Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 15
HOME
16.
Disconnect the following harness connectors located
x0594a2x
under the top frame tube:
a. Front turn signal connector [31].
b. Left hand control connector (gray) [24].
c. Right hand control connector (black) [22].
d. Headlamp connector [38].
e. Instruments connector [20].
17.
All models except XL 1200C: disconnect horn connec-
tors and remove horn. See 7.24 HORN.
18.
XL 1200C models: remove wiring harness connectors
from horn. See 7.24 HORN.
19.
Remove harness connector bracket from under top
frame tube and move harnesses back out of the way.
20.
Loosen enrichener knob mounting nut and remove cylin-
der head bracket. See 4.5 CARBURETOR.
21.
Remove air cleaner cover, air filter and air cleaner back-
1
ing plate. See 4.6 AIR CLEANER. California models:
remove additional EVAP hoses. See 4.9 EVAPORATIVE
5
EMISSIONS CONTROL-CA MODELS.
4
22.
Remove carburetor. See 4.5 CARBURETOR. Secure
2
carburetor and throttle cables out of the way.
3
23.
California models: remove EVAP canister and discon-
1.
Stabilizer link
nect hoses. See 4.9 EVAPORATIVE EMISSIONS CON-
2.
Grounding strap
TROL-CA MODELS.
3.
Screw
24.
See Figure 3-8. Remove screws (3, 4), grounding strap
4.
Screw
(2), stabilizer link (1) and spacer (5).
5.
Spacer
25.
See Figure 3-9. Remove upper front stabilizer link and
mounting bracket:
Figure 3-8. Rear Stabilizer Link Assembly
a. Remove screw (4) securing stabilizer link
(2) to
engine bracket (1).
NOTE
b. Remove screws (5), washers (8) and frame bracket
When unbolting rear brake master cylinder reservoir and
(3) with stabilizer link.
securing it out of the way in the next step, make sure to keep
the reservoir upright. If the reservoir is allowed to hang
26.
Remove lower front stabilizer link and mounting bracket:
upside down, air bubbles could be introduced into the rear
a. Remove screw (11) securing stabilizer link (9) to
master cylinder via the feed hose. If this happens, the rear
engine crankcase boss.
brake must be bled to remove all air from the hydraulic brake
b. Remove screws
(12), washers
(13) and frame
system. See 1.9 BLEEDING HYDRAULIC BRAKE SYSTEM.
bracket (10) with stabilizer link.
29. Unbolt rear brake master cylinder remote reservoir. Do
27.
Remove left front footrest assembly. Custom models:
not disconnect hose from reservoir. See 2.13 REAR
remove shift linkage. XL 883, XL 883L, XL 883R and XL
BRAKE MASTER CYLINDER RESERVOIR. Secure res-
1200R models, see LEFT FOOTREST AND SHIFT
ervoir upright, out of the way.
LEVER ASSEMBLY under 2.33 RIDER FOOT CON-
TROLS: XL 883, XL 883L, XL 883R, XL 1200R. XL 883C
30. Unbolt rear stop lamp switch from frame. Disconnect rear
and XL 1200C models, see LEFT FOOTREST AND
stop lamp switch connectors
[121]. See
7.20 REAR
SHIFT LEVER ASSEMBLY under 2.34 RIDER FOOT
STOP LAMP SWITCH. Carefully pull rear stop lamp
CONTROLS: XL 883C, XL 1200C.
switch and brake lines out of the way. Be careful not to
28.
XL 883C, XL 1200C, XL 883R and XL 1200R models:
bend or kink metal brake lines.
remove left and right passenger footrest and mounting
bracket assemblies. See
2.35 PASSENGER FOOT-
RESTS.
2006 Sportster: Engine
3-23
HOME
x0592a2x
x0593a2x
12
11
4
2
3
4
13
8
10
9
5
7
6
1
Upper front stabilizer link assembly
Lower front stabilizer link assembly
1.
Engine bracket
8.
Washer (2)
2.
Upper stabilizer link
9.
Lower stabilizer link
3.
Upper stabilizer link bracket
10. Lower stabilizer link bracket
4.
Screw
11. Screw (2)
5.
Screw (2)
12. Screw (2)
6.
Screw (2)
13. Washer (2)
7.
Lock washer (2)
Figure 3-9. Front Stabilizer Link Assemblies
31. Locate wiring harness section that connects main har-
36. Attach ENGINE HOOK and engine hoist. Carefully raise
ness to crank position sensor, neutral switch and voltage
engine enough to relieve pressure from mounting bolts.
regulator. This wiring harness runs along both bottom
37. See Figure 3-10. Remove front engine mount bolt (3)
frame rails under engine. Remove wiring harness from
and nut (4).
fasteners securing it to frame and pull harness back out
38. See Figure 3-11. Remove two rear engine mount/swing-
of the way.
arm bolts (1). Pull rear fork back until fork pivot bosses
32. See Figure 3-10. Loosen, but do not remove, two front
clear the frame.
isolator mounting bracket screws
(5) on left side of
39. Remove oil tank vent line from oil tank. See 3.25 OIL
engine.
TANK.
33. See Figure 3-11. Loosen, but do not remove, two rear
40. Remove screws (7) and rear isolator mounting bracket
isolator mounting bracket screws
(7) on left side of
(2) from frame.
engine.
41. Lift engine as necessary and swing assembly out from
34. With the aid of a FAT JACK, support motorcycle on
chassis toward the left side.
SHOP DOLLY.
35. Loosen rear axle and remove rear drive belt. Move rear
NOTE
axle all the way forward and tighten axle nut enough to
Swing rear of engine out first. Then remove engine from
hold the axle and wheel in position in the rear fork. See
chassis.
REMOVAL under 6.6 SECONDARY DRIVE BELT.
3-24
2006 Sportster: Engine
HOME
x0595a2x
1
3
1
5
1.
Isolator (2)
4
2
2.
Front isolator mount
3.
Bolt
4.
Nut
5.
Screw (2)
Figure 3-10. Front Engine Mount/Isolator Assembly
x0596b2x
1
1
2
7
6
3
5
4
1.
Bolt (2)
2.
Rear isolator mount
3.
Isolator (2)
3
4.
Swing arm pivot shaft
5.
Rear pivot lockplate
6.
Screw (3)
7.
Screw (2)
Figure 3-11. Rear Engine Mount/Isolator Assembly
2006 Sportster: Engine
3-25
HOME
INSTALLING ENGINE IN CHASSIS
3.13
12.
Swing rear fork into position and install rear engine
GENERAL
mount/swingarm bolts (1). Tighten to 60-70 ft-lbs (81.4-
95.0 Nm).
When installing the engine in the motorcycle, follow the step-
by-step procedure below. It is important to follow the proce-
13.
Tighten front motor mount bolt to 60-70 ft-lbs (81.4-95.0
dure as outlined, particularly in the areas of stabilizer link and
Nm).
engine mount assembly.
14.
Remove ENGINE HOOK.
15.
With the aid of a FAT JACK, remove motorcycle from
SHOP DOLLY.
PROCEDURE
16.
See Figure 3-8. Install spacer (5), rear stabilizer link (1),
grounding strap (2) and screws (3, 4). Tighten screws to
25-35 ft-lbs (33.9-47.5 Nm).
PART NO.
SPECIALTY TOOL
17.
California models: install EVAP canister and hoses.
HD-46284
Engine hook
18.
See Figure 3-9. Install lower front stabilizer link and
mounting bracket:
HD-45968
Fat jack
a. Install frame bracket (10) with stabilizer link (9), and
HD-45967
Shop dolly
secure with screws (12) and washers (13). Tighten
screws to 25-35 ft-lbs (33.9-47.5 Nm).
1.
See Figure 3-11. Make sure pivot shaft (4) and pressure
b. Install screw (11) securing stabilizer link to engine
plate (5) are mounted on engine mounting boss at rear of
crankcase boss. Tighten screw to 25-35 ft-lbs (33.9-
engine. Position right rear isolator (3) on pivot shaft on
47.5 Nm).
rear of engine. Do not install left rear isolator at this time.
19.
Install upper front stabilizer link and mounting brackets:
2.
See Figure 3-10. Position right front isolator (1) on front
of engine. Do not install left front isolator at this time.
a. Install frame bracket
(3) with stabilizer link
(2),
screws (5) and washers (8). Tighten screws to 25-35
3.
Attach ENGINE HOOK and engine hoist to engine.
ft-lbs (33.9-47.5 Nm).
4.
Lift engine and swing assembly into chassis from left
b. Install screw (4) securing stabilizer link to engine
side. Swing front of engine in first.
bracket (1). Tighten screw to 25-35 ft-lbs (33.9-47.5
5.
See Figure 3-11. Install left rear isolator (3) over pivot
Nm).
shaft (4). Install mounting bracket (2) over left rear isola-
20.
All models except XL 1200C: install horn.
tor and attach to frame with two screws (7). Do not
tighten screws at this time.
21.
Connect clutch cable to clutch lever on left handlebar.
See 2.26 CLUTCH CONTROL.
6.
Raise or lower engine until right front isolator lines up
with mounting hole in frame.
22.
Install rear drive belt and hand-tighten rear axle. Final
belt adjustment will be performed later. See INSTALLA-
7.
See Figure 3-10. Install left front isolator (1) and isolator
TION under 6.6 SECONDARY DRIVE BELT.
mounting bracket (2) to left side of frame with two screws
(5). Do not tighten screws at this time.
23.
Locate wiring harness section that connects main har-
ness to crank position sensor, neutral switch and voltage
8.
Insert front motor mount bolt (3) from left side, through
regulator. This wiring harness runs along bottom frame
isolators and crankcase boss. Place nut (4) on bolt but
rails under engine. Route wiring harness along frame
do not tighten at this time.
rails and secure with fasteners.
9.
Tighten two screws (5) securing front isolator mounting
bracket (2) to 25-35 ft-lbs (33.9-47.5 Nm).
10.
See Figure 3-11. Tighten two screws (7) securing rear
isolator mounting bracket (2) to 25-35 ft-lbs (33.9-47.5
Nm).
11.
Install oil tank vent line at oil tank. Use new hose clamp.
See 3.25 OIL TANK.
3-26
2006 Sportster: Engine
HOME
NOTE
34.
Connect the following electrical connectors to the
If wiring harness fasteners are damaged, they must be
engine:
replaced.
a. Starter relay wire (GN) at starter motor. See 5.4
STARTER MOTOR.
24.
Connect rear stop lamp switch connectors [121] to rear
stop lamp switch. See
7.20 REAR STOP LAMP
b. Ground wires (2) at powertrain ground bolt on
SWITCH.
crankcase,
25.
Carefully move rear stop lamp switch and brake lines into
c. Vehicle speed sensor (VSS) connector [65]. See
place and secure switch assembly to frame with bolt.
7.35 VEHICLE SPEED SENSOR (VSS).
Tighten to 72-120 in-lbs (8.1-13.6 Nm). Secure flexible
d. Crank position (CKP) sensor connector [79]. See
brake hose to frame with p-clamp and screw. Tighten to
7.34 CRANK POSITION SENSOR (CKP).
30-40 in-lbs (3.4-4.5 Nm). See 7.20 REAR STOP LAMP
e. oil pressure switch connector [120]. See 7.33 OIL
SWITCH.
PRESSURE SWITCH.
26.
Install rear brake master cylinder remote reservoir.
f.
Voltage regulator DC connector
[77]. See
7.13
Secure with screw with captive washer. Tighten to 20-25
VOLTAGE REGULATOR.
in-lbs (2.3-2.8 Nm).
g. Alternator AC connector [46]. See 7.13 VOLTAGE
27.
XL 883C, XL 1200C, XL 883R and XL 1200R models:
REGULATOR.
Install left and right passenger footrest assemblies.
Tighten screws to 45-50 ft-lbs (61.1-67.9 Nm). See 2.35
h. Manifold absolute pressure (MAP) sensor
PASSENGER FOOTRESTS.
connector
[80]. See
7.6 MANIFOLD ABSOLUTE
PRESSURE SENSOR (MAP).
28.
Install left front footrest assembly. Tighten screws to 45-
50 ft-lbs
(61.1-67.9 Nm). Custom models: install shift
i.
Neutral indicator switch connector [136]. See 7.36
linkage. XL 883, XL 883L, XL 883R and XL 1200R mod-
NEUTRAL INDICATOR SWITCH.
els, see LEFT FOOTREST AND SHIFT LEVER ASSEM-
j.
Ignition coil connector
[83]. See
7.10 IGNITION
BLY under 2.33 RIDER FOOT CONTROLS: XL 883, XL
COIL.
883L, XL 883R, XL 1200R. XL 883C and XL 1200C
k. Spark plug wires (2).
models, see LEFT FOOTREST AND SHIFT LEVER
35.
Install harness connector bracket under top frame tube.
ASSEMBLY under 2.34 RIDER FOOT CONTROLS: XL
883C, XL 1200C.
36.
Connect the following wiring harness connectors:
29.
Install carburetor. See 4.5 CARBURETOR.
a. Instruments connector [20].
30.
Install air cleaner backing plate, air filter and air cleaner
b. Headlamp connector [38].
cover. See 4.6 AIR CLEANER. California models: install
c. Right hand control connector (black) [22].
additional EVAP hoses. See 4.9 EVAPORATIVE EMIS-
d. Left hand control connector (gray) [24].
SIONS CONTROL-CA MODELS.
e. Front turn signal connector [31].
31.
Custom models: connect wiring harness connectors to
horn. See 7.24 HORN.
32.
Install cylinder head bracket. Mount enrichener knob and
secure with mounting nut. See 4.5 CARBURETOR.
33.
Position coil and bracket on frame behind steering head.
2006 Sportster: Engine
3-27
HOME
45. Install exhaust pipes and mufflers. See 2.27 EXHAUST
1WARNING
SYSTEM.
46. Fill oil tank. See Refilling Oil Tank under 1.5 ENGINE OIL
Stop the engine when refueling or servicing the fuel sys-
AND FILTER.
tem. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
47. Fill primary chaincase/transmission with transmission
explosive, which could result in death or serious injury.
lubricant. See REFILLING LUBRICANT under
1.14
(00002a)
TRANSMISSION LUBRICANT.
48. Adjust rear drive belt and tighten rear axle nut to 72-78 ft-
37.
Install fuel tank. Tighten screws to 15-20 ft-lbs (20.4-27.1
lbs
(98-106 Nm). Install new axle nut e-clip. See
Nm). See 4.8 FUEL TANK.
INSTALLATION under 6.6 SECONDARY DRIVE BELT.
38.
Install oil tank feed and return lines at oil tank. Use new
hose clamps. See 3.25 OIL TANK.
1
WARNING
39.
Install oil drain hose at oil tank. Use new hose clamp.
Route oil drain hose down under engine and attach to
Connect positive (+) battery cable first. If positive (+)
drain plug/frame clip with worm drive clamp. Attach
cable should contact ground with negative (-) cable con-
frame clip to bottom frame rail on the left side.
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
40.
Install exhaust system interconnect. See 2.27 EXHAUST
(00068a)
SYSTEM.
41.
Install transmission sprocket. See 6.15 TRANSMISSION
49. Connect positive (+) battery cables to battery. Connect
SPROCKET.
negative (-) battery cable to ground point on engine
crankcase. See BATTERY INSTALLATION AND CON-
42.
Install sprocket cover. Secure with two screws. Note that
NECTION under 1.7 BATTERY MAINTENANCE.
long screw goes in top hole, short screw in bottom hole.
Do not tighten screws at this time.
50. Install left side cover. No tools are required. See 1.6
LEFT SIDE COVER.
43.
Install exhaust pipe clamp bracket, washer and screw to
sprocket cover. Tighten to 30-33 ft-lbs (40.7-44.8 Nm).
51. Install seat. See 2.32 SEAT.
Now tighten other two sprocket cover screws to 80-120
in-lbs (9.0-13.6 Nm).
44.
Install right front footrest assembly and rear brake link-
age. XL 883, XL 883L, XL 883R and XL 1200R models,
see RIGHT FOOTREST AND REAR BRAKE PEDAL
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.
3-28
2006 Sportster: Engine
HOME
TOP END OVERHAUL: DISASSEMBLY
3.14
11. See Figure 3-12. Loosen nut (5) and remove enrichener
GENERAL
knob assembly from enrichener bracket (3).
This section describes disassembling the top end of the
12. See Figure 3-13. XL 1200C models: remove nut (1) and
engine, from the cylinder deck up. To perform a complete top
horn (5). See 7.24 HORN.
end overhaul, follow all steps listed in this section. Then follow
13. Remove screws (4), washers (3) and cylinder head
all steps listed in the following sections, including inspection
bracket (2).
and repair procedures: 3.15 CYLINDER HEAD, 3.16 CYLIN-
DER AND PISTON, and 3.19 VALVE TAPPETS.
x0605x3x
CAUTION
Dirt caked on cooling fins and other areas of engine can
fall into crankcase bore or stick to subassemblies as
parts are removed. Abrasive particles can damage
machined surfaces or plug oil passageways. Remove all
dirt and particles before disassembly to prevent compo-
nent damage.
1
2
5
3
4
STRIPPING MOTORCYCLE
1.
Fuel enrichener knob
FOR TOP END REPAIR
2.
Knurled plastic nut
3.
Enrichener bracket
1.
Remove seat. See 2.32 SEAT.
4.
Star lock washer
5.
Hex nut
1WARNING
Figure 3-12. Enrichener Control
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
x0606a3x
2.
Open left side cover and remove Maxi-Fuse. Close left
1.
Nut
side cover. See 7.25 MAXI-FUSE.
2.
Cylinder head bracket
3.
Washer (2)
3.
Remove exhaust system. See 2.27 EXHAUST SYSTEM.
4.
Screw (2)
4.
Disconnect spark plug cables from spark plugs.
5.
Horn assembly (XL 1200C)
5.
Drain and remove fuel tank. See 4.8 FUEL TANK.
5
4
6.
Disconnect manifold absolute pressure (MAP) sensor
connector [80]. See 7.6 MANIFOLD ABSOLUTE PRES-
3
SURE SENSOR (MAP).
7.
Remove air cleaner cover, air filter and air cleaner back-
ing plate. See 4.6 AIR CLEANER. California models:
remove additional EVAP hoses. See 4.9 EVAPORATIVE
2
EMISSIONS CONTROL-CA MODELS.
8.
Remove carburetor. See 4.5 CARBURETOR. Secure
carburetor and throttle cables out of the way.
1
9.
All models except XL 1200C: remove horn and horn
bracket. See 7.24 HORN.
10. Remove upper front engine stabilizer link assembly. See
2.21 STABILIZER LINKS.
Figure 3-13. Horn (XL 1200C) and
Cylinder Head Bracket (All Models)
2006 Sportster: Engine
3-29
HOME
1.
Remove spark plugs.
CYLINDER HEAD
2.
See Figure 3-14. Remove four screws with captive wash-
ers (1) and fiber seals (2). Remove outer rocker cover
Disassembling Rocker Covers
(3). Discard fiber seals.
3.
Remove screw (6) and crankcase breather valve (7).
CAUTION
4.
Remove and discard gaskets (4, 5).
All washers and fasteners used in the engine are hard-
5.
Rotate crankshaft until both valves are closed on head
ened. Do not mix or replace hardened washers and fas-
being removed.
teners with unhardened parts. Do not reuse fiber cover
seals. Engine damage may result.
x0452b3x
1.
Screw w/captive washer (4)
1
2.
Fiber seal (4)
3.
Outer rocker cover
4.
Gasket
3
2
5.
Gasket
6.
Screw
7.
Breather assembly
8.
Inner rocker cover
9.
Rocker arm shaft (2)
10.
Rocker arm bushing (4)
11.
Rocker arm
4
12.
Rocker arm
13.
Bolt (4)
9
14.
Screw (2)
15.
Bolt (3)
16.
Gasket
6
11
7
5
10
13
8
12
10
14
15
16
Figure 3-14. Rocker Cover Assembly
3-30
2006 Sportster: Engine
HOME
6.
See Figure
3-15. Remove hardware securing inner
rocker cover to cylinder head in the following order.
CAUTION
a. Remove two screws and washers (1).
Mark rocker arm shafts for reassembly in their original
b. Remove three bolts and washers (2).
positions. Valve train components must be reinstalled in
c. Loosen four rocker arm bolts (3) in
1/4-1/2 turn
their original positions during reassembly or increased
increments using a cross pattern. This relieves valve
engine wear may result.
spring pressure evenly on inner rocker cover.
9. See Figure 3-14. Remove rocker arms (11, 12); mark
NOTE
them for reassembly in their original locations.
Remove each inner rocker cover as an assembly; then disas-
10. Repeat steps 2 through 9 for other rocker cover.
semble as required.
Removing Cylinder Head
7.
See Figure
3-14. Remove inner rocker cover
(8).
Remove and discard gasket (16).
8.
See Figure 3-16. Remove rocker arm shafts by tapping
CAUTION
them out using a hammer and a soft metal punch.
See Figure 3-17. Distortion to the head, cylinder, and
crankcase studs may result if head screws are not loos-
ened (or tightened) gradually in the sequence shown.
10659
1
1. See Figure 3-17. Loosen each head screw 1/8-turn fol-
2
3
lowing the sequence shown.
3
x0128x3a
Front Cylinder
2
1st
3rd
3
3
2
1
Figure 3-15. Inner Rocker Cover Fasteners
8921
2nd
4th
2
Rear Cylinder
2nd
4th
1
1.
Retaining notch
2.
Position of rocker arm retaining bolts
Figure 3-16. Removing Rocker Arm Shafts
1st
3rd
Figure 3-17. Head Screw Loosening/Tightening Sequence
2006 Sportster: Engine
3-31
HOME
2.
Continue loosening in 1/8-turn increments until screws
4. Repeat previous steps for other head.
are loose. Remove head screws.
3.
See Figure 3-18. Remove cylinder head (8), head gasket
(10), and O-rings (11). Discard head gasket and O-rings.
x0453c3x
1.
Screw (2)
2.
Screw (2)
19
3.
Valve collar retainer (4)
20
4.
Upper valve spring collar (2)
5.
Valve spring (2)
6.
Valve seal and lower valve
spring collar assembly (2)
1
7.
Valve guide, intake and exhaust (2)
8.
Cylinder head
2
9.
Exhaust port stud (2)
10.
Cylinder head gasket
11.
Cylinder O-ring (2)
12.
Dowel (2)
8
18
13.
Cylinder w/piston and rings
14.
Cylinder base gasket
15.
Cylinder base stud (4)
16.
Valve (1) intake, (1) exhaust
17.
Valve seat (2)
18.
Cylinder head bracket
19.
Screw (2)
3
20.
Washer (2)
21.
Stabilizer link bracket
4
(front cylinder head only)
22.
Screw (2)
5
23.
Lock washer (2)
6
7
16
17
21
23
22
9
10
13
11
12
14
15
Figure 3-18. Cylinder Head, Cylinder and Piston Assembly
3-32
2006 Sportster: Engine
HOME
Disassembling Push Rods and Covers
CYLINDER AND PISTON
1.
See Figure 3-19. Remove push rod covers (2), O-rings
(1, 3) and push rods (4). Mark the location and orienta-
tion (top and bottom) of each push rod. Discard O-rings.
PART NO.
SPECIALTY TOOL
2.
Remove socket screws (5) and washers (6). Remove
retainer (7) and gasket (8). Discard gasket.
HD-34623-C
Piston pin lock ring remover/installer
3.
Repeat above steps for other cylinder.
HD-42320-A
Piston pin remover
HD-42322
Piston support plate
1.
O-ring (4)
1. See Figure 3-20. Clean crankcase around base of cylin-
2.
Push rod cover (4)
1
der (7) to prevent dirt and debris from entering crankcase
3.
O-ring (4)
while removing cylinder.
4.
Push rod (4)
2
5.
Screw (8)
6.
Washer (8)
x0458a3x
7.
Retainer (2)
3
3
8.
Gasket (2)
9.
Screw (2)
6
10. Anti-rotation device (2)
5
11. Tappet (4)
12. Right crankcase
4
4
11
5
3
2
6
1
10
9
7
12
8
7
10
9
11
8
1. Piston pin bushing
12
2. Connecting rod
3. Lock ring (2)
4. Piston pin
5. Piston ring set
6. Piston
7. Cylinder
x0202b3x
8. Cylinder stud (4)
9. Cylinder base gasket
Figure 3-19. Middle Valve Train Components
10. Dowel (2)
11. O-ring (2)
12. Head gasket
Figure 3-20. Cylinder and Piston
2006 Sportster: Engine
3-33
HOME
2.
Turn engine over until piston
(6) of cylinder being
7. See Figure 3-21. Remove piston pin lock ring as follows:
removed is at bottom of its stroke.
a. Insert PISTON PIN LOCK RING REMOVER/
3.
Carefully raise cylinder just enough to permit placing
INSTALLER into piston pin bore until claw on tool is
clean towel under piston to prevent any foreign matter
positioned in slot of piston (directly under lock ring).
from falling into crankcase.
b. Squeeze handles of tool together and pull from bore.
Hold a shop towel over bore during removal in the
NOTE
event that the lock ring should fly out. Remove lock
If cylinder does not come loose, tap lightly with rawhide or
ring from claw and discard.
plastic hammer perpendicular to cylinder fins. Never try to pry
cylinder up.
NOTE
4.
Carefully lift cylinder over piston and cylinder studs (8).
It is not necessary to remove both piston pin lock rings during
Do not allow piston to fall against cylinder studs.
piston removal. Leave second lock ring in piston pin bore.
CAUTION
CAUTION
Do not allow piston to fall against cylinder studs. Dam-
DO NOT reuse piston pin lock rings. Removal may
age to piston assembly and/or studs may result.
weaken lock rings and they may break or dislodge if
reused, resulting in engine damage.
5.
Discard cylinder base gasket (9).
CAUTION
x0633x3x
With cylinder removed, be careful not to bend the cylin-
der studs. The slightest bend could cause a stress riser
and could lead to stud failure.
6.
Install a 6.0 in. (150 mm) length of 1/2 in. (12.7 mm) I.D.
plastic or rubber hose over each cylinder stud. This will
protect the studs and the pistons.
CAUTION
Handle piston with extreme care. The alloy used in these
pistons is very hard. Any scratches, gouges or other
marks in the piston could score the cylinder during
1
2
engine operation and cause engine damage.
1WARNING
Wear safety glasses or goggles when removing or install-
ing piston pin retaining rings. Piston pin retaining rings
are compressed in the ring groove and can fly out when
removed from the groove, which could result in serious
eye injury. (00293a)
b1001a3x
1.
Piston pin lock ring
2.
Piston pin lock ring installer
(Part No. HD-34623-C)
Figure 3-21. Removing Piston Pin Lock Ring
3-34
2006 Sportster: Engine
HOME
NOTE
x0459b3x
See Figure 3-22. Piston pin has tapered ends to help seat the
round lock rings.
8.
Remove piston pin. Since pin is a loose fit in piston, pin
should easily slide out. If pin is difficult to remove, use
PISTON PIN REMOVER, as follows:
NOTE
To avoid damage to piston or cylinder base studs, use PIS-
TON SUPPORT PLATE to secure piston in place while
removing piston pin.
a. See Figure 3-23. Remove acorn nut and spacer (1)
from rod end of tool.
b. Slide rod end through piston pin. Install spacer and
acorn nut on end of rod.
c. Position rubber coated tips (2) of tool on flat on each
side of piston pin bore.
Figure 3-22. Tapered Ends on Piston Pin
d. Hold tool body (3) and turn handle (4) clockwise until
piston pin is pulled free of bore.
9.
Remove piston from connecting rod. Be sure to hold con-
x0nnnx3x
necting rod shank upright to prevent it from striking
crankcase.
10.
Place a 3.0 in. (76.2 mm) length of 1.0 in. (25.4 mm) I.D.
foam-type water pipe insulation around each connecting
rod to prevent damage.
11.
Mark each pin boss with either an “F” or an “R” to indi-
cate front or rear cylinder, respectively.
12.
See Figure 3-24. Spread piston rings outward until they
clear grooves in piston and lift off.
2
3
1
4
1.
Acorn nut and spacer
2.
Rubber coated tip (2)
3.
Tool body
4.
Handle
Figure 3-23. Removing Piston Pin with
HD-42320-A Piston Pin Remover
10701
Figure 3-24. Removing Piston Rings
2006 Sportster: Engine
3-35
HOME
CYLINDER HEAD
3.15
GENERAL
DISASSEMBLY
1.
See Figure 3-25. Remove two screws (17), lock washers
(18) and stabilizer link bracket (16) from front head.
PART NO.
SPECIALTY TOOL
2.
See Figure 3-26. Clamp VALVE SPRING COMPRES-
HD-34736-B
Valve spring compressor
SOR in vice and compress valve spring (item 5, Figure 3-
25.).
REMOVAL
See CYLINDER HEAD under 3.14 TOP END OVERHAUL:
DISASSEMBLY to remove cylinder head from engine.
x0627x3x
1.
Bolt (2)
2.
Bolt (2)
3.
Valve collar retainer (4)
14
4.
Upper valve spring collar (2)
15
5.
Valve spring (2)
6.
Valve seal and lower valve
spring collar assembly (2)
7.
Valve guide, intake and exhaust (2)
8.
Cylinder head
1
9.
Exhaust port stud (2)
10. Cylinder head gasket
2
11. Valve (1) intake, (1) exhaust
12. Valve seat (2)
13. Cylinder head bracket
4
14. Screw (2)
3
13
15. Washer (2)
16. Stabilizer link bracket
(front cylinder head only)
17. Screw (2)
18. Lock washer (2)
8
12
5
11
6
7
16
18
17
10
9
Figure 3-25. Cylinder Head, Cylinder and Piston Assembly
3-36
2006 Sportster: Engine
HOME
8926
Cylinder Heads
1WARNING
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1. Bead blast or scrape carbon from head and valve ports.
Be careful to avoid scratching or nicking cylinder head-
to-cylinder joint faces. Blow off loosened carbon or dirt
with compressed air.
2. Soak cylinder head in an aluminum-compatible cleaner/
solvent to loosen carbon deposits.
3. Wash all parts in non-flammable solvent, followed by a
thorough washing with hot, soapy water. Blow out oil
passages in head. Be sure they are free of sludge and
Figure 3-26. Compressing Valve Springs
carbon particles. Remove loosened carbon from valve
(Valve Spring Compressor, Part No. HD-34736-B)
head and valve stem using a wire wheel. Never use a file
or other hardened tool which could scratch or nick valve.
3.
See Figure 3-25. Remove valve collar retainers
(3),
Polish valve stem with very fine emery cloth or steel
upper valve spring collar (4) and valve spring (5). Mark
wool.
valve collar retainers for reassembly in original positions.
4. See Figure 3-27. Check head gasket surface on head for
4.
Use a fine tooth file to remove any burrs on the valve
flatness. Machine or replace any head which exceeds
stem at the retainer groove. Mark valve to ensure that it
SERVICE WEAR LIMIT of 0.006 in. (0.152 mm).
will be reassembled in the same head.
5.
Remove valve (11), and valve seal and lower valve
spring collar assembly (6) by hand. No special tools are
8932
required to remove valve seal and lower valve spring col-
lar assembly.
6.
Repeat above procedure for other valve. Then disassem-
ble other head following same procedure.
CLEANING AND INSPECTION
PART NO.
SPECIALTY TOOL
B-45525
Valve guide hone
HD-34751
Valve guide brush
HD-94804-57
Rocker arm bushing reamer
B-45524
Valve guide remover/installer
Figure 3-27. Checking Gasket Surface:
Must Be Flat Within 0.006 in. (0.152 mm)
B-45523
Valve guide reamer
HD-39782-A
Cylinder head support stand
HD-39786-A
Cylinder head holding fixture
HD-96796-47
Valve spring tester
2006 Sportster: Engine
3-37
HOME
Rocker Arm Assemblies
6607
1.
Check each rocker arm at pad end and push rod end for
uneven wear or pitting. Replace rocker arm if either con-
dition exists.
NOTE
Most of the wear in rocker arm shafts and bores results from
the up and down movement of the pushrods and valves.
Therefore, the following measurements should be taken top-
to-bottom on rocker arm shafts and bores.
2.
See Figure 3-28. Measure and record rocker arm shaft
diameter at the positions where rocker arm bushings ride
and where shaft fits in inner rocker cover.
6605
Figure 3-29. Measuring Rocker Arm Shaft Bore Diameter
in Inner Rocker Cover
6608
6606
Figure 3-30. Measuring Rocker Arm Bushing
Inner Diameter
Figure 3-28. Measuring Rocker Arm Shaft Diameter at
x0583x3x
Bushing Position (top) and Cover Position (bottom)
3
3.
Measure and record rocker arm shaft bore diameters.
2
a. See Figure
3-29. Measure bore in inner rocker
cover.
b. See Figure 3-30. Measure rocker arm bushing inner
diameter.
4.
Check clearances and measurements obtained in step 3
against specifications in 3.2 SERVICE WEAR LIMITS.
Repair or replace parts exceeding Service Wear Limits. If
rocker arm bushings require replacement, see REPLAC-
ING ROCKER ARM BUSHINGS later in this section.
5.
See Figure 3-31. Assemble rocker arms and rocker arm
shafts into inner rocker cover.
6.
Check end play of rocker arm with feeler gauge. Replace
rocker arm or inner rocker cover or both if end play
1
exceeds 0.025 in. (0.635 mm).
1.
Inner rocker cover
2.
Rocker arm shaft (2)
3.
Rocker arm (2)
Figure 3-31. Assembling Inner Rocker Cover
3-38
2006 Sportster: Engine
HOME
NOTE
Valves
Replacing a valve seat is a complex operation requiring spe-
1.
Replace the valve if there is evidence of burning or
cial equipment. If the valve seat is loose or is not fully seated
cracking.
in the head, seat movement will prevent the proper transfer of
2.
Inspect the end of the valve stem for pitting or uneven
heat from the valve. The valve seat surface must be flush with
wear. Replace the valve if either of these conditions
(or below) the head surface. See 3.1 SPECIFICATIONS for
exist.
valve seat-to-cylinder head fit.
3.
Inspect for burrs around the valve stem retainer groove.
Valve Guides
Remove burrs with a fine tooth file if found.
4.
Valve heads should have a seating surface width of
1. Clean valve guides by lightly honing with VALVE GUIDE
HONE.
0.040-0.062 in. (1.02-1.57 mm), and should be free of pit
marks and burn spots. The color of carbon on exhaust
2. Scrub valve guides with VALVE GUIDE BRUSH and hot
valves should be black or dark brown. White or light buff
soapy water. Measure valve stem outer diameter and
carbon indicates excessive heat and burning.
valve guide inner diameter. Check measurements
against 3.2 SERVICE WEAR LIMITS.
Valve Seats
Valve Springs
NOTE
Valve seats are subject to wear, pitting, and burning. Resur-
1. Inspect valve springs for broken or discolored coils.
face valve seats whenever valves are refinished.
NOTE
1.
Inspect valve seats for cracking, chipping or burning.
A single valve spring is used for each valve. The inner and
Replace valve seats if any evidence of these conditions
outer springs are combined into one progressively wound,
exists.
tapered spring.
2. See Figure 3-33. Check free length of each spring with
caliper as shown. Test compression force of spring using
10042
VALVE SPRING TESTER. Compare with 3.1 SPECIFI-
CATIONS and 3.2 SERVICE WEAR LIMITS. If spring
length is shorter than specification, or if spring compres-
sion force is below specification, replace spring.
b0966x3x
Figure 3-32. Measuring Valve Stem Protrusion
2.
See Figure 3-32. Check valve seats for recession by
Figure 3-33. Checking Spring Free Length
measuring valve stem protrusion.
a. Wipe valve seats and valve faces clean. Insert valve
into valve guide.
b. Measure valve stem protrusion from end of valve
stem to machined surface of head upon which the
lower valve collar sits, as shown. If valve stem pro-
trudes more than 2.082 in. (52.883 mm), replace
valve seat or cylinder head.
2006 Sportster: Engine
3-39
HOME
Spark Plug Threads
8732
Inspect spark plug threads for damage. If threads in cylinder
head are damaged, a special plug type insert can be installed
using a 12 mm spark plug repair kit.
Push Rods
Examine push rods, particularly the ball ends. Replace any
rods that are bent, worn, discolored, or broken.
REPLACING ROCKER ARM
BUSHINGS
PART NO.
SPECIALTY TOOL
HD-94804-57
Rocker arm bushing reamer
1.
See Figure 3-34. To replace worn bushings, press or
8733
drive them from the rocker arm. If bushing is difficult to
remove, turn a 9/16-18 tap into bushing. From opposite
side of rocker arm, press out bushing and tap using a
discarded rocker arm shaft.
2.
Press replacement bushing into rocker arm, flush with
rocker arm end, and split portion of bushing towards top
of rocker arm.
3.
Using remaining old bushing as a pilot, line ream new
bushing with ROCKER ARM BUSHING REAMER.
4.
Repeat for other end of rocker arm.
8734
Figure 3-34. Replacing Rocker Arm Bushings
3-40
2006 Sportster: Engine
HOME
REPLACING VALVE GUIDES
x0521x3x
2
PART NO.
SPECIALTY TOOL
B-45524
Valve guide remover/installer
1
HD-39782-A
Cylinder head support stand
4
Valve guide replacement, if necessary, must be done before
3
5
valve seat is ground. It is the valve stem bore in valve guide
that determines valve seat grinding location. Valve stem-to-
valve guide clearances are listed in Table 3-39. If valve stems
and/or valve guides are worn beyond service wear limits,
6
install new parts.
Table 3-39. Valve Stem
Clearance/Service Limits
SERVICE WEAR
VALVE
CLEARANCE
LIMIT
7
Intake
0.001-0.003 in.
0.0035 in.
1.
Valve guide remover/installer
(0.0254-0.0762 mm)
(0.0965 mm)
2.
Installer sleeve
3.
Cylinder head support stand
Exhaust
0.001-0.003 in.
0.0035 in.
4.
Intake seat adapter, 883
(0.0254-0.0762 mm)
(0.0965 mm)
5.
Exhaust seat adapter, 883
6.
Intake seat adapter, 1200
Removal
7.
Exhaust seat adapter, 1200
Figure 3-35. Valve Guide Replacement Tools
CAUTION
Cylinder head support stand ensures that valve guide
and valve seat are perpendicular. If perpendicularity is
not achieved, the cylinder head valve guide bore will be
Table 3-40. Valve Guide
damaged during the press procedure.
Remover/Installer Components
1.
See Figure 3-35. Prepare cylinder head for valve guide
PART NO
ITEM
replacement.
a. Insert sleeve of intake (4 or 6) or exhaust (5 or 7)
Valve guide remover/installer with
seat adapter into tube at top of cylinder head sup-
B-45524
installer sleeve
port stand (3).
HD-39782-A
Cylinder head support stand
b. Position cylinder head so that valve seat is centered
on seat adapter.
HD-39782-2
Intake seat adapter, 883
HD-39782-3
Exhaust seat adapter, 883
CAUTION
HD-39782-6
Intake seat adapter, 1200
Do not press out the valve guide from the bottom of the
cylinder head. Carbon buildup on the combustion cham-
HD-39782-7
Exhaust seat adapter, 1200
ber side of the valve guide can deeply gouge the cylinder
head bore diminishing the likelihood of achieving the
proper interference fit and possibly requiring replace-
ment of the cylinder head casting.
2006 Sportster: Engine
3-41
HOME
2.
See Figure 3-36. At top of the cylinder head, insert
Installation
VALVE GUIDE REMOVER/INSTALLER (1) into valve
guide bore until tool shoulder contacts end of valve
guide.
PART NO.
SPECIALTY TOOL
NOTE
Installer sleeve (item 2, Figure 3-35.) is not used for removal
B-45525
Valve guide hone
of valve guide.
B-45524
Valve guide remover/installer
3.
Center VALVE GUIDE REMOVER/INSTALLER under
HD-34751
Valve guide cleaning brush
ram (3) of press. Apply pressure until valve guide drops
free of cylinder head. Discard valve guide.
HD-39782-A
Cylinder head support stand
HD-39786-A
Cylinder head holding fixture
10051
HD-39847
Reamer T-handle
B-45523
Valve guide reamer
HD-39964
Reamer lubricant
NOTE
Only a single replacement oversize valve guide is available.
3
The O.D. of the replacement valve guide must be machined
to the correct size and proper interference fit.
1. Check valve guide to valve guide bore clearance.
a. Measure outer diameter of a new standard valve
1
guide.
b. Measure the cylinder head valve guide bore. The
valve guide diameter should be 0.0020-0.0033 in.
(0.0508-0.0838 mm) larger than cylinder head valve
guide bore.
c. If interference fit is within specification, a replace-
ment standard valve guide will be used. If interfer-
ence fit is not within specification, obtain oversize
valve guide and machine valve guide O.D. as
needed.
NOTES
2
Since some material is typically removed from the cylinder
head valve guide bore when the valve guide is pressed out, it
is common to go to the larger size for the proper interference
fit.
2. Measure cylinder head bore and outside diameter of
replacement valve guide to verify correct interference fit.
CAUTION
Cylinder head support stand ensures that valve guide
and valve seat are perpendicular. If perpendicularity is
1.
Valve guide remover/installer (Part no. B-45524)
not achieved, cylinder head valve guide bore will be dam-
2.
Cylinder head support stand (Part no. HD-39782-A)
aged during the press procedure.
3.
Ram
3. Prepare cylinder head for valve guide replacement.
Figure 3-36. Removing Shoulderless Valve Guide
a. See Figure 3-35. Insert sleeve of intake (4 or 6) or
exhaust (5 or 7) seat adapter into tube at top of cyl-
inder head support stand (3). Position cylinder head
so that valve seat is centered on seat adapter.
b. Apply Vaseline to lightly lubricate external surfaces
of valve guide. Spread lubricant so that thin film cov-
ers entire surface area.
3-42
2006 Sportster: Engine
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