Content      ..     8      9      10      11     ..

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 10

-------------------------------------------------------------------------------------------------------------------------------------------------------------

180

CHAPTER FOUR

295

296

295 for the inner bearing race. Also, check the roller

bearings for wear or damage. The bearings must

297

turn smoothly with no roughness. If any of these

parts are worn, replace the bearing assembly as de-

scribed under Left Side Main Bearing Assembly Re-

placement in this chapter.

6. Inspect the right side main needle bearing (Fig-

ure 296) for wear or damage. The bearing must

turn smoothly with no roughness. If damaged, re-

place the bearing assembly as described under

Right Side Main Bearing Replacement in this

chapter.

7. Inspect the camshaft needle bearings (Figure

297) in the right side crankcase for damage. To re-

place this bearing, refer to Camshaft Support Plate

298

in this chapter.

8. Inspect the valve lifter bore receptacles (Figure

298) for wear or damage. Refer to Valve Lifters in

this chapter.

NOTE

If the original piston cooling jets are

being reinstalled, apply Loctite No.

222

(purple) or an equivalent

threadlocking compound to the screw

threads prior to installation.

9. Make sure the piston cooling jets (Figure 299)

299

are clear. If necessary, remove the T20 Torx mount-

ing screws, remove the cooling jets and O-rings.

Clean the oil jets with compressed air. Install new

O-rings and tighten the screws securely.

Crankshaft and Connecting Rods

Cleaning and Inspection

If any portion of the crankshaft and/or connecting

rods are worn or damaged, they must be replaced as

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ENGINE

181

300

304

4

301

305

one assembly. If necessary, have the crankshaft

302

overhauled by a Harley-Davidson dealership.

1. Clean the crankshaft assembly in solvent and dry

thoroughly with compressed air.

2. Hold the shank portion of each connecting rod

where it attaches to the crankshaft (Figure 300).

Pull up and down on each connecting rod. Any

slight amount of up and down movement indicates

excessive lower bearing wear. If there is movement,

the crankshaft must be overhauled.

3. Measure connecting rod sideplay with a feeler

gauge (Figure 301) and check against the service

limit in Table 2.

4. Inspect the right side (pinion shaft) (Figure 302)

303

and the left side (sprocket shaft) (Figure 303) for

excessive wear or damage.

5. Support the crankshaft on a truing stand or in a

lathe and check runout at the flywheel outer rim (A,

Figure 304) and at the pinion shaft (B) with a dial

indicator. If the runout exceeds the service limit in

Table 2, have the crankshaft trued or overhauled.

6. Inspect the crankshaft position sensor timing

teeth (Figure 305) on the left side flywheel for dam-

aged or missing teeth.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

182

CHAPTER FOUR

7. On 2001 models only, make sure the retaining

ring (Figure 306) is secure on the right side of the

306

crankshaft.

Right Side Main Bearing

Replacement

A hydraulic press and a crankshaft bearing re-

mover and installer (JIMS part No. 1275) are re-

quired for the following procedure.

Removal

307

1. Remove the main bearing retaining ring (Figure

307) from one side of the bearing as follows:

a. Insert a small screwdriver under one end of

the retaining ring.

b. Push the end toward the bearing bore.

c. Raise the end of the ring up and out of the

crankcase groove.

d. Work around the circumference of the ring

and pull it out of the groove.

e. Discard the retaining ring as it cannot be re-

used.

2. Turn the crankcase half over and repeat Step 1

308

and remove the remaining retaining ring (A, Figure

308). Discard the retaining ring as it cannot be re-

used.

NOTE

The JIMS support tube is marked with

either REMOVER or INSTALLER

side.

3. Place the support tube with the side marked

REMOVER facing up on the press bed.

4. Position the right side crankcase with the outer

Installation

surface facing up and position the bearing directly

over the support tube on the press bed.

1. Apply a light coat of clean engine oil to the outer

5. Install the pilot shaft (Figure 309) through the

surface of the bearing and to the crankcase receptacle.

bearing and into the support tube.

2. Position the right side crankcase with the outer

6. Center the press driver over the pilot shaft.

surface facing up on the press bed.

7. Hold the crankcase half parallel to the press bed

3. Position the new bearing with the manufac-

and have an assistant slowly apply press pressure on

turer’s marks facing up (B, Figure 308) and place it

the pilot shaft until the bearing is free from the case

over the crankcase receptacle.

half.

4. Place the JIMS support tube with the side

8. Remove the case half and special tools from the

marked INSTALLER facing up (Figure 310) on top

press bed.

of the new bearing.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ENGINE

183

side of the bearing. If not, reposition the bearing un-

309

til it is centered correctly.

WARNING

The edges of the new retaining rings

are sharp. Wear shop gloves.

CAUTION

Both new retaining rings must be in-

stalled correctly to properly secure

4

the bearing in the crankcase half.

9. Install a new retaining ring (Figure 307) onto

each side of the new bearing as follows:

a. Position the new retaining ring with the cen-

310

ter of the closed end going into the ring

groove.

b. Press the center of the closed end into the

groove and hold it there to keep it within the

ring groove.

c. Alternating from side-to-side, using a small

screwdriver, press the retaining ring into the

ring groove, working with a small section at a

time.

d. Continue to work around the circumference

until the retaining ring is completely installed

within the ring groove. Make sure the retain-

ing ring is correctly seated in the ring groove.

311

10. Turn the crankcase half over and repeat Step 8

for the other retaining ring (A, Figure 308).

11. Spin the bearing to make sure it rotates

smoothly with no binding.

Left Side Main Bearing

Assembly Replacement

The left main bearing assembly must be replaced

as a complete set even if one bearing or race is dam-

aged.

5.

Center the press driver over the support tube.

6.

Slowly apply press pressure on the support tube,

Tools

pressing the bearing into the crankcase. Apply pres-

sure until the support tube contacts the crankcase

The following tools or their equivalents are re-

surface. This will correctly locate the bearing

quired to remove and install the left side main bear-

within the crankcase (A, Figure 311). Remove the

ing:

support tube (B).

1. Hydraulic press.

7. Remove the crankcase from the press bed.

2. Sprocket shaft bearing race tool (JIMS part No.

8. Check on each side of the crankcase to make

94547-80A)

sure the bearing is centered within the receptacle.

3. Race and bearing installation tool handle (JIMS

The retaining ring groove must be visible on each

part No. 33416-80).

-------------------------------------------------------------------------------------------------------------------------------------------------------------

184

CHAPTER FOUR

4. Snap ring removal and installation tool (JIMS

part No. 1710).

312

5. Sprocket bearing race installation tool (JIMS

part No. 2246).

Inner and outer bearing race replacement

NOTE

When replacing the bearing races in

the following steps, do not remove the

lock ring installed between the inner

and outer bearing races. This ring is

under heavy tension and will damage

the bearing bore as it passes through

it.

313

1. Place the crankcase on the workbench with the

inboard surface facing up.

2. Install one half of the bearing race remover tool

into the crankcase and push it against the inner bear-

ing race (A, Figure 312).

3. Install the other half of the bearing race remover

tool into the crankcase and push it against the inner

bearing race (B, Figure 312).

4. Hold the bearing race remover tools in place and

turn the crankcase over.

5. Insert the tool handle into the center of both race

remover tools. Press it into place until the ring (Fig-

314

ure 313) is locked into both bearing race remover

tools (Figure 314).

6. Support the left crankcase half on wooden blocks

on the press bed with the tool handle facing up.

7. Center the press ram directly over the tool han-

dle and slowly press the inner bearing race out the

crankcase.

8. Remove the crankcase and special tools from the

press bed.

9. Place the crankcase on the workbench with the

outboard surface facing up.

10. Install one half of the bearing race remover tool

into the crankcase and push it against the outer bear-

315

ing race (A, Figure 315).

11. Install the other half of the bearing race re-

mover tool into the crankcase and push it against the

outer bearing race (B, Figure 315).

12. Hold the bearing race remover tools in place

and turn the crankcase over.

13. Insert the tool handle into the race remover

tools. Press it into place until the ring (Figure 313)

is locked into both bearing race remover tools (Fig-

ure 316).

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ENGINE

185

14. Support the left crankcase half on wooden blocks

316

on the press bed with the tool handle facing up.

15. Center the press ram directly over the tool han-

dle and slowly press the outer bearing race out of

the crankcase.

16. Remove the crankcase and special tools from

the press bed.

17. Clean the crankcase half in solvent and dry

with compressed air.

4

18. Check the lock ring (Figure 317) for looseness

or damage. If the lock ring is loose or damaged, per-

form the following:

a. Place the crankcase on a workbench with the

outboard side facing up.

317

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

position, install the special tool clamps onto

each side of the lock ring at the 10 o’clock and

2 o’clock positions.

c. Securely tighten the 9/16 in. Allen screws se-

curing the clamps to the lock ring.

d. Use snap ring pliers with straight tips and in-

stall them in one of the holes in each clamp.

e. Squeeze the pliers, compress the lock ring

and withdraw it from the crankcase groove.

f. Remove the clamps from the old lock ring

and install them onto the new lock ring.

g. Squeeze the pliers (Figure 318) and insert the

318

lock ring into the crankcase groove.

h. Check that the lock ring gap is centered with

the crankcase oil hole as shown in Figure 317.

NOTE

Install both races with their larger di-

ameter side facing out. Install the

bearing races with the same tool used

to remove the old ones.

19. Apply clean engine oil, or press lube, to the

bearing receptacles in the crankcase and to the outer

surface of the inner bearing races.

20. Position the installer base with the large end

319

facing up and place it on the press bed.

21. Position the crankcase with the outboard sur-

face facing up.

22. Install the crankcase onto the installer base

(Figure 319) until the crankcase retaining ring rests

on top of the installer base.

23. Install the outboard outer race into position on

the crankcase receptacle.

24. Apply clean engine oil, or press lube, to the

shaft of the pressing plug and install the pressing

-------------------------------------------------------------------------------------------------------------------------------------------------------------

186

CHAPTER FOUR

plug into the installer base (Figure 320). Push it

down onto the bearing outer race.

320

25. 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 321).

26. Remove the crankcase and special tools from

the press.

27. Turn the crankcase over and repeat Steps 23-26

for the inboard outer bearing race.

Crankshaft inner sprocket

shaft bearing replacement

321

A sprocket shaft bearing cone installer (part No.

HD-997225-55B) is required to install the sprocket

shaft bearing (Figure 322).

1. Support the crankshaft with the bearing side fac-

ing up.

2. Install the bearing splitter under the bearing

(Figure 323) and tighten securely.

3. Attach a bearing puller onto the splitter (Figure

324).

4. Slowly tighten the center screw and withdraw

the bearing off the crankshaft shoulder.

5. Remove the bearing remover, splitter and bear-

ing from the crankshaft.

322

6. Clean the sprocket shaft with contact cleaner.

Check the sprocket shaft for cracks or other dam-

age. If damaged, refer service to a Harley-Davidson

dealership.

7. Slide the new bearing over the sprocket shaft.

8. Refer to Figure 325 and press the new bearing as

follows:

a. Apply clean graphite lubricant to the in-

staller’s pilot shaft threads, flat washer and

the bearing.

b. Thread the pilot shaft (A) onto the crank-

shaft until it contacts the crankshaft shoul-

der.

323

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

contacts the bearing inner race.

d. Install the tool’s bearing (C) and washer (D)

over 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 bearing bottoms on the crankshaft

shoulder.

g. Unscrew and remove all parts of the bearing

installer.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ENGINE

187

are reinstalled, then the same size shim can be rein-

324

stalled 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 H-D dealership.

Tools

4

The following tools or their equivalents are re-

quired assemble the crankcase halves:

1. Sprocket shaft bearing installation tool (JIMS

part No. 97225-55).

325

2. Crankshaft guide (JIMS part No. 1288).

3. Engine stand (JIMS part No. 1022).

Procedure

Refer to Figure 326.

1. Position the crankshaft with the left side facing

up.

2. Apply clean engine oil or assembly lube to the

inner bearing (Figure 321) and to the left side

crankcase inner bearing race.

3. Install the shim of the specified thickness (see

Crankshaft End Play Inspection) 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 correctly po-

sitioned within the crankcase openings as shown in

Figure 327.

6. Make sure the crankcase is located correctly

onto the crankshaft inner bearing.

7. Install the outer roller bearing onto the crank-

shaft (Figure 328) and push it into the outer bearing

race.

Crankshaft End Play Inspection

8. Install the sprocket shaft bearing installation tool

onto the crankshaft following the manufacturer’s

Correct crankshaft end play is critical. The end

instructions.

play must be between 0.001-0.005 in. (0.025-0.127

9. Hold onto the handle

(A, Figure

329) and

mm). End play is determined by the thickness of the

tighten the large nut with a wrench (B). Tighten the

shim between the inner and outer bearings on the

large nut until the outer bearing is seated correctly

left side. Table 6 lists the shim part numbers and

and makes firm contact with the shim installed in

thickness.

Step 3.

If the end play was measured before disassembly

10. Remove the special tools and make sure the

and within specification, and the same components

outer bearing is seated correctly (Figure 330).

-------------------------------------------------------------------------------------------------------------------------------------------------------------

188

CHAPTER FOUR

326

CRANKCASE ASSEMBLY

1. Connecting rod bushing

12

Bolt

2. Crankshaft assembly

13. Plug

3. Oil hose fitting

14. Bearing

4. Retaining ring

15. Bearing race

5. Right side main bearing

16. Lock ring

6. Needle bearing-camshaft

17. Spacer ring

7. Crankcase assembly

18. Oil seal

8. O-ring

19. Sprocket shaft spacer

9. Piston cooling jet

20. Left side main bearing

10. Screw

(sprocket shaft) assembly

11. Locating dowel

21. Locating dowel

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ENGINE

189

327

331

4

NOTE

328

The double check of the end play

check is important to ensure correct

crankshaft end play.

11. Check crankshaft end play as follows:

a. Securely attach a dial indicator to the left

crankcase half (A, Figure 331).

b. Position the dial indicator contact pointer

on the end of the crankshaft (B, Figure

331).

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

331) while turning it back and forth.

d. Hold the crankcase down and zero the dial

329

gauge.

e. Pull up on the crankcase as far as it will go

while turning 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 must be within 0.001-0.005 in.

(0.025-0.127 mm). If the end play is incor-

rect, the shim must be replaced using a shim

of a different thickness. Table 6 lists the

various thickness shims and their part num-

bers.

h. Remove the dial indicator.

330

12. Turn the crankcase assembly over and place it

on wooden blocks (Figure 332) thick enough so the

left side of the crankshaft clears the workbench sur-

face.

13. Install the locating dowels and new O-rings

(Figure 333) into both locations (Figure 334) in the

right crankcase half. Apply clean engine oil to the

O-rings.

14. Install the crankshaft guide (Figure 335) over

the crankshaft.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

190

CHAPTER FOUR

332

333

15. Thoroughly clean and dry both crankcase gas-

ket surfaces before applying the gasket sealer in

334

Step 16.

16. Apply a thin coat of a non-hardening gasket

sealer to the crankcase mating surfaces. Use one of

the following gasket sealers:

a. Harley-Davidson crankcase sealant (part No.

HD-99650-81).

b. 3M #800 sealant.

c. ThreeBond Liquid Gasket 1104.

17. Align the crankcase halves and carefully lower

the right crankcase half onto the crankshaft and left

crankcase half (Figure 336). Press it down until it is

seated correctly on the locating dowels. If neces-

sary, carefully tap the perimeter of the right crank-

335

case half until it is seated around the entire

perimeter (Figure 337).

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 at-

tempt to pull the case halves together

with the mounting bolts. Separate the

crankcase assembly and investigate

the cause of the interference.

18. Place the crankcase assembly in an engine

336

stand (A, Figure 338). Secure the engine stand to

the workbench so it cannot move.

19. Install the nine crankcase bolts into the left

crankcase half (B, Figure 338) and tighten as fol-

lows:

a. Alternately tighten the nine bolts finger-tight.

b. Using the torque pattern shown in Figure

339, 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).

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ENGINE

191

337

340

4

20. Install the left crankcase oil seal as described in

338

the following procedure.

21. 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 340).

22. Install the following components as described

in this chapter:

a. Alternator rotor and stator assembly (Chapter

Eight).

b. Oil pump.

c. Camshaft assembly.

d. Pushrods and valve lifters.

e. Pistons.

f. Cylinder heads and cylinders.

339

23. Install the engine into the frame as described in

this chapter.

Crankcase Left Side Oil Seal Replacement

A sprocket shaft seal installer tool (JIMS part No.

39361-69 or equivalent) is required to install the oil

seal.

1. Remove the sprocket shaft spacer (Figure 340)

from the crankshaft and the oil seal.

2. Carefully pry the old oil seal (Figure 341) out of

the bearing bore.

3. Position the new oil seal with the open side fac-

ing out.

4. Install the oil seal onto the crankshaft (A, Figure

342) and center it within the bearing bore.

5. Apply clean engine oil or press lube to the spe-

cial tool threads, both washers and the radial bear-

ing.

6. Install the main body onto the crankshaft and

screw it on until it stops (B, Figure 342).

7. Install the shaft seal installer tool following the

manufacturer’s instructions.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

192

CHAPTER FOUR

8. Hold onto the handle (A, Figure 343) of the

main body and tighten the large nut (B) with a

341

wrench. Tighten the large nut slowly and check that

the oil seal (Figure 344) is entering straight into the

bearing bore.

9. Tighten the large nut slowly until the shaft seal

installer tool makes contact with the crankcase sur-

face (Figure 345).

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 340).

342

Cylinder Stud Replacement

Replace bent or otherwise damaged cylinder

studs (Figure 346) 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.

2A. If the stud has broken off with the top surface of

the crankcase, remove it with a stud remover. Refer

to Chapter 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

343

tighten it against the first nut so that 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 with an aerosol parts

cleaner. If necessary, clean the threads with an ap-

propriate size tap.

NOTE

New studs may have a threadlocking

compound patch already applied to

the lower stud threads. If so, do not

344

apply any additional locking com-

pound to these studs.

4. If the new stud does not have the threadlocking

compound patch, apply ThreeBond TB1360 or an

equivalent to the lower stud threads.

NOTE

The cylinder studs have a shoulder on

one end and this end must be installed

next to the crankcase surface.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ENGINE

193

345

347

4

pact wrench until the stud shoulder (Figure 347)

346

contacts the top surface of the crankcase.

8. Use a torque wrench and hand-tighten the stud to

the torque specification listed in Table 4.

9. Remove the cylinder head bolt and steel ball

from the cylinder stud.

10. Repeat for any additional studs.

ENGINE BREAK-IN

Following cylinder service (boring, honing, new

rings) and major lower end work, the engine must

5. Place a 0.313 in. diameter steel ball (H-D part

be broken in just as though it were new. The service

No. 8860) into a cylinder head bolt, then thread the

and performance life of the engine depends on a

bolt onto the end of the new stud without the collar.

careful and sensible break-in.

6. Position the stud with the shoulder end going in

1. For the first 50 mi. (80 km), maintain engine

first and hand-thread the new stud into the crank-

speed below 2500 rpm in any gear. However, do not

case.

lug the engine. Do not exceed 50 mph during this

period.

CAUTION

2. From 50-500 mi. (80-804 km), vary the engine

Do not use a breaker bar, ratchet or

speed. Avoid prolonged steady running at one en-

similar tool to install the studs. These

gine speed. During this period, increase engine

tools may bend the stud and cause the

speed to 3000 rpm. Do not exceed 55 mph during

engine to leak oil.

this period.

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

3. After the first 500 mi. (804 km), the engine

the stud. Slowly tighten the new stud with an air im-

break-in is complete.

Table 1 GENERAL ENGINE SPECIFICATIONS

Item

Specifications

Engine type

Four-stroke, 45° OHV V twin, Twin Cam 88

Bore and stroke

3.75 x 4.00 in. (95.25 x 101.6 mm)

Displacement

88 cubic inch (1450 cc)

Compression ratio

8.9 to 1

Torque

82 ft. lb. (111 N·m) @ 3500 rpm

Maximum sustained engine speed

5600 rpm

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Content      ..     8      9      10      11     ..