Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 14
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SERVICE WEAR LIMITS
3.2
GENERAL
Table 3-25. Valves-883/1200 cc
Service wear limits are given as a guideline for measuring
REPLACE IF WEAR EXCEEDS
components that are not new. Replace components when
ITEM
their measurements exceed values listed here.
INCHES
MM
NOTE
For measurements not given under SERVICE WEAR LIMITS,
Exhaust fit in guide
0.0038
0.0965
see NEW COMPONENTS.
Intake fit in guide
0.0038
0.0965
Seat Width
0.090
2.286
Table 3-21. Rocker Arms-883/1200 cc
Stem protrusion from
2.082
52.883
cylinder valve pocket
REPLACE IF WEAR EXCEEDS
ITEM
INCHES
MM
Table 3-26. Valve Springs-883/1200 cc
Shaft in bushing (loose)
0.0035
0.0889
End Clearance
0.025
0.635
REPLACE IF LESS THAN
INCHES
MM
Free length
2.325
59.1
Table 3-22. Rocker Arm Shafts-
883/1200 cc
REPLACE IF WEAR EXCEEDS
Table 3-27. Cylinders-883/1200 cc
ITEM
INCHES
MM
REPLACE IF WEAR
EXCEEDS
Shaft fit in rocker cover
0.0035
0.0889
ITEM
INCHES
MM
Taper
0.002
0.0508
Table 3-23. Tappets-883/1200 cc
Out of round
0.003
0.0762
REPLACE IF WEAR EXCEEDS
Top gasket surface warpage
0.006
0.152
ITEM
INCHES
MM
Base gasket surface warpage
0.008
0.203
Fit in guide
0.003
0.0762
Roller End Clearance
0.026
0.660
Table 3-28. Cylinder Bore-883 cc
BORE DIAMETER
REPLACE IF WEAR EXCEEDS
+ 0.0002 in.
Table 3-24. Cylinder Heads-883/1200 cc
(0.0051 mm)
INCHES
MM
REPLACE IF
Standard
3.0035
76.289
ITEM
INCHES
MM
0.005 O.S. (Oversize)
3.0078
76.398
0.010 O.S.
3.0128
76.525
Head gasket surface
More than
More than
(flatness)
0.006
0.152
0.020 O.S.
3.0228
76.779
3-4
2006 Sportster: Engine
HOME
Table 3-29. Cylinder Bore-1200 cc
Table 3-33. Gearcase-883/1200 cc
BORE DIAMETER
REPLACE IF WEAR EXCEEDS
REPLACE IF WEAR
+ 0.0002 in.
EXCEEDS
ITEM
(0.0051 mm)
INCHES
MM
INCHES
MM
Standard
3.5008
88.920
Cam gear shaft in bushing (loose)
0.003
0.0762
0.005 O.S. (Oversize)
3.505
89.027
Cam gear shaft end play
0.025
0.635
0.010 O.S.
3.510
89.154
(except rear intake) (min.)
0.020 O.S.
3.520
89.408
Rear intake cam gear shaft end
0.040
1.016
play (min.)
Table 3-30. Pistons-883/1200 cc
Table 3-34. Flywheels-883/1200 cc
REPLACE IF WEAR
EXCEEDS
ITEM
REPLACE IF WEAR
EXCEEDS
INCHES
MM
ITEM
INCHES
MM
Top and 2nd compression ring gap
0.032
0.813
Runout (flywheels at rim)
0.010
0.254
Oil control ring rail gap
0.065
1.651
Runout (shaft at flywheel end)
0.002
0.0508
Top compression ring
0.0065
0.165
side clearance
End play
0.010
0.254
2nd compression ring
0.0065
0.165
side clearance
Oil control ring side clearance
0.0094
0.239
Table 3-35. Pinion Shaft Bearing-
Piston fit (loose; room temperature)
0.0010
0.0254
883/1200 cc
REPLACE IF WEAR
EXCEEDS
ITEM
Table 3-31. Connecting Rods-883/1200 cc
INCHES
MM
REPLACE IF WEAR
Pinion shaft journal diameter
1.2494
31.735
EXCEEDS
ITEM
Outer race diameter in
1.5672
39.807
INCHES
MM
right crankcase
Piston pin fit (loose)
0.00200
0.0508
Fit in cover bushing (loose)
0.0050
0.127
Side play between flywheels
0.030
0.762
Fit on Crankpin
0.0027
0.0686
Table 3-32. Oil Pump-883/1200 cc
REPLACE IF WEAR
EXCEEDS
ITEM
INCHES
MM
Feed/scavenge inner/outer
0.004
0.102
gerotor clearance
2006 Sportster: Engine
3-5
HOME
TORQUE VALUES
3.3
ITEM
TORQUE
NOTES
Anti-rotation device mounting
80-110 in-lbs
9.0-12.4 Nm
page 3-101
screw
Breather screw
35-55 in-lbs
4.0-6.2 Nm
page 3-64
Crankcase fasteners
15-19 ft-lbs
20.3-25.8 Nm
LOCTITE 262, page 3-95
Cylinder head bolts
-
-
See text for specific tightening procedure, page 3-64
Cylinder head bracket screw
17-24 ft-lbs
23.1-32.6 Nm
page 3-66
Cylinder studs
120-240 in-lbs
13.6-27.1 Nm
install shoulder end down, page 3-97
Enrichener cable hex nut
20-35 in-lbs
2.3-4.0 Nm
page 3-66
Exhaust pipe clamp bracket
30-33 ft-lbs
40.7-44.8 Nm
page 3-28
screw
Flywheel pinion shaft nut
35-45 ft-lbs
47.5-61.1 Nm
page 3-99
Footrest bracket screw
45-50 ft-lbs
61.1-67.9 Nm
page 3-27
Front isolator mounting bracket
25-35 ft-lbs
33.9-47.5 Nm
page 3-26
screw
Front motor mount bolt
60-70 ft-lbs
81.4-95.0 Nm
page 3-26
Fuel tank mounting screw
15-20 ft-lbs
20.4-27.1 Nm
page 3-28
Gearcase cover screw
80-110 in-lbs
9.0-12.4 Nm
See text for tightening sequence, page 3-100
High pressure feed hose fitting
60-90 in-lbs
6.8-10.2 Nm
page 3-81
(to crankcase)
High pressure feed hose fitting
85-105 in-lbs
9.6-11.8 Nm
page 3-81
nut
Horn nut (XL 1200C)
35-45 in-lbs
4.0-5.1 Nm
page 3-66
ICM mounting lock nut
12-20 in-lbs
1.4-2.3 Nm
page 3-105
Inner rocker cover bolt, large
18-22 ft-lbs
24.4-29.8 Nm
page 3-64
Inner rocker cover bolt, small
135-155 in-lbs
15.3-17.5 Nm
page 3-64
Inner rocker cover screw
135-155 in-lbs
15.3-17.5 Nm
page 3-64
Lower front stabilizer link
25-35 ft-lbs
33.9-47.5 Nm
page 3-26
bracket screw
Oil filter adapter
96-144 in-lbs
10.9-16.3 Nm
page 3-82
Oil pressure indicator switch
50-70 in-lbs
5.6-7.9 Nm
page 3-82
Oil pump cover screw
70-80 in-lbs
7.9-9.0 Nm
page 3-81
Oil pump feed fitting
55-65 in-lbs
6.2-7.4 Nm
page 3-81
Oil pump-to-crankcase screw
125-150 in-lbs
14.1-16.9 Nm
page 3-81
Oil tank mounting fastener
36-60 in-lbs
4.1-6.8 Nm
page 3-105
Piston oil jet screw
25-35 in-lbs
2.8-4.0 Nm
page 3-92
Push rod cover retainer screw
80-110 in-lbs
9.0-12.4 Nm
page 3-61
Rear axle nut
72-78 ft-lbs
98-106 Nm
page 3-28
Rear brake hose clamp screw
30-40 in-lbs
3.4-4.5 Nm
page 3-27
Rear brake reservoir mounting
20-25 in-lbs
2.3-2.8 Nm
page 3-27
screw
3-6
2006 Sportster: Engine
HOME
ITEM
TORQUE
NOTES
Rear engine mount/swingarm
60-70 ft-lbs
81.4-95.0 Nm
page 3-26
bolt
Rear isolator mounting bracket
25-35 ft-lbs
33.9-47.5 Nm
page 3-26
screw
Rear stabilizer link screw
25-35 ft-lbs
33.9-47.5 Nm
page 3-26
Rear stop light switch bracket
72-120 in-lbs
8.1-13.6 Nm
page 3-27
screw
Sprocket cover screw
80-120 in-lbs
9.0-13.6 Nm
page 3-28
Stabilizer link engine bracket
55-65 ft-lbs
74.6-88.2 Nm
page 3-49
screw
Stabilizer link screw
25-35 ft-lbs
33.9-47.5 Nm
page 3-26
Upper front stabilizer link
25-35 ft-lbs
33.9-47.5 Nm
page 3-26
bracket-to-frame screw
Upper rocker cover screw
120-168 in-lbs
13.5-19.0 Nm
page 3-64
2006 Sportster: Engine
3-7
HOME
ENGINE
3.4
Ignition spark is produced by the operation of a microproces-
GENERAL
sor-controlled Ignition Control Module (ICM), ignition coil, and
spark plugs. Spark timing is determined primarily by crank-
The engine is a two-cylinder, four-cycle, air-cooled, overhead-
shaft rotation, triggering a magnetic sensing unit.
valve V-twin. It has three major component assemblies: cylin-
der, crankcase, and gear case.
Each spark plug fires independently at the end of that cylin-
der’s compression stroke, igniting the air/fuel mixture in the
The cylinder assembly includes cylinder head, valves, rocker
cylinder.
arm cover, rocker arms, and piston. Cylinders mount on the
crankcase in a 45 degree “V”, with both connecting rods con-
The engine has a force-feed (pressure) type oiling system,
nected to a single crank pin.
incorporating oil feed and return pumps in one pump body,
with one check valve on the oil feed side. The feed pump
The up-and-down motion of the piston in the cylinder is con-
forces oil to the engine, lubricating lower connecting rod bear-
verted to circular motion in the crankcase. The multi-piece
ings, rocker arm bushings, valve stems, valve springs, push
crankshaft consists of a crank pin mounted between two
rods, and tappets. Cylinder walls, pistons, piston pins, timing
counterweighted flywheels, which rotate on two end shaft
gears and bushings, and main bearings are lubricated by oil
bearings. The lower end of the rear cylinder connecting rod is
spray thrown off connecting rods and crankshaft, and by oil
forked to fit around the single-end front cylinder connecting
draining from each rocker box through an internal drain pas-
rod, allowing a single connecting rod crank pin connection to
sage in each cylinder and each tappet guide. Piston jets
the flywheel.
spray oil on the underside of the pistons to cool the piston
The gear case is located on the right side of the crankcase.
crown and skirt area.
The gear case houses the gear train which operates and
A small amount of oil is sprayed through an oil galley jet onto
times the valves and ignition. The cam gear train, consisting
the rear intake cam gear in the gear case; oil is transferred to
of four cam shafts with one cam lobe on each shaft, is gear
the teeth of all the cam gears by way of the gear meshing
driven. The engine valves are opened and closed through the
action. The oil-scavenging section of the pump returns oil to
mechanical linkage of tappets, push rods, and rocker arms.
the tank from the engine. See 3.6 ENGINE LUBRICATION
Hydraulic lifters, located in the tappets, automatically com-
SYSTEM later in this section for further information.
pensate for heat expansion to maintain the no-lash fit of valve
train components. Tappets serve to transmit the cam action to
the valve linkage. Valve timing is obtained by aligning timing
marks when installing cam gears.
3-8
2006 Sportster: Engine
HOME
TROUBLESHOOTING
3.5
DIAGNOSING VALVE TRAIN NOISE
COMPRESSION TEST
To diagnose and correct noisy hydraulic lifters and valve train
components, use the following procedures:
PART NO.
SPECIALTY TOOL
1.
With engine and oil at normal operating temperature,
check oil pressure at 2000 RPM. If oil pressure is above
HD-33223-1
Cylinder compression gauge
50 PSI (345 kN/m2) or below 5 PSI (34 kN/m2), inspect
oil pump, crankcase passages and oil hoses for restric-
Satisfactory engine performance depends upon a mechani-
tions or blockage. Repair or replace parts as necessary.
cally sound engine. In many cases, unsatisfactory perfor-
mance is caused by combustion chamber leakage. A
2.
If oil is reaching the hydraulic lifters, remove and inspect.
compression test can help determine the source of cylinder
See 3.19 VALVE TAPPETS. Clean lifter bore of all foreign
leakage. Use CYLINDER COMPRESSION GAUGE.
material. Replace hydraulic lifter if required.
3.
Examine pushrod, lifter and lifter block for proper fit and
A proper compression test should be performed with the
any signs of unusual wear. Replace parts as necessary.
engine at normal operating temperature when possible.
4.
Visually inspect camshaft lobes for abnormal wear.
Compression Test Procedure
5.
Remove camshafts and pinion gear, clean and inspect
for wear and fit. Measure pitch diameters and check for
out-of-round condition. Replace parts as necessary.
CAUTION
6.
Remove cylinder head and rocker box assemblies.
After completing the compression test(s), make sure that
Check rocker arm end play and check for binding.
the throttle plate is in the closed position before starting
Inspect valve stems for scuffing and check stem to guide
the engine. Starting engine with throttle open may result
clearance. Check valve seats for signs of looseness or
in serious engine damage.
shifting.
1. Disconnect spark plug wires. Clean around spark plug
7.
Reface valves and valve seats.
base and remove spark plugs.
2. Connect CYLINDER COMPRESSION GAUGE to front
cylinder per manufacturer’s instructions.
3. Make sure transmission is in neutral. With throttle plate
and slide in wide open position, crank engine continu-
ously through 5 to 7 full compression strokes.
4. Note gauge readings at the end of the first and last com-
pression strokes. Record test results.
2006 Sportster: Engine
3-9
HOME
5.
Connect CYLINDER COMPRESSION GAUGE to rear
CYLINDER LEAKAGE TEST
cylinder and repeat Steps 3 and 4.
● Compression is normal if final readings are within
the range specified in Table 3-36., and do not indi-
cate more than a
10 psi
(0.689 Bar) variance
PART NO.
SPECIALTY TOOL
between cylinders.
HD-35667-A
Cylinder leakdown tester
Table 3-36. Normal Compression Ranges
The cylinder leakage test pinpoints engine problems includ-
ing leaking valves, worn, broken or stuck piston rings and
COMPRESSION
blown head gaskets. The cylinder leakage tester applies com-
ENGINE
pressed air to the cylinder at a controlled pressure and vol-
PSI
BAR
ume and measures the percent of leakage from the cylinder.
883 cc
125-140
8.62-9.65
Use CYLINDER LEAKDOWN TESTER and follow the spe-
1200 cc
200-225
13.8-15.5
cific instructions supplied with the tester.
Cylinder Leakage Test Procedure
● If compression is below 100 PSI (6.89 Bar) for 883
cc engines or
150 PSI (10.3 Bar) for
1200 cc
engines, refer to Table 3-37.
CAUTION
After completing the cylinder leakage test(s), make sure
Table 3-37. Compression Test Results
that the throttle plate is in the closed position before
starting the engine. Starting engine with throttle open
DIAGNOSIS
TEST RESULTS
may result in serious engine damage.
Compression low on first stroke, tends
The following are some general instructions that apply to Har-
to build up on the following strokes, but
Ring trouble
ley-Davidson V-twin engines:
does not reach normal. Improves con-
1. Run engine until it reaches normal operating tempera-
siderably when oil is added to cylinder.
ture.
Compression low on first stroke, does
2. Stop engine. Clean dirt from around spark plugs and
not build up much on following strokes.
remove the spark plugs.
Valve trouble
Does not improve considerably with the
3. Remove the air cleaner and set the carburetor choke and
addition of oil. Check for correct push-
throttle in the wide open position.
rod length.
4. The piston in the cylinder being tested must be at top
Head gasket leak
Same reaction as valve trouble.
dead center of compression stroke (both valves closed)
during the test.
6.
Inject approximately 1/2 oz. (15 ml) SAE 30 engine oil
5. To keep the engine from turning over when air pressure
into each cylinder and repeat the compression tests on
is applied to the cylinder, engage transmission in fifth
both cylinders. Readings that are considerably higher
gear and lock the rear brake.
during the second test indicate worn piston rings.
NOTE
Before performing the cylinder leakage test, verify that the
tester itself is free from leakage to obtain the most accurate
test results. With a soap solution [applied around all tester fit-
tings], connect the cylinder leakdown tester to the com-
pressed air source and look for any bubbles that would
indicate leakage from the tester.
6. Following the manufacturer's instructions, perform a cyl-
inder leakage test on the front cylinder. Make a note of
the percent of leakage. Leakage greater than 12% indi-
cates internal engine problems.
7. Listen for air leaks at carburetor intake, exhaust pipe and
head gasket. Air escaping through the carburetor indi-
cates a leaking intake valve. Air escaping through the
exhaust pipe indicates a leaking exhaust valve.
NOTE
If air is escaping through valves, check push rod length.
8. Repeat procedure on rear cylinder.
3-10
2006 Sportster: Engine
HOME
DIAGNOSING SMOKING ENGINE OR
ADJUSTMENT/TESTING
HIGH OIL CONSUMPTION
General
Perform COMPRESSION TEST or CYLINDER LEAKAGE
TEST as described previously. If further testing is needed,
When an engine needs repair, it is not always possible to
remove suspect head(s) and inspect for the following:
determine definitely beforehand whether repair is possible
with only cylinder heads, cylinders, and pistons disassem-
Check Prior To Cylinder Head Removal
bled, or whether complete engine disassembly is required for
crankcase repair.
1.
Oil tank overfilled.
Most commonly, only cylinder head and cylinder repair is
2.
Oil carryover.
needed (valves, rings, piston, etc.), and it is recommended
3.
Breather hose restricted.
procedure to service these units first, allowing engine crank-
4.
Restricted oil filter.
case to remain in frame.
Follow the procedure outlined in STRIPPING MOTORCYCLE
Check After Cylinder Head Removal
FOR TOP END REPAIR under 3.14 TOP END OVERHAUL:
1.
Oil return passages for clogging.
DISASSEMBLY, to strip motorcycle for removal of cylinder
2.
Valve guide seals.
heads, cylinders, and pistons.
3.
Valve guide to valve stem clearance.
After disassembling “upper end” only, it may be found that
crankcase repair is necessary; this requires removal of
4.
Gasket surface of both head and cylinder.
engine crankcase from chassis outlined in 3.12 REMOVING
5.
Cylinder head casting’s porosity allowing oil to drain into
ENGINE FROM CHASSIS.
combustion chamber.
6.
O-ring damaged or missing
from oil pump/crankcase
CAUTION
junction.
If engine is removed from chassis, do not lay engine on
primary side. Laying engine on primary side will damage
the clutch cable end fitting.
Symptoms indicating a need for engine repair are often mis-
leading; but generally, if more than one symptom is present,
possible causes can be narrowed down to make at least a
partial diagnosis. An above-normal consumption of oil, for
example, could be caused by several mechanical faults. See
1.31 TROUBLESHOOTING. However, when accompanied by
blue-gray exhaust smoke and low engine compression, it indi-
cates the piston rings need replacing. Low compression by
itself, however, may indicate improperly seated valves, in
addition to or in lieu of worn piston rings.
Piston slap is a condition where piston and/or cylinder are
worn out-of-round and are loose fitting, allowing the piston to
slap from front to rear of the cylinder as it moves up and
down.
Most frequently, valves, rings, pins, bushings, and bearings
need attention at about the same time. If the possible causes
can be narrowed down through the process of elimination to
indicate any one of the above components is worn, it is best
to give attention to all of the cylinder head and cylinder parts.
2006 Sportster: Engine
3-11
HOME
ENGINE LUBRICATION SYSTEM
3.6
14. Feed oil to the rocker area is returned to the gearcase
GENERAL
through a passage in the head, cylinder and crankcase.
15. Oil collected in the sump is splash-fed to the pistons, cyl-
NOTE
inder walls and flywheel components.
The following paragraph numbers correspond with the num-
16. Oil collected in the sump area returns to the scavenge
bered callouts in the Lubrication Diagram foldout.
section of the oil pump through a passage located in the
1.
Oil is gravity-fed from the oil tank to the gerotor-style oil
rear section of the sump. Oil flow to the pump is accom-
pump through a feed hose. Oil enters the feed section
plished by the scavenging effect of the pump and by the
and fills a cavity located under the feed pump.
pressure created by the downward stroke of the pistons.
NOTE
17. Return oil fills a cavity above the pump's return gears.
A complete explanation of the gerotor pump is given under
The return gears pump oil back to the oil tank.
OIL PUMP, which follows.
18. A small amount of oil flows from the feed galley in the
right crankcase through a restricted orifice, which
2.
The feed pump transfers oil from the inlet cavity through
sprays the oil onto the rear intake cam gear in the gear-
the feed hose to the oil filter mount.
case. Oil is transferred to the teeth of all the cam gears
3.
Oil flows through the filter mount cavity to the oil filter.
through the gear meshing action.
4.
Oil enters the peripheral cavity of the oil filter, passes
through the filtering medium into the central cavity of the
OIL PUMP
oil filter, and flows into the filter adapter (fitting which
connects filter to filter mount).
See Figure 3-1. The oil pump consists of two gerotor gear
5.
Adequate oil pressure in the filter mount cavity activates
sets, feed and scavenge (return), housed in one pump body.
the oil pressure indicator lamp switch and shuts off
The feed pump distributes oil to the engine, the scavenge
the oil pressure indicator lamp.
pump returns oil to the tank.
6.
Oil flowing from the filter adapter opens the check ball.
A gerotor-type gear set has two parts — an inner and an
The check ball opens at 4-6 psi (28-41 kN/m2) oil pres-
outer gerotor. The inner gerotor has one less tooth than the
sure.
outer gerotor. Both gerotors have fixed centers which are off-
7.
With the check ball open, oil flows into the crankcase
set to each other.
feed galley.
In a gerotor gear set, oil is transferred from inlet to outlet as it
8.
Oil flows through the feed galley in the crankcase to the
is trapped between the rotating inner and outer gerotors. The
tappet blocks and hydraulic lifters. Cross-drilled pas-
illustration shows the principle of gerotor operation:
sages intersect the main feed galley and carry oil to
each hydraulic lifter. From this cavity, oil is also fed to the
● During the first
180 degrees of rotation, the cavity
piston jets.
between inner and outer gerotors gradually increases in
size until it reaches its maximum size, equivalent to the
9.
Oil also enters an intersecting passage in the gearcase
full volume of the “missing tooth.” The gradually enlarging
cover. Oil flow is then routed to the crankshaft area.
cavity creates a vacuum into which oil flows from the
10.
Oil enters a hole in the end of the pinion gear shaft and
inlet.
travels to the right flywheel where it is routed through the
flywheel to the crank pin. Oil is forced through the crank
● During the next 180 degrees of rotation, the size of the
pin to properly lubricate the rod bearing assembly.
cavity decreases forcing oil into the outlet. See Figure 3-
2. Gravity-fed oil from the oil tank enters the pump
11.
Oil flows up passages in the push rods to the rocker arm
through fitting (5). It is forced by gerotor set (6) through a
shafts and bushings.
hose to the oil filter.
12.
The valve stems are lubricated by oil supplied through
Return oil from the flywheel compartment is drawn back
drilled oil holes in the rocker arms.
into the pump. Returning oil from the gearcase compart-
13.
Oil collected in the push rod areas of the cylinder heads
ment drains directly into the pump and is forced by gero-
flows down the push rod covers, through drain holes in
tor set (8) back to the oil tank.
the tappet blocks and into the gearcase. After providing
See Lubrication Diagram foldout for oil passages within the
lubrication to the gearcase components the oil flows to
engine.
the return side of the oil pump.
3-12
2006 Sportster: Engine
RETURN OIL
FEED OIL
RETURN OIL
FEED OIL
Lubrication Diagram
HOME
x0517x3x
x0160x3x
Outer
gerotor
Inner gerotor
15
14
12
Oil drawn
into cavity
between teeth
13
11
10
9
8
7
6
Oil
forced out
1
5
3
4
2
1.
Cover, oil pump
2.
Screw, w/washer (2)
3.
Screw, Torx (2)
4.
Connector
5.
Hose fitting
6.
Gerotor assy, feed
7.
Gerotor separator plate
Oil inlet
8.
Gerotor assy, scavenge
9.
Retaining ring
10. Washer, thrust
Oil outlet
11. O-ring
12. Body, oil pump
13. Elbow fitting
Trapped oil
14. Gear shaft
15. Gasket
Figure 3-1. Principle of Gerotor Operation
Figure 3-2. Oil Pump
2006 Sportster: Engine
3-13
HOME
OIL PRESSURE
3.7
NOTE
GENERAL
If the ignition is turned back on immediately after the engine
is stopped, the oil pressure indicator lamp may not turn on
The oil pump is non regulatory and delivers its entire volume
right away because of oil pressure retained in the filter hous-
of oil under pressure to the oil filter mount. When an engine is
ing.
cold, the engine oil will be more viscous (i.e., thicker). During
start-up of a cold engine, oil pressure will be higher than nor-
mal and oil circulation will be somewhat restricted within the
oiling system. As the engine warms to normal operating tem-
Table 3-38. Oil Lamp Troubleshooting
perature, the engine oil will warm up and become less vis-
cous — oil pressure decreases.
OIL
PRESSURE
When an engine is operated at high speeds, the volume of oil
PROBABLE CAUSES
INDICATOR
circulated through the oiling system increases, resulting in
LAMP
higher oil pressure. As engine speed is reduced, the volume
of oil pumped is also reduced, resulting in lower oil pressure.
Stays on at
●
Empty oil tank.
speeds above
●
Clogged feed line (ice and sludge,
Oil Pressure Indicator Lamp
idle.
freezing temperatures).
See Figure 3-3. The red OIL PRESSURE indicator lamp illu-
●
Air-bound oil line.
minates to indicate improper circulation of the engine oil.
●
Grounded oil pressure switch wire.
Refer to Table 3-38. The oil pressure indicator lamp turns ON
●
Malfunctioning oil pressure switch.
when:
●
Diluted oil.
● Ignition switch is turned on prior to starting engine.
●
Malfunctioning check valve
(see
● Oil is not circulating through the running engine.
3.22 OIL FILTER MOUNT).
● Oil pressure is abnormally low on the running engine.
Flickers at idle.
●
Incorrect idle speed. Malfunction-
ing or improperly installed check
● Engine is idling far below 1000 RPM.
valve
(see
3.22 OIL FILTER
The oil pressure indicator lamp turns OFF when oil is circulat-
MOUNT).
ing with adequate pressure through the engine running at
1000 RPM or greater.
Does not glow
●
Malfunctioning signal switch.
when ignition
●
Malfunction in wiring.
is turned on
●
Burned-out signal bulb.
(prior to oper-
d0414x3x
●
Dead battery.
ating engine).
●
See NOTE above this table.
CHECKING OIL PRESSURE
PART NO.
SPECIALTY TOOL
Figure 3-3. Oil Pressure Indicator Lamp
HD-96921-52B
Oil pressure gauge set
CAUTION
HD-41675
Oil pressure sending unit wrench
If the oil pressure indicator lamp remains lit, always
Check operating oil pressure as follows:
check the oil supply first. If the oil supply is normal and
1. Fill oil tank to proper level. See 1.5 ENGINE OIL AND
the lamp is still lit, stop the engine at once and do not
FILTER.
ride further until the trouble is located and the necessary
2. Place a container under vehicle to catch any oil that may
repairs are made. Failure to do so may result in engine
leak out when oil pressure switch is removed.
damage. (00157a)
3-14
2006 Sportster: Engine
HOME
3.
See Figure 3-4. Unplug connector (3) from oil pressure
11353
indicator lamp switch (2) located under oil filter (1) by
pulling elbow connector straight down from stud on oil
pressure switch. Using OIL PRESSURE SENDING UNIT
WRENCH, unscrew and remove oil pressure switch from
2
crankcase.
4.
See Figure
3-5. Install OIL PRESSURE GAUGE
1
ADAPTER (Part No. HD-96925-58) (2) in oil pressure
indicator lamp switch mounting hole. Tighten adapter
snugly. DO NOT OVERTIGHTEN.
5.
Assemble banjo bolt (3), washer (4), OIL PRESSURE
3
GAUGE (1) banjo fitting and second washer onto
adapter and tighten snugly. See Figure 3-6.
6.
Temporarily secure oil pressure gauge and hose to
1.
Oil filter
motorcycle frame with cable straps. Make sure gauge
2.
Oil pressure indicator lamp switch
and hose assembly do not interfere with normal opera-
3.
Oil pressure switch connector [120]
tion of the vehicle. Start engine and ride motorcycle at
least 20 miles (32 km) at or above 50 mph (80 km/h) to
Figure 3-4. Oil Pressure Indicator Lamp Switch
allow engine to reach operating temperature.
NOTE
Engine oil should be at normal operating temperature (230°F/
x0520x3x
110°C) for an accurate reading.
a. At 2500 RPM, oil pressure will vary from 10-17 psi
(69-117 kN/m2).
b. At idle speed (950-1050 RPM), oil pressure will vary
from 7-12 psi (48-83 kN/m2).
1
7.
Stop engine. Remove OIL PRESSURE GAUGE assem-
bly from oil pressure indicator lamp switch mounting hole
in crankcase. Cut cable straps that you installed in step
3
2
6. above, and remove banjo bolt, gauge assembly, wash-
4
ers and adapter from vehicle.
1.
Gauge
8.
See Figure 3-4. Coat threads of oil pressure switch (2)
2.
Adapter
with LOCTITE 565 HIGH PERFORMANCE PIPE SEAL-
3.
Banjo bolt
ANT with TEFLON. Reinstall oil pressure switch. Using
4.
Washers (2)
OIL PRESSURE SENDING UNIT WRENCH, tighten
switch snugly. DO NOT OVERTIGHTEN.
Figure 3-5. Oil Pressure Gauge Set
9.
Plug in connector
(3) by pushing elbow connector
(Part No. HD-96921-52B)
straight up onto stud on oil pressure switch.
NOTE
If an appreciable amount of oil leaked out when oil pressure
11364
switch was removed, it will have to be replaced with fresh oil.
3
10. Check oil level in oil tank. See 1.5 ENGINE OIL AND FIL-
TER. Top off oil level if necessary.
11. Start engine and test oil pressure switch for proper oper-
4
2
ation. Check oil pressure switch for leaks.
1
5
1.
Banjo bolt
2.
Oil pressure gauge banjo fitting
3.
Adapter
4.
Washer (2)
5.
Oil pressure gauge hose
Figure 3-6. Checking Oil Pressure
2006 Sportster: Engine
3-15
HOME
CRANKCASE BREATHING SYSTEM
3.8
The crankcase air is routed through a passage in each cylin-
GENERAL
der head. The crankcase air then travels through each air
cleaner backing plate mounting bolt (3) into the filtered side of
See Figure 3-7. On the piston downstroke, a mixture of crank-
the air cleaner.
case air and oil mist is vented up the push rod covers (1)
through a breather valve (2) in each inner rocker box section.
The oil mist separates from the crankcase air, collects and
passes through a small drain hole adjacent to the exhaust
valve in the head where it eventually returns to the crankcase.
x0563x3x
2
1
3
1.
Push rod cover (2)
2.
Breather valve
3.
Bolt, air cleaner backing plate mounting
Figure 3-7. Crankcase Breathing System - Typical Cylinder
3-16
2006 Sportster: Engine
HOME
HOW TO USE THIS SECTION
3.9
TYPICAL SYMPTOMS
TOP END REPAIR
Symptoms indicating a need for engine repair are often mis-
NOTE
leading, but generally if more than one symptom is present,
During top end disassembly, the engine may be left in the
possible causes can be narrowed down to make at least a
chassis for service.
partial diagnosis. An above normal consumption of oil, for
example, could be caused by several mechanical faults (see
If servicing only cylinder head components, pistons, cylinders
1.31 TROUBLESHOOTING). But when accompanied by a
and/or upper rod bushings, see 3.10 TOP END SERVICE.
blue-gray smoke from the exhaust, and when low compres-
Two options are available depending upon engine status.
sion is present, it indicates the rings need replacing. Low
● ENGINE IN CHASSIS on page 3-18.
compression by itself, however, indicates improperly seated
valves, not worn rings.
● ENGINE REMOVED FROM CHASSIS on page 3-19.
Certain knocking noises may be caused by loose bearings,
others by piston slap, a condition where piston or cylinder or
BOTTOM END REPAIR
both out of tolerance, allowing the piston to slap from front to
rear of the cylinder as it moves up and down.
NOTE
Most frequently, valves, rings, pins, bushings, and bearings
Servicing components in the cam compartment requires only
need attention at about the same time. If the symptoms can
partial disassembly. This can be done with the engine left in
be narrowed down through the process of elimination to indi-
the chassis.
cate that any one of the above components is worn, it is best
After disassembling as far as the cylinder heads you may find
to give attention to all of the cylinder head and cylinder parts.
that bottom end repair is necessary. Bottom end service may
require either partial or complete disassembly of the engine.
● To service the cam compartment, see ENGINE IN
CHASSIS: CAM COMPARTMENT SERVICE on page 3-
20.
● To service components in the flywheel compartment, the
engine must be removed and the crankcase halves split.
See ENGINE REMOVED: FLYWHEEL COMPARTMENT
SERVICE OR COMPLETE ENGINE OVERHAUL on
page 3-21.
2006 Sportster: Engine
3-17
HOME
TOP END SERVICE
3.10
ENGINE IN CHASSIS
Remove parts necessary to gain access to all
components above cylinder deck. See STRIPPING
When this step is completed during top
MOTORCYCLE FOR TOP END REPAIR under
end service, you may advance to 3.17
3.14 TOP END OVERHAUL: DISASSEMBLY.
*
TOP END OVERHAUL: ASSEMBLY if no
other work is to be done.
Continue with 3.14 TOP END OVERHAUL:
DISASSEMBLY. Remove/repair subassembly
components only if necessary.
Remove rocker arm outer covers. See Disassembling
Inspect and repair as necessary.
Rocker Covers under 3.14 TOP END OVERHAUL:
See 3.8 CRANKCASE BREATHING
DISASSEMBLY. Remove crankcase breathers. See
SYSTEM.
3.8 CRANKCASE BREATHING SYSTEM.
Remove cylinder heads. See Removing
Inspect and repair as necessary.
Cylinder Head under 3.14 TOP END
See 3.15 CYLINDER HEAD.
OVERHAUL: DISASSEMBLY
Remove push rods, push rod covers and
tappet covers. See page 3-33. Remove
Inspect and repair as necessary.
tappets. See TAPPETS under 3.18 BOTTOM
See 3.19 VALVE TAPPETS.
END OVERHAUL: DISASSEMBLY.
Remove cylinders and pistons.
Inspect and repair as necessary.
See CYLINDER AND PISTON
See 3.16 CYLINDER AND PISTON.
under 3.14 TOP END OVER-
HAUL: DISASSEMBLY.
Inspect upper connecting rod and repair as necessary.
See CONNECTING ROD BUSHINGS
under 3.16 CYLINDER AND PISTON
Complete all appropriate steps under
3.17 TOP END OVERHAUL: ASSEMBLY.
Complete motorcycle assembly. See ASSEM-
BLING MOTORCYCLE AFTER TOP END
REPAIR under 3.17 TOP END OVERHAUL:
ASSEMBLY.
3-18
2006 Sportster: Engine
HOME
ENGINE REMOVED FROM CHASSIS
Remove engine from motorcycle. See
When this step is completed during top
3.12 REMOVING ENGINE FROM CHASSIS.
end service, you may advance to 3.17
*
TOP END OVERHAUL: ASSEMBLY if no
other work is to be done.
Start 3.14 TOP END OVERHAUL: DISASSEMBLY.
Remove and repair subassembly components as necessary.
Remove rocker arm outer covers. See Disassembling
Inspect and repair as necessary.
Rocker Covers under 3.14 TOP END OVERHAUL:
See 3.8 CRANKCASE BREATHING
DISASSEMBLY. Remove crankcase breathers. See
SYSTEM.
3.8 CRANKCASE BREATHING SYSTEM.
Remove cylinder heads. See Removing
Inspect and repair as necessary.
Cylinder Head under 3.14 TOP END
See 3.15 CYLINDER HEAD.
OVERHAUL: DISASSEMBLY
Remove push rods, push rod covers and
tappet covers. See page 3-33. Remove
Inspect and repair as necessary.
tappets. See TAPPETS under 3.18 BOTTOM
See 3.19 VALVE TAPPETS.
END OVERHAUL: DISASSEMBLY.
Remove cylinders and pistons.
Inspect and repair as necessary.
See CYLINDER AND PISTON
See 3.16 CYLINDER AND PISTON.
under 3.14 TOP END OVER-
HAUL: DISASSEMBLY.
Inspect upper connecting rod and repair as necessary.
See CONNECTING ROD BUSHINGS
under 3.16 CYLINDER AND PISTON
Complete all appropriate steps under
3.17 TOP END OVERHAUL: ASSEMBLY.
Install engine in motorcycle.
Complete all appropriate steps under
3.13 INSTALLING ENGINE IN CHASSIS.
Complete motorcycle assembly. See ASSEM-
BLING MOTORCYCLE AFTER TOP END
REPAIR under 3.17 TOP END OVERHAUL:
ASSEMBLY.
2006 Sportster: Engine
3-19
HOME
BOTTOM END SERVICE
3.11
ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE
Remove parts necessary to gain access to all
components above cylinder deck. See STRIPPING
When this step is completed during bottom
MOTORCYCLE FOR TOP END REPAIR under
3.14 TOP END OVERHAUL: DISASSEMBLY.
end service, you may advance to 3.24 BOT-
*
TOM END OVERHAUL: ASSEMBLY if no
other work is to be done.
Continue with 3.14 TOP END OVERHAUL:
DISASSEMBLY. Remove/repair subassembly
components only if necessary.
Remove rocker arm outer covers. See Disassembling
Inspect and repair as necessary.
Rocker Covers under 3.14 TOP END OVERHAUL:
See 3.8 CRANKCASE BREATHING
DISASSEMBLY. Remove crankcase breathers. See
SYSTEM.
3.8 CRANKCASE BREATHING SYSTEM.
Remove push rods, push rod covers and
tappet covers. See page 3-33. Remove
Inspect and repair as necessary.
tappets. See TAPPETS under 3.18 BOTTOM
See 3.19 VALVE TAPPETS.
END OVERHAUL: DISASSEMBLY.
Continue with 3.18 BOTTOM END OVERHAUL: DISASSEMBLY.
Remove gearcase cover and cam gears. See 3.20
Inspect and repair as necessary. See 3.20
GEARCASE COVER AND CAM GEARS.
GEARCASE COVER AND CAM GEARS.
*
Inspect and repair as necessary.
Remove oil pump. See 3.21 OIL PUMP.
See 3.21 OIL PUMP.
Complete all appropriate steps under
3.24 BOTTOM END OVERHAUL: ASSEMBLY.
Complete motorcycle assembly.
See ASSEMBLING MOTORCYCLE AFTER
TOP END REPAIR under 3.17 TOP END
OVERHAUL: ASSEMBLY.
3-20
2006 Sportster: Engine
HOME
ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR
COMPLETE ENGINE OVERHAUL
Remove engine from motorcycle. See
3.12 REMOVING ENGINE FROM CHASSIS.
Start 3.14 TOP END OVERHAUL: DISASSEMBLY.
Remove and repair subassembly components as necessary.
Remove rocker arm outer covers. See Disassembling
Inspect and repair as necessary.
Rocker Covers under 3.14 TOP END OVERHAUL:
See 3.8 CRANKCASE BREATHING
DISASSEMBLY. Remove crankcase breathers. See
SYSTEM.
3.8 CRANKCASE BREATHING SYSTEM.
Remove cylinder heads. See Removing
Inspect and repair as necessary.
Cylinder Head under 3.14 TOP END
See 3.15 CYLINDER HEAD.
OVERHAUL: DISASSEMBLY
Remove push rods, push rod covers and
Inspect and repair as necessary.
tappet covers. See page 3-33. Remove
See 3.19 VALVE TAPPETS.
tappets. See TAPPETS under 3.18 BOTTOM
END OVERHAUL: DISASSEMBLY.
Remove cylinders and pistons.
See CYLINDER AND PISTON
Inspect and repair as necessary.
under 3.14 TOP END OVER-
See 3.16 CYLINDER AND PISTON.
HAUL: DISASSEMBLY.
Inspect upper connecting rod and repair as necessary.
See CONNECTING ROD BUSHINGS
Continue with 3.18 BOTTOM END OVERHAUL: DISASSEMBLY.
under 3.16 CYLINDER AND PISTON
Remove and repair subassembly components as necessary
Remove gearcase cover and cam gears. See 3.20
Inspect and repair as necessary. See 3.20
GEARCASE COVER AND CAM GEARS.
GEARCASE COVER AND CAM GEARS.
Inspect and repair as necessary.
Remove oil pump. See 3.21 OIL PUMP.
See 3.21 OIL PUMP.
Complete all appropriate steps under
Inspect and repair as necessary.
3.18 BOTTOM END OVERHAUL: DISASSEM-
See 3.23 CRANKCASE.
BLY, CRANKCASE, to split crankcases and
remove flywheel assembly, piston jets, etc.
Inspect and repair transmission assembly as necessary.
See 6.9 TRANSMISSION REMOVAL AND DISASSEMBLY,
6.10 TRANSMISSION ASSEMBLY, 6.14 TRANSMISSION
Complete all appropriate steps under
INSTALLATION and related subjects in Chapter 6.
3.24 BOTTOM END OVERHAUL: ASSEMBLY.
Complete all appropriate steps under
3.17 TOP END OVERHAUL: ASSEMBLY.
Install engine in motorcycle.
Complete all appropriate steps under
3.13 INSTALLING ENGINE IN CHASSIS.
Complete motorcycle assembly.
See ASSEMBLING MOTORCYCLE AFTER
TOP END REPAIR under 3.17 TOP END
OVERHAUL: ASSEMBLY.
2006 Sportster: Engine
3-21
HOME
REMOVING ENGINE FROM CHASSIS
3.12
8. Remove screw, washer and exhaust pipe clamp bracket
GENERAL
from sprocket cover. Remove two screws securing
sprocket cover to engine case. Remove sprocket cover.
If it becomes necessary to remove the engine from the motor-
cycle, follow the step-by-step procedure below. It is important
9. Remove transmission sprocket. See 6.15 TRANSMIS-
to follow the procedure as outlined, particularly in the areas of
SION SPROCKET.
stabilizer link and engine mount disassembly.
10. Remove exhaust system interconnect. See
2.27
EXHAUST SYSTEM.
11. Remove oil tank feed and return lines at oil tank. See
PROCEDURE
3.25 OIL TANK.
1WARNING
PART NO.
SPECIALTY TOOL
Stop the engine when refueling or servicing the fuel sys-
HD-46284
Engine hook
tem. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
HD-45968
Fat jack
explosive, which could result in death or serious injury.
HD-45967
Shop dolly
(00002a)
12.
Drain and remove fuel tank. See 4.8 FUEL TANK.
1.
Remove seat. See 2.32 SEAT.
13.
Disconnect the following electrical connectors from the
2.
Remove left side cover. No tools are required. See 1.6
engine:
LEFT SIDE COVER.
a. Spark plug wires (2),
b. Ignition coil connector
[83]. See
7.10 IGNITION
1WARNING
COIL.
Prevent accidental vehicle start-up, which could cause
c. Neutral indicator switch connector [136]. See 7.36
death or serious injury. First disconnect negative (-) bat-
NEUTRAL INDICATOR SWITCH.
tery cable at engine and then positive (+) cable from bat-
d. Manifold absolute pressure (MAP) sensor connector
tery. (00280a)
[80]. See 7.6 MANIFOLD ABSOLUTE PRESSURE
3.
Disconnect negative (-) battery cable from ground stud
SENSOR (MAP).
on crankcase. Disconnect positive (+) battery cables at
e. Alternator AC connector [46]. See 7.13 VOLTAGE
battery. See BATTERY DISCONNECTION AND
REGULATOR.
REMOVAL under 1.7 BATTERY MAINTENANCE.
f.
Voltage regulator DC connector
[77]. See
7.13
NOTE
VOLTAGE REGULATOR.
It is not necessary to remove battery or battery tray when
g. oil pressure switch connector [120]. See 7.33 OIL
removing engine from chassis.
PRESSURE SWITCH.
4.
Drain primary chaincase/transmission fluid. See DRAIN-
h. Crank position (CKP) sensor connector [79]. See
ING LUBRICANT under 1.14 TRANSMISSION LUBRI-
7.34 CRANK POSITION SENSOR (CKP).
CANT.
i.
Vehicle speed sensor (VSS) connector [65]. See
5.
Drain oil tank. See Draining Oil Tank under 1.5 ENGINE
7.35 VEHICLE SPEED SENSOR (VSS).
OIL AND FILTER. Disconnect oil drain hose from oil tank
j.
Ground wires (2) at powertrain ground stud on
and remove hose from vehicle.
crankcase,
6.
Remove exhaust pipes and mufflers. See
2.27
k. Starter relay wire
(GN) at starter motor. See 5.4
EXHAUST SYSTEM.
STARTER MOTOR.
7.
Remove right front footrest assembly and rear brake link-
14.
Disconnect clutch cable and remove from clutch lever on
age. XL 883, XL 883L, XL 883R and XL 1200R models,
left handlebar. See 2.26 CLUTCH CONTROL.
see RIGHT FOOTREST AND REAR BRAKE PEDAL
15.
Remove ignition coil and bracket assembly from frame.
ASSEMBLY under 2.33 RIDER FOOT CONTROLS: XL
883, XL 883L, XL 883R, XL 1200R. XL 883C and XL
1200C models, see RIGHT FOOTREST AND REAR
BRAKE PEDAL ASSEMBLY under 2.34 RIDER FOOT
CONTROLS: XL 883C, XL 1200C.
3-22
2006 Sportster: Engine
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