Harley Davidson 2013 Sportster Models. Service Manual — page 38
1
2
3
sm01555
1. Front
2. Rear
3. Piston pin
Figure 3-89. Position Ring End Gaps at Arrows
8.
See
. Install PISTON SUPPORT PLATE (Part
No. HD-42322) as shown. Rotate crankshaft to rest piston
on support plate.
9.
See
. Compress the piston rings using PISTON
RING COMPRESSOR (Part No. HD-96333-51E).
10. Gently slide cylinder over cylinder base studs and piston
crown, resting it on the top of the ring compressor band
as shown.
11. Push the cylinder down with a firm, quick motion until the
bottom of the cylinder bore slides below the piston ring
area.
12. Remove the piston ring compressor and piston support
plate, and push the cylinder all the way down onto the
crankcase cylinder deck.
13. Repeat for other piston and cylinder.
sm01582a
Figure 3-90. Piston Support Plate
sm01580
Figure 3-91. Installing Cylinder Over Piston
TAPPET COVERS, PUSHROD COVERS AND
PUSHRODS
TORQUE VALUE
FASTENER
10.2-13.6 Nm
90-120
in-lbs
Tappet cover fastener
1.
See
. If anti-rotation devices (10) and tappets
(11) have been removed, install the tappets. See
3.22 BOTTOM END OVERHAUL: ASSEMBLY, Tappets
2013 Sportster Service: Engine 3-77
2.
See
. Orient tabs of the front (1) and rear (2)
tappet covers to the front and rear cylinders.
3.
See
. Install tappet covers (7) with
new
gaskets
(8). Secure with screws (5) and washers (6). Tighten to
90-120
in-lbs
(10.2-13.6 Nm).
4.
Install
new
O-rings (3) in recesses in tappet covers. Press
pushrod covers (2) into O-rings.
5.
Identify pushrod location by its color and length. Refer to
6.
Slide intake and exhaust pushrods (4) down inside pushrod
covers until they rest on seat at top of tappet (11).
Table 3-33. Pushrod Specifications
LENGTH
COLOR
BAND
POSITION
cm
in
27.295
10.746
Orange
Intake
27.432
10.800
Purple
Exhaust
2
1
sm07615
1. Front cylinder
2. Rear cylinder
Figure 3-92. Tappet Cover Orientation
1
2
3
4
5
6
9
7
8
10
11
12
sm01587a
1. O-ring (4)
2. Pushrod cover (4)
3. O-ring (4)
4. Pushrod (4)
5. Screw (8)
6. Washer (8)
7. Tappet cover (2)
8. Gasket (2)
9. Screw (2)
10. Anti-rotation device (2)
11. Tappet (4)
12. Right crankcase
Figure 3-93. Middle Valve Train Components
3-78 2013 Sportster Service: Engine
CYLINDER HEAD
TORQUE VALUE
FASTENER
11-14 Nm
96-120
in-lbs
Cylinder headbolts, 1st torque
18-20 Nm
13-15 ft-lbs
Cylinder headbolts, final
torque
11-14 Nm
96-120
in-lbs
Cylinder headbolts, 1st torque
18-20 Nm
13-15 ft-lbs
Cylinder headbolts, final
torque
NOTES
•
Install the pushrod covers and lower cover retainers before
installing cylinder heads. See
ASSEMBLY, Tappet Covers, Pushrod Covers and Push-
rods
•
Thoroughly clean and lubricate threads of cylinder head
screws before installation. Friction caused by dirt and
grime will result in a false torque indication.
1.
Coat mating surfaces of cylinder base studs and headbolts
with parts cleaning solution.
2.
Scrape old oil and any carbon deposits from threads by
using a back-and-forth motion, threading each head screw
onto its mating cylinder stud.
3.
Remove headbolts from studs. Wipe or blow dry thread
surfaces.
4.
Thoroughly clean and dry gasket surfaces of cylinder and
cylinder head.
NOTE
XR 1200X: See
. The cylinder head gasket has
metal patches (2) that must be installed against the cylinder
head. When installing the gasket on the cylinder, be sure the
words "THIS SIDE UP" (1) and the metal patches (2) are visible.
5.
See
. Install a
new
head gasket to cylinder.
6.
Carefully lower cylinder head over studs and position on
dowels. Use great care so as not to disturb head gasket.
NOTE
Only oil film must remain on the cylinder head screw surfaces.
Too much oil will pool in the head screw sleeve preventing full
thread engagement.
7.
Lightly coat threads, underside of flange and bottom face
of cylinder headbolts in clean Harley-Davidson 20W50
engine oil. Wipe off excess oil.
8.
Start cylinder headbolts onto cylinder studs, two short bolts
on left side of engine, two long bolts on right. Tighten all
bolts only finger-tight at this time.
NOTE
The procedure for tightening the head screws is critical to
proper distribution of pressure over gasket area. It prevents
gasket leaks, stud failure and head and cylinder distortion.
9.
See
and
. In sequence, tighten
headbolts in the following steps:
a.
Tighten each bolt to 96-120
in-lbs
(11-14 Nm).
b.
Tighten each bolt to 13-15 ft-lbs (18-20 Nm).
c.
Loosen all bolts.
10. After headbolts are loosened from initial torque, tighten
bolts in three stages. Tighten in sequence:
a.
Tighten each bolt to 96-120
in-lbs
(11-14 Nm).
b.
Tighten each bolt to 13-15 ft-lbs (18-20 Nm).
c.
See
. Mark cylinder head and headbolt
shoulder with a line (1).
d.
Tighten each bolt an additional 85-95 degrees (2).
11.
XR 1200X:
Install Precision Cooling oil lines. See
3.12 PRECISION COOLING SYSTEM: XR 1200X, Cyl-
inder Head Oil Return Lines
.
1
2
2
sm05483c
1. THIS SIDE UP
2. Metal patches
Figure 3-94. Cylinder Head Gasket: XR 1200X
2013 Sportster Service: Engine 3-79
1
2
sm06883
1. Cylinder head
2. Gasket
Figure 3-95. Cylinder Head Installation
2
1
3
4
sm01476
1. Short bolt
2. Short bolt
3. Long bolt
4. Long bolt
Figure 3-96. Front Cylinder Headbolt Torque Sequence
2
1
4
3
sm03780
1. Short bolt
2. Short bolt
3. Long bolt
4. Long bolt
Figure 3-97. Rear Cylinder Headbolt Torque Sequence
1
2
sm03408
1. Mark
2. 85-95 degrees
Figure 3-98. Tighten Headbolts
3-80 2013 Sportster Service: Engine
ROCKER COVERS
TORQUE VALUE
FASTENER
24.4-29.8 Nm
18-22 ft-lbs
Rocker cover, inner, large bolt
15.3-17.5 Nm
135-155
in-lbs
Rocker cover, inner, small bolt
15.3-17.5 Nm
135-155
in-lbs
Rocker cover, inner, screw
4.0-6.2 Nm
35-55
in-lbs
Breather screw: XL Models
13.5-19.0 Nm
120-168
in-lbs
Rocker cover, outer, screw
Inner Cover
1.
For each cylinder, rotate crankshaft so that the lifters are
on the base circle of the cams.
2.
Install
new
gasket (1) with FRONT HEAD facing up on
the front head and REAR HEAD facing up on the rear
head.
a.
XL Models:
See
.
b.
XR 1200X:
See
.
3.
Install the inner rocker cover assembly (2) (with rocker
arms and shafts). Fit the ends of the pushrods in the rocker
arm sockets.
NOTE
To avoid damage to pushrods or rocker arms, do not rotate
crankshaft until both pushrods can be turned with fingers.
4.
Install and finger tighten all fasteners (3, 5, 4) one turn at
a time.
5.
See
. Tighten the fasteners in sequence:
a.
Tighten the four large bolts (1, 2, 3, 4) and then re-
tighten the first fastener (5) to 18-22 ft-lbs (24.4-29.8
Nm).
b.
Tighten the three small bolts (6, 7, 8) to 135-155
in-lbs
(15.3-17.5 Nm).
c.
Tighten the two screws (9, 10) to 135-155
in-lbs
(15.3-17.5 Nm).
1
8
7
4
6
2
9
10
3
5
sm07275
Figure 3-99. Inner Rocker Cover Torque Sequence
Breather: XL Models
1.
Identify breather location for front and rear cylinders.
2.
See
. Install breather (7) with
new
breather
seal (6).
3.
Install screw (8). Tighten to 35-55
in-lbs
(4.0-6.2 Nm).
Breather: XR 1200X
1.
See
. Inspect and replace the umbrella check
valve (8) if necessary.
2.
Install a
new
O-ring (6) on the breather assembly (7).
3.
Install breather in cavity.
Outer Cover
NOTES
•
XL Models: See
•
XR 1200X: See
1.
Install
new
gaskets (9, 10) on the inner rocker cover.
2.
Install outer rocker cover (11) on inner rocker cover. Install
fasteners (13) with captive washers and
new
sealing
washers (12).
3.
See
. Tighten fasteners (1, 2, 3, 4) in
sequence and then re-tighten the first fastener (5) to 120-
168
in-lbs
(13.5-19.0 Nm).
1
2
3
4
5
sm07288
Figure 3-100. Outer Cover Torque Sequence
2013 Sportster Service: Engine 3-81
8
7
6
13
3
4
5
2
1
10
12
11
9
sm07278
1. Gasket
2. Inner rocker cover
3. Large bolts (4)
4. Small bolts (3)
5. Screws (2)
6. Breather seal
7. Breather
8. Screw
9. Gasket
10. Cover gasket
11. Outer rocker cover
12. Sealing washer (4)
13. Fastener (4)
Figure 3-101. Rocker Cover: XL Models
6
7
10
3
4
5
1
2
9
11
12
13
8
sm07279
1. Gasket
2. Inner rocker cover
3. Large bolts (4)
4. Screws (2)
5. Small bolts (3)
6. O-ring
7. Breather
8. Umbrella valve
9. Gasket
10. Gasket
11. Outer rocker cover
12. Sealing washer (4)
13. Fastener (4)
Figure 3-102. Rocker Cover: XR 1200X
3-82 2013 Sportster Service: Engine
ASSEMBLING MOTORCYCLE AFTER TOP
END REPAIR
TORQUE VALUE
FASTENER
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link, upper front,
frame bracket mounting screw
33.9-47.5 Nm
25-35 ft-lbs
Stabilizer link, lower front,
frame bracket mounting screw
20.4-27.1 Nm
15-20 ft-lbs
Fuel tank mounting screw
1.
See
. Install upper front stabilizer link and
frame bracket:
a.
Install upper frame bracket (3) with upper stabilizer
link (2), horn bracket (9) (models with front mounted
horn), screws (5) and washers (8). Tighten to 25-35
ft-lbs (33.9-47.5 Nm).
b.
Install screw (4) securing stabilizer link to engine
bracket (1). Tighten to 25-35 ft-lbs (33.9-47.5 Nm).
2.
Install induction module assembly. See
or
3.
Install the following connectors into the induction module:
a.
TPS [88].
b.
IAC [87].
c.
TMAP sensor [80].
d.
Fuel injector connectors [84], [85].
4.
Install air cleaner assembly:
a.
XL Models except XL 1200V:
Install backplate, air
filter and air cleaner cover. See
ASSEMBLY, XL Models except XL 1200V
.
b.
XL 1200V:
Install backplate, air filter and air cleaner
cover. See
c.
XR 1200X:
Install air box assembly and connect
crankcase vent hoses. See
.
d.
EVAP Controlled Models:
Install EVAP purge hose
on induction module. See
.
5.
Install horn.
a.
Front Mount:
See
.
b.
Side Mount:
See
.
When servicing the fuel system, do not smoke or allow
open flame or sparks in the vicinity. Gasoline is extremely
flammable and highly explosive, which could result in
death or serious injury. (00330a)
6.
Install fuel tank.
a.
Tighten to 15-20 ft-lbs (20.4-27.1 Nm).
b.
Attach quick-connect fitting on fuel line to fuel tank
fitting.
c.
Gently tug on quick-connect fitting to verify that it is
securely locked in place. See
or
7.
Install exhaust pipes and mufflers. Plug in O2 sensor
connectors [137], [138]. See
or
.
8.
Connect spark plug cables to spark plugs.
9.
Install main fuse.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
10. Install seat.
8
5
7
6
1
9
4
3
2
4
sm03404
1. Engine bracket
2. Upper stabilizer link
3. Upper frame bracket
4. Screw
5. Screw (2)
6. Screw (2)
7. Lockwasher (2)
8. Washer (2)
9. Horn bracket (models with front mounted horn)
Figure 3-103. Upper Front Stabilizer Link Assembly (typical)
2013 Sportster Service: Engine 3-83
3.17
BOTTOM END OVERHAUL: DISASSEMBLY
GENERAL
This section describes disassembling the bottom end of the
engine. If engine overhaul requires disassembly of crankcases,
remove engine from vehicle. See
.
Then disassemble top end of engine. See
OVERHAUL: DISASSEMBLY, Cylinder Heads
and
END OVERHAUL: DISASSEMBLY, Cylinder and Piston
.
Thoroughly clean area around gearcase cover and tappets.
Blow loose dirt from crankcase with low pressure compressed
air.
The oil pump design and function differs between XL models
and the XR 1200X. See
.
OIL PUMP: XL MODELS
1.
Remove oil pump feed and return hoses. Mark hoses for
later installation. Discard hose clamps.
2.
See
. Carefully remove two screws (2) that
secure pump to crankcase. Pump will drop with screws
removed. Discard mounting gasket.
3.
If oil pump requires repair, see
.
1
2
3
4
sm01591
1. Oil pump
2. Screw w/ washer (2)
3. Screw, Torx (2)
4. Gasket
Figure 3-104. Oil Pump: XL Models
TAPPETS
1.
See
. Remove screw (1).
2.
Remove anti-rotation device (2). Tag anti-rotation device
for location (front/rear cylinder) as it is removed.
3.
Remove tappet (3). Tag tappet for location (front/rear cyl-
inder) and function (intake/exhaust) as it is removed. This
will simplify installation.
4.
Repeat previous steps for other cylinder.
5.
Place tappets in clean plastic bags to keep out dust, dirt
and debris.
3
2
1
4
sm03422a
1. Screw (2)
2. Anti-rotation device (2)
3. Tappet (4)
4. Right crankcase
Figure 3-105. Tappet Components
CAM GEAR END PLAY
NOTE
Gauge cam gear end play with the tappets removed.
1.
Rotate the crankshaft until the lobe of the cam gear is
pointing toward the tappet guide bore.
2.
With a flat blade screwdriver, gently pry the cam gear
toward the gearcase cover.
3.
Gauge the gap between the case bushing and the cam
gear shaft thrust face.
4.
Compare the gauge size to the cam gear end play specific-
ations. Refer to
3-84 2013 Sportster Service: Engine
GEARCASE COVER AND CAM GEARS: XL
MODELS
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Remove any parts that will interfere with gearcase disas-
sembly.
2.
Remove inner rocker cover to remove valve spring pres-
sure from the camshafts. See
OVERHAUL: ASSEMBLY, Cam Gears and Gearcase
Cover: XL Models
3.
Measure cam gear end play and record measurements.
See
3.17 BOTTOM END OVERHAUL: DISASSEMBLY,
.
4.
Place a pan under gearcase to collect oil.
NOTE
Never pry cover off. Tap lightly with a rawhide hammer.
5.
See
. Remove cover screws (1) and cover
(2). Discard old gasket (3).
6.
Remove cam gears (4, 5, 6 and 7). Mark each component
for installation.
NOTE
Nut is secured by LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red) on the nut threads.
7.
Remove nut (8). Slide pinion gear (9) and oil pump drive
gear (10) off pinion shaft.
4
1
6
10
5
3
8
2
7
9
11
sm06924
1. Fastener
2. Cover
3. Gasket
4. Rear exhaust cam
5. Rear intake cam
6. Front intake cam
7. Front exhaust cam
8. Nut
9. Pinion gear
10. Oil pump drive gear
11. Shaft key
Figure 3-106. Gearcase Cover and Cam Gears
OIL PUMP HOUSING/GEARCASE COVER
AND CAM GEARS: XR 1200X
The oil pump is integrated into the gearcase cover. Oil pump
rotors can be removed with gearcase cover in place. It is not
necessary to remove the oil pump rotors to remove the gear-
case cover.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Remove any parts that will interfere with gearcase disas-
sembly.
2.
Remove inner rocker cover to remove valve spring pres-
sure from the camshafts. See
3.
Measure cam gear end play and record measurements.
See
3.17 BOTTOM END OVERHAUL: DISASSEMBLY,
4.
Place a pan under gearcase to collect oil.
NOTE
Never pry cover off. Tap lightly with a rawhide hammer.
5.
See
. Remove cover screws (1) and remove
cover (2). Discard old gasket.
2013 Sportster Service: Engine 3-85
6.
See
. Remove rigid lines (1) and vent hose
(2) from gearcase cover. Mark lines and hoses for later
installation. Discard hose clamps. See
COOLING SYSTEM: XR 1200X, Oil Pump Lines
7.
Remove two check valve housing screws (3).
8.
Remove six screws (4) and remove oil pump cover (5).
Discard O-rings.
9.
Remove three fasteners (6). Loosely install oil pump cover
to prevent the gerotors from falling out unexpectedly.
NOTE
Never pry gearcase cover off. Tap lightly with a rawhide
hammer.
10. Carefully remove gearcase cover. Discard old gasket.
NOTE
Repair the oil pump if required. See
11. See
. Remove cam gears (1, 2, 3, and 4).
Carefully mark each component to verify correct installa-
tion.
NOTE
Nut (5) is secured by LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red).
12. Remove nut (5). Slide pinion gear (6) and spacer (7) off
pinion shaft.
13. Remove oil pump cover. Mark rotors with a permanent
marker to identify outer surfaces. Remove rotors from
housing.
1
2
sm05003a
1. Fastener (9)
2. Cover
Figure 3-107. Oil Pump Cover: XR 1200X
1
1
5
4
3
2
6
6
sm05004a
1. Rigid lines
2. Vent hose
3. Check valve screws (2)
4. Oil pump cover screw (6)
5. Oil pump cover
6. Gearcase cover fastener (3)
Figure 3-108. Gearcase Cover and Oil Pump: XR 1200X
1
2
3
4
7
6
5
sm05008a
1. Rear exhaust cam gear
2. Rear intake cam gear
3. Front intake cam gear
4. Front exhaust cam gear
5. Nut
6. Pinion gear
7. Spacer
Figure 3-109. Cam Gears: XR 1200X
CRANKCASE
Split Crankcase
1.
Remove clutch and primary drive components. See
5.4 PRIMARY DRIVE AND CLUTCH: XL MODELS
2.
Remove starter motor. See
.
3.
Mount crankcase assembly in engine stand. Position
crankcase so that it is tilted at a 45 degree angle, right
side down.
3-86 2013 Sportster Service: Engine
Do not rotate right crankcase half in engine stand such
that flywheel sprocket shaft is facing down. The flywheel
assembly can fall out, resulting in parts damage or mod-
erate injury. (00553b)
NOTE
XR 1200X: See
. The fastener between the cylin-
ders is a double headed bolt (2).
4.
Remove 11 long fasteners (1, 2) and four short fasteners
(3) from left side of crankcase assembly.
5.
Remove two fasteners (4) from right side of crankcase
assembly.
1
2
1
1
1
1
1
1
1
4
4
1
1
3
3
3
3
sm03405a
1. Long fastener: left side
2. XR 1200X: double-headed long fastener
3. Short fastener: left side
4. Long fastener: right side
Figure 3-110. Crankcase Fasteners
6.
See
. Tap crankcase gently with rawhide
mallet to loosen and separate the halves. Remove left
crankcase assembly with transmission.
NOTE
Flywheel assembly slides off left main bearing by hand. No
tools are required for this operation.
7.
See
. Remove the flywheel assembly from
right crankcase.
8.
Remove transmission assembly from left crankcase. See
5.9 TRANSMISSION REMOVAL AND DISASSEMBLY
.
sm06548
Figure 3-111. Separating Crankcase Halves
sm06549
Figure 3-112. Removing Flywheels from Right Crankcase
Piston Oil Jets
1.
See
. Remove two TORX screws (3) from
each piston oil jet assembly (2) to free piston oil jets from
right crankcase (1).
2.
Remove piston oil jets and gaskets (4) from right crank-
case. Discard gaskets.
3.
XR 1200X:
Remove three screws (6) and oil deflector
plate (5).
2013 Sportster Service: Engine 3-87
3
1
2
2
3
6
5
1
4
3
sm01596a
1. Right crankcase
2. Piston oil jet (2)
3. Screw (4)
4. Gasket (2)
5. Oil deflector plate (XR 1200X)
6. Screw (3) (XR 1200X)
Figure 3-113. Piston Oil Jet Assemblies
Removing Cylinder Base Studs
If cylinder base studs require replacement, proceed as follows.
1.
Thread a 3/8-16 nut onto cylinder base stud.
2.
Thread a second nut onto stud until it contacts the first
nut.
3.
Tighten nuts against each other.
4.
Placing wrench on first (lower) nut installed, remove stud
from cylinder deck.
5.
Loosen nuts and remove from cylinder base stud.
3-88 2013 Sportster Service: Engine
3.18
GEARCASE: XL MODELS
BUSHING INSPECTION AND REMOVAL: XL
ONLY
TOOL NAME
PART NUMBER
BUSHING AND BEARING PULLER
HD-95760-69A
NOTE
The camshaft and pinion gear shafts are supported by bushings
in both the cover and the crankcase.
1.
See
. Measure each bushing and its corres-
ponding cam gear shaft or pinion gear shaft. Replace
bushings that exceed service wear limits. Refer to
2.
See
. Use BUSHING AND BEARING PULLER
(Part No. HD-95760-69A) to remove bushings from gear-
case cover and crankcase.
4
4
2
2
3
1
1
5
5
sm06923
1. Rear intake
2. Front intake
3. Pinion
4. Rear exhaust
5. Front exhaust
Figure 3-114. Cam and Pinion Bushings
Table 3-34. Cam and Pinion Shaft Specifications
SERVICE WEAR
LIMIT
CORRECT CLEARANCE
SHAFT
mm
in
mm
in
0.08
0.003
0.018-0.056
0.0007-0.0022
Cam
0.13
0.005
0.058-0.109
0.0023-0.0043
Pinion
sm01480
Figure 3-115. Removing Cam Bushing from Gearcase
Cover
BUSHING INSTALLATION: XL ONLY
NOTE
Installing and reaming crankcase and gearcase cover bushings
can alter the center distances between mating gears. Incorrect
spacing can damage gears and increase gear noise.
Cam Gear Bushings in Right Crankcase
See
. Each cam gear bushing installed in right
crankcase must be positioned with its oiling slot at exact top
of bore (12 o'clock position).
1.
Using an arbor press, install each bushing in crankcase
bore until bushing shoulder contacts crankcase boss.
2.
Ream the
new
bushing to size after installation. See
3.18 GEARCASE: XL MODELS, Bushing Reaming: XL
Only
2013 Sportster Service: Engine 3-89
2
1
3
sm01481a
1. Cam gear bushing
2. Slot at top
3. Right crankcase
Figure 3-116. Cam Gear Bushing Installed in Crankcase
Cam Gear Bushings (Except Rear Intake
Bushing) in Gearcase Cover
1.
Using an arbor press, install each bushing in its gearcase
cover bore so that bushing shoulder contacts cover boss.
There is no need to orient these particular bushings in any
specific position of rotation within gearcase cover bores.
2.
Line-ream the
new
bushing to correct size after installation.
See
3.18 GEARCASE: XL MODELS, Bushing Reaming:
.
Rear Intake Cam Gear Bushing in Gearcase
Cover
Rear intake cam gear bushing must be installed in its gearcase
cover bore using an arbor press. The bushing must be oriented
in a specific position of rotation within the cover bore.
1.
See
. Position bushing (1) over bore of gear-
case cover (2) with chamfered edge downward and slot
upward. Align slot in bushing with slot in gearcase cover
boss. Press bushing into cover bore until bushing is flush
with cover boss.
2.
Line-ream the
new
bushing to correct size after installation.
See
3.18 GEARCASE: XL MODELS, Bushing Reaming:
.
Pinion Shaft Bushing in Gearcase Cover
1.
Using an arbor press, install pinion shaft bushing in gear-
case cover flush with cover boss. This bushing requires
no specific orientation.
2.
See
. The replacement bushing must be
secured from rotation by installation of a dowel pin. Drill
a No. 31 hole, 0.281 in (7.14 mm) deep, at top side of boss
(side toward top of gearcase cover). Center drill bit so hole
is drilled half in bushing and half in cover.
3.
Drive a
new
dowel pin no more than 0.020 in (0.51 mm)
below the bushing face. Carefully peen edges of hole to
lock the pin in place.
4.
Line-ream the
new
bushing to correct size after installation.
See
3.18 GEARCASE: XL MODELS, Bushing Reaming:
.
4
1
2
3
sm01482a
1. Rear intake cam gear bushing
2. Gearcase cover
3. Cam bushing slot
4. Gearcase cover slot
Figure 3-117. Rear Intake Cam Gear Bushing Installed in
Gearcase Cover
sm01483
Figure 3-118. Drilling Pinion Bushing Dowel Pin Hole in
Gearcase Cover
BUSHING REAMING: XL ONLY
TOOL NAME
PART NUMBER
CRANKSHAFT BUSHING PLATE
PILOT
HD-38871
REAR INTAKE CAM GEAR BUSHING
REAMER
HD-94803-67
REAMER
HD-94812-1
PILOT
HD-94812-87
NOTES
•
Installing and reaming crankcase and gearcase cover
bushings can alter the center distances between mating
3-90 2013 Sportster Service: Engine
gears. Incorrect spacing can damage gears and increase
gear noise.
•
Bushings in right crankcase serve as pilots for reaming
gearcase cover bushings and must, therefore, be reamed
to size first.
•
After reaming any bushing, check shaft fit in the bushing.
It may be necessary to make a second pass with reamer
to attain proper fit.
Cam Gear Bushings in Right Crankcase
1.
Separate two halves of crankcase, if not already done.
Place right crankcase on flat surface with gearcase side
up.
2.
See
. Position CRANKSHAFT BUSHING
PLATE PILOT (Part No. HD-38871) onto gearcase side
of crankcase. The upper right and lower left indexing holes
in pilot must be placed over dowels in crankcase. Insert
two bolts (supplied with pilot) through two remaining holes
in pilot, and into threaded holes of crankcase. Tighten
bolts securely.
3.
Insert a standard 11/16 reamer through pilot hole and into
bushing while turning reamer clockwise. Continue turning
reamer clockwise through bushing until smooth shank of
reamer passes through hole in pilot.
4.
Detach reamer from handle. Pull reamer out opposite side
of crankcase.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
5.
Thoroughly clean right crankcase, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.
3
2
1
sm01484a
1. Camshaft bushing reamer pilot (Part No. HD-
38871)
2. Standard 11/16 reamer
3. Reamer handle
Figure 3-119. Reaming Cam Gear Bushing in Right
Crankcase
Cam Gear Bushings (Except Rear Intake
Bushing) in Gearcase Cover
NOTE
Newly installed cam gear bushings must be line-reamed to
establish correct clearance and to produce perfect alignment.
Use the right crankcase as a pilot for the reamer. If crankcase
halves are not separated, use a spare right crankcase to per-
form the following line-reaming procedures.
1.
Bushings to be reamed must be installed in gearcase cover
as described in
3.18 GEARCASE: XL MODELS, Bushing
. Attach gearcase cover to right
crankcase, which has been disassembled from left
crankcase, securing with a minimum of three mounting
screws.
2.
Insert a standard 11/16 reamer through the previously
reamed cam gear bushing in right crankcase, which is in
line with one of the bushings to be reamed in gearcase
cover.
3.
Turn reamer clockwise through bushing in cover until
reamer bottoms. Then give reamer one complete clockwise
turn to size the bushing. Continue turning reamer clockwise
while extracting reamer from bushing.
4.
Repeat two previous steps for remaining two cam gear
bushings (except rear intake bushing) in gearcase cover,
if required.
5.
Separate gearcase cover from right crankcase. Inspect
bushings for proper cam gear shaft fit. Repeat line reaming
operation if necessary.
2013 Sportster Service: Engine 3-91
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
6.
Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.
Rear Intake Cam Gear Bushing in Gearcase
Cover
NOTE
Newly installed cam gear bushings must be line-reamed to
establish correct clearance and to produce perfect alignment.
Use the right crankcase as a pilot for the reamer. If crankcase
halves are not separated, use a spare right crankcase to per-
form the following line reaming procedures.
1.
Rear intake cam gear bushing must be installed in gear-
case cover as described in
MODELS, Bushing Installation: XL Only
.
2.
Identify the previously reamed rear intake cam gear
bushing in right crankcase, which has been disassembled
from left crankcase. Insert the shank end of REAR INTAKE
CAM GEAR BUSHING REAMER (Part No. HD-94803-67)
through gearcase side of this bushing.
3.
With reamer inserted into bushing in right crankcase,
attach gearcase cover to right crankcase, securing with a
minimum of three mounting screws.
4.
Turn reamer clockwise through bushing in gearcase cover
until reamer bottoms. Then give reamer one complete
clockwise turn to size the bushing. Continue turning reamer
clockwise while extracting reamer from bushing.
5.
Separate gearcase cover from right crankcase. Inspect
bushing for proper cam gear shaft fit. Repeat line reaming
operation if necessary.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
6.
Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.
Pinion Shaft Bushing in Gearcase Cover
NOTE
Ream a new pinion shaft bushing in the gearcase cover with
the right crankcase and the PILOT (Part No. HD-94812-87) as
pilots for the reamer. If the crankcase halves are not separated,
use a spare right crankcase to line ream the bushing.
1.
Pinion shaft bushing must be installed in gearcase cover
as described in
3.18 GEARCASE: XL MODELS, Bushing
. Attach gearcase cover to right
crankcase, which has been disassembled from left
crankcase, securing with a minimum of three mounting
screws.
2.
See
. Install a PILOT (Part No. HD-94812-
87) into right crankcase roller race. Insert REAMER (Part
No. HD-94812-1) through the pilot.
3.
Turn reamer clockwise through bushing in gearcase cover
until reamer bottoms. Then give reamer one complete
clockwise turn to size the bushing. Continue turning reamer
clockwise while extracting reamer from bushing.
4.
Separate gearcase cover from right crankcase. Inspect
bushing for proper pinion shaft fit. Repeat line reaming
operation if necessary.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
5.
Remove pilot from right crankcase roller race. Thoroughly
clean gearcase cover, removing all metal chips/shavings.
Blow out all bushing bores and oil passages using low
pressure compressed air.
sm01485a
Figure 3-120. Line Reaming Pinion Shaft Bushing
3-92 2013 Sportster Service: Engine
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