Harley Davidson 2013 Sportster Models. Service Manual — page 36
sm04993b
Figure 3-29. Return Oil Manifold Fastener
Installation
1.
Install
new
O-rings in manifold assembly and apply a light
film of oil to them.
2.
Start return oil manifold on rigid lines and install rear cyl-
inder head oil line in quick connect fitting. Verify that it is
securely held by the retainer clip.
3.
See
. Slide oil manifold onto rigid lines and
secure with screw (1). Tighten to 84-108
in-lbs
(9.5-12.2
Nm).
4.
Connect oil return hose to oil tank. Secure with clamp.
5.
Install and connect oil tank drain hose. Install and secure
plug in drain hose.
6.
Connect battery positive (+) cable to starter. See
.
7.
Install battery. See
8.
Fill the oil tank. See
.
CYLINDER HEAD OIL RETURN LINES
TOOL NAME
PART NUMBER
OIL LINE REMOVER, 3/8 INCH
HD-49096
TORQUE VALUE
FASTENER
12.2-17.6 Nm
108-156
in-lbs
Oil line quick connect fitting,
cylinder head return: XR
1200X
9.5-12.2 Nm
84-108
in-lbs
Oil line retainer, front, nut: XR
1200X
9.5-12.2 Nm
84-108
in-lbs
Oil rigid line retainer, rear,
screw: XR 1200X
Removal
1.
Remove return oil manifold. See
COOLING SYSTEM: XR 1200X, Return Oil Manifold
2.
See
. Remove fastener (1) and raise retainer
until alignment pin (2) is clear of bore in crankcase. Roll
retainer out from beneath rigid oil lines to remove.
3.
See
. Remove nut (1) and washer.
4.
Separate front oil line (2) from cylinder head using OIL
LINE REMOVER, 3/8 INCH (Part No. HD-49096).
5.
Separate rear oil line (3) from cylinder head using OIL
LINE REMOVER, 3/8 INC (Part No. HD-49096).
6.
If front oil line needs to be completely removed, remove
starter. See
.
7.
If necessary, remove quick connect fitting from cylinder
head.
1
2
sm04994a
1. Fastener
2. Alignment pin (hidden)
Figure 3-30. Rigid Oil Line Retainer
1
3
2
sm06544
1. Locknut
2. Front oil line
3. Rear oil line
Figure 3-31. Cylinder Head Oil Lines
Installation
NOTE
Used O-rings can leak. Always install new O-rings when per-
forming repairs.
1.
If removed from cylinder head, install quick connect fittings
with
new
O-rings. Tighten to 108-156
in-lbs
(12.2-17.6
Nm).
2.
Install
new
internal O-rings in quick connect fittings.
3.
If removed, place front cylinder head oil line on engine
and install electric starter. See
.
2013 Sportster Service: Engine 3-45
NOTE
Apply a light film of oil to the end of the line before inserting it
into the fitting.
4.
See
. Connect front oil line (2) to cylinder head.
Verify that it is securely held by the retainer clip.
5.
Secure front line to crankcase with locknut (1) and washer.
Tighten to 84-108
in-lbs
(9.5-12.2 Nm).
6.
Install retainer.
a.
See
. Roll retainer under rigid lines at rear
of crankcase.
b.
Orient alignment pin to bore in case.
c.
Verify that the flanges on lines are on the manifold
side of the retainer.
d.
Secure with fastener (1).
e.
Tighten to 84-108
in-lbs
(9.5-12.2 Nm).
7.
Install return oil manifold. See
SYSTEM: XR 1200X, Return Oil Manifold
8.
See
. Connect rear oil line (3) to cylinder head.
Verify that it is securely held by the retainer clip.
CYLINDER HEAD OIL FEED ASSEMBLY
TORQUE VALUE
FASTENER
20.3-28.5 Nm
15-21 ft-lbs
Check valve plug fitting: XR
1200X
10.3-13.6 Nm
90-120
in-lbs
Check valve housing fastener:
XR 1200X
29.8-35.3 Nm
22-26 ft-lbs
Cylinder head oil feed flare fit-
ting: XR 1200X
18-23 Nm
13-17 ft-lbs
Cylinder head oil feed line
flare nut: XR 1200X
Removal
1.
Disconnect the battery. See
2.
Drain oil tank. See
3.
See
. Disconnect flare nuts (1) from each cyl-
inder head.
4.
Pull oil feed hose connector (2) straight up to remove feed
hose assembly from check valve assembly (3).
5.
Remove two fasteners (4) and check valve assembly (3).
6.
See
. Carefully clamp assembly in vise and
remove plug fitting (7).
7.
Remove spring (5) and ball (4).
8.
If necessary, remove flare fittings from cylinder heads.
9.
Inspect components for wear or damage and replace as
necessary.
4
3
4
4
2
1
sm04998a
1. Feed oil line flare nut
2. Feed oil line connector
3. Check valve assembly
4. Fastener
Figure 3-32. Cylinder Head Oil Feed Assembly
6
3
2
1
5
7
4
sm04999a
1. Base O-ring
2. Check valve housing
3. O-ring
4. Check ball
5. Spring cartridge assembly
6. O-ring
7. Plug fitting
Figure 3-33. Check Valve Components
Installation
1.
See
. Install ball (4) and spring (5) into housing
(2).
NOTE
Used O-rings can leak. Always install new O-rings when per-
forming repairs.
2.
Install
new
O-ring (6) on check valve plug fitting (7) and
install fitting. Tighten to 15-21 ft-lbs (20.3-28.5 Nm).
3.
Install
new
O-ring (3) in bore of housing.
3-46 2013 Sportster Service: Engine
4.
Install housing (2) with
new
base O-ring (1). Tighten
fasteners to 90-120
in-lbs
(10.3-13.6 Nm).
5.
If removed, apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to the flare fit-
tings. Install in cylinder heads with
new
O-rings. Tighten
to 22-26 ft-lbs (29.8-35.3 Nm).
NOTE
Apply a light film of oil to the end of the line before inserting it
into the fitting.
6.
See
. Push oil feed hose assembly straight
down to install. Connect oil line flare nuts (1) to cylinder
head flare fittings. Hold lines to prevent rotation and tighten
to 13-17 ft-lbs (18-23 Nm).
7.
Install and connect battery. See
8.
Fill oil tank. See
OIL PUMP LINES
TOOL NAME
PART NUMBER
OIL LINE REMOVER, 1/2 INCH
HD-46503
OIL LINE REMOVER, 3/8 INCH
HD-49096
TORQUE VALUE
FASTENER
12.2-17.6 Nm
108-156
in-lbs
Oil pump quick connect fitting:
XR 1200X
10.2-13.6 Nm
90-120
in-lbs
Oil rigid line retainer, rear,
screw: XR 1200X
Removal
1.
Remove return oil manifold. See
COOLING SYSTEM: XR 1200X, Return Oil Manifold
2.
Remove retainer.
a.
See
. Remove fastener (1).
b.
Raise retainer until alignment pin (2) is clear of bore
in crankcase.
c.
Roll retainer out from beneath rigid oil lines.
3.
See
. Remove return oil line (1) from gearcase
cover using OIL LINE REMOVER, 3/8 INCH (Part No. HD-
49096).
4.
If removing the return oil line, remove starter. See
.
5.
Remove feed oil line (2) from gearcase cover using OIL
LINE REMOVER, 1/2 INCH (Part No. HD-46503).
6.
Disconnect vent hose (3) from fitting on oil pump.
7.
See
. Remove locknut (1) and washer. Remove
oil cooler line retainer (2) from lines.
8.
See
. Release each oil cooler line (4, 5) from
bottom of gearcase cover using OIL LINE REMOVER, 1/2
INCH (Part No. HD-46503).
9.
If necessary, remove quick connect fittings.
1
2
sm04994a
1. Fastener
2. Alignment pin (hidden)
Figure 3-34. Rigid Oil Line Retainer
2
1
3
5
4
sm04996
1. Oil pump return line
2. Oil pump feed line
3. Vent hose
4. Oil cooler line, to cooler
5. Oil cooler line, from cooler
Figure 3-35. Oil Pump Lines
1
2
sm06937
1. Fastener
2. Line retainer (partially hidden)
Figure 3-36. Oil Cooler Line Retainer
2013 Sportster Service: Engine 3-47
Installation
NOTE
Used O-rings can leak. Always install new O-rings when per-
forming repairs.
1.
If removed, install quick connect fittings with
new
O-rings.
Tighten to 108-156
in-lbs
(12.2-17.6 Nm).
2.
Install
new
O-rings in quick connect fittings.
NOTE
Apply a light film of oil to the end of each line before inserting
it into the fitting.
3.
See
. Connect oil cooler lines (4, 5) to lower
gearcase cover. Verify each is securely held by the retainer
clip.
4.
See
. Install oil cooler line retainer (2) and
tighten fastener (1) securely.
5.
See
. If removed, place return line (1) on
engine and install starter. See
6.
Connect vent (3), feed oil (2) and return oil (1) lines to oil
pump body and cam support. Verify each is securely held
by the retainer clip.
7.
Remove retainer.
a.
See
. Roll retainer under rigid lines at rear
of crankcase.
b.
Orient alignment pin (2) to bore in case.
c.
Verify flanges on lines are on the manifold side of the
retainer.
d.
Secure with screw (1).
e.
Tighten to 90-120
in-lbs
(10.2-13.6 Nm).
8.
Install return oil manifold. See
SYSTEM: XR 1200X, Return Oil Manifold
9.
Fill oil tank. See
OIL COOLER
TOOL NAME
PART NUMBER
OIL LINE REMOVER, 1/2 INCH
HD-46503
TORQUE VALUE
FASTENER
4.1-6.8 Nm
36-60
in-lbs
Oil cooler fastener: XR 1200X
Removal
1.
Disconnect the battery. See
2.
Drain oil tank. See
3.
Using OIL LINE REMOVER, 1/2 INCH (Part No. HD-
46503), separate oil cooler lines from oil cooler.
4.
See
. Remove fasteners (1) securing oil cooler
to frame brackets.
5.
Remove oil cooler from motorcycle.
6.
If necessary, remove oil cooler rigid lines from gearcase
cover. See
3.12 PRECISION COOLING SYSTEM: XR
1
2
sm04953
1. Fastener (2)
2. Oil cooler mount (2)
Figure 3-37. Oil Cooler Mounts
Installation
NOTE
Used O-rings can leak. Always install new O-rings when per-
forming repairs.
1.
Install
new
O-rings in quick connect fittings.
2.
If removed, install oil cooler rigid lines. See
SION COOLING SYSTEM: XR 1200X, Oil Pump Lines
NOTE
See
. Position oil cooler parallel with down tubes
as shown. Do not orient oil cooler forward of down tubes or
clutch cable damage will result.
3.
See
. Secure oil cooler to frame brackets.
Tighten fasteners (1) to 36-60
in-lbs
(4.1-6.8 Nm).
NOTE
Apply a light film of oil to the end of the line before inserting it
into the fitting.
4.
Connect oil lines to oil cooler fittings. Verify that each is
securely held by the retainer clip.
5.
Fill the oil tank. See
.
6.
Connect the battery. See
3-48 2013 Sportster Service: Engine
2
2
1
1
sm06545
1. Down tube
2. Oil cooler
Figure 3-38. Oil Cooler Orientation
2013 Sportster Service: Engine 3-49
3.13
TOP END OVERHAUL: DISASSEMBLY
GENERAL
This section describes disassembling the top end of the engine,
from the cylinder deck up. To perform a complete top end
overhaul, follow all steps listed in this section.
Then follow all steps listed in the following sections, including
inspection and repair procedures: See
and
NOTE
Clean engine before disassembly. Abrasive particles can
damage machined surfaces or plug oil passageways. Remove
all dirt and particles before disassembly to prevent component
damage.
STRIPPING MOTORCYCLE FOR TOP END
REPAIR
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)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
or
2.
Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
3.
Remove main fuse.
4.
Unplug O2 sensor connectors [137], [138] and remove
exhaust pipes and mufflers. See
or
.
5.
Disconnect spark plug cables from spark plugs.
6.
Drain and remove fuel tank. See
or
7.
Remove horn.
a.
Front Mount:
See
.
b.
Side Mount:
See
.
8.
Remove air cleaner assembly:
a.
XL Models except XL 1200V:
Remove cover, air
filter and air cleaner backing plate. See
CLEANER ASSEMBLY, XL Models except XL 1200V
b.
XL 1200V:
Remove cover, air filter and air cleaner
backing plate. See
.
c.
CA Models:
Remove EVAP purge hose from induc-
tion module. See
9.
Remove induction module. See
or
4.9 INDUCTION MODULE: XR 1200X
.
10. Secure induction module assembly and throttle cables out
of the way.
11. See
. Remove upper front stabilizer link and
frame bracket:
a.
Remove screw (4) securing stabilizer link (2) to engine
bracket (1).
b.
Remove screws (5) and washers (8). Remove horn
bracket (9) (models with front mounted horn) and
frame bracket (3) with stabilizer link.
4
3
2
4
7
6
1
9
5
8
sm01472
1. Engine bracket
2. Upper stabilizer link
3. Upper frame bracket
4. Screw
5. Screw (2)
6. Screw (2)
7. Lock washer (2)
8. Washer (2)
9. Horn bracket
Figure 3-39. Upper Front Stabilizer Link Assembly
3-50 2013 Sportster Service: Engine
CYLINDER HEADS
Disassembling Rocker Covers
Prevent engine damage. Washers and fasteners used in
the engine are hardened parts. Do not use unhardened
parts. (00544b)
1.
Remove spark plugs.
2.
See
. Remove four screws with captive
washers (1) and sealing washers (2). Discard sealing
washers.
3.
Remove outer rocker cover (3) or (20).
4.
Remove and discard gaskets (4, 5).
5.
Rotate crankshaft until both valves are closed on head
being removed.
6.
See
. Remove hardware securing inner rocker
cover to cylinder head in the following order.
a.
Remove two screws and washers (1).
b.
Remove three bolts and washers (2).
c.
Loosen four rocker arm bolts (3) in 1/4-1/2 turn
increments using a cross pattern. This relieves valve
spring pressure evenly on inner rocker cover.
7.
See
. Remove inner rocker cover (8) or (24).
Remove and discard gasket (16).
8.
Remove breather assembly:
a.
XL Models:
Remove screw (6), breather assembly
(7) and breather seal (17). Discard seal.
b.
XR 1200X:
Push breather assembly (23) and O-ring
(22) out from the under side.
NOTE
Mark rocker arm shafts for reassembly in their original positions.
Install valve train components in their original positions or
increased engine wear may result.
9.
See
. Remove rocker arm shafts by tapping
them out using a hammer and a soft metal punch.
10. See
. Remove rocker arms (11, 12). Mark the
rocker arms for reassembly in their original locations.
3
2
3
1
3
1
2
3
2
sm06546a
1. Screws and washers
2. Bolts and washers
3. Rocker arm bolts
Figure 3-40. Inner Rocker Cover Fasteners (typical)
2
2
1
sm06547
1. Retaining notch
2. Position of rocker arm retaining bolts
Figure 3-41. Removing Rocker Arm Shafts (typical)
2013 Sportster Service: Engine 3-51
3
1
2
1
2
8
18
16
21
17
6
7
19
15
14
13
10
20
9
10
11
4
5
5
4
24
22
23
12
sm01473
13.
1.
Bolt (4)
Screw w/captive washer (4)
2.
14.
Sealing washer (4)
Screw (2)
15.
3.
Bolt (3)
Outer rocker cover: XL Models
4.
16.
Gasket
Gasket
17.
5.
Breather seal: XL Models
Gasket
6.
18.
Screw
Breather location: Front Cylinder: XL Models
19.
7.
Breather location: Rear Cylinder: XL Models
Breather assembly: XL Models
8.
20.
Inner rocker cover: XL Models
Outer rocker cover: XR 1200X
21.
9.
Breather hose fitting hole: XR 1200X
Rocker arm shaft (2)
10.
22.
Rocker arm bushing (4)
O-ring: XR 1200X
23.
11.
Breather filter and valve assembly: XR 1200X
Rocker arm
12.
24.
Rocker arm
Inner rocker cover: XR 1200X
Figure 3-42. Rocker Cover Assembly
Removing Cylinder Head
NOTE
See
or
. Follow sequence of incremental
removal as described below to prevent component damage.
1.
XR 1200X:
Remove precision cooling lines. See
3.12 PRECISION COOLING SYSTEM: XR 1200X, Cyl-
inder Head Oil Return Lines
.
2.
See
and
. Loosen each head bolt
1/8-turn following the sequence shown.
3-52 2013 Sportster Service: Engine
3.
Continue loosening in 1/8-turn increments until screws are
loose. Remove head screws.
4.
Remove cylinder head and head gasket. Discard head
gasket.
2
1
3
4
sm01476
1. Short bolt
2. Short bolt
3. Long bolt
4. Long bolt
Figure 3-43. Front Cylinder Headbolt Torque Sequence
2
1
4
3
sm03780
1. Short bolt
2. Short bolt
3. Long bolt
4. Long bolt
Figure 3-44. Rear Cylinder Headbolt Torque Sequence
Disassembling Pushrods and Covers
1.
See
. Remove pushrod covers (2), O-rings (1,
3) and pushrods (4). Mark the location and orientation (top
and bottom) of each pushrod. Discard O-rings.
2.
Remove socket screws (5) and washers (6). Remove
tappet cover (7) and gasket (8). Discard gasket.
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 3-45. Middle Valve Train Components
2013 Sportster Service: Engine 3-53
CYLINDER AND PISTON
TOOL NAME
PART NUMBER
PISTON PIN LOCK RING
REMOVER/INSTALLER
HD-34623-C
PISTON PIN REMOVER
HD-42320-A
PISTON SUPPORT PLATE
HD-42322
1.
Clean engine before disassembly.
2.
See
. Rotate crankshaft until piston (6) of cyl-
inder being removed is at bottom of its stroke.
3
6
5
4
8
10
11
9
7
3
2
1
sm01492
1. Piston pin bushing
2. Connecting rod
3. Lock ring (2)
4. Piston pin
5. Piston ring set
6. Piston
7. Cylinder
8. Cylinder stud (4)
9. Cylinder base gasket
10. Dowel (2)
11. Head gasket
Figure 3-46. Cylinder and Piston
3.
Carefully raise cylinder just enough to permit placing clean
towel under piston to prevent any foreign matter from
falling into crankcase.
NOTE
If cylinder does not come loose, tap lightly with rawhide or
plastic hammer perpendicular to cylinder fins. Never try to pry
cylinder up.
4.
Carefully lift cylinder over piston and cylinder studs (8).
Do not allow piston to fall against cylinder studs.
NOTE
To avoid damage to piston assembly and/or cylinder studs, do
not allow piston to fall against studs.
5.
Discard cylinder base gasket (9).
NOTE
With cylinder removed, be careful not to bend the cylinder
studs. The slightest bend could cause a stress riser and could
lead to stud failure.
6.
Install a 6.0 in (150 mm) length of 1/2 in (12.7 mm) ID
plastic or rubber hose over each cylinder stud. This will
protect the studs and the pistons.
Handle piston with extreme care. The alloy used in these
pistons is very hard. Any scratches, gouges or other marks
in the pistons could score the cylinder during engine
operation and cause engine damage. (00546b)
Wear safety glasses or goggles when removing or
installing piston pin retaining rings. Piston pin retaining
rings are compressed in the ring groove and can fly out
when removed from the groove, which could result in
serious eye injury. (00293a)
7.
See
. Remove piston pin lock ring as follows:
a.
I n s e r t
P I S TO N
P I N
L O C K
R I N G
REMOVER/INSTALLER (Part No. HD-34623-C) into
piston pin bore until claw on tool is positioned in slot
of piston (directly under lock ring).
b.
Squeeze handles of tool together and pull from bore.
Hold a shop towel over bore during removal in the
event that the lock ring should fly out. Remove lock
ring from claw and discard.
NOTES
•
It is not necessary to remove both piston pin lock rings
during piston removal. Leave second lock ring in piston
pin bore.
•
Do not reuse piston pin lock rings. Removal may weaken
lock rings and they may break or dislodge if reused, res-
ulting in engine damage.
3-54 2013 Sportster Service: Engine
1
2
sm01496
1. Piston pin lock ring
2. Piston pin lock ring installer
Figure 3-47. Removing Piston Pin Lock Ring
NOTE
To avoid damage to piston or cylinder base studs, use PISTON
SUPPORT PLATE (Part No. HD-42322) to secure piston in
place while removing piston pin.
8.
Remove piston pin. Since pin is a loose fit in piston, pin
should easily slide out. If pin is difficult to remove, use
PISTON PIN REMOVER (Part No. HD-42320-A), as fol-
lows:
a.
See
. Remove acorn nut and spacer (1)
from rod end of tool.
b.
Slide rod end through piston pin. Install spacer and
acorn nut on end of rod.
c.
Position rubber coated tips (2) of tool on flat on each
side of piston pin bore.
d.
Hold tool body (3) and turn handle (4) clockwise until
piston pin is pulled free of bore.
9.
Remove piston from connecting rod. Be sure to hold con-
necting rod shank upright to prevent it from striking
crankcase.
10. Place a 3.0 in (76.2 mm) length of 1.0 in (25.4 mm) ID
foam-type water pipe insulation around each connecting
rod to prevent damage.
11. Mark each pin boss with either an "F" or an "R" to indicate
front or rear cylinder, respectively.
12. Spread piston rings outward until they clear grooves in
piston and lift off.
4
3
2
1
sm03431
1. Acorn nut and spacer
2. Rubber coated tip (2)
3. Tool body
4. Handle
Figure 3-48. Removing Piston Pin with HD-42320-A Piston
Pin Remover
2013 Sportster Service: Engine 3-55
3.14
CYLINDER HEAD
DISASSEMBLY
TOOL NAME
PART NUMBER
VALVE SPRING COMPRESSOR
HD-34736-B
1.
See
. Clamp VALVE SPRING COMPRESSOR
(Part No. HD-34736-B) in vise and compress valve spring.
2.
See
. Remove valve collar retainers (7), upper
valve spring collar (6) and valve spring (5). Mark valve
collar retainers for reassembly in original positions.
3.
Use a fine tooth file to remove any burrs on the valve stem
at the retainer groove. Mark valve to match with cylinder
head.
4.
Remove valve (1), and valve seal (2) and lower valve
spring collar assembly (4) by hand. No special tools are
required to remove valve seal and lower valve spring collar
assembly.
sm00134
Figure 3-49. Valve Spring Compressor
4
6
3
5
2
1
7
sm06922
1. Valve
2. Valve seat
3. Valve guide
4. Valve seal and lower spring collar
5. Spring
6. Upper valve spring collar
7. Collar retainer
Figure 3-50. Cylinder Head
CLEANING AND INSPECTION
TOOL NAME
PART NUMBER
VALVE GUIDE HONE
B-45525
VALVE GUIDE CLEANING BRUSH
HD-34751
VALVE SPRING TESTER
HD-96796-47
Cylinder Heads
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.
Bead blast or scrape carbon from head and valve ports.
Be careful to avoid scratching or nicking cylinder head-to-
cylinder joint faces. Blow off loosened carbon or dirt with
compressed air.
3-56 2013 Sportster Service: Engine
2.
Soak
cylinder
head
in
an
aluminum-compatible
cleaner/solvent to loosen carbon deposits.
3.
Wash all parts in non-flammable solvent, followed by a
thorough washing with hot, soapy water.
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)
4.
Blow out oil passages in head. Be sure they are free of
sludge and carbon particles.
5.
Remove loosened carbon from valve head and valve stem
using a wire wheel. Never use a file or other hardened
tool which could scratch or nick valve.
6.
Polish valve stem with very fine emery cloth or steel wool.
7.
See
. Check head gasket surface on head for
flatness. Machine or replace any head which exceeds
SERVICE WEAR LIMIT of 0.006 in (0.152 mm).
sm01512a
Figure 3-51. Gasket Surface: Flat Within 0.006 in (0.152
mm)
Rocker Arm Assemblies
1.
Check each rocker arm at pad end and pushrod end for
uneven wear or pitting. Replace rocker arm if either condi-
tion exists.
NOTE
Most of the wear in rocker arm shafts and bores results from
the up and down movement of the pushrods and valves.
Therefore, the following measurements should be taken top-
to-bottom on rocker arm shafts and bores.
2.
See
. Measure and record rocker arm shaft
diameter at the positions where rocker arm bushings ride
and where shaft fits in inner rocker cover.
sm01514a
Figure 3-52. Measuring Rocker Arm Shaft Diameter at
Bushing Position (top) and Cover Position (bottom)
3.
Measure and record rocker arm shaft bore diameters.
a.
See
. Measure rocker arm shaft bore in
inner rocker cover.
b.
See
. Measure rocker arm bushing inner
diameter.
4.
Check clearances and measurements obtained in step 3
against specifications in
. Repair
or replace parts exceeding Service Wear Limits. If rocker
arm bushings require replacement, see
HEAD, Replacing Rocker Arm Bushings
5.
See
. Assemble rocker arms and rocker arm
shafts into inner rocker cover.
6.
Check end play of rocker arm with feeler gauge. Replace
rocker arm or inner rocker cover or both if end play
exceeds 0.025 in (0.635 mm).
2013 Sportster Service: Engine 3-57
sm01515a
Figure 3-53. Measuring Rocker Arm Shaft Bore Diameter
in Inner Rocker Cover
sm01516a
Figure 3-54. Measuring Rocker Arm Bushing Inner
Diameter
3
2
1
sm01518
1. Inner rocker cover
2. Rocker arm shaft (2)
3. Rocker arm (2)
Figure 3-55. Assembling Inner Rocker Cover (typical)
Valves
1.
Replace the valve if there is evidence of burning or
cracking.
2.
Inspect the end of the valve stem for pitting or uneven
wear. Replace the valve if necessary.
3.
Inspect for burrs around the valve stem retainer groove.
Remove burrs with a fine tooth file if found.
4.
Valve heads should have a seating surface width of 0.040-
0.062 in (1.02-1.57 mm), and should be free of pit marks
and burn spots. The color of carbon on exhaust valves
should be black or dark brown. White or light buff carbon
indicates excessive heat and burning.
Valve Seats
NOTE
Valve seats are subject to wear, pitting, and burning. Resurface
valve seats after finishing valves.
1.
Inspect valve seats for cracking, chipping or burning.
Replace valve seats if necessary.
3-58 2013 Sportster Service: Engine
sm01519a
Figure 3-56. Measuring Valve Stem Protrusion
2.
See
. Check valve seats for recession by
measuring valve stem protrusion.
a.
Wipe valve seats and valve faces clean. Insert valve
into valve guide.
b.
Measure valve stem protrusion from end of valve stem
to machined surface of head upon which the lower
valve collar sits, as shown. If valve stem protrudes
more than 2.082 in (52.883 mm), replace valve seat
or cylinder head.
NOTE
If the valve seat is loose or is not fully seated in the head, seat
movement will prevent the proper transfer of heat from the
valve. The valve seat surface must be flush with (or below) the
head surface. See
for valve seat-to-
cylinder head fit.
Valve Guides
1.
Clean valve guides by lightly honing with VALVE GUIDE
HONE (Part No. B-45525).
2.
Scrub valve guides with VALVE GUIDE CLEANING
BRUSH (Part No. HD-34751) and hot soapy water.
3.
Measure valve stem outer diameter and valve guide inner
diameter. Replace if the guides do not match specifica-
tions. See
.
Valve Springs
1.
Inspect valve springs for damaged or discolored coils.
2.
See
. Measure free length of each spring. Refer
to
.
3.
Test compression force of spring using VALVE SPRING
TESTER (Part No. HD-96796-47). Refer to
4.
Replace as necessary.
sm01520
Figure 3-57. Checking Spring Free Length
Table 3-28. Valve Spring Specifications
METRIC
U.S.
SPRING
59.1 mm
2.325 in
Length (min)
1321 N @ 33.02 mm
297 lb @ 1.300 in
Compression (min)
1455 N @ 33.02 mm
327 lb @ 1.300 in
Compression (max)
Spark Plug Threads
Inspect spark plug threads for damage. If threads in cylinder
head are damaged, a special plug type insert can be installed
using a 12 mm spark plug repair kit.
Pushrods
Examine pushrods, particularly the ball ends. Replace any rods
that are bent, worn, discolored or damaged.
REPLACING ROCKER ARM BUSHINGS
TOOL NAME
PART NUMBER
ROCKER ARM BUSHING REAMER
HD-94804-57
1.
See
. To replace worn bushings, press or drive
them from the rocker arm. If bushing is difficult to remove,
turn a 9/16-18 tap into bushing. From opposite side of
rocker arm, press out bushing and tap using a discarded
rocker arm shaft.
2.
Press replacement bushing into rocker arm, flush with
rocker arm end, and split portion of bushing towards top
of rocker arm.
3.
Using remaining old bushing as a pilot, line ream
new
bushing with ROCKER ARM BUSHING REAMER (Part
No. HD-94804-57).
4.
Repeat for other end of rocker arm.
2013 Sportster Service: Engine 3-59
sm01521
sm01521a
Figure 3-58. Replacing Rocker Arm Bushings
REPLACING VALVE GUIDES
TOOL NAME
PART NUMBER
VALVE GUIDE REAMER
B-45523
VALVE GUIDE REMOVER/INSTALLER
B-45524
VALVE GUIDE HONE
B-45525
VALVE GUIDE CLEANING BRUSH
HD-34751
CYLINDER HEAD SUPPORT STAND
HD-39782-A
CYLINDER HEAD HOLDING FIXTURE
HD-39786
REAMER T-HANDLE
HD-39847
REAMER LUBRICANT
HD-39964
Replace valve guides before grinding valve seats. It is the valve
stem bore in valve guide that determines valve seat grinding
location. If valve stems and/or valve guides are worn beyond
service wear limits, install new parts. Refer to
.
Removal
NOTES
•
Always use cylinder head support stand. Misalignment
during valve guide replacement will cause damage to cyl-
inder head valve guide bore.
•
Lock ring is present on OEM intake and exhaust valve
guides on XR 1200X only.
1.
See
. Prepare cylinder head for valve guide
replacement.
a.
XR 1200X:
Remove and discard lock ring from valve
guide groove.
b.
Insert sleeve of intake (4 or 6) or exhaust (5 or 7) seat
adapter into tube at top of CYLINDER HEAD SUP-
PORT STAND (Part No. HD-39782-A) (3).
c.
Position cylinder head so that valve seat is centered
on seat adapter.
NOTE
Do not press out the valve guide from the bottom of the cylinder
head. Excessive carbon buildup prevents a proper interference
fit for valve guides.
2.
See
. At top of the cylinder head, insert VALVE
GUIDE REMOVER/INSTALLER (Part No. B-45524) (1)
into valve guide bore until tool shoulder contacts end of
valve guide.
NOTE
See
. Installer sleeve (2) is not used for removal of
valve guide.
3.
Center VALVE GUIDE REMOVER/INSTALLER under ram
(3) of press. Apply pressure until valve guide drops free
of cylinder head. Discard valve guide.
3-60 2013 Sportster Service: Engine
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст