Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 18
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CRANKCASE
3.23
GENERAL
REMOVAL
When connecting rod and flywheel assembly, pinion shaft
1. Remove engine from motorcycle. See 3.12 REMOVING
bearing, or sprocket shaft bearing are in need of replace-
ENGINE FROM CHASSIS.
ment, it is recommended procedure to check and make
2. Disassemble top end of engine. See CYLINDER HEAD
repairs to cylinder heads, cylinders, gear case and transmis-
and CYLINDER AND PISTON under 3.14 TOP END
sion at the same time (perform entire engine overhaul).
OVERHAUL: DISASSEMBLY.
CAUTION
Laying engine on primary side will damage clutch cable
end fitting. If fitting is damaged, clutch cable must be
replaced.
x0582a3x
1
2
9
3
10
4
11
5
6
7
8
12
1.
Sprocket shaft spacer
7.
Retaining ring
2.
Retaining ring
8.
Connecting rod and flywheel assembly
3.
Left main oil seal
9.
Pinion shaft bearing
4.
Thrust washer
10. Retaining ring
5.
Left crankcase
11. Outer bearing race
6.
Left main bearing
12. Right crankcase
Figure 3-94. Crankcase and Flywheel Assembly
DISASSEMBLY
PART NO.
SPECIALTY TOOL
HD-44358
Flywheel support fixture
HD-95637-46A
Claw puller wedge attachment
PART NO.
SPECIALTY TOOL
HD-34902B
Bearing race remover/installer
J-5586-A
Transmission shaft retaining ring pliers
HD-34902-7
End cap
2006 Sportster: Engine
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3. See Figure 3-96. Place flywheel assembly in FLYWHEEL
PART NO.
SPECIALTY TOOL
SUPPORT FIXTURE. Pull sprocket shaft bearing inner
race with WEDGE ATTACHMENT for CLAW PULLER
B-45655,
Crankcase bearing remover/installer
with BEARING RACE REMOVER/INSTALLER and END
HD-42720-2 and
with adapter
CAP.
HD-46663
NOTE
1.
Disassemble crankcase, see CRANKCASE under 3.18
Left main bearing inner race does not need to be ground
BOTTOM END OVERHAUL: DISASSEMBLY.
once it is installed on the sprocket shaft.
NOTE
4. See Figure 3-97. See Figure 3-94. Remove outer left
See Figure 3-94. If it is necessary to remove either the pinion
main bearing retaining ring (2).
shaft bearing (9) or left main bearing (6), proceed as follows:
5. See Figure 3-94. Remove left main oil seal (3) from left
crankcase using Snap-On Tool (Part No. CJ 114, Body
2.
See Figure 3-95. Pinion shaft bearing assembly (3) will
Dent Puller)
remain on pinion shaft (2) when flywheel assembly (1) is
removed from right crankcase. Using TRANSMISSION
6. Remove thrust washer (4) next to left main bearing (6).
SHAFT RETAINING RING PLIERS, remove retaining
ring (4) and slip bearing off pinion shaft.
10332
1
2
10569
1
4
3
3
5
2
4
6
1.
Flywheel assembly
1.
Forcing screw (J-21686-12)
2.
Pinion shaft
2.
Bridge (J-7830-5)
3.
Pinion shaft bearing assembly
3.
End cap (HD-34902-7)
4.
Retaining ring
4.
Bolts (2)
5.
Bearing SEPARATOR (Snap-on CJ950
Figure 3-95. Removing Pinion Shaft Bearing
or equivalent)
Retaining Ring
6.
Flywheel support fixture (HD-44358)
Figure 3-96. Removing Sprocket Shaft Inner Bearing
Race
3-84
2006 Sportster: Engine
HOME
7. See Figure 3-98. See Figure 3-94. Remove left main
10328
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 Figure
3-99. Using CRANKCASE BEARING
REMOVER/INSTALLER with ADAPTER 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) fac-
ing 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.
Figure 3-97. Removing Left Main Oil Seal Retaining Ring
d. Carefully apply pressure with press ram (6) until left
main bearing drops free.
10327
Figure 3-98. Removing Left Main Bearing Retaining Ring
2006 Sportster: Engine
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FITTING PINION BEARINGS
10329
5
6
2
PART NO.
SPECIALTY TOOL
4
HD-34902-B
Bearing race remover and installer kit
See Figure 3-94. A pressed-in bushing in the right crankcase
is the outer race (11). The inner race is pressed on the pinion
shaft.
3
See Figure 3-100. To remove pinion shaft inner race, use
BEARING SEPARATOR (Snap-on Tools Stock No. CJ950 or
equivalent), three items from BEARING RACE REMOVER
AND INSTALLER KIT: 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
10331
1
2
1.
Support tube (HD-42720-2)
4
2.
Left crankcase
3.
Crankshaft bearing bore
4.
Adapter (HD-46663)
5
3
5.
Pilot/driver (B-45655)
6.
Press ram
6
Figure 3-99. Removing Left Main Bearing From Crankcase
1.
Forcing screw (J-21686-12)
2.
Bridge (J-7830-5)
3.
End cap (HD-34902-7)
4.
Bolts (2)
5.
Bearing SEPARATOR (Snap-on CJ950
or equivalent)
6.
Flywheel support fixture (HD-44358)
Figure 3-100. Pulling Pinion Shaft Inner Bearing
3-86
2006 Sportster: Engine
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Pinion bearing selection at the factory, during engine rebuild,
Bearing Selection
or replacement of crankcase set or flywheel assembly is
based on the largest measured outside diameter (O.D.) of the
Select bearings using the identification information given for
inner race and the smallest measured inside diameter (I.D.)
inner and outer races and bearings. Refer to Table 3-49.
of the outer race (crankcase bushing).
NOTE
A running clearance of 0.0002-0.0008 in. (0.005-0.020 mm.)
If either inner or outer race show wear, measure both races to
is established during crankcase set or flywheel assembly
confirm correct bearing fit.
replacement and engine rebuild.
See Figure 3-101. Installed inner races are identified at the
factory as shown.
Table 3-46. Paint Dot Specifications
See Figure 3-102. Outer races are identified at the factory as
RACE O.D.
CLASS
IDENTIFICATION*
shown.
1.2498-1.2500 in.
A
White
(31.745-31.750 mm)
8996
1.2496-1.2498 in.
B
Green
(31.740-31.745 mm)
2
* Paint dot on end of spline.
1
Table 3-47. Roller Specifications
ROLLER O.D. (A)
IDENTIFICATION (PACKAGE COLOR)
Red
Blue
Largest
White (Grey)
Smallest
Green
1.
Paint dot
2.
Inner race
Figure 3-101. 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 Figure 3-103. Pinion bearings are identified as shown.
2006 Sportster: Engine
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Table 3-48. Stamp Specifications
x0481x3x
A - Roller O.D. cannot
be measured to
CLASS
STAMPED
RACE I.D.
required accuracy
NO.
IDENTIFICATION*
with micrometer
1.5646-1.5648 in.
1
1
(39.741-39.746 mm)
1.5648-1.5650 in.
2
2
(39.746-39.751 mm)
1.5650-1.5652 in.
3
3
(39.751-39.756 mm)
*Stamped number inside crankcase near race
Figure 3-103. Bearing Identification
x0480x3x
Outer race
Right crankcase
Stamped
class no.
Service wear limit: 1.5672 in. (39.807 mm)
Figure 3-102. Factory Outer Race Sizes
Table 3-49. Pinion Shaft Bearing Selection
FACTORY
STAMPED
OUTER RACE I.D.
BEARING SIZE AS IDENTIFIED BY COLOR CODING
NUMBER
over 1.5658 in.
Service Wear Limit Exceeded - Replace Outer Race and Resize
(39.771 mm)
1.5656-1.5658 in.
Red
Blue
(39.766-39.771 mm)
1.5654-1.5656 in.
Red
Blue
White-Gray
(39.761-39.766 mm)
1.5652-1.5654 in.
Red
Blue
White-Gray
Green
(39.756-39.761 mm)
3
1.5650-1.5652 in.
Red
Blue
White-Gray
Green
(39.751-39.756 mm)
2
1.5648-1.5650 in.
Blue
White-Gray
Green
(39.746-39.751 mm)
1
1.5646-1.5648 in.
White-Gray
Green
(39.741-39.746 mm)
INNER RACE O.D. (in.)
1.2496-1.2498
1.2498-1.2500
1.2500-1.2502
1.2502-1.2504
1.2504-1.2506
INNER RACE O.D. (mm)
31.740-31.745
31.745-31.750
31.750-31.755
31.755-31.760
31.760-31.765
FACTORY COLOR CODE
Green
White
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2006 Sportster: Engine
HOME
1.
Measure I.D. of outer race at four places with a dial bore
Table 3-51. New Outer Pinion Bearing
gauge. Take measurement on I.D. where bearing rollers
Race Specifications
ride. Record the four measurements.
2.
If the largest measurement is larger than
1.5672 in.
ITEM
SPECIFICATION
(39.807 mm) or the required lapping to remove wear
marks would enlarge bore beyond 1.5672 in. (39.807
I.D.
1.5646-1.5652 in. (39.741-39.756 mm)
mm), continue at Step 8.
Roundness
within 0.0002 in. (0.005 mm)
3.
If the largest measurement is 1.5672 in. (39.807 mm) or
Taper
within 0.0002 in. (0.005 mm)
less, cover the cam bearings with masking tape to pre-
vent debris from entering bearings. Assemble crankcase
Surface finish
16 RMS
halves.
NOTE
10.
See Figure 3-100. Pull inner race from pinion shaft using
BEARING SEPARATOR
(Snap-on Tools Stock No.
The next step requires lapping the outer race. To keep
CJ950), three items from BEARING RACE REMOVER
sprocket shaft and pinion shaft bearings aligned the lap must
AND INSTALLER KIT: END CAP (Part No. HD-34902-7),
be supported by an adaptor or pilot in the left crankcase.
BRIDGE (Part No. J-7830-5) and FORCING SCREW
4.
See LAPPING ENGINE MAIN BEARING RACES under
(Part No. J-21686-12), and two bolts. Apply heat to race
3.23 CRANKCASE. Race must be lapped until all wear
to aid removal.
marks are removed.
11.
See Figure 3-104. Press new inner race on pinion shaft
5.
Measure I.D. of race at four places and record the mea-
as shown. The new inner race must be ground by a
surements.
machinist to O.D. dimension range (given in Table 3-49.)
for the finished lapped I.D. of the outer race. The finished
6.
Check measurements against the specifications listed in
inner race must meet these specifications.
Table 3-50.
x0482x3x
Table 3-50. Outer Pinion Bearing
1.135 in.
Race Specifications
(28.83 mm)
-
1.145 in.
ITEM
SPECIFICATION
(29.08 mm)
Largest I.D. measured
1.5672 in. (39.807 mm)
Roundness of I.D.
within 0.0002 in. (0.005 mm)
Taper
within 0.0002 in. (0.005 mm)
2
7.
If lapping increased bore I.D. to larger than 1.5672 in.
(39.807 mm), go to Step 8. 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.
1
8.
Press the outer race from the right crankcase. Press
new outer race into crankcase flush with inside edge of
1.
Pinion shaft inner race
cast-in insert.
2.
Flywheel (gear side)
See Figure 3-105. Dimensions are shown for fabrication
Figure 3-104. Inner Race Location
of tools used in pressing the outer race into or out of
crankcase.
9.
The new outer race must be lapped slightly to true and
aligned with left case bearing and to meet the following
specifications; see LAPPING ENGINE MAIN BEARING
RACES under 3.23 CRANKCASE.
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12. For necessary dimensions for constructing a press-on
NOTE
tool, see Figure 3-105. When the tool bottoms against
Have machinist grind outer race to center or middle of
the flywheel, correct inner race location is automatically
required O.D. range. This will prevent grinding outer race
established.
undersize and gives a more easily achieved tolerance range.
b. Grind inner race. Measure O.D. at four places and
Roundness: within 0.0002 in. (0.005 mm)
check that specifications in Step 11 are met.
Taper: within 0.0002 in. (0.005 mm)
c. For example purposes, the largest measured O.D. of
Surface finish: 16 RMS
inner race after grinding is 1.2499 in. (31.747 mm)
O.D.
13. The following example illustrates how to determine the
required inner race O.D.
d. Refer to Table 3-49. With a 1.5651 in. (39.754 mm)
I.D. outer race and a 1.2499 in. (31.747 mm) O.D.
EXAMPLE:
inner race, a blue bearing is required.
NOTE
a. If smallest measured I.D. of outer race is 1.5651 in.
Always use the smallest outer race I.D. measurement and the
(39.754 mm) the Pinion Shaft Bearing Selection
largest O.D. inner race measurement when selecting bear-
table
(Table 3-49.) indicates an inner race O.D.
ings.
range of 1.2496-1.2504 in. (31.740-31.760 mm) is
required.
x0483x3x
2.00"
(50.8 mm)
0.187" (4.75 mm)
Pinion outer race
installation
1.00"
5/16"
(25.4 mm)
(7.94 mm)
DRILL
1.560"
(39.62 mm)
1.70"
(43.2 mm)
0.187" (4.75 mm)
Pinion outer
1.00"
race removal
5/16"
(25.4 mm)
(7.94 mm)
DRILL
1.560"
(39.62 mm)
1.50" (38.1 mm)
1.00"
(25.4 mm)
Pinion inner race
installation
5.50" (139.7 mm)
1.145" (29.08 mm)
1.135" (28.83 mm)
1.272"
(32.31 mm)
1.262"
(32.05 mm)
Figure 3-105. Pinion Shaft Bearing Tools
3-90
2006 Sportster: Engine
HOME
LAPPING ENGINE MAIN BEARING
11539
RACES
PART NO.
SPECIALTY TOOL
HD-96710-40C
Crankcase main bearing lapping tool
HD-96718-87
Crankcase main bearing lap
HD-46287
Lapping tool adapter
1.
See Figure 3-106. Obtain CRANKCASE MAIN BEAR-
ING LAPPING TOOL. Assemble CRANKCASE MAIN
BEARING LAP to lapping handle.
NOTE
Left main bearing must be installed in left crankcase in order
to use LAPPING TOOL ADAPTER in the next step. See
Installing Left Main Bearing under
3.24 BOTTOM END
OVERHAUL: ASSEMBLY.
2.
Assemble LAPPING TOOL ADAPTER to left main bear-
ing.
3.
Secure right and left crankcase halves with three crank-
Figure 3-106. Lapping Pinion Shaft Main Bearing
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
ASSEMBLING CRANKCASE
arbor expansion collars using a length of 0.156 in. (3.96
HALVES
mm) rod as spanner until arbor begins to drag. Do not
adjust arbor snug in bushing or bushing will bell, a condi-
To assemble bottom end, see 3.24 BOTTOM END OVER-
tion where hole is larger at ends than it is in the center.
HAUL: ASSEMBLY.
5.
Withdraw arbor far enough to coat lightly with 220 grit
lapping compound. Do not apply a heavy coat. Reposi-
tion 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. If necessary, flush off lap in
cleaning solvent, air dry and apply fresh, light coat of fine
lapping compound.
2006 Sportster: Engine
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BOTTOM END OVERHAUL: ASSEMBLY
3.24
GENERAL
x0581a3x
2
3
This section describes assembling the bottom end of the
4
engine.
PART NO.
SPECIALTY TOOL
J-5586-A
Transmission shaft retaining ring pliers
B-45655 and
Crankcase bearing remover/installer
HD-42720-2
2
B-45520
Gear detent assembly aid
4
HD-42326A
Crankshaft guide tool
1
HD-42579
Sprocket shaft bearing/seal installation
tool
B-45676
Sprocket shaft seal/spacer installer
10423
HD-43984
Crankshaft locking tool
3
CRANKCASE
Installing Piston Oil Jets
CAUTION
Gaskets that are missing, distorted, pinched or other-
1
2
wise damaged will result in either oil leakage or low oil
pressure.
1.
Right crankcase
2.
Piston oil jet (2)
NOTE
3.
Screw (4)
See Figure 3-107. Gasket (4) is part of piston oil jet (2)
4.
Gasket (2)
assembly and is not sold separately.
1.
See Figure 3-107. With oil jet pointed upward, install new
Figure 3-107. Piston Oil Jet Assemblies
piston oil jet assemblies
(2) with gaskets (4) in right
crankcase.
2.
Apply Loctite Low Strength Threadlocker 222 (purple) to
threads of TORX screws (3).
3.
Install TORX screws to secure piston oil jet assembly to
crankcase. Tighten to 25-35 in-lbs (2.8-4.0 Nm).
3-92
2006 Sportster: Engine
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Installing Pinion Shaft Bearing
10569
1.
See Figure 3-108. See Figure 3-109. Lubricate pinion
shaft and pinion shaft bearing with clean Harley-David-
son 20W50 engine oil.
2.
Slip bearing on pinion shaft.
3.
Using TRANSMISSION SHAFT RETAINING RING PLI-
ERS, install new retaining ring (10) in groove of pinion
shaft bearing inner race. Make sure retaining ring is fully
seated in groove.
Figure 3-108. Installing Pinion Shaft Bearing
and Retaining Ring
x0582a3x
1
2
9
3
10
4
11
5
6
7
8
12
1.
Sprocket shaft spacer
7.
Retaining ring
2.
Retaining ring
8.
Connecting rod and flywheel assembly
3.
Left main oil seal
9.
Pinion shaft bearing
4.
Thrust washer
10. Retaining ring
5.
Left crankcase
11. Outer bearing race
6.
Left main bearing
12. Right crankcase
Figure 3-109. Crankcase and Flywheel Assembly
2006 Sportster: Engine
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HOME
Installing Left Main Bearing
Assembling Crankcase Halves
NOTE
1. If not already done, install transmission assembly in left
When installing the left main bearing, the bearing presses
crankcase. See 6.14 TRANSMISSION INSTALLATION.
from the inside of the left crankcase toward the outside. A
NOTE
shoulder is incorporated into the left crankcase which allows
See Figure 3-112. The Gear Detent Assembly Aid is used to
the bearing to be installed in one direction only.
move the gear detent lever clear of the shifter drum for
1.
See Figure
3-110. Using CRANKCASE BEARING
assembly purposes.
REMOVER/INSTALLER, press left main bearing into the
2. See Figure 3-112. Retract detent assembly in right case
left crankcase.
half and install GEAR DETENT ASSEMBLY AID until it
a. Place support tube (1) on press bed with recessed
has bottomed in right case half.
cup end facing up.
b. With the inboard side of the left crankcase (2) facing
upward, position crankshaft bearing bore (3) over
10327
support tube.
c. Place left main bearing (4) over bearing bore. Insert
pilot/driver
(5) through left main bearing, through
crankshaft bearing bore and into support tube.
d. Apply pressure with press ram (6) until left main
bearing bottoms out in bearing bore.
2.
See Figure 3-111. See Figure 3-109. Install new retain-
ing ring (7) from the inside of the left crankcase.
10330
6
3
5
Figure 3-111. Installing Left Main Bearing Retaining Ring
x0624a3x
1
4
2
1
2
1.
Support tube (HD-42720-2)
2.
Left crankcase
3.
Crankshaft bearing bore
4.
Left main bearing
1.
Detent assembly
5.
Pilot/driver (B-45655)
2.
Detent assembly aid
6.
Press ram
Figure 3-112. Using Gear Detent Assembly Aid
Figure 3-110. Installing Left Main Bearing In Crankcase
(Part No. B-45520)
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2006 Sportster: Engine
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3.
Shift transmission to 1st gear.
d. See Figure 3-114. Carefully fit crankcases together.
4.
Lubricate left main bearing with clean Harley-Davidson
e. See Figure 3-115. Apply a few drops of LOCTITE
20W-50 engine oil.
262 (red) to last few threads of each crankcase fas-
tener and install fasteners (thirteen long and four
5.
Assemble crankcase halves together.
short) in crankcase assembly, in locations shown.
a. See Figure 3-113. Install flywheel assembly in right
f.
Tighten fasteners to 15-19 ft-lbs (20.3-25.8 Nm) in
crankcase. Slide pinion shaft through outer race in
the sequence shown in Figure 3-115.
right crankcase.
6. Remove transmission gear detent assembly aid.
b. Slide CRANKSHAFT GUIDE TOOL onto flywheel
sprocket shaft.
c. Apply a thin coat of GRAY HIGH-PERFORMANCE
11537
SEALANT to crankcase joint faces.
11522
Figure 3-114. Assembling Crankcases With
Crankshaft Guide Tool (Part No. HD-42326-A)
Figure 3-113. Installing Flywheels in Right Crankcase
x0568a3x
x0659x3x
Left side
8
16
7
9
11
12
17
6
10
13
5
Right side
15
14
*
*
*
1
2
3
4
- Indicates crankcase fastener locations
- Short fastener
*
Figure 3-115. Crankcase Fasteners
2006 Sportster: Engine
3-95
HOME
7.
See Figure 3-116. See Figure 3-117. Install spacer in I.D.
of new seal. With the open (lipped) side of seal facing
CAUTION
outward, center seal/spacer assembly over bearing bore.
Do not remove the spacer after installation or the new
seal will have to be discarded and the procedure
repeated.
12091
8. See Figure 3-118. Install bearing seal and spacer.
a. Center seal/spacer driver (2) over seal, so that the
sleeve (smaller O.D.) seats between seal wall and
garter spring.
b. Assemble SPROCKET SHAFT BEARING/SEAL
INSTALLATION TOOL (1) and SPROCKET SHAFT
SEAL/SPACER INSTALLER onto sprocket shaft.
c. Rotate handle clockwise until the spacer makes
contact with the bearing. Remove tool from sprocket
shaft.
11541
1
Figure 3-116. Open (Lipped) Side of Seal Faces Out
2
11540
1.
Bearing/seal installer (Part No. HD-42579)
2.
Seal/spacer installer (Part No. B-45676)
Figure 3-118. Install Bearing Seal/Spacer
Figure 3-117. Install Spacer and Seal
3-96
2006 Sportster: Engine
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Installing Cylinder Base Studs
8931
See Figure 3-119. If cylinder studs were removed, install
them as follows.
1.
Pack clean towels into crankcase opening.
2.
Place a steel ball into a head screw (1).
3.
The cylinder studs (2) have a shoulder (3) at the lower
1
end. Place the end of the stud without the shoulder into
the head screw.
4.
Install the stud in the crankcase with the shoulder end
4
down. Use an air gun (4) to drive the stud until the shoul-
der reaches the crankcase.
3
5.
Remove air gun. Use a torque wrench to tighten stud to
120-240 in-lbs (13.6-27.1 Nm).
2
1. Head screw with ball inside
2. Cylinder stud
3. Shoulder on cylinder stud
4. Air gun
Figure 3-119. Cylinder Studs
2006 Sportster: Engine
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HOME
2. See Figure 3-120. Clean threads on pinion shaft and nut
CAM GEARS AND
(11). Apply several drops of LOCTITE THREADLOCKER
GEARCASE COVER
272 (red) to threads of nut.
CAUTION
PART NO.
SPECIALTY TOOL
See Figure 3-120. When using CRANKSHAFT LOCKING
TOOL, Do NOT use impact wrench to drive nut (11) onto
HD-43984
Crankshaft locking tool
pinion shaft.
1.
See Figure 3-120. Make sure shaft key (18) is installed
on flywheel pinion shaft. Install oil pump drive gear (12)
and pinion gear (5) on pinion shaft.
NOTE
Timing mark on pinion gear tooth is aligned with keyway in
I.D. of pinion gear, as shown in Figure 3-121. The timing mark
will allow you to easily position pinion gear over shaft key and
against oil pump drive gear on pinion shaft.
x0206b3x
10
1
13
14
9
15
12
18
13
2
19
4
5
11
16
3
8
7
17
20
6
1.
Rear exhaust cam gear
10. Right crankcase
2.
Rear intake cam gear
11. Nut
3.
Front intake cam gear
12. Oil pump drive gear
4.
Front exhaust cam gear
13. Cam gear bushing (4)
5.
Pinion gear
14. Rear exhaust cam gear bushing
6.
Screw (11)
15. Rear intake cam gear bushing
7.
Front intake cam gear bushing
16. Pinion shaft bushing
8.
Front exhaust cam gear bushing
17. Gearcase cover
9.
Gearcase cover gasket
18. Shaft key
Figure 3-120. Gearcase and Valve Train Components
3-98
2006 Sportster: Engine
HOME
x0474x3x
x0476x3x
x0207x3x
1
2
1.
Keyway
2.
Timing mark at centerline of keyway
Figure 3-121. Pinion Gear Timing Mark and Keyway
x0475x3x
4
Figure 3-123. Crankshaft Locking Tool
2
(Part No. HD-43984)
6. Install rear exhaust cam
(1). Rotate cam until timing
mark (a slot) points exactly at centerline of rear intake
cam bushing.
7. Install front intake cam (3). Rotate cam until slotted tim-
ing mark points exactly at centerline of rear intake cam
bushing.
3
NOTE
1
See Figure 3-124. “V” marks on rear intake cam (2) are not
used for timing of Sportster model engines.
1.
Pinion gear
2.
Shaft key
8. Install rear intake cam (2). As you install this cam, rotate
3.
Oil pump drive gear
it so that the three timing marks (dots) line up exactly
4.
Pinion shaft
with timing marks on the pinion gear, rear exhaust cam
and front intake cam.
Figure 3-122. Oil Pump Drive Gear and Pinion Gear
9. Install front exhaust cam (4). As you install this cam,
Installed on Pinion Shaft
rotate it so that its timing mark (a dot) lines up with timing
mark (dot) of front intake cam.
3.
See Figure
3-123. Install CRANKSHAFT LOCKING
NOTE
TOOL over pinion shaft. Install nut on pinion shaft.
Make sure all timing marks on cams just installed line up cor-
Tighten to 35-45 ft-lbs (47.5-61.1 Nm). Remove CRANK-
rectly, as shown in Figure 3-124. If necessary, remove a cam,
SHAFT LOCKING TOOL.
rotate it slightly, and re-install it. If timing marks are off even
NOTE
one tooth, engine will not run correctly.
See Figure 3-124. Because of the larger diameter additional
gear (which meshes with the pinion gear) on the outboard
10. See Figure 3-120. Install a new dry gasket (9) on gear-
end of the rear intake (2) cam gear, the rear exhaust (1) and
case cover (17).
front intake (3) cam gears must both be installed before the
rear intake cam gear is installed.
4.
Lubricate all cams and all cam bushings in right crank-
case with clean Harley-Davidson 20W-50 engine oil.
5.
See Figure 3-124. Rotate crankshaft until timing mark on
pinion gear (5) points exactly at centerline of rear intake
cam bushing.
2006 Sportster: Engine
3-99
HOME
x0183a3x
2
3
1
4
5
Cam #2 “V” marks are not used for timing
1.
Rear exhaust cam gear 1D (or 1W)
2.
Rear intake cam gear 2D (or 2W)
3.
Front intake cam gear 3D (or 3W)
4.
Front exhaust cam gear 4D (or 4W)
5.
Pinion gear
Figure 3-124. Cam, Pinion Gear and Timing Mark Indexing
11. Lubricate all cam bushings in gearcase cover with clean
8997
Harley-Davidson 20W-50 engine oil.
1
8
9
3
7
12. Install gearcase cover over all gears and onto right
crankcase. Secure cover to crankcase with 11 socket
head screws. Tighten screws evenly to 80-110 in-lbs
(9.0-12.4 Nm) according to the tightening sequence
shown in Figure 3-125.
10
6
11
4
2
5
Figure 3-125. Gearcase Cover Mounting Screw
Torque Sequence
3-100
2006 Sportster: Engine
HOME
13. Check cam gear end play through tappet bores in right
x0518b3x
crankcase, for each cam gear as follows:
a. Turn engine over until lobe of cam gear being
checked is pointing toward its respective tappet
1
guide hole.
b. Using a flat blade screwdriver, gently pry cam gear
2
toward gearcase cover.
c. Using a feeler gauge, measure gap between bush-
ing (in crankcase) and cam gear shaft thrust face
4
(shoulder). This is cam gear end play.
3
d. Compare your cam gear end play measurements
with the
3.1 SPECIFICATIONS. Make repairs as
required if end gap is less than the minimum speci-
fied, or greater than the maximum specified (Service
Wear Limits).
TAPPETS
1.
See Figure 3-126. Rotate engine so that both tappets (3)
from the cylinder being serviced will be installed on the
base circle (lowest position) of the cam.
1.
Screw (2)
2.
Anti-rotation device (2)
2.
Apply a liberal amount of engine oil to tappet assembly
3.
Tappet (4)
(especially roller needles), to ensure smooth initial oper-
4.
Right crankcase
ation.
3.
insert both tappets (intake and exhaust) into anti-rotation
Figure 3-126. Tappet Installation
device (2) with flats at upper end of each tappet posi-
tioned so they will be facing front and rear when assem-
bly is installed in engine.
4.
Install anti-rotation device with tappets into bore in right
crankcase (4). Secure with screw (1). Tighten to 80-110
in-lbs (9.0-12.4 Nm).
ASSEMBLING TOP END OF ENGINE
To continue with engine assembly, see 3.17 TOP END OVER-
HAUL: ASSEMBLY.
2006 Sportster: Engine
3-101
HOME
OIL TANK
3.25
From the feed section of the oil pump, another feed hose
OIL HOSE ROUTING
directs the flow up to the oil filter mount. Eventually, oil drains
to the sump where it collects in the scavenge section of the oil
See Figure 3-127. The feed, vent and return ports are located
pump. The return hose routes the oil back to the tank where
on the bottom of the oil tank to reduce under seat congestion
the cycle is repeated.
A hose routes the oil from the feed port at the lower right front
corner to a fitting on the oil pump.
x0006d3x
5
1
2
4
Feed
Vent
Return
3
1.
Filler cap and dipstick
2.
Oil tank
3.
Oil pump
4.
Oil fIlter
5.
Gear case cover
Figure 3-127. Engine Oil Tank, Oil Filter and Hose Routing Locations
3-102
2006 Sportster: Engine
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