR

20. If necessary, disassemble and remove the cam-

shafts as described in this chapter.

214

Installation

NOTE

It is necessary to release the second-

ary chain tension in order to install

the camshaft inner ends into the

crankcase bearings (D, Figure 213).

If the tension is not released, the inner

ends of the camshafts are pulled to-

gether and out of alignment with the

bearings, making installation difficult

if not impossible.

215

1. 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 counterclock-

wise and insert the hold pin (Figure 214)

through the hole in the outer surface of the

support plate and into the hole in the

tensioner. Push the hold pin all the way in un-

til it bottoms.

c. Remove the wrench and tensioner tool from

216

the tensioner.

2. Push on the oil pump assembly to make sure it is

correctly seated against the crankcase.

3. Install a new O-ring (A, Figure 213) 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.

4. On 2000-on models, install a new upper O-ring

(C, Figure 213). Apply a light coat of clean engine

oil to the O-ring.

5. Lubricate the camshaft needle bearing (Figure

215) in the crankcase and the camshaft bearing sur-

During

installation,

the

camshaft

faces (Figure 216) with clean engine oil.

ends may not be correctly aligned

6. If the camshafts were removed from the support

with the needle bearings. If force is

plate, check that the timing mark (Figure 217) on

applied, the needle bearing(s) will

each camshaft is aligned with each other. If not, re-

be damaged.

position the camshafts prior to installing the assem-

bly into the crankcase.

Slowly install the camshaft support plate

as-

7. If removed, install the two locating dowels (E,

sembly into the crankcase. Guide the camshaft

Figure 213) onto the crankcase.

ends into the crankcase needle bearings. If neces-

CAUTION

sary, slightly rotate and/or wiggle the end of the

Do not force the camshaft support

rear cylinder camshaft (Figure 218) to assist in the

plate assembly into the crankcase.

alignment.

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ENGINE

161

CAUTION

217

When properly aligned, the camshaft

support plate assembly will fit snugly

against the crankcase mating surface.

If they do not meet correctly, do not

attempt to pull the parts together with

the mounting bolts. Separate the cam-

shaft support plate assembly and in-

vestigate 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.

10. Once again, check that the timing marks (Fig-

ure 219) on each camshaft are still aligned with

218

each other. If not, correct the problem at this time.

11. Tighten the six camshaft support plate to crank-

case Allen bolts in the following sequence:

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

Figure 211).

b. Using a crisscross pattern, tighten the Allen

bolts to the specification in Table 4.

12. Tighten the four camshaft support plate-to-oil

pump Allen bolts in the following sequence:

a. Install the Allen bolts

(A, Figure

211).

Tighten the bolts until they just contact the

support plate and then back them out 1/4 turn.

b. Rotate the engine until the oil pump is in neu-

219

tral center with no load on it.

c. Tighten the bolts until they are snug against

the support plate. Then, using a crisscross

pattern, tighten the Allen bolts to the specifi-

cation in Table 4.

13. After all ten Allen bolts are tightened, check

around the perimeter of the support plate to make

sure it is seated against the crankcase mating surface.

14. Install an angled pick into the opening and

against the secondary camshaft chain tensioner

shoe (A, Figure 220). Slowly release the hold pin

(B) and allow the tensioner shoe to gradually make

220

contact with the chain surface. If released too fast,

the shoe surface will slam against the chain and be

damaged.

15. Squeeze the tabs and install the camshaft chain

guide (Figure 210) onto the two posts.

NOTE

Step 16 is not necessary if the original

camshaft support plate, both cam-

shafts, the rear camshaft sprocket, the

crankshaft drive sprocket, and the

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162

CHAPTER FOUR

crankshaft assembly are being reused

and installed. If any one of these com-

221

ponents have been replaced, Step 16

is necessary to ensure correct align-

ment between the rear camshaft

sprocket and the crankshaft drive

sprocket. If this alignment is incor-

rect, the primary drive chain and both

sprockets will bind and cause prema-

ture wear.

16. If new parts have been installed, check the

alignment of the rear camshaft sprocket and the

crankshaft drive sprocket as described under Rear

Camshaft Sprocket and Crankshaft Drive Sprocket

222

Alignment in the following procedure. 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 (Fig-

ure 221) onto the camshaft primary chain

tensioner.

b. Using a wrench (A, Figure 222), rotate the

tool counterclockwise and insert the hold pin

(B) through the hole in the tensioner and into

the hole in the support plate. Push the hold pin

all the way in until it bottoms.

c. Remove the wrench and tensioner tool from

223

the tensioner.

18. Position the sprocket spacer with the manufac-

turer’s mark side going on first, and install the

sprocket spacer (Figure 209) onto the rear camshaft.

NOTE

Refer to the mark made prior to re-

moval and position the camshaft pri-

mary drive chain so it will be

traveling in the same direction. If in-

stalled incorrectly, the drive chain

will wear prematurely.

19. Correctly assemble the rear camshaft sprocket,

224

the crankshaft drive sprocket and the primary drive

chain together as an assembly. Align the index mark

on both sprockets so they face each other as shown

in Figure 223.

20. On models so equipped, install the Woodruff

key onto the rear camshaft.

21. Install the rear camshaft drive sprocket (A, Fig-

ure 208), the crankshaft sprocket (B), and the pri-

mary camshaft drive chain (C) as an assembly onto

the crankshaft and rear camshaft. Align the flat on

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ENGINE

163

24. Install a new camshaft sprocket bolt (A, Figure

225

207) and new crankshaft sprocket bolt and washer

(B). Tighten the bolts finger-tight at this time.

25. Install and mesh the camshaft and crankshaft

sprocket lock (Figure 225) between the camshaft

and crankshaft sprockets.

26. Place a flat blade screwdriver (A, Figure 226)

between the primary camshaft drive chain and the

tensioner. Slowly release the hold pin (B), then

slowly withdraw the screwdriver and allow the

tensioner to gradually make contact with the chain

surface. If released too fast, the shoe surface will

slam against the chain and be damaged.

27. Tighten both bolts in the following steps:

226

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 to 34 ft.-lb. (46

N•m).

d. Tighten the crankshaft bolt to 24 ft.-lb. (33

N•m).

28. Remove the tool installed in Step 25.

29. Install the crankshaft position sensor (Figure

204) into the crankcase and tighten the bolt securely.

30. Install a new camshaft cover gasket (Figure

227) onto the crankcase.

227

NOTE

On 1999-2000 models, do not damage

the cam position sensor wiring (Fig-

ure 202) during cover installation.

31. Install the camshaft cover onto the crankcase.

Install the bolts and tighten them securely in a criss-

cross pattern.

32. Install the lifter covers, lifters and pushrods as

described in this chapter.

33. Install the exhaust system as described in

Chapter Seven.

the crankshaft sprocket with the flat on the crank-

shaft (A, Figure 224). Check the alignment of the

Rear Camshaft Sprocket and

index mark on both sprockets, and make sure they

Crankshaft Drive Sprocket Alignment

face each other as shown in B, Figure 224. Realign

the sprocket index marks if necessary.

This procedure is required if any of the following

parts have been replaced: the camshaft support

22. Apply clean engine oil to the underside of both

plate, either or both camshafts, the rear camshaft

new sprocket bolts prior to installation.

sprocket, the crankshaft drive sprocket and the

23. Apply a small amount of ThreeBond TB1360,

crankshaft assembly.

or an equivalent, threadlocking compound to the

If any of these components have been replaced,

threads of the new rear camshaft sprocket bolt. Do

the procedure is necessary to ensure correct align-

not apply the locking agent to the crankshaft bolt.

ment between the rear camshaft sprocket and the

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CHAPTER FOUR

crankshaft drive sprocket. If this alignment is incor-

rect, the primary drive chain and both sprockets will

228

bind and cause premature wear.

For the correct relationship between the two

sprocket faces, the rear camshaft sprocket must be

0.005 in. (0.127 mm) below the surface of the

crankshaft sprocket.

1. Position the sprocket spacer with the manufac-

turer’s-mark side going on first. Install the sprocket

spacer (Figure 209) onto the rear camshaft and

push it on until it bottoms.

2. On models so equipped, install the Woodruff key

onto the rear camshaft.

3. Apply clean engine oil to the camshaft splines (or

229

Woodruff key) and rear camshaft sprocket splines.

4. Install the rear camshaft sprocket onto the cam-

shaft. Install the used mounting bolt and flat washer

(A, Figure 228). Tighten the bolt finger-tight.

5. Install the crankshaft sprocket (B, Figure 228)

onto the crankshaft. Install the used mounting bolt

and a washer with a smaller outer diameter (C).

Tighten the bolt finger-tight at this time.

6. Install and mesh the camshaft and crankshaft

sprocket lock (Figure 225) between the camshaft

and crankshaft sprockets.

7. Tighten both bolts in the following steps:

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

230

b. Loosen both bolts one complete revolution

(360 degrees).

c. Tighten the rear camshaft bolt to 34 ft.-lb. (46

N•m).

d. Tighten the crankshaft bolt to 24 ft.-lb. (33

N•m).

8. Remove the special tool from the sprockets.

9. Place a straightedge (A, Figure 229) against the

face of both sprockets. Push the straightedge

against the crankshaft sprocket and hold it there.

10. Try to insert a 0.005 in. (0.127 mm) feeler

gauge (B, Figure 229) between the straightedge and

the camshaft sprocket face.

231

11A. If the 0.005 in. (0.127 mm) thickness flat

feeler gauge can be inserted, the sprockets are cor-

rectly aligned to each other. 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 in-

serted indicating a height difference other than

0.005 in. (0.127 mm) the rear camshaft spacer must

be changed. Continue to insert the feeler gauge of a

different thickness until the dimension difference is

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ENGINE

165

14B. If the crankshaft sprocket is less than 0.005 in.

232

(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 correct amount of height difference of

0.005 in. (0.127mm). is obtained.

16. After the correct thickness spacer is estab-

lished, proceed with Step 17 of Camshaft Support

Plate Installation in the previous procedure.

Camshaft Support Plate and Camshafts

233

A hydraulic press, camshaft chain tensioner tool

(JIMS part No. 1283) and camshaft remover and in-

staller (JIMS part No. 1277) are required to perform

the following procedure.

Disassembly

1. Remove the camshaft support plate as previ-

ously described.

2. Remove the snap ring (Figure 230) from the

front cylinder camshaft.

3. Release the tension on the camshaft secondary

chain tensioner as follows:

234

a. Install the camshaft chain tensioner tool onto

the camshaft secondary chain tensioner.

b. Using a wrench, rotate the tool counterclock-

wise and insert the hold pin (Figure 231)

through the hole in the outer surface of the

support plate and into the hole in the

tensioner. Push the hold pin all the way in un-

til it bottoms.

c. Remove the wrench and tensioner tool from

the tensioner.

4. Loosen and remove the four T20 Torx screws

(Figure 232) securing the bearing retainer plate.

noted. Write down this dimension as it will be used

Remove the bearing retainer plate (Figure 233).

to choose a new spacer.

5. Press the camshafts and secondary drive chain

12. Remove the rear camshaft sprocket

bolt,

out of the camshaft support plate as follows:

washer and sprocket.

a. Turn the camshaft support cover face up on

13. Remove the existing sprocket spacer (Figure

two support blocks in a press bed. Make sure

208) from the rear camshaft. Compare the part num-

the support blocks are tall enough to allow the

ber stamped on the spacer with the parts numbers in

complete removal of the camshafts from the

Table 5 to determine the thickness.

cover.

14A. If the crankshaft sprocket is more than 0.005 in.

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

(0.127 mm) above the camshaft sprocket, install the

staller onto the top of the camshafts (Figure

next thicker size spacer under the camshaft sprocket.

234) following the manufacturer’s instructions.

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166

CHAPTER FOUR

235

236

c. Center the press ram over the center of the

tool (Figure 235).

237

d. Slowly apply pressure and press the assembly

out of the support cover.

e. Remove the assembly, cover, and special tool

from the press bed.

6. To ensure that the camshaft secondary drive

chain is reinstalled in the same direction of travel,

mark one of the link plates on the bearing side with

a permanent marking pen (Figure 236) or scribe.

7. Separate the camshafts from the secondary drive

chain.

Inspection

238

There are no manufacturer’s specifications avail-

able for the camshaft. The following procedure is a

visual inspection to determine if the camshafts re-

quire replacement.

1. Check the camshaft lobes (Figure 237) for wear.

The lobes should not be scored and the edges should

be square.

2. Inspect the drive chain sprocket (Figure 238) for

broken or chipped teeth. Also check the teeth for

cracking or rounding. If the sprocket is damaged or

severely worn, replace the camshaft.

3. If the camshaft sprockets are worn, check the cam-

239

shaft secondary drive chain (Figure 239) for damage.

4A. On early models, inspect the Woodruff key and

key slot in the rear cylinder camshaft for wear or

damage.

4B. On later models, inspect the external splines (A,

Figure 240) on the rear cylinder camshaft and the

internal splines (B, Figure 240) on the sprocket.

Check for worn or damaged splines and replace ei-

ther or both parts if necessary. The sprocket must be

a tight fit on the camshaft.

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ENGINE

167

240

244

241

245

5. Check the snap ring groove (Figure 241) on the

242

front cylinder camshaft for wear or damage.

6. Inspect the ball bearing (Figure 242) on each

camshaft and rotate it. It must rotate smoothly with

no roughness. If damaged, replace the ball bearing

as described in this section.

Assembly

NOTE

This procedure is shown with the ball

bearings in place on the camshafts

since they did not require replacement.

243

1. Prior to installing the camshaft assembly, the

tension must be relieved on the secondary cam

chain tensioner. Perform the following :

a. Install the camshaft chain tensioner tool (Fig-

ure 243) onto the camshaft secondary chain

tensioner.

b. Using a wrench, rotate the tool counterclock-

wise (Figure 244) and insert the hold pin

through the hole in the tensioner and into the

hole in the support plate. Push the hold pin all

the way in until it bottoms (Figure 245).

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CHAPTER FOUR

c. Remove the wrench and tensioner tool from

the tensioner.

246

2. Assemble the camshafts and the secondary drive

chain as follows:

Locate the index marks on the front of the

camshafts (Figure 246). Transfer these marks

to the backside of the sprockets, in the exact

same location, with a permanent marking pen

or scribe (Figure 247). These marks are used

later to observe proper alignment of the cam-

shaft as they are pressed into the camshaft

support plate.

NOTE

247

Refer to the mark made on one of the

link plates in Disassembly Step 6 and

position the camshaft secondary drive

chain so it will be traveling in the

same direction as noted prior to re-

moval. If installed incorrectly, the

drive chain will wear prematurely.

Position the camshafts with the index marks

facing directly opposite each other (Figure

248).

Correctly position the secondary chain with

the marked link plate facing up (Figure 236)

and assemble the secondary chain onto both

248

camshafts.

Rotate the camshafts in either direction sev-

eral times and recheck the alignment of the

index marks. If necessary, readjust one of the

camshafts to achieve correct alignment (Fig-

ure 248).

Apply a light coat of clean engine oil, or press

lube, to the camshaft ends and to the bearing recep-

tacles in the camshaft support plate.

4. Place the camshaft support plate on the press

bed with the bearing receptacles facing up (Figure

249).

249

5. Correctly position the camshaft assembly onto

the camshaft support plate with the rear cylinder

camshaft (Figure 250) located 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 assem-

bly into place, check the alignment of

the camshaft index marks on the back-

side of the sprockets (Figure 251). If

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ENGINE

169

250

254

out of alignment, remove the assem-

251

bly and correct this alignment.

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

staller onto the top of the camshafts (Figure 252),

following the manufacturer’s instructions.

7. Center the press ram over the center of the tool

(Figure 253).

8. Slowly apply pressure and press the assembly

into the support cover until it bottoms.

9. Remove the assembly and special tool from the

press bed.

10. Turn the assembly over and double check that

252

the camshaft index marks are still correctly aligned

as shown in Figure 254.

11. Rotate the camshafts several complete revolu-

tions and check for binding.

12. Install the retainer plate (Figure 233) into posi-

tion.

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 232) and tighten securely.

14. Place a flat blade screwdriver between the sec-

ondary camshaft drive chain and the tensioner.

253

Slowly release the hold pin (Figure 231), then

slowly withdraw the screwdriver and allow the

tensioner to gradually make contact with the chain

surface. If released too fast, the shoe surface will

slam against the chain and be damaged.

15. Install the circlip (Figure 255) onto the front

cylinder camshaft. Make sure the snap ring is cor-

rectly seated in the camshaft groove.

16. Install the camshaft support plate as previously

described.

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CHAPTER FOUR

Bushing replacement

255

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

required to remove and install the crankshaft bush-

ing.

1. Place the bushing support tool on the press bed.

NOTE

The crankshaft bushing edge is

knurled on the side that faces the pri-

mary chain side.

2. Position the camshaft support plate with the pri-

mary chain side facing up. Place the camshaft sup-

port plate onto the bushing support tool and center

the bushing over the tool (Figure 256).

256

3. Install the remove side of the driver (Figure 257)

through the bushing and into the support tool until

the shoulder of the driver contacts the edge of the

bushing.

4. Apply pressure and press the bushing out of the

support plate until the driver collar contacts the sup-

port plate.

5. If removed, place the bushing support tool on the

press bed.

6. Position the camshaft support plate with the sec-

ondary 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

257

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 and align it.

9. Install the install side of the driver (Figure 258)

through the bushing and into the support tool until

the driver contacts the edge of the bushing.

10. Press the bushing into the support plate until

the driver collar contacts the support plate.

11. Remove the special tools and the support plate

from the press bed.

258

Camshaft Bearing Replacement

Ball bearings

A hydraulic press, camshaft bearing puller (JIMS

part No 1280) and camshaft remover and installer

(JIMS part No. 1277) are required to remove and in-

stall the camshaft ball bearings.

1. Install the camshaft bearing puller tool onto the

camshaft ball bearing (Figure 259) and remove it

following the manufacturer’s instructions.

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ENGINE

171

b. Place the camshaft support plate (A, Figure

259

260) onto a support block. Make sure the sup-

port plate is indexed correctly into the support

block.

c. Apply a light coat of clean engine oil or

press lube to the outer surface of the ball

bearing and to the support plate bearing re-

ceptacle.

d. Place the ball bearing onto the support plate

(B, Figure 260).

e. Install the bearing pilot (Figure 261) into the

260

ball bearing.

f. Apply pressure and press the bearing straight

into the support plate until it bottoms.

g. Remove the pilot from the bearing and re-

move the support plate from the press bed.

Needle bearings

NOTE

The camshaft needle bearings can be

removed with the engine mounted in

the frame and the camshaft support

261

plate removed. This procedure is

shown with the engine removed and

partially disassembled to better illus-

trate the steps.

NOTE

Replace both needle bearings as a set

even though only one requires re-

placement.

A twin cam 88 engine stand (JIMS part No. 1022)

and flywheel press (JIMS part No. 1047-TP) were

Repeat for the other camshaft bearing.

used in the following procedure.

NOTE

1. Remove the camshaft support plate assembly

The ball bearing is installed into the

from the engine as described in this chapter.

camshaft support plate, not onto the

camshaft(s).

2. Install the puller portion of the tool set (A, Fig-

ure 262) part way into the needle bearing. Install a

small hose clamp (B) onto the end closer to the nee-

Install the ball bearing(s) into the camshaft sup-

dle bearing and tighten. This will close the end of

port plate using the camshaft remover and installer

the tool so it can pass through the needle bearing.

as follows:

Push the puller all the way through the needle bear-

a. Place the support block on the press bed.

ing and remove the hose clamp.

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172

CHAPTER FOUR

3. Assemble the remainder of the tool components

onto the puller portion (Figure 263), following the

262

manufacturer’s instructions.

4. Place a 5/8 in. wrench on the flats of the puller

(A, Figure 264).

5. Place a

1 1/8

in. wrench, or an adjustable

wrench, on the large nut (B, Figure 264).

CAUTION

Do not turn the 5/8 in. wrench as this

will damage the special tool and the

crankcase receptacle.

6. Hold onto the 5/8 in. wrench to keep the puller

from rotating. Turn the 1 1/8 in. wrench clockwise

263

on the large nut. Tighten the large nut and pull the

needle bearing out of the crankcase receptacle.

7. Disassemble the special tool and remove the

needle bearing from it.

8. Repeat Steps 2-7 for the other needle bearing.

9. Apply a light coat of clean engine oil, or press

lube, to the outer surface of the ball bearings and to

the crankcase needle bearing receptacles (Figure

265).

NOTE

The following photographs are shown

with the crankcase disassembled to

better illustrate the steps.

264

10. Apply a light coat of clean engine oil to the

threads of the screw portion and to the installer

plate.

11. Insert the screw portion of the special tool part

way into the installer plate.

12. Install the installer onto the screw and push it

on until it locks into place.

13. Position the new bearing with the manufacturer’s

marks facing out on the installer (Figure 266).

14. Install the installer plate onto the crankcase,

aligning the tool to the bearing receptacle (A, Fig-

ure 267).

265

15. Install the thumb screws through the installer

plate

(B, Figure

267) and onto the crankcase

threaded holes. Tighten the thumb screws securely.

16. Slowly tighten the screw until the bearing starts

to enter the crankcase receptacle. Continue to

tighten until the installer contacts the crankcase sur-

face. This will correctly locate the needle bearing

within the crankcase.

17. Remove the special tools.

18. Repeat Steps 10-17 for the other needle bearing.

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ENGINE

173

266

270

Oil Pressure Relief Valve

267

Removal/Installation

NOTE

This procedure is shown with the cam-

shaft assembly removed to better il-

lustrate these steps.

1. Remove the camshaft support plate assembly

from the engine as described in this chapter.

2A. If the camshaft assembly is still in place, secure

the camshaft support plate in a vise with soft jaws.

2B. If the camshaft assembly is removed, place the

268

camshaft support plate on a piece of soft wood.

3. Use a 1/8 in. punch and drive out the roll pin

(Figure 268) securing the valve body and spring in

place. Discard the roll pin (A, Figure 269).

4. Remove the valve body (B, Figure 269) and

spring (C) from the bypass port of the camshaft sup-

port plate.

5. Inspect the valve body, spring and bypass port

(Figure 270) for wear or damage. Replace as neces-

sary.

6. Apply a light coat of clean engine oil to the by-

269

pass port and to the valve body.

7. Position the valve body (A, Figure 271) with the

closed end going into the bypass port first.

8. Install the spring (B, Figure 271) into the valve

body.

9. Push the valve body and spring into the bypass

port, hold them in place and install a new roll pin

(Figure 272). Tap the roll pin in until it bottoms

(Figure 268).

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CHAPTER FOUR

Cleaning Plug

Removal/Installation

271

NOTE

This procedure is shown with the cam-

shaft assembly removed to better il-

lustrate these steps.

1. Remove the camshaft support plate assembly

from the engine as described in this chapter.

2A. If the camshaft assembly is still in place, secure

the camshaft support plate in a vise with soft jaws.

2B. If the camshaft assembly is removed, place the

camshaft support plate on piece of soft wood.

3. Use a pair of pliers and carefully remove the

272

cleaning plug (Figure 273) from the camshaft sup-

port plate. Remove the O-ring.

4. Thoroughly clean the cleaning plug receptacle

and support plate in solvent. Dry with compressed

air.

5. Apply low-pressure compressed air to the clean-

ing plug receptacle (Figure 274) and blow out any

debris. Make sure the oil hole is clear.

6. Install a new O-ring onto the cleaning plug and

install the cleaning plug. Press it in until it bot-

toms.

273

Camshaft Primary and

Secondary Chain Tensioner

Removal/Inspection/Installation

NOTE

This procedure is shown on the pri-

mary chain tensioner and also ap-

plies to the secondary chain

tensioner.

1. Remove the camshaft primary and/or secondary

chain as described in this chapter.

2. Remove the snap ring (Figure 275) securing the

274

chain tensioner to the mounting post. Discard the

snap ring.

3. Slide the chain tensioner (A, Figure 276) off the

mounting post.

4. Inspect the chain tensioner shoe (A, Figure 277)

for wear. If the pad surface is worn halfway through

(A, Figure 278) or chipped (B), replace the assem-

bly.

5. Check the spring (B, Figure 277) for sagging or

damage. Replace the assembly if necessary.

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ENGINE

175

275

279

6. Install the chain tensioner onto the mounting

276

post and insert the spring end into the receptacle in

the cover (B, Figure 276). Push the chain tension on

until it bottoms.

7. Install a new snap ring and press it into place

(Figure 279). Make sure it is correctly seated in the

mounting post groove.

CRANKCASE AND CRANKSHAFT

Disassembly

A twin cam 88 engine stand (JIMS part No. 1022)

277

and flywheel press (JIMS part No. 1047-TP) were

used in the following procedure.

CAUTION

Prior to disassembling the crankcase,

measure the crankshaft end play as

described in Crankcase Assembly.

Refer to Figure 280.

1. Remove the engine from the frame as described

in this chapter.

CAUTION

Do not lift the crankcase assembly by

278

the cylinder studs. Bent or damaged

cylinder studs may cause the engine to

leak oil.

2. Remove the following components as described

in this chapter:

a. Cylinder heads and cylinders.

b. Pistons.

c. Pushrods and valve lifters.

d. Camshaft assembly.

e. Oil pump.

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176

CHAPTER FOUR

280

CRANKCASE ASSEMBLY

1. Connecting rod bushing

2. Crankshaft assembly

3. Oil hose fitting

4. Retaining ring

5. Right side main bearing

6. Needle bearing-camshaft

7. Crankcase assembly

8. O-ring

9. Piston cooling jet

10. Screw

11. Locating dowel

12. Bolt

13. Plug

14. Bearing

15. Bearing race

16. Lock ring

17. Spacer ring

18. Oil seal

19. Sprocket shaft spacer

20. Left side main bearing

(sprocket shaft) assembly

21. Locating dowel

f. Alternator rotor and stator assembly (Chapter

Eight).

281

NOTE

The bolts for the left side are to be left

off so the case halves can be sepa-

rated in the following steps.

3. Attach the crankcase assembly to an engine

stand (Figure 281), following the manufacturer’s

instructions. Make sure that the stand is attached

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ENGINE

177

282

285

286

so the case can be separated in the following

283

steps.

4. Secure the engine stand to the workbench so it

cannot move.

5. Using the torque pattern shown in Figure 282,

loosen in two to three stages, then remove the

bolts from the left side of the crankcase (Figure

283).

6. Place the crankcase assembly on wooden blocks

with the camshaft cover (left side) facing up. Use

wooden blocks thick enough so the right side of the

crankshaft clears the workbench surface (Figure

284).

7. Tap around the perimeter of the crankcase with a

284

plastic mallet and remove the left crankcase half

(Figure 285).

8. If the crankcase halves will not separate easily,

perform the following:

a. Install a flywheel press (A, Figure 286) onto

the left side of the crankcase, following the

manufacturer’s instructions.

b. Make sure the right side engine stand bolts

(A, Figure 287) are not installed onto the

crankcase half.

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178

CHAPTER FOUR

Apply clean engine oil, or press lube, to the

end of the center screw and install it into the

287

tool.

CAUTION

Do not use a hand impact driver or air

impact wrench on the center screw, as

they will damage the crankcase

halves, as well as the tool.

Slowly turn the center screw with a wrench

(B, Figure 286) 1/2 turn at a time. After each

turn, tap on the end of the center screw with a

brass mallet to relieve the stress on the center

screw and the tool.

288

Repeat substep d until the center screw turns

freely and the crankcase halves begin to sepa-

rate (B, Figure 287).

Remove the crankcase from the engine

stand.

Remove the right side crankcase half (Figure

288).

Remove the special tool from the left side

crankcase unless the crankshaft is going to be

removed in Step 10.

9. Remove the locating dowels and O-rings (Fig-

ure 289) from the right side crankcase.

289

WARNING

Wear safety glasses when pressing out

the crankshaft.

CAUTION

Do not remove the crankshaft by us-

ing a hammer to drive it out of the

crankcase half.

10A. If a hydraulic press is available, press the

crankshaft out of the right crankcase half as fol-

lows:

a. Support the right crankcase half in a press on

290

wooden blocks with the outer surface facing up.

b. Center the press ram onto the end of the crank-

shaft, then press the crankshaft out of the right

crankcase half. Have an assistant support the

crankshaft as it is being pressed out.

c. Remove the crankshaft.

d. Remove the right crankcase half from the press

bed and take to workbench for further service.

10B. If a hydraulic press is not available, perform

the following:

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ENGINE

179

Install a flywheel press onto the left side of

291

the crankcase, following the manufacturer’s

instructions (A, Figure 290).

Apply clean engine oil, or press lube, to the end

of the center screw and install it into the tool.

CAUTION

Do not use a hand impact driver or air

impact wrench on the center screw, as

they will damage the crankcase as

well as the tool.

Secure the right side of the crankshaft with a

wrench (B, Figure 290) to prevent it from ro-

tating in the following step.

292

Slowly turn the center screw with a wrench

(C, Figure 290) 1/2 turn at a time. After each

turn, tap on the end of the center screw with a

brass mallet to relieve the stress on the center

screw and the tool.

Repeat substep d until the center screw

pushes the crankshaft out of the left side

crankcase half.

Remove the special tool from the left side

crankcase half.

11. To remove the left side crankshaft outer roller

bearing and oil seal assembly, perform the following:

a. Place the left side crankcase on the work-

293

bench with the outer surface facing up.

b. Carefully pry the sprocket shaft spacer out of

the oil seal.

c. Carefully pry the oil seal out of the crankcase

using a wide-blade screwdriver. Support the

screwdriver with a rag to prevent damaging

the crankcase.

d. Lift the outer roller bearing from the crank-

case.

Crankcase Cleaning

and Inspection

294

1. Clean both case halves in solvent and dry with

compressed air.

2. Apply a light coat of oil to the races to prevent rust.

3. Inspect the right side (Figure 291) and left side

(Figure 292) case halves for cracks or other damage.

4. Inspect the case studs (Figure 293) for damage.

If necessary, replace studs as described under Cylin-

der Stud Replacement in this chapter.

5. Inspect the left side main bearing races. Refer to

Figure 294 for the outer bearing race and Figure

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 9