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Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 26

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500

CHAPTER THIRTEEN

3. Carefully slide the windshield forward and off

the fork brackets. Remove the windshield.

1

4. Install by reversing these removal steps. Do not

overtighten the two screws on each side to avoid

cracking the windshield.

Removal/Installation

(FXDXT)

1. Place the motorcycle on level ground on the jiffy

stand.

2. Remove the headlamp as described under Head-

light Bulb Replacement in Chapter Eight.

3. Loosen, but do not remove, the upper screw on

2

each side securing the windshield and front fairing

to the support brackets on the fork.

4. Remove the lower screw on each side securing

the windshield and front fairing to the support

brackets on the fork.

5. Carefully pull the windshield and front fairing

slightly away from the support bracket on each side.

6. Move the windshield and front fairing up and

away toward the front of the motorcycle.

7. Slide the front fairing support brackets off the

upper screws loosened in Step 3.

c.

Lift the saddlebag assembly slightly up and

8. Remove the windshield and front fairing.

forward and pull it off the mounting studs.

9. Install by reversing these removal steps. Tighten

d.

Remove the saddlebag assembly.

the screws securely.

3.

On FXDXT models, perform the following:

a. Hold onto the saddlebag handle.

SADDLEBAGS

b. Press the release pin at the rear of the

saddlebag frame.

1. Place the motorcycle on level ground on the jiffy

c. Pull the bottom of the saddlebag slightly

stand.

away from the frame.

2. On FXDS-CONV models, perform the follow-

d. Slide the saddlebag up and toward the front of

ing:

the motorcycle and pull it off the mounting

a. Hold onto the saddlebag handle.

bushings and acorn nuts.

b. Working under the saddlebag, unscrew the

e. Remove the saddlebag assembly.

two large knobs securing the saddlebag frame

4.

Install by reversing these removal steps. Make

to the mounting studs on the fender brace.

sure the saddlebag is locked into place.

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504

SUPPLEMENT

CHAPTER THREE

LUBRICATION, MAINTENANCE AND TUNE-UP

1

2

TIRES AND WHEELS

3

Tire Inspection

Tire inspection is the same as on previous models

with the addition of tread wear indicator bars on

original equipment Dunlop tires.

When the tire tread is worn to 1/32 in. (0.8 mm)

or less, the tread wear indicator bars will appear on

the tread surface as shown in Figure 1. The location

of the bars is noted with a raised triangle on the tire

sidewall. The tire must be replaced at this time.

4

PERIODIC LUBRICATION

Primary Chaincase Oil Level Check

(All 2005 Models)

The primary chaincase oil level check is identical

to prior to years with the exception of the seal on the

clutch inspection cover. The O-ring has been replaced

with a large gasket. Install the new large gasket as fol-

lows:

1. Position the new gasket with the rubber molding

CAUTION

and the words Toward Engine facing away from the

Do not push the screw through the tri-

clutch inspection cover.

angular shaped hole in the new gasket

2. Align the triangular shaped hole in the new gasket

as the sealing qualities of the gasket

with the top hole in the clutch inspection cover.

will be damaged.

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2002-2005 MODEL SERVICE INFORMATION

505

6. Use a T27 Torx driver and tighten the screws in a

5

crisscross pattern to 84-108 in.-lb. (9.5-12.2 N•m).

Primary Chaincase Oil Change

(2004-On Models)

The primary chaincase oil change is the same as

on previous models with the exception of the addi-

tional O-ring seal on the drain plug (Figure 3). The

drain plug is now equipped with an O-ring seal that

must be replaced every time the drain plug is re-

moved. Install a new O-ring onto the drain plug, in-

stall it and tighten to 36-60 in.-lb (4.1-6.8 N•m).

6

Refer to the preceding procedure regarding the

installation of the new clutch cover gasket.

PERIODIC MAINTENANCE

Throttle Cable Adjustment

(Fuel Injected Models)

There are two different throttle cables. At the throt-

tle grip, the front cable is the throttle control cable (A,

Figure 4) and the rear cable is the idle control cable

(B). At the fuel induction module, the throttle control

7

cable is located at the bottom receptacle in the throttle

wheel and the idle control cable is located at the top.

1. Remove the air filter and backing plate as de-

scribed in Chapter Seven.

2. At the handlebar, perform the following:

a. Roll the rubber boots (Figure 5) off the adjust-

ers.

b. Loosen both control cable adjuster locknuts (A,

Figure 6), then turn the cable adjusters (B)

clockwise as far as possible to increase cable

14

slack.

3. Turn the handlebars so the front wheel points

straight ahead. Then turn the throttle grip to open the

throttle completely and hold it in this position.

4. At the handlebar, turn the throttle control cable ad-

3.

Insert the screw, with the captive washer, though

juster (B, Figure 6) counterclockwise until the throt-

the clutch inspection cover and carefully thread it it all

tle cam (A, Figure 7) stops just touches the cam stop

the way through the triangular shaped hole in the

(B) on the throttle body. Then tighten the throttle cable

new gasket.

adjuster and release the throttle grip.

4. Install the clutch inspection cover and new gasket

5. Turn the front wheel all the way to the full right

onto the chaincase cover and thread the top screw part

lock position and hold it there.

way in.

6. At the handlebar, turn the idle cable adjuster until

5. Make sure the clutch inspection cover (Figure 2) is

the lower end of the idle control cable housing just

correctly aligned with the chaincase cover and install

contacts the spring in the cable support sleeve (C, Fig-

the remaining four screws with captive washers.

ure 7). Tighten the idle control cable locknut.

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2002-2005 MODEL SERVICE INFORMATION

507

8

11

ROCKER ARM

ASSEMBLY

12

1. Bolt

2. Breather assembly

3. Filter assembly

4. Rocker arm assembly

into a one-piece unit along with the filter element and

9

gasket (Figure 8). The 2004-on models use the com-

ponents equipped on the 1999-2002 models.

Front cylinder head

Rear cylinder head

CYLINDER HEAD

Removal/Installation

On 2004-on models, refer to Figure 9 for the front

and rear cylinder head bolt tightening sequence.

14

Tighten the cylinder head bolts as follows:

1. Starting with bolt No. 1, tighten each bolt in order

to 120-144 in.-lb. (13.6-16.3 N•m).

2. Starting with bolt No. 1, tighten each bolt in order

10

to 15-17 ft.-lb. (20.3-23.1 N•m).

3. Make a vertical mark with a permanent marker on

each bolt head (A, Figure 10). Make another mark on

the cylinder head (B, Figure 10) at a 90° angle, or 1/4

turn from the mark on the head bolt.

4. Use the marks as a guide and tighten each bolt head

90°, or 1/4 turn, clockwise until the marks are aligned

(Figure 11).

On 2004-on models, the two O-rings (Figure 12)

are no longer used in junction with the cylinder head

dowel pins.

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508

SUPPLEMENT

VALVE AND VALVE COMPONENTS

13

(2005 MODELS)

CYLINDER HEAD

(2005 MODELS)

Complete valve service requires a number of spe-

cial tools, including a valve spring compressor, to re-

move and install the valves. The following procedures

describe how to check for valve component wear and

to determine what type of service is required.

Refer to Figure 13.

Valve Removal

1. Remove the cylinder head as described in Chap-

ter Four.

2. Install the valve spring compressor (Figure 14)

squarely over the valve spring upper retainer (Fig-

ure 15) and against the valve head.

CAUTION

To avoid loss of spring tension, com-

press the spring only enough to re-

move the valve keepers.

3. Tighten the valve spring compressor until the

valve keepers separate from the valve stem. Lift the

valve keepers out through the valve spring com-

pressor with a magnet or needlenose pliers.

4. Gradually loosen the valve spring compressor

and remove it from the cylinder head.

5. Remove the spring upper retainer and the

valve spring.

CAUTION

Remove any burrs from the valve stem

groove before removing the valve

(Figure

16); otherwise the valve

guide will be damaged as the valve

stem passes through it.

6. Remove the valve from the cylinder head while

1.

Valve keepers

rotating it slightly.

2.

Upper retainer

7. Using needlenose pliers, carefully twist and re-

3.

Spring

move the valve stem seal/spring seat assembly from

4.

Valve stem seal/spring

seat assembly

the valve guide. Discard the valve stem seal/spring

5.

Valve guide

seat assembly.

6.

Valve guide collar

(exhaust valve only)

CAUTION

7.

Bolt-short

Keep the components of each valve

8.

Bolt-long

assembly together by placing each set

9.

Cylinder head

in a divided carton, or into separate

10.

Valve seat

small boxes or small reclosable plas-

11.

Valve

tic bags. Identify the components as

12.

Gasket

either intake or exhaust. If both cylin-

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2002-2005 MODEL SERVICE INFORMATION

509

14

18

ders are disassembled, also label the

15

components as front and rear. Do not

intermix components from the valves

or excessive wear may result.

8. Repeat Steps 3-7 to remove the remaining valve.

Valve Inspection

When measuring the valves and valve compo-

nents in this section, compare the actual measure-

ments to the new and wear limit specifications in

Table 6. Replace parts that are out of specification

or are damaged as described in this section.

16

1. Clean valves in solvent. Do not gouge or damage

the valve seating surface.

2. Inspect the valve face. Minor roughness and pit-

Deburr

ting (Figure 17) can be removed by lapping the

valve as described in this chapter. Excessive un-

evenness to the contact surface indicates the valve

is not serviceable.

3. Inspect the valve stem for wear and roughness.

Valve

Then measure the valve stem outside diameter with

stem

a micrometer (Figure 18).

14

4. Remove all carbon and varnish from the valve

guides with a stiff spiral wire brush before measur-

ing wear.

17

5. Measure the valve guide inside diameter with a

small hole gauge (Figure 19) at the top, center and

bottom locations. Then measure the small hole gauge.

6. Determine the valve stem-to-valve guide clear-

ance by subtracting the valve stem outside diameter

from the valve guide inner diameter.

7. If a small hole gauge is not available, insert each

valve into its guide. Attach a dial indicator to the

valve stem next to the head (Figure 20). Hold the

valve slightly off its seat and rock it sideways in

both directions 90° to each other. If the valve rocks

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SUPPLEMENT

19

20

Dial gauge

Valve

more than slightly, the guide is probably worn. Take

the cylinder head to a Harley-Davidson dealership

21

or machine shop and have the valve guides

measured.

8. Check the valve spring as follows:

a. Inspect the valve spring for visual damage.

b. Use a square to visually check the spring for

distortion or tilt (Figure 21).

c. Measure the valve spring free length with a

vernier caliper (Figure 22) and compare it to

the specifications.

d. Repeat sub-steps a-c for each valve spring.

e. Replace the defective spring(s).

9. Check the valve spring upper retainer seats for

22

cracks or other damage.

10. Check the valve keepers fit on the valve stem

end (Figure 23). They should index tightly into the

valve stem groove.

11. Inspect the valve seats (Figure 24) in the cylin-

der head. If they are worn or burned, they can be re-

conditioned as described in Chapter Four. Seats and

valves in near-perfect condition can be recondi-

tioned by lapping with fine Carborundum paste.

a. Clean the valve seat and corresponding valve

mating areas with contact cleaner.

b. Coat the valve seat with layout fluid.

c. Install the valve into its guide and tap it

23

against its seat. Do not rotate the valve.

d. Lift the valve out of the guide and measure

the seat width at various points around the

seat with a vernier caliper.

e. Compare the seat width with the specifica-

tions. If the seat width is less than specified or

uneven, resurface the seats as described in

Chapter Four.

f. Remove all layout fluid residue from the seats

and valves.

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2002-2005 MODEL SERVICE INFORMATION

511

Valve Installation

24

1. Clean the end of the valve guide.

2. Assemble the valve stem seal/spring seat assem-

bly as follows:

a. Apply engine oil to the oil seal (A, Figure 25)

and the spring seat (B).

b. Position the oil seal with the spring end going

in last (C, Figure 25) and insert it into the

spring seat.

c. Press the oil seal down until it seats com-

pletely within the spring seat (D, Figure 25).

3. Coat a valve stem with Torco MPZ, molybde-

num disulfide paste or equivalent. Install the valve

25

part way into the guide. Then slowly turn the valve

as it enters the oil seal and continue turning it until

the valve is installed all the way.

4. Work the valve back and forth in the valve guide

to ensure the lubricant is distributed evenly within

the valve guide.

5. Withdraw the valve and apply an additional coat

of the lubricant.

6. Reinstall the valve into the valve guide but do

not push the valve past the top of the valve guide.

7. Push the valve all the way into the cylinder head

until it bottoms (A, Figure 26).

CAUTION

The oil seal will be torn as it passes

the valve stem keeper groove if the

plastic capsule is not installed in Step

8. The capsule is included in the top

end gasket set.

8. Hold the valve in place and install the plastic

capsule (B, Figure 26) onto the end of the valve

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

14

outer surface of the capsule.

9. With the valve held in place, slowly slide the

valve stem seal/spring seat assembly onto the valve

26

stem. Push the assembly down until it bottoms on

the machined surface of the cylinder head.

10. Remove the plastic capsule from the valve

stem. Keep the capsule as it will be used on the re-

maining valves.

11. Position the valve spring with tapered end go-

ing on last and install the valve spring (A, Figure

27). Make sure it is properly seated on the spring

seat.

12. Install the upper spring retainer (B, Figure 27)

on top of the valve spring.

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SUPPLEMENT

CAUTION

To avoid loss of spring tension, only

27

compress the springs enough to in-

stall the valve keepers.

13. Compress the valve spring with a valve spring

compressor (Figure 14) and install the valve keep-

ers (Figure 28).

14. Make sure both keepers are seated around the

valve stem prior to releasing the compressor.

15. Slowly release tension from the compressor

and remove it. After removing the compressor, in-

spect the valve keepers to make sure they are prop-

erly seated (Figure 29). Tap the end of the valve

stem with a soft-faced hammer to ensure the keepers

28

are properly seated.

16. Repeat Steps 1-15 for the remaining valve.

17. Install the cylinder head as described in this

Supplement.

Valve Guide Replacement

Tools

The following tools or their equivalents are re-

quired to replace the valve guides.

1. Cylinder head support stand (HD-39782-A).

2. Intake valve seat adapter (HD-39782A-3).

29

3. Exhaust valve seat adapter (HD-39782A-4).

4. Valve guide driver (B-45524-1).

5. Valve guide installer sleeve (B-45524-2A).

6. Valve guide brush (HD-34751-A).

7. Valve guide reamer (B-45523) and T-handle

(HD-39847).

8. Valve guide reamer honing lubricant (HD- 39964).

9. Valve guide hone (B-45525).

10. Hydraulic press.

Procedure

a.

Install the intake (A, Figure

30) or exhaust (B)

CAUTION

valve seat adapter into the tube at the top of the

The valve guides must be removed and

support stand (C).

installed using the following special

b.

Install the support stand on the hydraulic press

tools to avoid damage to the cylinder

table.

head. Use the correct size valve guide

removal tool to remove the valve guides

c.

Install the cylinder head (A, Figure 31) onto the

or the tool may expand the end of the

support stand (B) centering the cylinder head

guide. An expanded guide will widen

valve seat onto the seat adapter.

and damage the guide bore in the cylin-

d.

Insert the valve guide driver (C, Figure 31) into

der head as it passes through it.

the valve guide bore until it stops on the valve

1. Remove the old valve guide as follows:

guide shoulder.

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2002-2005 MODEL SERVICE INFORMATION

513

30

32

new guides. Then purchase the new valve guides to

31

match their respective bore diameters. Determine the

bore diameter as follows:

a. Measure the valve guide bore diameter in the

cylinder head with a bore gauge or snap gauge.

Record the bore diameter.

b. The new valve guide outside diameter must be

0.0020-0.0033 in. (0.050-0.083 mm) larger

than the guide bore in the cylinder head. When

purchasing new valve guides, measure the

new guide’s outside diameter with a microme-

ter. If the new guide’s outside diameter is not

within this specification, install oversize valve

guide(s). See a Harley-Davidson dealership

for available sizes and part numbers.

NOTE

14

e.

Center the valve guide driver under the press

The intake valves are not equipped with

ram and make sure the driver is perpendicular to

the valve guide collar. On exhaust

the press table.

valves, the collar must be installed onto

f.

Support the cylinder head, slowly apply pres-

the valve guide, see Step 4.

sure and drive valve guide out through the com-

4. On exhaust valve guides, install the collar onto

bustion chamber side. Discard the valve guide.

the valve guide as follows:

g.

Remove the cylinder head and special tools

a. Insert the valve guide collar (A, Figure 32) onto

from the press bed.

the installer sleeve (B) and center it squarely onto

h.

Repeat sub-steps a-g for the remaining valve

the counter bore of the installer sleeve.

guide.

b. Install the new valve guide (C, Figure 32) into

2.

Clean the valve guide bores in the cylinder head.

the installer sleeve (B) until it contacts the valve

3.

Because the valve guide bores in the cylinder head

guide collar.

may have enlarged during removal of the old guides,

c. Install the installer sleeve and valve guide onto

measure each valve guide bore prior to purchasing the

the press table and center it.

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SUPPLEMENT

d. Slowly apply pressure and drive valve guide

33

onto the collar until the valve guide bottoms in

the installer sleeve.

e. Remove the valve guide/collar assembly (D,

Figure 32) from the installer sleeve.

5. Apply a thin coat of Vaseline to the entire outer

surface of the valve guide before installing it in the

cylinder head.

CAUTION

When installing oversize valve guides,

make sure to match each guide to its re-

spective bore in the cylinder head.

6.

Install the new valve guide as follows:

a.

Install the intake (A, Figure 30) or exhaust (B)

valve seat adapter into the tube at the top of the

support stand (C).

b.

Install the support stand on the hydraulic press

table.

c.

Install the cylinder head (A, Figure 33) onto the

support stand (B) centering the cylinder head

valve seat onto the seat adapter.

d.

On exhaust valves, position the valve guide

ceptacle until the installer sleeve (C, Figure 33)

with the collar end going in last. The intake

contacts the machined surface of the cylinder

valve guides are non-directional, either end can

head.

go in first.

l.

Remove the cylinder head and special tools

e.

Install the valve guide onto the cylinder head re-

from the press bed.

ceptacle.

m. Repeat sub-steps a-l for the remaining valve

f.

Install the valve guide installer sleeve (C, Fig-

guides.

ure 33) over the valve guide, and insert the ta-

7.

Replacement valve guides are sold with a smaller

pered end of the valve guide driver (D) into the

inside diameter than the valve stem. Ream the guide to

installer sleeve.

fit the valve stem as follows:

g.

Center the valve guide driver under the press

ram and make sure the driver is perpendicular to

a. Apply a liberal amount of reamer lubricant to

the press table.

the ream bit and to the valve guide bore.

h.

Support the cylinder head, slowly apply pres-

b. Start the reamer straight into the valve guide

sure and slowly start to drive the valve guide

bore.

into the cylinder head receptacle. Stop and back

off the press ram to allow the valve guide to

CAUTION

center itself.

Only apply pressure to the end of the

i.

Verify that the support stand (A, Figure 33) and

drive socket. If pressure is applied to the

valve guide driver (D) are square with the press

T-handle, the bore will be uneven,

table.

rough cut and tapered.

j.

Once again apply press pressure and continue

to drive the valve guide part way into the cylin-

c. Apply thumb pressure to the end of the drive

der head receptacle. Once again, stop and back

socket portion of the T-handle while rotating the

off the press ram to allow the valve guide to

T-handle clockwise. Only light pressure is re-

center itself.

quired. Apply additional lubricant to the

k.

Again apply press pressure and continue to

reamer and into the valve guide while rotating

drive the valve guide into the cylinder head re-

the reamer.

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2002-2005 MODEL SERVICE INFORMATION

515

d. Start the drill and move the hone back and

34

forth in the valve guide bore for 10 to 12 com-

plete strokes to obtain a 60° crosshatch pat-

tern.

9. Repeat Steps 7 and 8 for each valve guide.

10. Soak the cylinder head in a container filled with

hot, soapy water. Then clean the valve guides with a

valve guide brush or an equivalent bristle brush. Do

not use a steel brush. Do not use cleaning solvent,

kerosene or gasoline as these chemicals will not re-

move all of the abrasive particles produced during

the honing operation. Repeat this step until all of the

valve guides are thoroughly cleaned. Then rinse the

cylinder head and valve guides in clear, cold water

35

and dry them with compressed air.

11. After cleaning and drying the valve guides, apply

clean engine oil to the guides to prevent rust.

12. Resurface the valve seats as described in Valve

Seat Reconditioning in this chapter.

PISTONS AND PISTON RINGS

Piston Clearance

Later model 2003 and the 2004-on models have a

d.

Continue to rotate the reamer until the entire bit

small oval-shaped opening on the piston skirt coat-

has traveled through the valve guide and the

ing. This opening is used to locate the micrometer

shank of the reamer rotates freely.

for an accurate outer diameter measurement. This

small oval-shaped opening is too small for the stan-

CAUTION

dard flat anvil micrometer to obtain an accurate

Never back the reamer out through the

measurement. Use a 3-4 in. blade or ball anvil style

valve guide as the guide will be dam-

micrometer, or a 4-5 in. micrometer with spherical

aged.

ball adapters to achieve a correct measurement.

1. Make sure the piston skirt and cylinder bore is

e.

Remove the T-handle from the reamer. Remove

clean and dry.

the reamer from the combustion chamber side

14

2. Measure the cylinder bore with a bore gauge

of the cylinder head.

(Figure 34) as described under Cylinder Block In-

f.

Apply low-pressure compressed air to remove

spection in Chapter Four.

the small shavings from the valve guide bore.

Then clean the valve guide bore with the small

NOTE

spiral brush.

Some early 2003 models were not

8.

Hone the valve guide as follows:

equipped with the bare aluminum

spots on the piston skirt coating.

a. Install the valve guide hone into a high-speed

electric drill.

3A. On early 2003 models, measure the piston di-

b. Lubricate the valve guide bore and hone

ameter with a micrometer as follows:

stones with the reamer lubricant—do not use

a. Hold the micrometer at the bottom of the pis-

motor oil.

ton skirt at a right angle to the piston pin bore

c. Carefully insert the hone stones into the valve

(Figure 35). Adjust the micrometer so the

guide bore.

spindle and anvil just touch the skirt.

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SUPPLEMENT

b. Start below the bottom ring and slowly move

36

the micrometer toward the bottom of the skirt.

c. The micrometer will be loose, then tight at

about 0.5 in. (12.7 mm) from the bottom and

then loose again.

d. Measure the piston skirt at the tightest point.

3B. On late 2003 and 2004-on models, measure the

piston diameter with a micrometer as follows:

a. Use the previously described special microm-

eter and correctly position it on the bare alu-

minum spot on each side of the piston as

shown in Figure 36.

1. Place the support tube with the A side facing up

b. Measure the piston at this location only.

on the press bed.

4. Subtract the piston diameter from the largest

2. Position the right side crankcase with the outer

bore diameter; the difference is piston-to-cylinder

surface facing up and position the bearing directly

clearance. If the clearance exceeds the specification

over the support tube on the press bed.

in Table 6, the pistons should be replaced and the

3. Install the pilot shaft through the bearing and

cylinders bored oversize and then honed. Purchase

into the support tube.

the new pistons first. Measure their diameter and

4. Center the press driver over the pilot shaft.

add the specified clearance to determine the proper

5. Hold the crankcase half parallel to the press bed

cylinder bore diameter.

and have an assistant slowly apply press pressure on

the pilot shaft until the bearing is free from the case

CAMSHAFT SUPPORT PLATE

half.

6. Remove the case half and special tools from the

Rear Camshaft Sprocket and

press bed.

Crankshaft Drive Sprocket Alignment

The procedure is identical to previous models.

Installation

Refer to Table 7 for sprocket spacer thickness and

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

part numbers.

surface of the bearing and to the crankcase recepta-

cle.

CRANKCASE AND CRANKSHAFT

2. Place the support tube with the B side facing up

on the press bed.

Right Side Main Bearing Replacement

3. Position the right side crankcase with the outer

surface facing up on the press bed.

Refer to Figure 37.

4. Position the new bearing with the manufac-

The following tools or their equivalents are re-

turer’s marks facing up and place it over the crank-

quired to remove and install the right side main

case receptacle.

bearing:

5. Install the pilot/driver through the bearing and

1. Hydraulic press.

into the support tube.

2. Crankshaft bearing support tube: (HD-42720-5).

6. Center the press driver over the pilot driver.

3. Pilot/driver: (B-45655).

7. Slowly apply press pressure on the pilot driver,

pressing the bearing into the crankcase. Apply pres-

sure until resistance is felt and the bearing bottoms

Removal

in the support tube. This will correctly locate the

bearing within the crankcase. Remove the pilot

NOTE

driver.

The Harley-Davidson support tube is

marked with an A on one end and a B

8. Remove the crankcase and the support tube from

on the other.

the press bed.

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2002-2005 MODEL SERVICE INFORMATION

517

37

CRANKCASE ASSEMBLY

1. Connecting rod bushing

11. Retaining ring

2. Crankshaft assembly

12. Locating dowel

3. Oil hose fitting

13. O-ring

4. Crankshaft main bearing

14. O-ring

5. Needle bearing-camshaft

15. Locating dowel

6. Dowel pin

16. Medallion plate

7. Plug

17. Thrust washer

8. O-ring

18. Oil seal

9. Piston cooling jet

19. Sprocket shaft spacer

14

10. Screw

20. Bolt

9. Check on each side of the crankcase to make

The following tools or their equivalents are re-

sure the bearing is centered within the receptacle. If

quired to remove and install the right side main

not, reposition the bearing until it is centered

bearing:

correctly.

1. Hydraulic press.

10. Spin the bearing to make sure it rotates

2. Crankshaft bearing support tube: (HD-42720-5).

smoothly with no binding.

3. Pilot/driver: (B-45655).

Left Side Main Bearing Assembly

Bearing removal

Replacement

1. Place the crankcase on the workbench with the

Refer to Figure 37.

inboard surface facing up.

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518

SUPPLEMENT

2. If still in place, remove the crankshaft spacer

38

from the bearing bore.

3. Carefully pull the thrust washer from the outer

surface of the crankcase past the oil seal.

4. Place the support tube on the workbench with

the A side facing up.

5. Position the crankcase with the inner surface

facing up and place the bearing bore over the sup-

port tube.

6. Use a suitable size drift and tap the oil seal out of

the bearing bore. Discard the oil seal.

7. Turn the crankcase over with the inner surface

facing up.

39

CAUTION

Do not damage the crankcase retain-

ing ring groove with the screwdriver.

The groove must remain sharp to cor-

rectly seat the retaining ring.

8. The roller bearing (A, Figure 38) is secured in

the crankcase with a retaining ring (B) on the inner

surface of the bearing bore. Remove the retaining

ring (B, Figure 38) as follows:

a. Use a flat tip screwdriver and place it under

the retaining ring. Carefully lift the edge of

the retaining ring up and out of the crankcase

groove.

Bearing installation

b. Slide the tip of the screwdriver around the

edge of the bearing and continue to lift the re-

1. Apply clean engine oil, or press lube, to the bear-

taining ring out of the crankcase groove.

ing receptacle in the crankcase and to the outer race

c. Remove the retaining ring.

of the new bearing.

2. Position the support tube (A, Figure 40) on the

9. Position the support tube (A, Figure 39) on the

press bed with the A side facing up.

press bed with the A side facing up.

3. Position the crankcase half with the inner side

10. Position the crankcase half with the outer side

facing up and position the crankshaft’s bearing

facing up and position the crankshaft’s bearing bore

bore over the support tube. Correctly align the two

over the support tube. Correctly align the two parts.

parts.

11. Slide the pilot/driver (B, Figure 39) through

4. Correctly position the new bearing (B, Figure

the crankcase bearing and into the support.

40) over the crankcase bore with the manufacturer’s

12. Center the press ram (C, Figure 39) directly

marks facing down.

over the pilot/driver (B) and slowly press the bear-

5. Slide the pilot/driver (C, Figure 40) through the

ing out of the crankcase.

new bearing and the crankcase and into the support.

13. Remove the crankcase and special tools from

6. Center the press ram (D, Figure 40) directly

the press bed.

over the pilot/driver (C) and slowly press the bear-

14. Clean the crankcase half in solvent and dry it

ing into the crankcase until it lightly bottoms in the

with compressed air.

crankshaft bearing bore.

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2002-2005 MODEL SERVICE INFORMATION

519

CAUTION

40

Do not damage the crankcase retain-

ing ring groove with the screwdriver.

The groove must remain sharp to cor-

rectly seat the retaining ring.

NOTE

If the retaining ring will not correctly

seat in the crankcase groove, the

bearing is not correctly seated in the

crankcase bore. Repeat Steps 2-6

10. Install the bearing’s new retainer ring as fol-

lows:

a. Work the retaining ring into the crankcase

groove being careful not to damage the crank-

case groove.

b. Use a flat tip screwdriver and push the retain-

41

ing ring. Continue to push the retaining ring

into the crankcase groove and make sure it is

correctly seated in the groove.

Crankshaft End Play Inspection

All 2003-on models are equipped with assembled

roller bearings and this procedure is no longer nec-

essary.

Crankshaft Left Side Main Bearing Assembly

Inner Race Replacement

Removal

1. Support the crankshaft in a support fixture

(HD-44358), or an equivalent, with the bearing side

14

facing up (A, Figure 41).

2. Place a hardened plug (B, Figure 41) between the

bearing puller and the end of the crankshaft.

3. Install the bearing splitter under the bearing inner

race (C, Figure 41).

4. Apply graphite lubricant to the bearing puller

7.

Remove the crankcase and special tools from the

center screw, and attach a bearing puller (D, Figure

press.

41) to the splitter.

8. Make sure the bearing has been pressed in past

the retaining ring groove. If the groove is not visible

WARNING

above the bearing, repeat Steps 2-6 until the groove

In Step 5, never use the heat gun in

is visible.

conjunction with the penetrating oil.

9. Position the crankcase on the workbench with

The heat from the gun may ignite the

the inner surface facing up.

oil resulting in a fire.

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