Harley Davidson 2009 Dyna Models. Service manual — page 19
3
4
2
1
1
2
4
3
5
5
6
7
sm02182
1.
Expander ring
2.
Bottom oil rail
3.
Top oil rail
4.
Second compression ring
5.
Top compression ring
6.
Front
7.
Rear
Figure 3-106. Piston Ring Gap Alignment
INSTALLATION OVERVIEW
See
3.17 TOP END OVERHAUL: ASSEMBLY
1.
Attach piston to connecting rod.
2.
Install cylinder.
3.
Install cylinder head.
4.
Install push rod covers and push rods.
5.
Install rocker arm support plate.
6.
Install breather assembly.
7.
Continue with vehicle assembly as directed.
3-84 2009 Dyna Service: Engine
3.26
CAM SUPPORT PLATE AND COVER
REMOVAL OVERVIEW
1.
3.16 TOP END OVERHAUL: DISASSEMBLY
a.
Remove breather assembly.
b.
Remove rocker arm support plate.
c.
Remove push rods and push rod covers. Do not
remove lifters or lifter covers.
2.
. Fashion lifter holding tool to prevent
the hydraulic lifters from dropping into the cam compart-
ment during cam support plate removal.
a.
Obtain a large binder clip (1) which is available at any
office supply store. Squeeze wireforms (2) to remove
from binder clip.
b.
Compress wireform (2) slightly and insert free ends
into outer and inner lifter cover bores so that legs
engage walls of both hydraulic lifter sockets.
3.
To remove cover and cam support plate, see
3.18 BOTTOM END OVERHAUL: DISASSEMBLY
.
1
2
2
sm02510
1.
Binder clip
2.
Wireform
Figure 3-107. Hydraulic Lifter Holding Tool
CAMSHAFTS
TOOL NAME
PART NUMBER
CAMSHAFT ASSEMBLY TOOL
HD-47956
Removal
1.
. Remove screws (4) and remove sec-
ondary cam chain tensioner (3).
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
2.
Remove retaining ring from groove at end of front cam-
shaft. Discard retaining ring.
3.
Remove spacer from front camshaft. Do not mix front and
rear camshaft spacers. Front spacer is 0.100 in. (2.54 mm)
thick.
4.
Using a colored marker, mark one of the links of the sec-
ondary cam chain. Maintaining the original direction of
rotation during assembly may prolong service life.
5.
Slide camshafts and secondary cam chain out of cam
support plate.
6.
Remove secondary cam chain from cam sprockets.
1
3
2
4
4
5
sm02512
1.
Cam support plate
2.
Front cam
3.
Secondary cam chain tensioner
4.
Secondary cam chain tensioner fasteners
5.
Rear cam
Figure 3-108. Camshafts
Assembly
1.
See
. Align timing marks on teeth of sec-
ondary cam sprockets (outboard faces).
NOTE
Do not mix camshafts during the installation procedure. The
rear camshaft, which can be identified by the splined shaft,
must go into the hole at the rear of the cam support plate.
2009 Dyna Service: Engine 3-85
2.
Place the secondary cam chain around the sprockets of
both the front and rear camshafts while keeping the timing
marks (3) in alignment. To maintain the original direction
of rotation, be sure that the mark placed on the chain link
during disassembly is visible during installation.
1
2
3
sm02513
1.
Rear camshaft
2.
Front camshaft
3.
Timing marks
Figure 3-109. Camshaft Timing Marks
4
7
5
3
2
1
6
sm02514
1.
Rear camshaft
2.
Small guide
3.
Front camshaft
4.
Large guide
5.
Cam chain
6.
Timing marks
7.
Assembly tool base
Figure 3-110. Camshaft Assembly Tool
3.
. Obtain CAMSHAFT ASSEMBLY
TOOL (Part No. HD-47956). Place crankcase side of
camshaft/cam chain assembly into assembly tool base (7)
while maintaining cam timing mark (6) alignment.
4.
Place small guide (2) on rear camshaft (1). Place large
guide (4) on front camshaft (3).
5.
Lubricate support plate camshaft cavities with clean H-D
20W50 engine oil.
6.
Install cam support plate over guides.
7.
Remove guides and base.
8.
. Using a straightedge, verify that the
timing marks are in alignment. If they are not, then the
camshafts must be removed, realigned and reinstalled.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
9.
Install 0.100 in. (2.54 mm) thick front camshaft spacer
over end of front camshaft.
10. With the sharp edge out, install new retaining ring in
groove at end of front camshaft.
11. Inspect primary and secondary cam chain tensioners.
a.
Inspect tensioners for wear. Replace tensioners if
damaged or if chain contact portion of shoe material
is less than 0.060 in. (1.52 mm) thick.
b.
. Be sure primary and secondary
cam chain tensioners are assembled as shown. If
assembled incorrectly, tensioners will not function
properly.
12. Install secondary cam chain tensioner. Tighten fasteners
to 100-120 in-lbs (11.3-13.6 Nm).
2
1
3
sm02300
1.
Rear camshaft
2.
Front camshaft
3.
Timing marks
Figure 3-111. Verify Alignment of Timing Marks
3-86 2009 Dyna Service: Engine
2
3
1
4
5
3
4
5
sm02515
1.
Secondary cam chain tensioner
2.
Primary cam chain tensioner
3.
Piston
4.
Spring
5.
Shoe
Figure 3-112. Cam Chain Tensioner Assemblies
OIL PRESSURE RELIEF VALVE
Removal
1.
Before removal, see
.
2.
Secure the cam support plate in a vise with access to the
roll pin. Be sure to install a pair of brass jaw inserts in the
vise to avoid damage to the casting.
3.
See
. Using a 1/8 in. punch with a small
hammer, carefully tap roll pin (1) from pin hole in cam
support plate. Discard roll pin.
4.
Remove spring (2) and valve body (3) from bypass port.
Installation
1.
Secure the cam support plate in a vise. Be sure to install
a pair of brass jaw inserts to avoid damage to the casting.
2.
. Lubricate valve body (3) with clean H-
D 20W50 engine oil. Slide valve body into bypass port of
cam support plate with the open side facing outward.
3.
Slide spring (2) into bypass port until seated in open side
of valve body.
4.
Start new roll pin (1) into hole in cam support plate.
Compress spring in port using the blade of a small
screwdriver.
5.
Holding spring compressed, tap roll pin into cam support
plate until it approaches pin hole on opposite side.
6.
Remove screwdriver to release spring. Verify that spring
is straight and square in bore.
7.
Using a 1/8 in. punch with a small hammer, carefully tap
roll pin until flush with casting.
4
1
2
3
sm02516
1.
Roll pin
2.
Spring
3.
Valve body
4.
Bypass port
Figure 3-113. Oil Pressure Relief Valve Assembly
Inspection
NOTE
If diagnosing low oil pressure, start with step 1. If diagnosing
high oil pressure, then begin with step 2.
1.
Insert straight stiff wire into unplugged hole outboard of
roll pin until it bottoms. Mark wire and measure distance
from edge of cam support plate to inboard side of piston.
With piston fully seated in the bore, depth should be
approximately 2.25 in. (57.15 mm). If it is not, continue
with next step.
2.
Remove oil pressure relief valve.
3.
Inspect spring for stretching, kinks, or distortion.
4.
Inspect piston and bore for burrs, scoring or other damage.
Look for steel particles or aluminum chips. Replace cam
support plate and piston if any of these conditions are
found.
5.
Install piston in bore and measure running clearance. If
running clearance exceeds 0.003 in. (0.076 mm), install
new piston and measure again. Replace cam support
plate if running clearance still exceeds specification.
CAM NEEDLE BEARINGS
TOOL NAME
PART NUMBER
CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER
HD-42325-A
Removal
1.
Obtain the CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER (Part No. HD-42325-A).
2.
. Remove four thumb screws (1) from
threaded holes in support plate (2), if installed.
3.
Sparingly apply graphite lubricant (9) to threads of collet
(3) to prolong service life and verify smooth operation.
2009 Dyna Service: Engine 3-87
4.
Slide collet through support plate so that threaded end
exits stamped side of plate.
5.
Aligning two large holes in support plate with needle
bearing bores, hang right side of plate on ring dowel in
crankcase flange.
6.
Align four holes at corners of support plate with threaded
holes in crankcase flange. Install thumb screws in these
holes to secure support plate to crankcase.
7.
Center expandable end of collet in bearing bore and slide
Nice bearing (7) and flat washer (5) on threaded end. Start
hex nut (8) on threaded end.
8.
Push expandable end of collet through bearing bore into
flywheel compartment. Feel for inside edge of needle
bearing using end of collet and then back off slightly.
2
1
sm02517
1.
Flat
2.
Hex
Figure 3-114. Expanding Collet by Turning Hex Clockwise
2
3
4
5
6
7
8
1
9
5
7
8
3
2
1
sm02533
6.
1.
Installer (1 in., 25.4 mm)
Thumb screw
2.
7.
Support plate
Nice bearing
8.
3.
Hex nut
Removal collet (Threaded end: left, Expandable
end: right)
9.
Graphite lubricant
4.
Installer forcing screw
5.
Flat washer
Figure 3-115. Camshaft Needle Bearing Remover/Installer (Part No. HD-42325-A)
9.
Holding collet to prevent lateral movement, finger tighten
hex nut until Nice bearing contacts support plate.
10. See
. Using a 7/16 in. open end wrench, hold
flat on collet to prevent rotation. Using a second 7/16 in.
open end wrench, expand collet by turning hex at end of
shaft in a clockwise direction. Expandable end of collet
makes contact with needle bearing ID.
11. See
. Using a 15/16 in. open end wrench,
turn hex nut in a clockwise direction until bearing is free.
If necessary, hold flat on collet to prevent rotation.
12. Remove four thumb screws and pull support plate from
crankcase.
13. Holding flat on collet, turn hex at end of shaft in a counter-
clockwise direction to close collet. Remove and discard
needle bearing.
14. Remove hex nut, flat washer and Nice bearing from
threaded end of collet. Pull collet from support plate.
15. Repeat this procedure to remove second needle bearing.
3-88 2009 Dyna Service: Engine
sm02518
Figure 3-116. Bearing Removal
Installation
1.
Obtain the CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER (Part No. HD-42325-A).
NOTE
To avoid engine damage, care must be taken to install needle
bearings to the correct depth. The correct depth is achieved
only when the edge of the needle bearing is 3.10 in. (78.7 mm)
from the cam cover flange.
2.
Since measuring from the top of the support plate is easier
and produces the most accurate and consistent results,
proceed as follows:
a.
. Using a dial caliper, measure
thickness of support plate.
b.
To determine the required distance from the top of
the support plate to the edge of the installed needle
bearing, add measurement obtained in the previous
step to 3.10 in. (78.7 mm).
NOTE
For example, if the support plate is 0.50 in. (12.7 mm) thick,
then the measurement from the top of the support plate to the
edge of the needle bearing should be 3.60 in. (91.4 mm).
3.
. Sparingly apply graphite lubricant (9)
to threads of installer forcing screw (4) to prolong service
life and verify smooth operation.
4.
Thread installer forcing screw into stamped side of support
plate (2) until threads begin to emerge from opposite side.
5.
Place installer (6) at end of installer forcing screw.
6.
Place new needle bearing on installer with lettered side
facing shoulder of installer.
7.
. Aligning two large holes in support plate
with needle bearing bores, hang right side of plate on ring
dowel in crankcase flange.
8.
Align four holes at corners of support plate with threaded
holes in crankcase flange. Install thumb screws in these
holes to secure support plate to crankcase.
sm03818
Figure 3-117. Measure Thickness of Support Plate
sm02519
Figure 3-118. Installer Forcing Screw Installation
2009 Dyna Service: Engine 3-89
9.
Install first needle bearing as follows:
a.
. Turn hex at end of installer forcing
screw in a clockwise direction to press needle bearing
into bore.
b.
Back out forcing screw. Reaching into crankcase,
remove installer. Remove forcing screw from support
plate.
c.
. Inserting dial caliper through forcing
screw bore, measure distance from top of support
plate to edge of needle bearing.
d.
If bearing is not installed to the correct depth (as cal-
culated earlier), install forcing screw and installer and
repeat the three previous steps.
e.
Install forcing screw back into support plate. Reaching
into crankcase, place installer at end of forcing screw.
Hand turn forcing screw until shoulder on installer
makes contact with edge of needle bearing.
NOTE
In the next step, a measurement will be taken of the distance
from the head of the installer forcing screw to the support plate.
This measurement will be used for installing the second needle
bearing. For an accurate measurement, be sure the shoulder
on the installer is in contact with the edge of the needle bearing.
10. See
. Using a dial caliper, measure from head
(top) of installer forcing screw to support plate. Record
this measurement.
11. Back out forcing screw. Reaching into crankcase, remove
installer. Remove forcing screw from support plate.
12. Install forcing screw in support plate over second needle
bearing bore. Reaching into crankcase, place installer at
end of forcing screw. Place new needle bearing on installer
with lettered side facing shoulder of installer.
13. Turn hex on forcing screw in a clockwise direction until
distance from head (top) of forcing screw to support plate
equals measurement obtained previously.
sm02520
Figure 3-119. 1 Inch (25.4 mm) Bearing Installation
sm03843
Figure 3-120. Measure from Top of Support Plate to Edge
of Needle Bearing
sm03844
Figure 3-121. Measure from Top of Forcing Screw to
Support Plate
CLEANING AND INSPECTION
Oil Pressure Valve
3.26 CAM SUPPORT PLATE AND COVER, Oil Pressure
Cam Support Plate
Verify that all oil holes are clean and open.
NOTE
Exercise caution to avoid enlarging the oil holes or oil pressure
will be adversely affected.
INSTALLATION OVERVIEW
1.
Begin with
3.19 BOTTOM END OVERHAUL: ASSEMBLY,
2.
Continue with
3.17 TOP END OVERHAUL: ASSEMBLY
.
3-90 2009 Dyna Service: Engine
3.27
OIL PUMP
REMOVAL OVERVIEW
1.
3.16 TOP END OVERHAUL: DISASSEMBLY
a.
Remove breather assembly.
b.
Remove rocker arm support plate.
c.
Remove push rods and push rod covers. Do not
remove lifters or lifter covers.
2.
Fashion lifter holding tool to prevent the hydraulic lifters
from dropping into the cam compartment during cam
support plate removal. See
.
3.
To remove cover and cam support plate, see
3.18 BOTTOM END OVERHAUL: DISASSEMBLY
.
Remove oil pump after removing cam support plate.
CLEANING AND INSPECTION
1.
Clean all parts in a non-volatile cleaning solution or
solvent.
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)
2.
Blow parts dry with low pressure compressed air. Verify
that all oil passages are clean and open.
3.
Look for scoring, gouging or cracking caused by foreign
material that may have passed through the oil pump.
4.
Look for grooves or scratches on the cam support plate,
which serves as the outboard side of the oil pump.
5.
Check for excessive wear or damage on lobes of outer
gerotor gears and between lobes on inner gerotor gears.
6.
. Check gerotor wear.
a.
Mesh pieces of one gerotor set together.
b.
Use a feeler gauge to determine clearance between
tips of lobes on inner and outer gerotors.
c.
Replace gerotors as a set if clearance exceeds 0.004
in. (0.10 mm). Inspect second gerotor set in the same
manner.
7.
Measure thickness of inner gerotor of one set with a
micrometer. Measure the outer gerotor of the same set.
Replace the gerotor set if the difference exceeds 0.001
in. (0.025 mm). Inspect second gerotor set in the same
manner.
8.
See
. Assemble the oil pump. Verify that feed
gerotors stand proud of the oil pump surface 0.015-0.025
in. (0.38-0.64 mm). If measurement is less than 0.015 in.
(0.38 mm), remove feed gerotor set and reassemble using
new wave washer. Repeat measurement and replace oil
pump body if still not within specification.
3
2
1
sm02521
1.
Outer gerotor
2.
Inner gerotor
3.
Wear limit
Figure 3-122. Measure Gerotor Sets for Wear
1
6
2
3
2
4
5
sm02187
1.
Narrow gerotor set (feed)
2.
Separator plate
3.
Wave washer
4.
Wide gerotor set (scavenge)
5.
Oil pump housing
6.
Scavenge port O-ring
Figure 3-123. Assembling Oil Pump
INSTALLATION OVERVIEW
1.
3.26 CAM SUPPORT PLATE AND COVER, Installa-
.
2.
Continue with
3.17 TOP END OVERHAUL: ASSEMBLY
.
2009 Dyna Service: Engine 3-91
3.28
CRANKCASE
REMOVAL OVERVIEW
1.
Perform all steps under
2.
Perform all steps under
RIGHT CRANKCASE HALF
TOOL NAME
PART NUMBER
CRANKCASE BEARING
REMOVER/INSTALLER
B-45655
CRANKCASE BEARING
REMOVER/INSTALLER BASE
HD-42720-5
Main Bearing Removal
NOTE
Do not move or lift the crankcase by grasping the cylinder
studs. The crankcase is too heavy to be carried in this manner
and could be dropped.
1.
. Obtain CRANKCASE BEARING
REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER
BASE (Part No. HD-42720-5).
2.
Place support tube (2) on hydraulic press table with the
"A" end up. Note that the sides of the support tube are
stamped to ensure proper orientation.
3.
With the outboard side of the right crankcase half facing
upward, position main bearing bore over support tube.
During removal it is important that the curved edges on
the pilot/driver (1) match the curved edges of the crank-
case.
4.
Slide pilot/driver (1) through bearing into support tube.
5.
Center pilot/driver under ram (3) of press. Apply pressure
to pilot/driver until bearing is free.
6.
Remove crankcase, pilot/driver and bearing from support
tube. Discard bearing.
4
1
3
2
1
sm02301
1.
Pilot/driver
2.
Support tube
3.
Ram
4.
Support tube (2) "A" end up
Figure 3-124. Right Main Bearing Removal
Main Bearing Installation
1.
See
. Obtain CRANKCASE BEARING
REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER BASE
(Part No. HD-42720-5).
2.
Obtain new main bearing (4). Spread a thin film of clean
engine oil on O.D. of new bearing.
3.
Turn support tube (2) over so that the "B" end is up. The
sides of the support tube are stamped "A" and "B" to
ensure proper orientation.
4.
With the outboard side of the right crankcase half facing
upward, position main bearing bore over support tube.
5.
Lubricate leading edge (letter side) of new main bearing
with clean engine oil. Start leading edge of bearing in
bearing bore.
3-92 2009 Dyna Service: Engine
6.
Slide pilot/driver (1) through bearing into support tube.
7.
Center pilot/driver under ram (3) of press. Apply pressure
to pilot/driver until resistance is felt and bearing is bot-
tomed on the support tube.
8.
Remove pilot/driver and crankcase half from support tube.
4
1
3
2
1
5
sm02304
1.
Pilot/driver
2.
Support tube
3.
Ram
4.
Main bearing
5.
Support tube (2) "B" end up
Figure 3-125. Right Main Bearing Installation
Piston Jets Removal
1.
See
. Remove two T20 TORX screws (1) to
free piston jet (2) from crankcase.
2.
Remove o-ring (3) from groove in mounting flange of jet.
Discard o-ring.
1
2
3
sm02305
1.
T20 TORX screw
2.
Piston jet
3.
O-ring
Figure 3-126. Piston Jets
Piston Jets Installation
NOTES
•
If piston jet is being reused, apply LOCTITE THREAD-
LOCKER 222 (purple) to threads of TORX screws before
installation.
•
O-rings that are missing, distorted, pinched or otherwise
damaged will result in either oil leakage or low oil pressure.
Use of the wrong o-ring will have the same results. Since
many o-rings are similar in size and appearance, always
use new o-rings keeping them packaged until use to avoid
confusion.
1.
See
. Apply a very thin film of clean H-D
20W50 engine oil to new o-ring (3) for piston jet. Install
new o-ring in groove of jet mounting flange.
2.
With jet pointed upward, start two T20 TORX screws (1)
to secure piston jet (2) to crankcase. Tighten to 25-35 in-
lbs (2.8-3.9 Nm).
LEFT CRANKCASE HALF
TOOL NAME
PART NUMBER
CRANKCASE BEARING
REMOVER/INSTALLER
B-45655
CRANKCASE BEARING
REMOVER/INSTALLER BASE
HD-42720-5
Main Bearing Removal
NOTE
Never move or lift the crankcase by grasping the cylinder studs.
The crankcase is too heavy to be carried in this manner and
could be dropped.
2009 Dyna Service: Engine 3-93
Do not rotate left crankcase half in engine stand such that
flywheel sprocket shaft is facing up.The flywheel assembly
can fall out, resulting in parts damage or moderate injury.
(00552b)
1.
While holding flywheel assembly so that it does not fall
out of left crankcase half, rotate bottom end assembly in
engine stand so assembly is upright and flywheel shafts
are horizontal.
2.
Carefully slide flywheel assembly out of left crankcase and
place it in a clean safe place.
3.
Unbolt left crankcase half from stand and move it to bench
area. Remove thrust washer from outboard side of crank-
case half by pulling it past oil seal. Set thrust washer aside
for inspection or reuse.
4.
Remove oil seal from crankcase bore. Discard oil seal.
5.
See
. The left main bearing (1) is press-fit
into the main bearing bore (2) in the left crankcase and
secured with a retaining ring (3) on the inboard side. See
. Using the tip of a flat blade screwdriver,
carefully lift the edge of the retaining ring up out of its
groove in the crankcase. Slide the screwdriver tip around
the edge of the bearing, lifting the retaining ring up and
out of the groove. Be careful not to damage the lip of the
groove in the crankcase.
1
2
3
sm02522
1.
Main bearing
2.
Main bearing bore
3.
Retaining ring
Figure 3-127. Left Main Bearing Assembly
sm02523
Figure 3-128. Removing Retaining Ring
1
2
sm02307
1.
Support tube
2.
Pilot/driver
Figure 3-129. Left Main Bearing Remover and Installer
Tools
3-94 2009 Dyna Service: Engine
3
1
3
2
sm02524
1.
Ram
2.
Pilot/driver
3.
Support tube ("B" end up)
Figure 3-130. Left Main Bearing Removal
NOTE
. If the ram of the press is wider than the head
of pilot/driver (2), a suitable press plug will be needed in order
to remove the main bearing.
6.
O b t a i n C R A N K C A S E B E A R I N G
REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER
BASE (Part No. HD-42720-5).
7.
See
. Place support tube (3) on hydraulic
press table with "B" end up. Note that sides of support
tube are stamped "A" and "B" to verify proper orientation.
8.
With the outboard side of the left crankcase half facing
upward, position main bearing bore over support tube.
9.
Slide pilot/driver (2) through main bearing into support
tube (3).
10. If the ram of the press is wider than the head of pilot/driver
(2), place a suitable press plug on top of pilot/driver (2).
11. Center pilot/driver under ram (1) of press. Apply pressure
to pilot/driver until bearing is free.
12. Remove crankcase half, pilot/driver and bearing from
support tube. Discard bearing.
Main Bearing Installation
NOTE
Never move or lift the crankcase by grasping the cylinder studs.
The crankcase is too heavy to be carried in this manner and
could be dropped.
1.
. Obtain CRANKCASE BEARING
REMOVER/INSTALLER (Part No. B-45655) and
CRANKCASE BEARING REMOVER/INSTALLER BASE
(Part No. HD-42720-5).
1
3
4
2
3
sm02525
1.
Ram
2.
Pilot/driver
3.
Support tube ("A" end up)
4.
Main bearing
Figure 3-131. Left Main Bearing Installation
2.
See
. Obtain new main bearing (4). Place a
thin film of clean engine oil on outer diameter of bearing.
3.
Place support tube (3) on hydraulic press table with the
"A" end up.
4.
With the inboard side of the left crankcase half facing
upward, position main bearing bore over support tube.
5.
Lubricate leading edge of new main bearing before
placement. Start new main bearing in bearing bore, letter
side down.
6.
Slide pilot/driver (2) through bearing into support tube.
7.
Center pilot/driver (2) under ram (1) of press. Apply pres-
sure to pilot/driver until bearing is lightly bottomed in main
bearing bore.
8.
Remove crankcase half and pilot/driver from support tube.
9.
Obtain new retaining ring and install in bearing bore in
inboard side of crankcase half. Work retaining ring into
groove, being careful not to damage edges of groove.
Make sure retaining ring is fully seated in groove.
NOTE
If retaining ring will not fit into groove in bearing bore, it is a
sign that the bearing is not fully seated in the bore. Examine
the bearing and bore. If necessary, remove bearing, clean bore
and install bearing. Then install retaining ring.
2009 Dyna Service: Engine 3-95
SPROCKET SHAFT BEARING INNER RACE
TOOL NAME
PART NUMBER
ROBINAIR HEAT GUN
HD-25070
MAINSHAFT BEARING INNER RACE
PULLER/INSTALLER
HD-34902-B
FLYWHEEL SUPPORT FIXTURE
HD-44358
WEDGE ATTACHMENT
HD-95637-46B
SPROCKET SHAFT BEARING
INSTALLER
HD-97225-55C
Removal
If reusing flywheel, remove bearing inner race and thrust
washer as follows:
1.
Obtain FLYWHEEL SUPPORT FIXTURE (Part No. HD-
44358). See
. Install brass jaws or shop
towels around teeth of vise to prevent damage to tool.
Clamp tool in vise with the round hole topside.
2.
Insert crankshaft end through hole resting flywheel
assembly on fixture. Slide knurled locating pin down slot
in tool to engage crank pin hole. Hand tighten locating pin.
3.
Slide hold-down clamp down slot to engage inboard side
of right flywheel half, and then hand tighten knurled nut at
bottom to secure. Repeat step to secure hold-down clamp
on opposite side of flywheel.
NOTE
For proper clamping force, hold-down clamp must not be tilted.
Rotate hex on outboard stud until clamp is level.
1
2
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1.
Locating pin
2.
Hold-down clamp
Figure 3-132. Flywheel Fixture (Part No. HD-44358)
4.
Position WEDGE ATTACHMENT (Part No. HD-95637-
46B) on inboard side of thrust washer and turn hex nuts
an equal number of turns to draw halves of wedge
together.
Install wedge attachment only so far as necessary to
ensure positive contact with bearing inner race. Installing
tool with more contact than necessary will result in damage
to the flywheel (00500b)
5.
Obtain two 3/8-16 inch bolts 7-1/2 inches long (with flat
washers). Install flat washers on bolts. Obtain bridge and
forcing screw from MAINSHAFT BEARING INNER RACE
PULLER/INSTALLER (Part No. HD-34902-B). Also obtain
a suitable hardened washer to use between the puller
screw and the end of the shaft.
6.
Slide one bolt into channel on each side of bridge so that
flat washer is between bridge and bolt head. Thread bolts
into wedge attachment an equal number of turns.
7.
Sparingly apply graphite lubricant to threads of forcing
screw to prolong service life and ensure smooth operation.
Start forcing screw into center hole of bridge.
NOTE
Failure to use hardened washer may result in damage to forcing
screw and/or sprocket shaft.
8.
Place hardened washer against end of sprocket shaft.
Thread forcing screw into bridge until the steel ball at the
end of the screw makes firm contact with hardened
washer.
9.
Using the ROBINAIR HEAT GUN (Part No. HD-25070),
uniformly heat the bearing inner race for about 30 seconds
using a circular motion.
NOTE
To facilitate removal without heat, apply a light penetrating oil
to shaft and leading edge of bearing inner race.
Do not use heating devices with penetrating oil. Penet-
rating oil is flammable which could result in death or ser-
ious injury. (00375a)
10. Turn forcing screw until thrust washer and bearing inner
race move approximately 1/8 in. (3.2 mm).
11. Turn hex nuts an equal number of turns to separate halves
of WEDGE ATTACHMENT (Part No. HD-95637-46B).
12. After bottoming thrust washer on shaft, reposition WEDGE
ATTACHMENT (Part No. HD-95637-46B) on inboard side
of bearing inner race. Turn hex nuts an equal number of
turns to draw halves of wedge together.
Install wedge attachment only so far as necessary to
ensure positive contact with bearing inner race. Installing
tool with more contact than necessary will result in damage
to the flywheel (00500b)
13. See
. Verify that the tool assembly is square,
so that the bearing inner race is not cocked during
removal.
3-96 2009 Dyna Service: Engine
14. Using the ROBINAIR HEAT GUN (Part No. HD-25070),
uniformly heat the bearing inner race for about 30 seconds
using a circular motion.
NOTE
To facilitate removal without heat, apply a light penetrating oil
to shaft and leading edge of bearing inner race.
15. Turn forcing screw until bearing inner race is pulled free
of sprocket shaft.
16. Remove thrust washer from sprocket shaft.
2
1
3
7
6
5
4
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1.
Forcing screw
2.
3/8-16 in. bolt with flat washer
3.
Bridge
4.
Hardened washer
5.
Wedge attachment
6.
Bearing inner race
7.
Sprocket shaft
Figure 3-133. Remove Inner Race from Sprocket Shaft
Installation
1.
Place new thrust washer over sprocket shaft.
2.
Place new bearing inner race on bench top. Using the
ROBINAIR HEAT GUN (Part No. HD-25070), uniformly
heat bearing inner race for about 60 seconds using a cir-
cular motion.
3.
Wearing suitable gloves to protect hands from burns, place
heated bearing inner race over sprocket shaft.
NOTE
To facilitate installation without heat, apply a light penetrating
oil to shaft and leading edge of bearing inner race.
Do not use heating devices with penetrating oil. Penet-
rating oil is flammable which could result in death or ser-
ious injury. (00375a)
4.
See
. Obtain the SPROCKET SHAFT
BEARING INSTALLER (Part No. HD-97225-55C).
Assemble tool as described below.
a.
See
. Thread pilot adapter into sprocket
shaft.
b.
Thread pilot shaft onto pilot adapter.
c.
Slide long collar over pilot shaft until it contacts
bearing inner race.
d.
Slide short collar over pilot shaft until it contacts long
collar.
e.
Slide Nice bearing and large flat washer over pilot
shaft.
f.
Sparingly apply graphite lubricant to threads of pilot
shaft to prolong service life and ensure smooth oper-
ation.
g.
See
.Thread handle onto pilot shaft.
5.
. Rotate handle of tool in a clockwise
direction until bearing inner race makes firm contact with
thrust washer. Verify that thrust washer cannot be rotated
by hand.
6.
Remove handle, flat washer, Nice bearing, short collar,
long collar, pilot shaft and pilot adapter from sprocket shaft.
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Figure 3-134. Sprocket Shaft Bearing Installer (Part No.
HD-97225-55C)
2009 Dyna Service: Engine 3-97
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Figure 3-135. Thread Pilot Adapter into Sprocket Shaft
1
2
3
4
5
6
7
8
9
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1.
Pilot adapter
2.
Pilot shaft
3.
Handle
4.
Flat washer
5.
Nice bearing
6.
Short collar
7.
Long collar
8.
Inner race
9.
Thrust washer
Figure 3-136. Press Inner Race onto Sprocket Shaft: Setup
sm03857
Figure 3-137. Press Inner Race onto Sprocket Shaft:
Operation
CYLINDER STUDS
Removal
1.
Thread a 3/8"-16 nut onto cylinder stud.
2.
Thread a second nut onto stud until it contacts the first.
3.
Placing wrench on first nut installed, remove stud.
Installation
1.
Place a steel ball inside a head screw. Put the head screw
on the end of the cylinder stud without the collar.
2.
Start the stud in the cylinder deck with the collar side down.
Tighten using air gun until collar reaches crankcase.
3.
Hand tighten stud to 10-20 ft-lbs (3.6-27.1 Nm).
3-98 2009 Dyna Service: Engine
PIPE PLUG AND OIL FITTINGS
Removal
. Turn pipe plug counterclockwise until free.
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Figure 3-138. Pipe Plug
Installation
1.
Apply LOCTITE PIPE SEALANT 565 to threads.
2.
Install pipe plug. Tighten pipe plug to 120-144 in-lbs (13.6-
16.3 Nm).
CLEANING AND INSPECTION
1.
Scrape old gasket material from the crankcase flanges.
Old gasket material left on mating surfaces will cause
leaks.
2.
Clean all parts in a non-volatile cleaning solution or
solvent.
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)
3.
Blow parts dry with low pressure compressed air.
4.
Verify that all oil holes and passageways are clean and
open.
5.
Check ring dowels for looseness, wear or damage.
Replace as necessary.
6.
Use a file to carefully remove any nicks or burrs from
machined surfaces.
7.
Clean out tapped holes and clean up damaged threads.
8.
Check the top of the crankcase for flatness with a
straightedge and feeler gauge. Replace if warped.
9.
Spray all machined surfaces with clean engine oil.
INSTALLATION OVERVIEW
1.
Perform all steps under
2.
Perform all steps under
2009 Dyna Service: Engine 3-99
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