Harley Davidson Sportster Models 2009. Service Repair Manual — page 29
Table 3-34. Cylinder Bore Service Wear Limits
1200 CC
883 CC
BORE SIZE
3.5008 in. (88.920 mm)
3.0035 in. (76.289 mm)
Standard bore
3.5050 in. (89.027 mm)
3.0078 in. (76.398 mm)
0.005 in. (0.13 mm) OS bore
3.5100 in. (89.154 mm)
3.0128 in. (76.525 mm)
0.010 in. (0.25 mm) OS bore
XR 1200 Models: Oversized pistons are not available. Replace piston and/or cylinder if exceeds wear limits.
NOTE
If piston clearance exceeds service limit, cylinders should be
re-bored and/or honed to next standard oversize, and refitted
with the corresponding piston and rings. Do not fit piston tighter
than 0.0007 in. (0.018 mm). See
.
sm01540
Figure 3-137. Measuring Cylinder Bore
Measuring Piston to Cylinder Fit
NOTE
This inspection is very heat sensitive. Do not check piston
running clearance immediately after honing or deglazing cyl-
inder. Even holding the piston in your hand for too long can
cause measurements to vary by as much as 0.002 in. (0.051
mm). Both piston and cylinder must be at room temperatures
before proceeding.
Measure the piston running clearance. Proceed as follows:
NOTE
Check the piston clearance in the cylinder in which the piston
will run. The torque plates must be installed on the cylinder to
simulate an assembled cylinder for accurate measurement of
cylinder.
sm01543
Figure 3-138. Measurement Area (typical; XL model shown)
1.
. the measurement is taken on bare
aluminum to avoid measuring errors. An oval-shaped
opening in the coating is present on each side of the piston
for proper placement of the micrometer.
1
2
sm01545
1.
4-5 inch micrometer
2.
Spherical ball anvil adapter (2)
Figure 3-139. Micrometer with Anvil Adapters
NOTE
The oval openings are too small for a standard flat anvil
micrometer. Using such a device would result in measuring
errors. See
. Use a 3-4 inch blade or ball anvil
2009 Sportster Service: Engine 3-115
style micrometer, or a 4-5 inch micrometer with spherical ball
anvil adapters.
2.
Measure the piston skirt at the oval openings and then
transfer that measurement to a dial bore gauge.
3.
Using a grease pencil, mark the top, middle and bottom
of the piston ring travel zone in the cylinder bore. Measure
at markings in cylinder parallel and perpendicular to
crankshaft.
4.
Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).
Boring and Honing Cylinder
Table 3-35. Cylinder Final Bore Sizes
1200 CC
883 CC
BORE SIZE
MM
IN.
MM
IN.
88.844
3.4978
76.213
3.0005
Standard bore*
88.95
3.502
76.323
3.0048
0.005 in. (0.13 mm) OS bore
89.08
3.507
76.449
3.0098
0.010 in. (0.25 mm) OS bore
* All bore sizes + 0.0002 in. (0.00508 mm)
XR 1200 Models: Oversized pistons are not available. Replace piston and/or cylinder if exceeds wear limits.
1.
The cylinder must be bored with gaskets and torque plates
attached. Bore the cylinder to 0.003 in. (0.08 mm) under
the desired finished size.
2.
Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing must
be done with the torque plates attached. All honing must
be done from the bottom (crankcase) end of the cylinder.
Work for a 60° crosshatch pattern.
for final cylinder bore sizes after honing.
NOTES
•
When cylinder requires oversize re-boring to beyond 0.010
in. (0.25 mm), the oversize limit has been exceeded and
cylinder must be replaced.
•
The same piston may be used if cylinder bore was not
changed, unless it is scuffed or grooved. However, replace
rings and hone the cylinder walls with a No. 240 grit flexible
ball hone.
Failure to remove all abrasive particles may result in pre-
mature cylinder, piston and ring wear and engine failure.
(00537b) .
3.
Thoroughly wash the cylinder bore with liquid dishwashing
soap and warm water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth shows
no remaining dirt or debris.
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.
Hot rinse the cylinder and dry with moisture free low
pressure compressed air.
5.
Immediately apply a thin film of clean engine oil to a clean
white paper towel and thoroughly wipe the inside of the
cylinder.
NOTE
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.
6.
With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run.
Fitting Piston Rings
See
. Piston rings are of two types: compression
and oil control. The two compression rings are positioned in
the two upper piston ring grooves. The dot on the second
compression ring must face upward. Ring sets are available
to fit standard and oversize pistons.
Piston ring sets must be properly fitted to piston and cylinder:
1.
See
. Place piston in cylinder about 1/2 in.
(13 mm) from top. Set ring to be checked inside cylinder,
squarely against piston. Remove piston and check ring
end gap with thickness gauge. See
for tolerance.
NOTE
See piston ring gap Service Wear Limits in
for end gap dimensions. Do not file rings to obtain
proper gap.
3-116 2009 Sportster Service: Engine
1
2
3
sm01598
1.
Top ring - Install either side up
2.
Second ring - Install dot toward top
3.
Oil control rings
Figure 3-140. Piston Rings
sm01548
Figure 3-141. Measuring Ring End Gap
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.
Use low pressure compressed air to remove any dirt or
dust that may have settled in piston oil drain holes and
ring grooves. Apply clean engine oil to piston ring grooves.
3.
. Install oil control ring expander spring.
Make sure ends of spring point upward. Spiral bottom oil
control ring into space in ring groove below expander
spring. Position oil control ring gap 90° from gap in
expander spring. Spiral top oil control ring into space in
ring groove above expander spring. Position oil control
ring gap 180° from gap in bottom oil control ring
sm01553
Figure 3-142. Installing Oil Control Ring Expander Spring
(typical; XL model shown)
4.
See
. Use a piston ring expander tool to slip
compression rings over piston into their respective
grooves. Install second compression ring first, then top
compression ring. Be extremely careful not to over expand
or twist rings, or damage piston surface when installing
rings.
NOTE
Install second compression ring with dot towards top of piston.
sm01554
Figure 3-143. Installing Piston Rings (typical; XL model
shown)
5.
. Position rings so end gaps of adjacent
rings are a minimum of 90° apart. Ring gaps are not to be
within 10° of the thrust face centerline.
2009 Sportster Service: Engine 3-117
6.
. Check for proper side clearance with
thickness gauge, as shown. See
for tolerance.
NOTE
If the ring grooves are clean, and the side play is still not cor-
rect, replace the rings, the piston, or both.
1
2
3
sm01555
1.
Front
2.
Rear
3.
Piston Pin
Figure 3-144. Position Ring End Gaps at Arrows
sm1556
Figure 3-145. Measuring Ring Clearance in Groove (typical;
XL model shown)
CONNECTING ROD BUSHINGS
TOOL NAME
PART NUMBER
WRIST PIN BUSHING HONE
HD-35102
REAMER LUBRICANT
HD-39964
CONNECTING ROD BUSHING
REAMER
HD-94800-26A
CONNECTING ROD CLAMPING TOOL
HD-95952-33C
CONNECTING ROD BUSHING
REMOVER/INSTALLER
HD-95970-32D
Removing Upper Connecting Rod Bushings
NOTES
•
Replace the upper connecting rod bushing if the piston
pin to rod bushing clearance exceeds 0.002 in. (0.051
mm).
•
Place clean shop towels in and around the crankcase bore
to prevent chips and shavings from falling into the crank-
case.
•
If CONNECTING ROD CLAMPING TOOL (Part No. HD-
95952-33C) holes are too small, enlarge the holes in the
tool.
1.
See
. Obtain the CONNECTING ROD
CLAMPING TOOL and install as follows:
a.
Slide clamp (2) over connecting rod so that slots
engage cylinder head studs. Exercise caution to avoid
scratching or bending studs.
b.
With the knurled side up, screw threaded cylinders
(1) onto studs to secure position of clamp.
c.
Alternately turn each clamp thumbscrew (3) a few
turns to gradually fix position of connecting rod.
Turning only one thumbscrew will move rod off-center,
while tightening second thumbscrew can cause rod
to flex or bend.
2.
Install rubber hoses over remaining two cylinder studs.
3.
See
. Obtain the CONNECTING ROD
BUSHING REMOVER/INSTALLER (Part No. HD-95970-
32D).
a.
Sparingly apply graphite lubricant to threads of bolt
(6) to prolong service life and ensure smooth opera-
tion.
b.
Slide receiver cup (5) onto bolt with the closed side
facing bolt head.
c.
Insert bolt through upper connecting rod bushing.
3-118 2009 Sportster Service: Engine
3
1
2
sm01557
1.
Threaded cylinder (2)
2.
Clamp
3.
Thumb screw (2)
Figure 3-146. Connecting Rod Clamping Tool (Part No.
HD-95952-33C)
4
6
2
1
3
5
sm01558
1.
Nut
2.
Flat washer
3.
Nice bearing
4.
Remover/Installer
5.
Receiver cup
6.
Bolt
Figure 3-147. Connecting Rod Bushing Remover/Installer
(Part No. HD-95970-32D)
4.
Remove bushing as follows:
a.
See
. Slide remover side of
remover/installer onto bolt. The driver is stamped to
ensure proper orientation.
b.
. Slide Nice bearing (3) and flat
washer (2) onto bolt (6) until they contact
remover/installer (4).
c.
Thread nut (1) onto bolt until assembly is snug.
d.
Using two box end wrenches, tighten nut on bolt until
bushing is free.
e.
Remove nut from bolt. Remove flat washer, Nice
bearing and remover/installer. Remove bolt from
bushing bore.
f.
Remove bushing from receiver cup and discard.
NOTE
Leave CONNECTING ROD CLAMPING TOOL installed during
bushing installation procedure which follows.
sm01559
Figure 3-148. Remover Stackup. Use Remover Side Of
Remover/Installer
2009 Sportster Service: Engine 3-119
Installing Upper Connecting Rod Bushings
1.
. Obtain the CONNECTING ROD
BUSHING REMOVER/INSTALLER (Part No. HD-95970-
32D).
a.
Sparingly apply graphite lubricant to threads of bolt
(6) to prolong service life and ensure smooth opera-
tion.
b.
Slide receiver cup (5) onto bolt with the closed side
facing bolt head.
c.
Insert bolt through upper connecting rod bushing bore.
d.
. Slide new bushing onto bolt. Start
bushing into bore. Verify that center of slot in bushing
(2) is aligned with oil hole in connecting rod (3). Also,
be sure that bushing is square in bore and not cocked.
e.
Slide installer side of remover/installer (1) onto bolt
until shoulder contacts bushing. The remover/installer
is stamped to ensure proper orientation.
f.
See
. Slide Nice bearing (3) and flat
washer (2) onto bolt until they contact
remover/installer.
g.
Thread nut (1) onto bolt until assembly is snug.
h.
Using two box end wrenches, tighten nut on bolt until
collar on remover/installer bottoms against connecting
rod. See
.
2.
Remove nut from bolt and remove flat washer, Nice
bearing and remover/installer. Remove bolt from bushing
bore, but exercise caution to avoid scratching or gouging
bushing.
NOTE
Leave CONNECTING ROD CLAMPING TOOL installed during
bushing reaming procedure which follows.
2
1
3
sm01573
1.
Installer side of remover/installer
2.
Slot in bushing
3.
Oil hole in connecting rod
Figure 3-149. Installer Stackup
1
2
sm01575
1.
Piston bushing tool
2.
Rod clamping fixture
Figure 3-150. Installing New Piston Pin Bushing
Reaming Upper Connecting Rod Bushings
NOTE
Sizing bushing with less than 0.00125 in. (0.0317 mm) clear-
ance can result in a bushing loosening and/or seized pin in
rod.
1.
Clean up and size bushing to 0.0010-0.0005 in. (0.025-
0.013 mm) undersize using the CONNECTING ROD
BUSHING REAMER (Part No. HD-94800-26A) .
a.
Carefully insert bit of reamer into upper connecting
rod bushing. Do not apply lubricant to reamer or
bushing. Ream the bushing dry or cut will not be
accurate.
b.
Install a 11/16-inch 12-pt socket and T-handle on
reamer lug.
c.
Placing thumb on drive socket, apply slight pressure
on reamer while rotating handle/drive socket in a
clockwise direction.
NOTE
For best results, do not push on reamer or apply pressure
to the reamer handle. While excessive pressure results in
a rough cut, bushing bore will be tapered if pressure is not
centrally applied.
d.
Continue rotating handle/drive socket until entire bit
has passed through bushing and shank of reamer
rotates freely in the bore.
NOTE
Never back reamer out of connecting rod or bushing will be
damaged.
2.
Remove T-handle and socket, and carefully pulling on bit,
draw shaft of reamer out of connecting rod bushing.
3-120 2009 Sportster Service: Engine
NOTE
Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure.
3.
Using contact cleaner or cleaning solvent, thoroughly wipe
upper connecting rod and bushing of any metal shavings
or debris.
NOTE
Leave CONNECTING ROD CLAMPING TOOL installed during
bushing honing procedure which follows.
Honing Upper Connecting Rod Bushings
1.
Obtain the WRIST PIN BUSHING HONE (Part No. HD-
35102) and REAMER LUBRICANT (Part No. HD-39964)
to hone bushing to final size. Use a liberal amount of
honing oil to prevent damage to hone or bushing. Use
care to prevent foreign material from falling into the
crankcase.
a.
Install hone in a high speed electric drill.
b.
Apply reamer lubricant to finishing stones of hone and
inside of upper connecting rod bushing.
c.
Start finishing stones of hone into bushing.
d.
Activating the drill, move the entire length of the fin-
ishing stone arrangement forward and backward
through the bushing bore for 10 to 12 complete
strokes. Work for a crosshatch pattern of approxim-
ately 60°.
NOTE
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine failure.
2.
Using contact cleaner or cleaning solvent, thoroughly wipe
upper connecting rod and bushing of any metal shavings
or debris. Continue wiping until a clean cloth shows no
evidence of dirt or debris.
3.
Lightly oil a good piston pin and insert it into the upper
connecting rod bushing bore to feel for the proper interfer-
ence fit. The pin should slide in and out of the bushing
without binding, but also without pivoting or rocking.
4.
Remove CONNECTING ROD CLAMPING TOOL.
5.
Remove shop towels exercising caution that shavings,
chips and other debris do not fall into crankcase.
Repair
If connecting rod is bent, do not attempt to straighten. Flywheel
and connecting rod assembly must be replaced. Straightening
connecting rods by bending will damage the bearing on the
crank pin and the piston pin bushing.
ASSEMBLY AND INSTALLATION
3.16 TOP END OVERHAUL: ASSEMBLY, Piston and
to install piston and cylinder onto engine.
2009 Sportster Service: Engine 3-121
3.23
CRANKCASE
GENERAL
When connecting rod and flywheel assembly, pinion shaft
bearing, or sprocket shaft bearing are in need of replacement,
it is recommended procedure to check and make repairs to
cylinder heads, cylinders, gear case and transmission at the
same time (perform entire engine overhaul).
NOTE
When engine is removed from chassis, do not lay engine on
primary side. Laying engine on primary side will damage the
clutch cable end fitting. If fitting is damaged, clutch cable must
be replaced.
11
12
8
7
5
4
3
2
1
6
10
9
sm03411
7.
1.
Retaining ring
Sprocket shaft spacer
2.
8.
Retaining ring
Connecting rod and flywheel assembly
9.
3.
Pinion shaft bearing
Left main oil seal
4.
10.
Thrust washer
Retaining ring
11.
5.
Outer bearing race
Left crankcase
6.
12.
Left main bearing
Right crankcase
Figure 3-151. Crankcase and Flywheel Assembly (typical; XL model shown)
REMOVAL
1.
Remove engine from motorcycle. See
.
2.
Disassemble top end of engine. See
OVERHAUL: DISASSEMBLY, Cylinder Heads
3.15 TOP END OVERHAUL: DISASSEMBLY, Cylinder
and Piston
.
3-122 2009 Sportster Service: Engine
DISASSEMBLY
TOOL NAME
PART NUMBER
CRANKCASE BEARING
REMOVER/INSTALLER WITH
ADAPTER
B-45655, HD-42720-
2, HD-46663
END CAP
HD-34902-7
BEARING RACE REMOVER AND
INSTALLER KIT
HD-34902-C
FLYWHEEL SUPPORT FIXTURE
HD-44358
CLAW PULLER WEDGE ATTACH-
MENT
HD-95637-46B
TRANSMISSION SHAFT RETAINING
RING PLIERS
J-5586-A
1.
Disassemble crankcase, see
.
NOTE
See
. If it is necessary to remove either the pinion
shaft bearing (9) or left main bearing (6), proceed as follows:
2.
See
. Pinion shaft bearing assembly (3) will
remain on pinion shaft (2) when flywheel assembly (1) is
removed from right crankcase. Using TRANSMISSION
SHAFT RETAINING RING PLIERS (Part No. J-5586-A),
remove retaining ring (4) and slip bearing off pinion shaft.
1
2
3
4
sm01488
1.
Flywheel assembly
2.
Pinion shaft
3.
Pinion shaft bearing assembly
4.
Retaining ring
Figure 3-152. Removing Pinion Shaft Bearing Retaining
Ring
3.
. Place flywheel assembly in FLYWHEEL
SUPPORT FIXTURE (Part No. HD-44358). Pull sprocket
shaft bearing inner race with CLAW PULLER WEDGE
ATTACHMENT (Part No. HD-95637-46B) with BEARING
RACE REMOVER AND INSTALLER KIT (Part No. HD-
34902-C) and END CAP (Part No. HD-34902-7).
NOTE
The sprocket shaft inner race is not replaceable. If it is worn
or damaged, the crankshaft assembly must be replaced.
4.
See
. Remove outer left
main bearing retaining ring (2).
5.
See
. Remove left main oil seal (3) from left
crankcase using Snap-On Tool (Part No. CJ 114, Body
Dent Puller).
6.
Remove thrust washer (4) next to left main bearing (6).
sm01491
Figure 3-153. Removing Left Main Oil Seal Retaining Ring
7.
See
and
. Remove left main
bearing retaining ring (7) from the inside of the left crank-
case (5).
NOTE
When removing the left main bearing, the bearing presses from
the outside of the left crankcase toward the inside. A shoulder
is incorporated into the left crankcase which allows the bearing
to be removed in one direction only.
8.
See
. Using CRANKCASE BEARING
REMOVER/INSTALLER WITH ADAPTER (Part No. B-
45655, HD-42720-2, HD-46663) press left main bearing
out of the left crankcase.
a.
Place support tube (1) on press bed with recessed
cup end facing up.
b.
With the outboard side of the left crankcase (2) facing
upward, position crankshaft bearing bore (3) over
support tube.
c.
Place adapter (4) over left main bearing. Insert
pilot/driver (5) through adapter, through left main
bearing and into support tube.
d.
Carefully apply pressure with press ram (6) until left
main bearing drops free.
2009 Sportster Service: Engine 3-123
sm01493
Figure 3-154. Removing Left Main Bearing Retaining Ring
6
4
3
1
2
5
sm01494
1.
Support tube
2.
Left crankcase
3.
Crankshaft bearing bore
4.
Adapter
5.
Pilot/driver
6.
Press ram
Figure 3-155. Removing Left Main Bearing from Crankcase
FITTING PINION BEARINGS
TOOL NAME
PART NUMBER
END CAP
HD-34902-7
FORCING SCREW
J-21686-12
BRIDGE
J-7830-5
BEARING SEPARATOR
SNAP-ON TOOLS
STOCK NO. CJ950
. The outer race (11) is a pressed-in bushing
in the right crankcase. The inner race is pressed on the pinion
shaft.
. To remove pinion shaft inner race, use
BEARING SEPARATOR (Part No. Snap-on Tools Stock No.
CJ950), three items from END CAP (Part No. HD-34902-7),
BRIDGE (Part No. J-7830-5) and FORCING SCREW (Part
No. J-21686-12), and two bolts. Apply heat to race to aid
removal. Four sizes of pinion bearings are available.
1
2
3
5
6
4
sm01495
1.
Forcing screw
2.
Bridge
3.
End cap
4.
Bolts (2)
5.
Bearing separator
6.
Flywheel support fixture
Figure 3-156. Pulling Pinion Shaft Inner Bearing
Pinion bearing selection at the factory, during engine rebuild,
or replacement of crankcase set or flywheel assembly, is based
on the largest measured outside diameter (O.D.) of the inner
race and the smallest measured inside diameter (I.D.) of the
outer race (crankcase bushing).
A running clearance of 0.0002-0.0008 in. (0.005-0.020 mm) is
established during crankcase set or flywheel assembly
replacement and engine rebuild.
. Installed inner races are identified at the
factory as shown.
See
. Outer races are identified at the factory as
shown.
3-124 2009 Sportster Service: Engine
1
2
sm01497
1.
Paint dot
2.
Inner race
Figure 3-157. Factory Inner Race Sizes
NOTE
The different sizes of crankcase sets and flywheel assemblies
will not have separate part numbers. That is, a replacement
crankcase set may have a class 1, 2 or 3 pinion outer race.
Replacement flywheel assemblies will have either a class A or
B inner race.
See
. Pinion bearings are identified as shown.
Bearing Selection
Select bearings using the identification information given for
inner and outer races and bearings. Refer to
NOTE
If either inner or outer race show wear, measure both races to
confirm correct bearing fit of 0.0002-0.0008 in. (0.005-0.020
mm). The service wear limit of the outer race I.D. is 1.5672 in.
(39.807 mm).
Table 3-36. Inner Race Specifications
IDENTIFICATION*
CLASS
RACE O.D.
MM
IN.
White
A
31.745-31.750
1.2498-1.2500
Green
B
31.740-31.745
1.2496-1.2498
* Paint dot on end of spline.
Table 3-37. Roller Specifications
IDENTIFICATION (PACKAGE
COLOR)
ROLLER O.D. (A)
Red
Largest
Blue
White (Grey)
Green
Smallest
Table 3-38. Outer Race Specifications
STAMPED IDENTIFICATION*
CLASS NO.
RACE I.D.
MM
IN.
1
1
39.741-39-746
1.5646-1.5648
2
2
39.746-39.751
1.5648-1.5650
3
3
39.751-39.756
1.5650-1.5652
* Stamped number inside crankcase near race.
2009 Sportster Service: Engine 3-125
1
2
3
sm03412
1.
Outer race
2.
Stamped class no.
3.
Right crankcase
Figure 3-158. Factory Outer Race Sizes
1
sm03413
1.
A - Roller O.D. cannot be measured to required
accuracy with micrometer
Figure 3-159. Bearing Identification
Table 3-39. Pinion Shaft Bearing Selection
BEARING SIZE AS IDENTIFIED BY COLOR CODING
OUTER RACE I.D.
FACTORY
STAMPED
NUMBER
Service Wear Limit Exceeded - Replace Outer Race and Resize
over
1.5658 in. (39.771 mm)
Blue
Red
1.5656-1.5658 in.
(39.766-39.771 mm)
White-Gray
Blue
Red
1.5654-1.5656 in.
(39.761-39.766 mm)
Green
White-Gray
Blue
Red
1.5652-1.5654 in.
(39.756-39.761 mm)
Green
White-Gray
Blue
Red
1.5650-1.5652 in.
(39.751-39.756 mm)
3
Green
White-Gray
Blue
1.5648-1.5650 in.
(39.746-39.751 mm)
2
Green
White-Gray
1.5646-1.5648 in.
(39.741-39.746 mm)
1
1.2504-1.2506
1.2502-1.2504
1.2500-1.2502
1.2498-1.2500
1.2496-1.2498
Inner Race O.D. (in.)
31.760-31.765
31.755-31.760
31.750-31.755
31.745-31.750
31.740-31.745
Inner Race O.D. (mm)
White
Green
Factory Color Code
NOTE
Removal and installation of the inner and outer bearing races
require the use of shop-made tools. Dimensions for fabricating
the tools are shown in
,
.
1.
. Measure I.D. of outer race at four places
with a dial bore gauge. Take measurement on I.D. where
bearing rollers ride. Record the four measurements.
Table 3-40. Used Pinion Bearing Outer Race Specifications
SPECIFICATION
ITEM
1.5672 in. (39.807 mm)
Largest I.D. allowed
within 0.0002 in. (0.005 mm)
Roundness of I.D.
within 0.0002 in. (0.005 mm)
Taper
2.
If the largest measurement is larger than 1.5672 in.
(39.807 mm) or the required lapping to remove wear marks
would enlarge bore beyond 1.5672 in. (39.807 mm), con-
tinue at Step 8.
3-126 2009 Sportster Service: Engine
3.
If the largest measurement is 1.5672 in. (39.807 mm) or
less, cover the cam bearings with masking tape to prevent
debris from entering bearings. Assemble crankcase halves.
NOTE
The next step requires lapping the outer race. To keep sprocket
shaft and pinion shaft bearings aligned, the lap must be sup-
ported by an adaptor or pilot in the left crankcase.
4.
Lap the outer race. See
. The race must be lapped
until all wear marks are removed.
5.
After lapping race, again measure I.D. of race at four
places and record the measurements.
6.
Check measurements against the specifications listed in
.
7.
If lapping increased bore I.D. to larger than 1.5672 in.
(39.807 mm), go to next step. If roundness or taper do not
meet specifications, continue lapping until specifications
are met. If all specifications are met, continue at Step 10
to remove and size inner race.
NOTE
Always use the smallest outer race I.D. measurement and the
largest O.D. inner race measurement when selecting bearings.
8.
Press the outer race from the right crankcase. Press new
outer race into crankcase flush with inside edge of cast-in
insert.
9.
The new outer race must be lapped slightly to true and
align with left case bearing, and to meet the specifications
in
3.23 CRANKCASE, Lapping Engine
.
Table 3-41. New Pinion Bearing Outer Race Fit and Finish
SPECIFICATION
ITEM
1.5646-1.5652 in. (39.741-39.756 mm)
I.D.
within 0.0002 in (0.005 mm)
Roundness
within 0.0002 in (0.005 mm)
Taper
16 RMS
Surface Finish
10. See
. Pull inner race from pinion shaft using
BEARING SEPARATOR (Part No. Snap-on Tools Stock
No. CJ950), three items from END CAP (Part No. HD-
34902-7), BRIDGE (Part No. J-7830-5) and FORCING
SCREW (Part No. J-21686-12), and two bolts. Apply heat
to race to aid removal.
11. Press new inner race on pinion shaft using shop-made
tool. When the tool bottoms against the flywheel, the cor-
rect inner race location is automatically established as
shown in
. The new inner race must be
ground by a machinist to an O.D. dimension range based
on the finished lapped I.D. of the outer race, as shown in
. See the example that follows.
Table 3-42. Inner Race Fit and Finish
SPECIFICATION
ITEM
within 0.0002 in. (0.005 mm)
Roundness
within 0.0002 in. (0.005 mm)
Taper
16 RMS
Surface finish
2
1
3
sm03414
1.
Pinion shaft inner race
2.
Flywheel (gear side)
3.
1.135-1.145 in. (28.83-29.08 mm)
Figure 3-160. Inner Race Location
Inner Bearing Finish Example
The following example illustrates how to determine the required
inner race O.D.
1.
If smallest measured I.D. of outer race is 1.5651 in.
(39.754 mm) the
indicates an inner race O.D.
range of 1.2496-1.2504 in. (31.740-31.760 mm) is
required.
NOTE
Have machinist grind outer race to center or middle of required
O.D. range. This will prevent grinding outer race undersize and
gives a more easily achieved tolerance range.
2.
Grind inner race O.D. to the middle of the desired range
as determined by
. Measure O.D. at four places
and check that specifications in
3.
For example purposes:
a.
the largest measured O.D. of inner race after grinding
is 1.2499 in. (31.747 mm) O.D.
b.
Refer to
. With a 1.5651 in. (39.754 mm)
I.D. outer race and a 1.2499 in. (31.747 mm) O.D.
inner race, a blue bearing is required.
2009 Sportster Service: Engine 3-127
4
5
3
2
1
sm03435
1.
2.00 in. (50.8 mm)
2.
1.00 in. (25.4 mm)
3.
1.560 in. (39.62 mm)
4.
0.187 in. (4.75 mm)
5.
5/16 in. drill
Figure 3-161. Pinion Shaft Outer Race Installation Tool
4
5
1
3
2
sm03436
1.
1.70 in. (43.2 mm)
2.
1.00 in. (25.4 mm)
3.
1.560 in. (39.62 mm)
4.
0.187 in. (4.75 mm)
5.
5/16 in. drill
Figure 3-162. Pinion Shaft Outer Race Removal Tool
3
4
5
2
1
sm03437
1.
1.50 in. (38.1 mm)
2.
1.00 in. (25.4 mm)
3.
5.50 in. (139.7 mm)
4.
1.135-1.145 in. (28.83-29.08 mm)
5.
1.262-1.272 in. (32.05-32.31 mm)
Figure 3-163. Pinion Shaft Inner Race Installation Tool
LAPPING ENGINE MAIN BEARING RACES
TOOL NAME
PART NUMBER
LAPPING TOOL ADAPTER
HD-46287
CRANKCASE MAIN BEARING LAP-
PING TOOL
HD-96710-40C
CRANKCASE MAIN BEARING LAP
HD-96718-87
1.
. Obtain CRANKCASE MAIN BEARING
LAPPING TOOL (Part No. HD-96710-40C). Assemble
CRANKCASE MAIN BEARING LAP (Part No. HD-96718-
87) to lapping handle.
NOTE
Left main bearing must be installed in left crankcase in order
to use LAPPING TOOL ADAPTER (Part No. HD-46287) in the
next step. See
3.18 BOTTOM END OVERHAUL: ASSEMBLY,
.
2.
Assemble LAPPING TOOL ADAPTER (Part No. HD-
46287) to left main bearing.
3-128 2009 Sportster Service: Engine
3.
Secure right and left crankcase halves with three crank-
case stud bolts (top center and bottom left and right).
4.
Insert lap shaft with arbor assembled through pinion
bearing bushing and into lapping tool adapter. Tighten
arbor expansion collars using a length of 0.156 in. (3.96
mm) rod as spanner until arbor begins to drag. Do not
adjust arbor snug in bushing or bushing will bell, a condi-
tion where hole is larger at ends than it is in the center.
5.
Withdraw arbor far enough to coat lightly with 220 grit
lapping compound. Do not apply a heavy coat. Reposition
lap in bushing and turn handle at moderate hand speed.
Work lap back and forth in bushing, as it is revolved, to
avoid grooving and tapering.
6.
At frequent intervals, remove lap from crankcase, wash
and inspect bushing. Lapping is completed when entire
bushing surface has a dull, satin finish rather than a glossy,
smooth appearance.
7.
When finished, flush off lap tool using cleaning solvent
and dry using compressed air. Apply fresh, light coat of
fine lapping compound.
sm01499
Figure 3-164. Lapping Pinion Shaft Main Bearing
ASSEMBLING CRANKCASE HALVES
To assemble bottom end, see
2009 Sportster Service: Engine 3-129
3.24
OIL PUMP: XL MODELS
GENERAL
The oil pump seldom needs servicing. Before you disassemble
an oil pump suspected of not producing adequate oil pressure,
be sure that all possible related malfunctions have been elim-
inated.
1.
Make sure all oil line connections are tight and that lines
are not pinched or damaged.
2.
Check level and condition of oil in tank. Pressure will be
affected if oil is diluted. In freezing weather, proper circu-
lation of oil can be affected if the oil feed line becomes
clogged with ice or sludge.
3.
Check for a grounded oil pressure switch wire [120] or
faulty switch if oil pressure indicator light fails to go out
with engine running.
See
and
for additional information.
15
14
13
11
10
9
5
1
3
2
4
7
12
8
6
sm03410
9.
1.
Retaining ring
Oil pump cover
2.
10.
Screw w/ washer (2)
Thrust washer
11.
3.
O-ring
Torx screw (2)
4.
12.
Connector
Oil pump body
13.
5.
Elbow fitting
Hose fitting
6.
14.
Feed gerotor set
Gear shaft
15.
7.
Gasket
Gerotor separator plate
8.
Scavenge gerotor set
Figure 3-165. Oil Pump: XL Models
3-130 2009 Sportster Service: Engine
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