Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 16

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c. At top of cylinder head, start valve guide into bore.

Verify that cylinder head support stand

(3) and

VALVE GUIDE REMOVER/INSTALLER are square.

d. Place installer sleeve (2) over valve guide and then

Center VALVE GUIDE REMOVER/INSTALLER

insert VALVE GUIDE REMOVER/INSTALLER (1)

under ram and press valve guide further into bore,

into installer sleeve.

then back off ram again to allow valve guide to find

e. See Figure 3-37. Center VALVE GUIDE REMOVER/

center.

INSTALLER (1) under ram of press and apply pres-

g. Repeat previous step and then apply pressure to

sure only until valve guide is started in bore and

VALVE GUIDE REMOVER/INSTALLER until

then back off ram slightly to allow valve guide to cen-

installer sleeve (2) contacts machined area of cylin-

ter itself.

der head surrounding valve guide.

Secure cylinder head for service.

CAUTION

a. See Figure 3-38. Thread 12 mm end of CYLINDER

Always back off ram to allow the valve guide to find cen-

HEAD HOLDING FIXTURE into cylinder head spark

ter. Pressing valve guide into cylinder head in one stroke

plug hole.

can bend remover/installer, break valve guide, distort

b. Clamp tool in vise at a 45 degree angle or one that

cylinder head casting and/or damage cylinder head valve

offers a comfortable working position.

guide bore.

NOTE

Valve guides must be reamed to within 0.0005-0.0001 in.

(0.013-0.0025 mm) of finished size.

10052

10050

T-handle (Part no. HD-39847)

Valve guide reamer (Part no. B-45523)

Cylinder head holding fixture

(Part no. HD-39786-A)

Figure 3-38. Reaming Valve Guide Bore

Valve guide remover/installer (Part no. B-45524)

Installer sleeve (Included in Part no. B-45524)

Cylinder head support stand (Part no. HD-39782-A)

Figure 3-37. Installing Shoulderless Valve Guide

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Obtain the VALVE GUIDE REAMER (2) and REAMER T-

10048

HANDLE (1).

a. Install T-handle on reamer.

b. Start bit of reamer into bore at top of cylinder head.

c. Placing thumb on drive socket of REAMER T-HAN-

DLE, apply slight pressure on reamer while rotating

in a clockwise direction.

CAUTION

For best results, do not push on reamer or apply pres-

sure to the reamer handle. While excessive pressure

results in a rough cut, bore will be tapered if pressure is

not centrally applied.

d. Continue rotating REAMER T-HANDLE until entire

bit has passed through valve guide bore and shank

of reamer rotates freely.

CAUTION

Valve guide brush (Part no. HD-34751)

Cylinder head holding fixture

Never back reamer out of valve guide or bore will be

(Part no. HD-39786-A)

damaged.

Figure 3-39. Scrubbing Valve Guide Bore

e. Remove T-handle from reamer. Carefully pulling on

bit, draw shaft of reamer out combustion chamber

side of valve guide.

10046

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

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)

Direct compressed air into the valve guide bore to

remove any metal shavings or debris.

See Figure 3-39. Clean valve guide bore with the VALVE

GUIDE CLEANING BRUSH (1).

Valve guide hone (Part no. B-45525)

See Figure 3-40. Obtain the VALVE GUIDE HONE and

Cylinder head holding fixture

REAMER LUBRICANT.

(Part no. HD-39786-A)

a. Install hone in a high speed electric drill.

Figure 3-40. Honing Valve Guide Bore

b. Apply REAMER LUBRICANT to finishing stones of

hone and valve guide bore.

c. Start finishing stones of hone into bore.

d. Activating the drill, move the entire length of the fin-

ishing stone arrangement forward and backward

through the bore for 10 to 12 complete strokes. Work

for a crosshatch pattern of approximately 60˚.

NOTE

The hone is not intended for the removal of material.

3-44

2006 Sportster: Engine

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REFACING VALVE SEATS

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

PART NO.

SPECIALTY TOOL

ure.

HD-35758-B

Neway valve seat cutter set

1WARNING

HD-39786-A

Cylinder head holding fixture

Compressed air can pierce the skin and flying debris from

HD-34751

Valve guide brush

compressed air could cause serious eye injury. Wear

safety glasses when working with compressed air. Never

NOTES

use your hand to check for air leaks or to determine air

●

Verify correct valve stem to valve guide clearance before

flow rates. (00061a)

refacing. Refer to Table 3-39. If new valve guides must

Direct low pressure compressed air into the valve guide

be installed, see REPLACING VALVE GUIDES on previ-

bore to remove any debris.

ous page and complete that task before refacing valve

seats.

10. See Figure 3-39. Clean bore with the VALVE GUIDE

CLEANING BRUSH (1).

●

This procedure is not based on the lapping of valves. The

end result is an interference fit between the 45° valve

NOTE

face and the valve seat which will be 46°.

Always verify valve stem to valve guide clearance after hon-

ing, since a worn reamer may cut the bore undersize.

Secure cylinder head for servicing.

11. Check valve stem to valve guide clearance.

a. Thread 12 mm end of CYLINDER HEAD HOLDING

FIXTURE into cylinder head spark plug hole.

a. Measure the inside diameter of the valve guide with

an inside ball micrometer.

b. Clamp fixture in vise and further tighten cylinder

head onto the fixture to prevent any movement dur-

b. Measure the outside diameter of the valve stem with

ing operation.

an outside micrometer.

c. Place cylinder head at a 45° angle or one that offers

c. Refer to Table 3-39. If the clearance between valve

a comfortable working position.

stem and valve guide is not within the limits shown,

In order to determine the correct location of the 46° valve

the low end being preferable, then the valve stem

seat in the head, measure the width of the valve to be

may be excessively worn or the valve guide bore

used and subtract 0.080 in. (2.032 mm) from that num-

undercut.

ber.

12. Clean cylinder head assembly again.

Set your dial caliper to the lesser measurement and lock

a. Using cleaning solvent, thoroughly clean cylinder

it down for quick reference. This is the location of your

head and valve guide bore.

valve seat.

b. Scrub valve guide bore with the VALVE GUIDE

Use a permanent magic marker to highlight the valve

CLEANING BRUSH. For best results, use a thin

seat area that is going to be cut. Be sure to highlight all

engine oil and clean valve guide bore with the type

three angles. Allow marker to dry before proceeding.

of swabs or patches found in gun cleaning kits.

NOTES

c. Continue to wipe bore until clean cloth shows no evi-

●

Always ensure cutter blades and cutter pilot are clean

dence of dirt or debris. Follow up with a thorough

before beginning the cutting process. The correct clean-

wash in hot soapy water.

ing brush is supplied with the Neway tool set.

1WARNING

●

Always ensure the inside of the valve guide is clean by

using VALVE GUIDE BRUSH.

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)

13. Blow parts dry with low pressure compressed air.

2006 Sportster: Engine

3-45

HOME

Next, with your dial caliper locked to the predetermined

a0087x3x

setting, measure the 46° cut at the outermost edge at the

widest point of the circle to determine what cut needs to

be made next.

a. If the 46° cut is too high (towards the combustion

chamber), use the 31° cutter to lower the valve seat

closer to the port.

b. If the 46° cut is too low, use the 60° cutter to raise

the valve seat or move it away from the port.

NOTES

●

Because you are using the top measurement of the valve

seat as a reference point, it will usually be necessary to

use the 31° cutter following the initial 46° cut.

●

Always highlight the valve seat with the permanent

magic marker in order to ensure the location of the 46°

valve seat.

If the location of the valve seat is not correct, repeat

steps 7 and 8.

Figure 3-41. Neway Valve Seat Cutter Set

(Part No. HD-35758-B)

10.

When you accomplish a complete clean-up of the 46°

angle and the width is at least 0.062 in. (1.575 mm), pro-

See Figure 3-41. Obtain the NEWAY VALVE SEAT CUT-

ceed to the next step.

TER SET. Select the correct cutter pilot (Part No. B-

11.

Select the proper 60° cutter and gently slide the cutter

35758-52). Securely seat the pilot by pushing down and

down the cutter pilot to the valve seat.

turning using the installation tool supplied in the tool set.

12.

Remove just enough material to provide an even valve

Choose the proper 46° cutter (intake or exhaust) and

seat width of 0.040-0.062 in. (1.016-1.575 mm).

gently slide the cutter onto the pilot. Be careful not to

drop the cutter onto the valve seat.

13.

Remove cutter and cutter pilot.

While applying a constant and consistent pressure,

14.

Repeat the process on any valve seat that needs ser-

remove just enough material to show a complete clean-

vice.

up on the 46° angle. Do not remove any more metal than

15.

Insert valve to be used in the valve guide and bottom on

is necessary to clean up the valve seat (that is, to provide

the valve seat. Positioning the cylinder head port

a uniform finish and remove pitting).

upwards and with slight thumb pressure against the

valve, completely fill the port with solvent to verify proper

NOTES

seal between the valve and the valve seat.

●

If the width of the clean-up angle is greater on one side

of the valve seat than the other, the valve guide may

NOTE

need to be replaced due to improper installation.

Hold pressure against the valve for a minimum of 10 seconds.

●

After making the 46° cut, if you discover a groove cut

If any leakage occurs, examine the valve seat for irregularities

completely around the valve seat, this means the blades

or defects and if necessary repeat the above cutting process.

of the cutter are in alignment and need to be staggered.

16. Clean valves, cylinder head and valve seats in solvent.

This is accomplished by loosening all of the blades from

Follow up with a thorough wash in hot soapy water.

the cutter body and moving each blade slightly in its cra-

17. Scrub valve guide bores with VALVE GUIDE BRUSH and

dle in opposite directions on the cutter. The tool needed

hot, soapy water.

to loosen the blades is supplied in the tool set. A perma-

nent magic marker mark every 90° will help in determin-

ing where new angles are.

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)

18. Blow parts dry with low pressure compressed air.

3-46

2006 Sportster: Engine

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b0972x3x

Intake and Exhaust Valve and Seat

Seat

60°

Min. 0.040 in. (1.016 mm)

Max. 0.062 in. (1.575 mm)

Valve

Margin

31°

46°

Figure 3-42. Valve and Seat Dimensions

Replacing Valve Seats

Replacing a valve seat is a complex operation requiring spe-

cial equipment. If the valve seat is loose or is not fully seated

in the head, then valve seat movement will prevent the proper

transfer of heat from the valve. The valve seat surface must

be flush with (or below) the head surface. See 3.1 SPECIFI-

CATIONS for valve seat-to-cylinder head fit.

CAUTION

To remove the old valve seat, lay a bead of weld material

around the inside diameter of the valve seat. This will

shrink the valve seat outside diameter and provide a sur-

face for driving the valve seat out the port side.

2006 Sportster: Engine

3-47

HOME

ASSEMBLY

8702

PART NO.

SPECIALTY TOOL

HD-34736-B

Valve spring compressor

Apply a liberal amount of engine oil to the valve stem.

See Figure 3-25. Insert valve (11) into valve guide (7)

and bottom valve on valve seat (12).

See Figure 3-43. Place a protective sleeve over the valve

stem keeper groove. Coat the protective sleeve with oil.

8703

6610

8704

Figure 3-43. Valve Guide Seal Protector Sleeve

CAUTION

Always use a protective sleeve on the valve stem keeper

groove when installing valve stem seal. If the seal is

installed without using the protective sleeve, the seal will

be damaged, causing leakage around the valve stem,

excessive oil consumption and valve sticking.

NOTES

● See Figure 3-44. The valve seal is incorporated into the

lower valve collar and is installed by hand. NO SPECIAL

TOOLS ARE REQUIRED.

Figure 3-44. Valve Seal and Lower Valve Collar Assembly

● The valve seal is completely installed when the lower

(seal and lower collar replaced as assembly only)

valve collar contacts the machined surface of the head.

3-48

2006 Sportster: Engine

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8926

10043

Figure 3-45. Valve Seal and Lower Valve Collar

Assembly Installation

See Figure 3-45. Place a new seal and lower valve collar

assembly over valve stem and onto valve guide.

CAUTION

Figure 3-46. Compress Valve Spring With

Valve Spring Compressor (Part No. HD-34736-B)

Do not remove valve after seal is installed. Otherwise,

sharp edges on keeper groove will damage seal.

INSTALLATION

NOTE

A single valve spring is used for each valve. The inner and

outer springs are combined into one progressively wound,

NOTE

tapered spring.

Push rod covers and lower cover retainers MUST be installed

prior to installing cylinder heads. See PUSH RODS, COV-

See Figure 3-25. Install valve spring (5) and upper collar

ERS AND RETAINERS under 3.17 TOP END OVERHAUL:

(4).

ASSEMBLY.

See Figure 3-46. Compress valve spring with VALVE

See CYLINDER HEAD under 3.17 TOP END OVERHAUL:

SPRING COMPRESSOR.

ASSEMBLY to install cylinder head onto engine.

See Figure 3-25. Insert valve collar retainers (3) into

upper collar (4), making sure they engage groove in

valve stem. The retainer gaps should be equal.

Release and remove VALVE SPRING COMPRESSOR.

Repeat Steps 1. - 8. for remaining valve(s).

10. See Figure 3-25. Install stabilizer link bracket (16) to front

head with two screws

(17) and lock washers

(18).

Tighten to 55-65 ft-lbs (74.6-88.2 Nm).

2006 Sportster: Engine

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CYLINDER AND PISTON

3.16

6. Clean piston pin lock ring grooves.

REMOVAL/DISASSEMBLY

7. Examine piston and cylinder for cracks, burnt spots,

See CYLINDER AND PISTON under 3.14 TOP END OVER-

grooves and gouges.

HAUL: DISASSEMBLY to remove cylinder and piston from

NOTE

engine.

Check connecting rod for up and down play in lower bearings.

When up and down play is detected, flywheel and connecting

rod assembly must be replaced. This requires removing and

CLEANING, INSPECTION, AND

disassembling engine crankcase.

REPAIR

Checking Gasket Surface

CAUTION

PART NO.

SPECIALTY TOOL

If either cylinder gasket surface does not meet flatness

HD-33446-A

Cylinder torque plates

specifications, replace cylinder and piston.

HD-33446-86

Torque plate bolts

1. See Figure 3-47. Check that cylinder top (head) gasket

surface is flat within 0.006 in. (0.15 mm). Lay a straight

Soak cylinder and piston in an aluminum-compatible

edge across the surface, then try to insert a feeler gauge

cleaner/solvent until deposits are soft, then clean with a

between the straightedge and the gasket surface.

brush. Blow off loosened carbon and dirt particles and

wash in solvent.

2. Check that the cylinder base gasket surface is flat within

0.008 in. (0.20 mm). Lay a straightedge across the sur-

face, then try to insert a feeler gauge between the

1WARNING

straightedge and the gasket surface.

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

8933

use your hand to check for air leaks or to determine air

flow rates. (00061a)

Clean oil passage in cylinder with low pressure com-

pressed air.

Clean piston ring grooves with a piece of compression

ring ground to a chisel shape.

Examine piston pin to see that it is not pitted or scored.

Check piston pin bushing to see that it is not loose in

connecting rod, grooved, pitted or scored.

a. A piston pin properly fitted to upper connecting rod

bushing has a

0.00125 to

0.00175 in.

(0.0317-

0.0444 mm) clearance in bushing.

b. If piston pin-to-bushing clearance exceeds 0.00200

in. (0.0508 mm), replace worn parts. See 3.16 CYL-

INDER AND PISTON, CONNECTING ROD BUSH-

INGS.

Figure 3-47. Checking Gasket Surfaces

3-50

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Measuring Cylinder Bore

x0460x3x

See Figure 3-48. Remove any burrs from the cylinder

gasket surfaces.

Install a head and base gasket, and CYLINDER

TORQUE PLATES and TORQUE PLATE BOLTS.

Tighten the bolts using the same method used when

installing the cylinder head screws. See 3.15 CYLINDER

HEAD, INSTALLATION.

NOTE

Torque plates, properly tightened and installed with gaskets,

simulate engine operating conditions. Measurements will vary

as much as 0.001 in. (0.025 mm) without torque plates.

Take cylinder bore measurement in ring path, starting

about 1/2 in. (13 mm) from top of cylinder, measuring

from front to rear, and then side to side. Record readings.

Repeat measurement at center, and then at bottom of

ring path. Record readings. This process will determine if

cylinder is out-of-round (or “egged”) and will also show

any cylinder taper or bulge. Refer to Table 3-41. If cylin-

der is not scuffed or scored and is within service limit,

see

3.16 CYLINDER AND PISTON, CLEANING,

INSPECTION, AND REPAIR, Measuring Piston to Cyl-

inder Fit.

Table 3-41. Cylinder Bore

Service Wear Limits

BORE SIZES

883CC

1200CC

Figure 3-48. Measuring Cylinder Bore

Standard Bore

3.0035 in.

3.5008 in.

76.289 mm

88.920 mm

0.005 in. O.S. bore

3.0078 in.

3.5050 in.

0.13 mm

76.398 mm

89.027 mm

0.010 in. O.S. bore

3.0128 in.

3.5100 in.

0.25 mm

76.525 mm

89.154 mm

NOTE

If piston clearance exceeds service limit, cylinders should be

re-bored and/or honed to next standard oversize, and refitted

with the corresponding piston and rings. Do not fit piston

tighter than

0.0007 in. (0.018 mm). See 3.1 SPECIFICA-

TIONS.

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NOTE

Measuring Piston to Cylinder Fit

The oval openings are too small for a standard flat anvil

NOTE

micrometer. Using such a device would result in measuring

This inspection is very heat sensitive. Do not check piston

errors. See Figure 3-50. Use a 3-4 inch blade or ball anvil

running clearance immediately after honing or deglazing cyl-

style micrometer, or a 4-5 inch micrometer with spherical ball

inder. Even holding the piston in your hand for too long can

anvil adapters.

cause measurements to vary by as much as 0.002 in. (.051

b. Measure the piston skirt at the oval openings and

mm). Both piston and cylinder must be at room temperatures

then transfer that measurement to a dial bore

before proceeding.

gauge.

Measure the piston running clearance. Proceed as fol-

c. Using a grease pencil, mark the top, middle and bot-

lows:

tom of the piston ring travel zone in the cylinder

NOTE

bore. Measure at markings in cylinder parallel and

perpendicular to crankshaft.

Check the piston clearance in the cylinder in which the piston

will run. The torque plates must be installed on the cylinder to

d. Replace piston and/or cylinder if running clearance

simulate an assembled cylinder for accurate measurement of

exceeds 0.003 in. (0.076 mm).

cylinder.

Boring and Honing Cylinder

1. The cylinder must be bored with gaskets and torque

10699

plates attached. Bore the cylinder to 0.003 in. (0.08 mm)

under the desired finished size.

2. Hone the cylinder to its finished size using a 280 grit rigid

hone followed by a 240 grit flexible ball hone. Honing

must be done with the torque plates attached. All honing

must be done from the bottom (crankcase) end of the

cylinder. Work for a 60˚ crosshatch pattern.

Final cylinder bore sizes, after honing are as follows:

Table 3-42. Cylinder Final Bore Sizes

BORE SIZES

883 CC

1200 CC

Standard bore*

3.0005 in.

3.4978 in.

(76.213 mm)

(88.844 mm)

Figure 3-49. Measurement Area

0.005 in. O.S. bore

3.0048 in.

3.502 in.

See Figure 3-49. the measurement is taken on bare

0.13 mm

(76.323 mm)

(88.95 mm)

aluminum to avoid measuring errors. An oval-

shaped opening in the coating is present on each

0.010 in. O.S. bore

3.0098 in.

3.507 in.

side of the piston for proper placement of the

0.25 mm

(76.449 mm)

(89.08 mm)

micrometer.

*All bore sizes + 0.0002 in.

f2109x3x

4-5 inch micrometer

Spherical ball anvil adapter (2)

Figure 3-50. Micrometer with Anvil Adapters

3-52

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NOTES

● When cylinder requires oversize re-boring to beyond

2747a

0.010 in.

(0.25 mm), the oversize limit has been

exceeded and cylinder must be replaced.

● The same piston may be used if cylinder bore was not

changed, unless it is scuffed or grooved. However,

replace rings and hone the cylinder walls with a No. 240

grit flexible ball hone.

CAUTION

Failure to remove all abrasive particles may result in pre-

mature cylinder, piston and ring wear and possible

engine failure.

Thoroughly wash the cylinder bore with liquid dishwash-

ing soap and warm water to remove all abrasive particles

and residual grit. Continue cleaning until a clean cloth

shows no remaining dirt or debris.

1WARNING

Top ring - Install either side up

Second ring - Install dot toward top

Compressed air can pierce the skin and flying debris from

Oil control rings

compressed air could cause serious eye injury. Wear

safety glasses when working with compressed air. Never

Figure 3-51. Piston Rings

use your hand to check for air leaks or to determine air

flow rates. (00061a)

8999

Hot rinse the cylinder and dry with moisture free low

pressure compressed air.

Immediately apply a thin film of clean engine oil to a

clean white paper towel and thoroughly wipe the inside

of the cylinder.

NOTE

After wiping the cylinder with a clean, oiled paper towel, the

towel will be dark with contamination. Repeat this process

using a new lightly oiled paper towel each time until the towel

remains white. The cylinder is now clean.

With the cylinder at room temperature, check the piston

clearance in the cylinder in which the piston will run.

Fitting Piston Rings

See Figure 3-51. Piston rings are of two types: compression

and oil control. The two compression rings are positioned in

the two upper piston ring grooves. The dot on the second

compression ring must face upward. Ring sets are available

to fit standard and oversize pistons.

Piston ring sets must be properly fitted to piston and cylinder:

Figure 3-52. Measuring Ring End Gap

See Figure 3-52. Place piston in cylinder about 1/2 in.

(13 mm) from top. Set ring to be checked inside cylinder,

squarely against piston. Remove piston and check ring

end gap with thickness gauge. See 3.1 SPECIFICA-

TIONS for tolerance.

NOTE

See SERVICE WEAR LIMITS for end gap dimensions. Do not

file rings to obtain proper gap.

2006 Sportster: Engine

3-53

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10701

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)

Use low pressure compressed air to remove any dirt or

dust that may have settled in piston oil drain holes and

ring grooves. Apply clean engine oil to piston ring

grooves.

See Figure 3-53. Install oil control ring expander spring.

Figure 3-54. Installing Piston Rings

Make sure ends of spring point upward. Spiral bottom oil

control ring into space in ring groove below expander

5. See Figure 3-55. Position rings so end gaps of adjacent

spring. Position oil control ring gap 90 degrees from gap

rings are a minimum of 90˚ apart. Ring gaps are not to

in expander spring. Spiral top oil control ring into space

be within 10˚ of the thrust face centerline.

in ring groove above expander spring. Position oil control

6. See Figure 3-56. Check for proper side clearance with

ring gap 180 degrees from gap in bottom oil control ring.

thickness gauge, as shown. See 3.1 SPECIFICATIONS

for tolerance.

11521

NOTE

If the ring grooves are clean, and the side play is still not cor-

rect, replace the rings, the piston, or both.

x0486x3x

Front

Piston

Pin

Figure 3-53. Installing Oil Control Ring Expander Spring

Rear

See Figure 3-54. Use a piston ring expander tool to slip

compression rings over piston into their respective

grooves. Install second compression ring first, then top

Figure 3-55. Position Ring End Gaps At Arrows

compression ring. Be extremely careful not to over

expand or twist rings, or damage piston surface when

installing rings.

NOTE

10700

Install second compression ring with dot towards top of pis-

ton.

Figure 3-56. Measuring Ring Clearance in Groove

3-54

2006 Sportster: Engine

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3. See Figure 3-58. Obtain the CONNECTING ROD BUSH-

CONNECTING ROD BUSHINGS

ING REMOVER/INSTALLER.

a. Sparingly apply graphite lubricant to threads of bolt

(6) to prolong service life and ensure smooth opera-

PART NO.

SPECIALTY TOOL

tion.

b. Slide receiver cup (5) onto bolt with the closed side

HD-95952-33C

Connecting rod clamping tool

facing bolt head.

Connecting rod bushing remover/

c. Insert bolt through upper connecting rod bushing.

HD-95970-32D

installer

HD-94800-26A

Connecting rod bushing reamer

d0189x3x

1. Threaded cylinder (2)

HD-35102

Wrist pin bushing hone

2. Clamp

3. Thumbscrew (2)

HD-39964

Reamer lubricant

Removing Upper Connecting Rod Bushing

NOTE

Replace the upper connecting rod bushing if the piston pin to

rod bushing clearance exceeds 0.002 in. (0.051 mm).

Figure 3-57. Connecting Rod Clamping Tool

CAUTION

(Part No. HD-95952-33C)

Place clean shop towels in and around the crankcase

bore to prevent chips and shavings from falling into the

crankcase.

x0602x3x

NOTE

If CONNECTING ROD CLAMPING TOOL holes are too

small, enlarge the holes in the tool.

See Figure

3-57. Obtain the CONNECTING ROD

CLAMPING TOOL and install as follows:

a. Slide clamp (2) over connecting rod so that slots

engage cylinder head studs. Exercise caution to

avoid scratching or bending studs.

b. With the knurled side up, screw threaded cylinders

1. Nut

(1) onto studs to secure position of clamp.

2. Flat washer

3. Nice bearing

c. Alternately turn each clamp thumbscrew (3) a few

4. Remover/installer

turns to gradually fix position of connecting rod.

5. Receiver cup

Turning only one thumbscrew will move rod off-cen-

6. Bolt

ter, while tightening second thumbscrew can cause

rod to flex or bend.

Figure 3-58. Connecting Rod Bushing Remover/Installer

Install rubber hoses over remaining two cylinder studs.

(Part No. HD-95970-32D)

2006 Sportster: Engine

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d. See Figure 3-59. Slide remover side of remover/

Installing Upper Connecting Rod Bushing

installer onto bolt. The driver is stamped to ensure

proper orientation.

See Figure 3-58. Obtain the CONNECTING ROD BUSH-

ING REMOVER/INSTALLER.

e. See Figure 3-58. Slide Nice bearing (3) and flat

washer (2) onto bolt (6) until they contact remover/

a. Sparingly apply graphite lubricant to threads of bolt

installer (4).

(6) to prolong service life and ensure smooth opera-

tion.

Thread nut (1) onto bolt until assembly is snug.

b. Slide receiver cup (5) onto bolt with the closed side

g. Using two box end wrenches, tighten nut on bolt

facing bolt head.

until bushing is free.

c. Insert bolt through upper connecting rod bushing

h. Unthread nut from bolt. Remove flat washer, Nice

bore.

bearing and remover/installer. Remove bolt from

bushing bore.

d. See Figure 3-60. Slide new bushing onto bolt. Start

bushing into bore. Verify that center of slot in bush-

Remove bushing from receiver cup and discard.

ing (2) is aligned with oil hole in connecting rod (3).

NOTE

Also, be sure that bushing is square in bore and not

Leave CONNECTING ROD CLAMPING TOOL installed dur-

cocked.

ing bushing installation procedure which follows.

e. Slide installer side of remover/installer (1) onto bolt

until shoulder contacts bushing. The remover/

installer is stamped to ensure proper orientation.

x0603x3x

See Figure 3-58. Slide Nice bearing (3) and flat

washer (2) onto bolt until they contact remover/

installer.

g. Thread nut (1) onto bolt until assembly is snug.

h. Using two box end wrenches, tighten nut on bolt

until collar on remover/installer bottoms against con-

necting rod. See Figure 3-61.

Unthread nut from bolt and remove flat washer, Nice

bearing and remover/installer. Remove bolt from bushing

bore, but exercise caution to avoid scratching or gouging

bushing.

NOTE

Leave CONNECTING ROD CLAMPING TOOL installed dur-

ing bushing reaming procedure which follows.

Figure 3-59. Remover Stackup.

Use Remover Side Of Remover/Installer

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2006 Sportster: Engine

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Reaming Upper Connecting Rod Bushing

Installer side of remover/installer

Slot in bushing

1. Clean up and size bushing to

0.0010-0.0005 in.

Oil hole in connecting rod

(0.025-0.013 mm) undersize using the CONNECTING

ROD BUSHING REAMER.

NOTE

Sizing bushing with less than 0.00125 in. (0.0317 mm) clear-

ance can result in a bushing loosening and/or seized pin in

rod.

a. Carefully insert bit of reamer into upper connecting

rod bushing. Do not apply lubricant to reamer or

bushing. Ream the bushing dry or cut will not be

accurate.

b. Install a

11/16-inch 12-pt socket and T-handle on

reamer lug.

c. Placing thumb on drive socket, apply slight pressure

on reamer while rotating handle/drive socket in a

x0604x3x

clockwise direction.

Figure 3-60. Installer Stackup

CAUTION

For best results, do not push on reamer or apply pres-

10479

sure to the reamer handle. While excessive pressure

results in a rough cut, bushing bore will be tapered if

pressure is not centrally applied.

d. Continue rotating handle/drive socket until entire bit

has passed through bushing and shank of reamer

rotates freely in the bore.

CAUTION

Never back reamer out of connecting rod or bushing will

be damaged.

2. Remove T-handle and socket, and carefully pulling on bit,

draw shaft of reamer out of connecting rod bushing.

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

3. Using contact cleaner or cleaning solvent, thoroughly

Piston Bushing Tool (Part no. HD-95970-32D)

wipe upper connecting rod and bushing of any metal

Rod Clamping Fixture (Part no. HD-95952-33C)

shavings or debris.

Figure 3-61. Installing New Piston Pin Bushing

NOTE

Leave CONNECTING ROD CLAMPING TOOL installed dur-

ing bushing honing procedure which follows.

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3. Lightly oil a good piston pin and insert it into the upper

Honing Upper Connecting Rod Bushing

connecting rod bushing bore to feel for the proper inter-

Obtain the CONNECTING ROD BUSHING HONE and

ference fit. The pin should slide in and out of the bushing

REAMER LUBRICANT to hone bushing to final size. Use

without binding, but also without pivoting or rocking.

a liberal amount of honing oil to prevent damage to hone

4. Remove CONNECTING ROD CLAMPING TOOL.

or bushing. Use care to prevent foreign material from fall-

ing into the crankcase.

5. Remove shop towels exercising caution that shavings,

chips and other debris do not fall into crankcase.

a. Install hone in a high speed electric drill.

b. Apply reamer lubricant to finishing stones of hone

Repair

and inside of upper connecting rod bushing.

If connecting rod is bent, do not attempt to straighten. Fly-

c. Start finishing stones of hone into bushing.

wheel and connecting rod assembly must be replaced.

d. Activating the drill, move the entire length of the fin-

Straightening connecting rods by bending will damage the

ishing stone arrangement forward and backward

bearing on the crank pin and the piston pin bushing.

through the bushing bore for 10 to 12 complete

strokes. Work for a crosshatch pattern of approxi-

mately 60 degrees.

ASSEMBLY/INSTALLATION

See PISTON AND CYLINDER under 3.17 TOP END OVER-

CAUTION

HAUL: ASSEMBLY to install piston and cylinder onto engine.

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

Using contact cleaner or cleaning solvent, thoroughly

wipe upper connecting rod and bushing of any metal

shavings or debris. Continue wiping until a clean cloth

shows no evidence of dirt or debris.

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2006 Sportster: Engine

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TOP END OVERHAUL: ASSEMBLY

3.17

GENERAL

10698

This section describes assembling the top end of the engine,

from the cylinder deck up. If the engine crankcase has been

disassembled for repair, it must be assembled before assem-

bling the top end of the engine. See 3.24 BOTTOM END

OVERHAUL: ASSEMBLY.

PISTON AND CYLINDER

PART NO.

SPECIALTY TOOL

HD-34623-C

Piston pin lock ring installer

HD-42322

Piston support plate

HD-96333-51C

Piston ring compressor

Figure 3-62. Arrows on Piston Must Point

Slide approximately 6.0 in. (152 mm) of plastic tubing,

Toward Front of Engine

rubber hose or conduit over each cylinder stud to protect

cylinder studs and piston from damage.

NOTE

See Figure 3-62. New 883cc and 1200cc pistons must be

11577

installed with the arrows on the top and side of the piston

pointing toward the front of the engine.

Install piston assembly over connecting rod.

Install piston pin.

NOTE

You may wish to place clean shop towels over cylinder and

lifter bores prior to the next step, to prevent the piston pin lock

ring from falling into the crankcase.

See Figure 3-63. Install new piston pin lock rings with the

PISTON PIN LOCK RING INSTALLER. Make sure the

ring groove is clean and that the ring is fully seated in the

groove with the gap away from the slot at the bottom.

CAUTION

Figure 3-63. Installing Piston Lock Rings

Always use new lock ring. Make sure lock ring groove is

clean and that ring seats firmly in groove. If it does not,

discard the ring. Never install a used lock ring or a new

one if it has been installed and then removed for any rea-

son. A loosely installed ring will come out of the piston

groove and damage cylinder and piston beyond repair.

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See Figure 3-64. Make sure the piston ring end gaps are

11575

properly positioned as shown.

Lubricate cylinder wall, piston, pin and rod bushing with

engine oil

Remove cylinder stud sleeves. Install a new cylinder

base gasket. Make sure the piston does not bump the

studs or crankcase.

x0486x3x

Front

11578

Piston

Pin

Rear

Figure 3-64. Position Ring End Gaps At Arrows

See Figure 3-65. Install PISTON SUPPORT PLATE as

Figure 3-65. Piston Support Plate

shown. Turn engine to rest piston on support plate.

See Figure 3-66. Compress the piston rings using PIS-

11576

TON RING COMPRESSOR.

10. Gently slide cylinder over cylinder base studs and piston

crown, resting it on the top of the ring compressor band

as shown.

11. Push the cylinder down with a firm, quick motion until the

bottom of the cylinder bore slides below the piston ring

area.

12. Remove the piston ring compressor and piston support

plate, and push the cylinder all the way down onto the

crankcase cylinder deck.

13. Repeat above procedure for other piston and cylinder.

Figure 3-66. Installing Cylinder Over Piston

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PUSH RODS, COVERS AND

O-ring (4)

Push rod cover (4)

RETAINERS

O-ring (4)

Push rod (4)

See Figure 3-67. If anti-rotation devices (10) and tappets

Screw (8)

(11) have been removed, install them now. See TAP-

Washer (8)

PETS under 3.24 BOTTOM END OVERHAUL: ASSEM-

Retainer (2)

BLY.

Gasket (2)

Install retainer

(7) with new gasket (8). Secure with

Screw (2)

screws (5) and washers (6). Tighten to 80-110 in-lbs

10.

Anti-rotation device (2)

(9.0-12.4 Nm).

11.

Tappet (4)

Install O-rings (3) in recesses in retainer. Press push rod

12.

Right crankcase

covers (2) into o-rings.

Repeat steps 1-3 above for other cylinder.

Identify push rod color coding and length, and respective

push rod positions in engine (refer to Table 3-43.). Slide

intake and exhaust push rods (4) down inside push rod

covers until they rest on seat at top of tappet (11).

Table 3-43. Push Rod Specifications

COLOR

POSITION

LENGTH

PART NO.

CODE

Exhaust

1 band -

10.800 in.

17908-02

(front and rear)

purple

(27.432 cm)

Intake

1 band -

10.746 in.

17909-02

(front and rear)

orange

(27.295 cm)

x0202b3x

Figure 3-67. Middle Valve Train Components

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CYLINDER HEAD

CAUTION

NOTE

See Figure 3-68. To ensure proper head gasket (10) align-

Push rod covers and lower cover retainers MUST be installed

ment, install new O-rings (11) over cylinder ring dowels

prior to installing cylinder heads. If this has not been done,

(12) before installing head gasket. Improper head gasket

see PUSH RODS, COVERS AND RETAINERS on previous

alignment will cause leaks.

page.

5. Apply a very thin film of clean H-D 20W50 engine oil to

new O-rings (11) and install O-rings on two dowels (12)

at top of cylinder (13).

CAUTION

6. Install a new head gasket to cylinder.

Thoroughly clean and lubricate threads of cylinder head

7. Carefully lower cylinder head over studs and position on

screws before installation. Friction caused by dirt and

dowels. Use great care so as not to disturb head gasket.

grime will result in a false torque indication.

See Figure 3-68. Coat mating surfaces of cylinder base

CAUTION

studs (15) and head bolts (1 and 2) with parts cleaning

solution.

Only oil film must remain on the cylinder head screw sur-

Scrape old oil and any carbon deposits from threads by

faces. Too much oil will pool in the head screw sleeve

using a back-and-forth motion, threading each head

preventing full thread engagement.

screw onto its mating cylinder stud.

8. Lightly coat threads, underside of flange and bottom face

Remove head bolts from studs. Wipe or blow dry thread

of cylinder head bolts in clean Harley-Davidson 20W50

surfaces.

engine oil. Wipe off excess oil.

Thoroughly clean and dry gasket surfaces of cylinder

9. Start cylinder head bolts (1 and 2) onto cylinder studs,

(13) and cylinder head (8).

two short bolts on left side of engine, two long bolts on

right. Tighten all bolts only finger tight at this time.

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2006 Sportster: Engine

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Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 16

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