Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 17
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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 3-68. Cylinder Head, Cylinder and Piston Assembly
2006 Sportster: Engine
3-63
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x0128x3a
CAUTION
2nd
4th
The procedure for tightening the head screws is critical
to proper distribution of pressure over gasket area. It
prevents gasket leaks, stud failure, and head and cylin-
der distortion.
10. See Figure 3-69. For each cylinder head, start with bolt
numbered one, as shown. In increasing numerical
sequence (i.e. - 1, 2, 3, 4), tighten head bolts in the fol-
lowing steps:
a. Tighten each bolt to 96-120 in-lbs (11-14 Nm).
b. Tighten each bolt to 13-15 ft-lbs (18-20 Nm).
c. Loosen all bolts.
11. After head bolts are loosened from initial torque, tighten
bolts in three stages. Tighten in increasing numerical
sequence (i.e. - 1, 2, 3, 4), as follows:
1st
3rd
a. Tighten each bolt to 96-120 in-lbs (11-14 Nm).
Front Cylinder
b. Tighten each bolt to 13-15 ft-lbs (18-20 Nm).
c. See Figure 3-70. Mark cylinder head and head bolt
1st
3rd
shoulder with a line as shown (View A).
d. Tighten each bolt an additional 85˚-95˚ (View B).
12. Repeat above procedure for other cylinder head.
ROCKER COVERS
1.
See Figure 3-71. Install new gasket (16), with the bead
facing up. Place inner rocker cover assembly (8) (with
rocker arms and shafts) into position, fitting ends of push
rods in rocker arm sockets.
CAUTION
Do not turn engine over until both push rods can be
2nd
4th
turned with fingers. Otherwise, damage to push rods or
Rear Cylinder
rocker arms may result.
2.
Install fasteners (13, 15, 14). Slowly snug all fasteners in
Figure 3-69. Head Bolt Loosening/Tightening Sequence
small increments (one turn at a time). Use a cross pat-
tern on the four large bolts (13) that fasten the inner
rocker cover to the head. This will bleed the lifters.
Tighten fasteners in the following sequence:
x0457x3x
a. Tighten bolts (13) to 18-22 ft-lbs (24.4-29.8 Nm).
View A
View B
b. Tighten bolts (15) to 135-155 in-lbs (15.3-17.5 Nm).
c. Tighten screws
(14) to
135-155 in-lbs
(15.3-
17.5 Nm).
3.
Place new gaskets (4, 5) on inner rocker cover. Install
breather assembly (7), secure with screw (6). Tighten to
35-55 in-lbs (4.0-6.2 Nm).
4.
Install outer rocker cover (3) on inner rocker cover. Install
screws with captive washers (1) and new fiber seals (2).
Tighten screws to 120-168 in-lbs (13.5-19.0 Nm).
5.
Repeat above procedure for other cylinder.
Figure 3-70. Tightening Head Bolts
3-64
2006 Sportster: Engine
HOME
x0452b3x
1.
Screw w/captive washer (4)
2.
Fiber seal (4)
3.
Outer rocker cover
1
4.
Gasket
5.
Gasket
6.
Screw
3
2
7.
Breather assembly
8.
Inner rocker cover
9.
Rocker arm shaft (2)
10. Rocker arm bushing (4)
11. Rocker arm
12. Rocker arm
13. Bolt (4)
14. Screw (2)
4
15. Bolt (3)
16. Gasket
9
6
11
7
10
5
8
12
10
13
14
15
16
Figure 3-71. Rocker Cover Assembly
2006 Sportster: Engine
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ASSEMBLING MOTORCYCLE
x0606a3x
1.
Nut
AFTER TOP END REPAIR
2.
Cylinder head bracket
3.
Washer (2)
4.
Screw (2)
1.
Install lower front engine stabilizer link assembly. See
5.
Horn assembly (XL 1200C)
2.21 STABILIZER LINKS.
5
2.
Install upper front engine stabilizer link assembly. See
4
2.21 STABILIZER LINKS.
3
3.
All models except XL
1200C: install horn and horn
bracket. See 7.24 HORN.
4.
Install intake manifold and carburetor. See 4.5 CARBU-
RETOR.
2
5.
Install air cleaner backing plate, air filter and air cleaner
cover. See 4.6 AIR CLEANER. California models: install
additional EVAP hoses. See 4.9 EVAPORATIVE EMIS-
1
SIONS CONTROL-CA MODELS.
6.
See Figure 3-72. Install cylinder head bracket (2), wash-
ers (3) and screws (4). Tighten to 17-24 ft-lbs (23.1-32.6
Nm).
7.
XL 1200C models: Install horn (5) and nut (1). Tighten to
35-45 in-lbs (4.0-5.1 Nm).
8.
See Figure 3-73. Mount enrichener knob assembly (1) to
enrichener bracket (3). Tighten nut (5) to 20-35 in-lbs
(2.3-4.0 Nm).
9.
Connect manifold absolute pressure (MAP) sensor con-
Figure 3-72. Horn (XL 1200C) and
nector
[80]. See
7.6 MANIFOLD ABSOLUTE PRES-
Cylinder Head Bracket (All Models)
SURE SENSOR (MAP).
10.
Connect spark plug cables to spark plugs.
11.
Install exhaust system. See 2.27 EXHAUST SYSTEM.
x0605x3x
12.
Install fuel tank. See 4.8 FUEL TANK.
13.
Open left side cover and install Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
14.
Install seat. See 2.32 SEAT.
1
5
2
3
4
1.
Fuel enrichener knob
2.
Knurled plastic nut
3.
Enrichener bracket
4.
Star lock washer
5.
Hex nut
Figure 3-73. Enrichener Control
3-66
2006 Sportster: Engine
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BOTTOM END OVERHAUL: DISASSEMBLY
3.18
GENERAL
OIL PUMP
This section describes disassembling the bottom end of the
1. Remove oil pump feed and return hoses. Mark hoses for
engine. If engine overhaul requires disassembly of crank-
later installation. Discard hose clamps.
cases, remove engine from vehicle as described in 3.12
2. See Figure 3-75. Carefully remove two screws (2) that
REMOVING ENGINE FROM CHASSIS. Then disassemble
secure pump to crankcase. Pump will drop with screws
top end of engine. See CYLINDER HEAD and CYLINDER
removed. Discard mounting gasket.
AND PISTON under 3.14 TOP END OVERHAUL: DISAS-
3. If oil pump requires repair, see 3.21 OIL PUMP for proce-
SEMBLY.
dure.
TAPPETS
x0519x3x
1.
See Figure 3-74. Remove screw (1).
2.
Remove anti-rotation device (2). Tag anti-rotation device
for location (front/rear cylinder) as it is removed.
4
3.
Remove tappet (3). Tag tappet for location (front/rear cyl-
inder) and function (intake/exhaust) as it is removed. This
will simplify installation.
4.
Repeat previous steps for other cylinder.
1
5.
Place tappets in clean plastic bags to keep out dust, dirt
and debris.
x0518b3x
1
3
2
2
1.
Oil pump
4
2.
Screw, w/washer (2)
3
3.
Screw, Torx (2)
4.
Gasket
Figure 3-75. Oil Pump
1.
Screw (2)
2.
Anti-rotation device (2)
3.
Tappet (4)
4.
Right crankcase
Figure 3-74. Tappet Removal
2006 Sportster: Engine
3-67
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3. Check for minimum cam gear end play; see 3.20 GEAR-
GEARCASE COVER AND
CASE COVER AND CAM GEARS, ASSEMBLY/INSTAL-
CAM GEARS
LATION. Record readings.
4. Place a pan under gearcase to collect oil. Remove cover
screws (6). Carefully remove gearcase cover. Discard old
1WARNING
gasket (9).
Compressed air can pierce the skin and flying debris from
NOTE
compressed air could cause serious eye injury. Wear
If cover does not come loose on removal of screws, tap lightly
safety glasses when working with compressed air. Never
with a rawhide hammer. Never pry cover off.
use your hand to check for air leaks or to determine air
5. Remove cam gears (1, 2, 3, and 4). Carefully mark each
flow rates. (00061a)
component to ensure correct installation.
1.
See Figure 3-76. Thoroughly clean area around gear-
NOTE
case cover (17) and tappets. Blow loose dirt from crank-
Nut (11) is secured by Loctite-272 on the nut threads.
case with low pressure compressed air.
2.
Remove any parts that will interfere with gearcase disas-
6. Remove nut (11). Slide pinion gear (5) and oil pump
sembly (i.e., exhaust pipe, footrest, air cleaner, brake
drive gear (12) off pinion shaft.
pedal, etc.).
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
11. Nut
2.
Rear intake cam gear
12. Oil pump drive gear
3.
Front intake cam gear
13. Cam gear bushing (4)
4.
Front exhaust cam gear
14. Rear exhaust cam gear bushing
5.
Pinion gear
15. Rear intake cam gear bushing
6.
Screw (11)
16. Pinion shaft bushing
7.
Front intake cam gear bushing
17. Gearcase cover
8.
Front exhaust cam gear bushing
18. T-key
9.
Gearcase cover gasket
19. Cover plate
10. Right crankcase
20. Screw (2)
Figure 3-76. Gearcase and Valve Train Components
3-68
2006 Sportster: Engine
HOME
NOTE
CRANKCASE
See Figure 3-77. New crankcase assembly has 17 fasteners;
15 inserted from left side and two inserted from right side.
1.
Remove clutch and primary drive components. See 6.5
PRIMARY DRIVE/CLUTCH REMOVAL.
4. See Figure
3-77. Remove
15 crankcase fasteners
2.
Remove starter motor. See REMOVAL under
5.4
(eleven long and four short) from left side of crankcase
STARTER MOTOR.
assembly.
3.
Mount crankcase assembly in engine stand. Position
5. Remove two fasteners from right side of crankcase
crankcase so that it is tilted at a 45-degree angle, right
assembly.
side down.
1WARNING
Once the crankcase assembly has been split, do NOT
rotate right crankcase in stand so that flywheel sprocket
shaft is pointing down. Doing so can cause flywheel to
fall out of crankcase which may result in death or serious
injury.
x0568a3x
x0659x3x
Left side
Right side
*
*
*
– Indicates crankcase fastener locations
- Short fastener
*
Figure 3-77. Crankcase Fasteners
2006 Sportster: Engine
3-69
HOME
6.
Tap crankcase gently with rawhide mallet to loosen and
Removing Piston Oil Jets
separate the halves. See Figure 3-78. Remove left
crankcase assembly with transmission.
1. See Figure 3-80. Remove two TORX screws (3) from
each piston oil jet assembly (2) to free piston oil jets from
NOTE
right crankcase (1).
Flywheel assembly slides off left main bearing by hand. No
tools are required for this operation.
2. Remove piston oil jets and gaskets (4) from right crank-
case. Discard gaskets.
7.
See Figure 3-79. Remove the flywheel assembly from
right crankcase.
8.
Remove transmission assembly from left crankcase. See
x0581a3x
2
3
6.9 TRANSMISSION REMOVAL AND DISASSEMBLY.
4
11538
2
4
1
10423
3
Figure 3-78. Separating Crankcase Halves
11522
1
2
1.
Right crankcase
2.
Piston oil jet (2)
3.
Screw (4)
4.
Gasket (2)
Figure 3-80. Piston Oil Jet Assemblies
Removing Cylinder Base Studs
If cylinder base studs require replacement, proceed as fol-
lows.
1. Thread a 3/8”-16 nut onto cylinder base stud.
2. Thread a second nut onto stud until it contacts the first
nut.
3. Tighten nuts against each other.
4. Placing wrench on first (lower) nut installed, unscrew
stud from cylinder deck.
Figure 3-79. Removing Flywheels from Right Crankcase
5. Loosen nuts and remove from cylinder base stud.
3-70
2006 Sportster: Engine
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VALVE TAPPETS
3.19
GENERAL
x0470x3x
2
See Figure 3-81. The tappet assembly consists of tappet and
roller. The tappet and roller, under compression force from
valve spring, follow the surface of the revolving cam. The up-
and-down motion produced is transmitted to the valve by the
push rod and rocker arm. The tappet contains a piston (or
plunger) and cylinder; it also contains a check valve, which
allows the unit to fill with engine oil, thereby reducing clear-
ance in the valve train.
When a tappet is functioning properly, the assembly operates
1
1
with minimal tappet clearance. The unit automatically com-
pensates for heat expansion to maintain a no-clearance
condition.
3
It is normal for tappets to click when engine is started after
standing for some time. Tappets have a definite leakdown rate
which permits the oil in the tappets to escape. This is neces-
sary to allow units to compensate for various expansion con-
ditions of parts and still maintain correct clearance operation.
4
Tappets are functioning properly if they become quiet after a
few minutes of engine operation.
REMOVAL
1.
Oil
2.
Piston
See TAPPETS under 3.18 BOTTOM END OVERHAUL: DIS-
3.
Check valve
ASSEMBLY to remove tappets from engine.
4.
Roller
Figure 3-81. Tappet Assembly
CLEANING AND INSPECTION
4.
Check tappet roller end clearance.
1.
Clean all parts, except roller/tappet assembly, thoroughly
in solvent. Blow dry with compressed air.
5.
Tappets should be soaked in clean engine oil and kept
covered until assembly.
2.
Refer to Table 3-44. Inspect valve tappets for excessive
clearance in guide. Accurately measure tappet bore
inner diameter with a gauge. Excessive tappet guide
INSTALLATION
clearance is corrected by fitting a new tappet and/or
replacing crankcases.
To install tappets, see TAPPETS under 3.24 BOTTOM END
NOTE
OVERHAUL: ASSEMBLY.
Inside and outside micrometers used for measuring tappets
and tappet guides must be calibrated to ensure accurate
readings.
3.
Check tappet roller free play. Recommended service
practice is tappet replacement.
Table 3-44. Valve Tappet Specifications
ITEM
VALUE
SERVICE WEAR LIMIT
Tappet clearance in guide
0.0008-0.0020 in. (0.020-0.051 mm)
0.0030 in. (0.076 mm)
Tappet roller free play (clearance on pin)
0.0006-0.0010 in. (0.015-0.025 mm)
0.0015 in. (0.038 mm)
Tappet roller end clearance
0.008-0.022 in. (0.203-0.559 mm)
0.026 in. (0.660 mm)
2006 Sportster: Engine
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NOTES
3-72
2006 Sportster: Engine
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GEARCASE COVER AND CAM GEARS
3.20
GENERAL
x0471x3x
Read the complete gearcase section carefully before you
begin any service work.
For the gearcase components to operate at their optimum, all
components must be properly fitted and matched. Changing
one component can affect many others. It is important to
know and understand all inspection procedures and how
components interact.
REMOVAL/DISASSEMBLY
See GEARCASE COVER AND CAM GEARS under 3.18
BOTTOM END OVERHAUL: DISASSEMBLY to remove gear-
case cover and cam gears from engine.
CLEANING, INSPECTION AND
REPAIR
Figure 3-82. Cam Identification
PART NO.
SPECIALTY TOOL
Cam and Pinion Gear Identification,
Inspection and Selection
HD-95760-69A
Bushing and bearing puller
See Figure 3-82. Cam lobes are stamped with a number (1,
1.
Thoroughly clean gearcase compartment, gearcase
2, 3, or 4) followed by letter “D” or “W.” The number identifies
cover and gears in solvent to remove oil and carbon
the cam location/function; the letter
“D” or
“W” indicates
deposits.
model year application:
1D (or W) = rear exhaust
1WARNING
2D (or W) = rear intake
3D (or W) = front intake
Compressed air can pierce the skin and flying debris from
4D (or W) = front exhaust
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
Use only “W” cams on 1200cc models. “D” cams are used on
use your hand to check for air leaks or to determine air
883cc models.
flow rates. (00061a)
NOTE
Prior to changing any cam gears, check gear shaft fit within
2.
Blow out all gearcase cover oil passages and bushings
corresponding bushings. Worn bushings can cause excessive
with low pressure compressed air.
backlash.
3.
Clean old gasket material from gearcase and gearcase
cover faces with cleaning solvent.
2006 Sportster: Engine
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x0206b3x
10
1
13
14
9
15
12
18
13
2
19
4
5
16
11
3
8
7
17
20
6
1.
Rear exhaust cam gear
11. Nut
2.
Rear intake cam gear
12. Oil pump drive gear
3.
Front intake cam gear
13. Cam gear bushing (4)
4.
Front exhaust cam gear
14. Rear exhaust cam gear bushing
5.
Pinion gear
15. Rear intake cam gear bushing
6.
Screw (11)
16. Pinion shaft bushing
7.
Front intake cam gear bushing
17. Gearcase cover
8.
Front exhaust cam gear bushing
18. T-key
9.
Gearcase cover gasket
19. Cover plate
10. Right crankcase
20. Screw (2)
Figure 3-83. Gearcase and Valve Train Components
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2006 Sportster: Engine
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Bushing Inspection and Removal
10418
1.
See Figure 3-83. Bushings (7, 8, 13, 14, 15, 16) are
press fit in gearcase cover and crankcase. Inspect each
bushing against its corresponding cam gear shaft or pin-
ion gear shaft. Refer to Table 3-45. for clearances and
service wear limits.
2.
See Figure
3-84. Use BUSHING AND BEARING
PULLER to remove bushings from gearcase cover and
crankcase.
BUSHING INSTALLATION
NOTE
Installing and reaming crankcase and gearcase cover bush-
ings may alter the center distances between mating gears
and may result in an increase in gear noise. For quiet-running
gears, the gears should be matched to the center distances.
Cam Gear Bushings in Right Crankcase
See Figure 3-85. Each cam gear bushing, to be installed in
right crankcase, must be positioned in crankcase bore with its
Figure 3-84. Removing Cam Bushing
oiling slot at exact top of bore (12 o’clock position)
from Gearcase Cover
1.
Using an arbor press, install each bushing in its crank-
case bore so that bushing shoulder contacts crankcase
boss.
10425
2.
After you install a new bushing in right crankcase, ream
the bushing to correct size. See BUSHING REAMING
2
later in this section.
Table 3-45. Inspection
GEAR
CORRECT
SERVICE WEAR
SHAFT
CLEARANCE
LIMIT
1
3
Cam
0.0007-0.0022 in.
0.003 in.
1.
Cam gear bushing
(0.018-0.056 mm)
(0.08 mm)
2.
Slot at top
3.
Right crankcase
Pinion
0.0023-0.0043 in.
0.005 in.
Figure 3-85. Cam Gear Bushing Installed in Crankcase
(0.058-0.109 mm)
(0.13 mm)
2006 Sportster: Engine
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Cam Gear Bushings (Except Rear Intake
10422
Bushing) in Gearcase Cover
4
3
1.
See Figure 3-83. Using an arbor press, install each
bushing (7, 8, and 14) in its gearcase cover (17) bore so
that bushing shoulder contacts cover boss. There is no
need to orient these particular bushings in any specific
position of rotation within gearcase cover bores.
2.
After you install a new bushing in gearcase cover, line-
2
ream the bushing to correct size. See BUSHING REAM-
ING later in this section.
1
Rear Intake Cam Gear Bushing in Gear-
1.
Rear intake cam gear bushing
case Cover
2.
Gearcase cover
See Figure 3-83. Rear intake cam gear bushing (15) must be
3.
Cam bushing slot
installed in its gearcase cover (17) bore using an arbor press.
4.
Gearcase cover slot
You will need to orient the bushing in a specific position of
Figure 3-86. Rear Intake Cam Gear Bushing
rotation within the cover bore.
Installed in Gearcase Cover
1.
See Figure 3-86. Position bushing (1) over bore of gear-
case cover (2) with chamfered edge downward and slot
upward. Align slot in bushing with slot in gearcase cover
boss. Press bushing into cover bore until bushing is flush
10419
with cover boss.
2.
After you install the new bushing in the gearcase cover,
line-ream the bushing to the correct size. See BUSHING
REAMING later in this section.
Pinion Shaft Bushing in Gearcase Cover
1.
See Figure 3-83. Using an arbor press, install pinion
shaft bushing (16) in gearcase cover (17) so that bushing
is flush with cover boss. There is no need to orient this
particular bushing in any specific position of rotation
within the gearcase cover bore.
2.
See Figure 3-87. Although the original pinion shaft bush-
ing is not “pinned,” the replacement bushing must be
secured from possible rotation within the cover bore, by
installation of a dowel pin. Drill a No. 31 hole, 0.281 in.
(7.14 mm) deep, at top side of boss (side toward top of
gearcase cover), centering the drill bit on the cover bore
circle (hole is drilled half in bushing O.D. and half in cover
bore I.D.).
3.
Drive a new dowel pin no more than 0.20 in. (5.1 mm)
Figure 3-87. Drilling Pinion Bushing Dowel Pin Hole
below the bushing face. Carefully peen edges of hole to
in Gearcase Cover
lock the pin in place.
4.
After you install a new bushing in gearcase cover, line-
ream the bushing to the correct size. See BUSHING
REAMING later in this section.
3-76
2006 Sportster: Engine
HOME
BUSHING REAMING
11984
PART NO.
SPECIALTY TOOL
3
HD-38871
Camshaft bushing reamer pilot
HD-94803-67
Rear intake cam gear bushing reamer
2
HD-94812-1
Pinion shaft bushing reamer
HD-94812-87
Pinion shaft bushing reamer pilot
NOTES
● Installing and reaming crankcase and gearcase cover
bushings may alter the center distances between mating
gears and may result in an increase in gear noise. For
quiet-running gears, the gears should be matched to the
center distances.
● Bushings in right crankcase serve as pilots for reaming
gearcase cover bushings and must, therefore, be
1
reamed to size first.
1.
Camshaft bushing reamer pilot
● After reaming any bushing, check shaft fit in the bushing.
(Part No. HD-38871)
It may be necessary to make a second pass with reamer
2.
Standard 11/16-in. reamer
to attain proper fit.
3.
Reamer handle
Cam Gear Bushings in Right Crankcase
Figure 3-88. Reaming Cam Gear Bushing in
Right Crankcase
1.
Separate two halves of crankcase, if not already done.
Place right crankcase on flat surface with gearcase side
4. Detach reamer from handle. Pull reamer out opposite
up.
side of crankcase.
2.
See Figure
3-88. Position CAMSHAFT BUSHING
REAMER PILOT onto gearcase side of crankcase; upper
1WARNING
right and lower left indexing holes in pilot must be placed
over dowels in crankcase. Insert two bolts (supplied with
Compressed air can pierce the skin and flying debris from
pilot) through two remaining holes in pilot, and into
compressed air could cause serious eye injury. Wear
threaded holes of crankcase. Tighten bolts securely.
safety glasses when working with compressed air. Never
3.
Insert a standard 11/16-in. diameter reamer through pilot
use your hand to check for air leaks or to determine air
hole and into bushing while turning reamer clockwise.
flow rates. (00061a)
Continue turning reamer clockwise through bushing until
5. Thoroughly clean right crankcase, removing all metal
smooth shank of reamer passes through hole in pilot.
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.
2006 Sportster: Engine
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Cam Gear Bushings (Except Rear Intake
Rear Intake Cam Gear Bushing in Gear-
Bushing) in Gearcase Cover
case Cover
NOTE
NOTE
Newly installed cam gear bushings in the gearcase cover
A newly installed rear intake cam gear bushing in the gear-
must be line reamed, using the right crankcase as a pilot for
case cover must be line reamed, using the right crankcase as
the reamer, to establish correct clearance and to ensure per-
a pilot for the reamer, to establish correct clearance and to
fect alignment. If crankcase halves are not separated on your
ensure perfect alignment. If crankcase halves are not sepa-
motorcycle, use a spare right crankcase to perform the follow-
rated on your motorcycle, use a spare right crankcase to per-
ing line reaming procedures.
form the following line reaming procedures.
1.
See Figure 3-83. Bushings (7, 8 and 14) to be reamed
1. See Figure 3-83. Rear intake cam gear bushing (15)
must be installed in gearcase cover (17) as described in
must be installed in gearcase cover (17) as described in
BUSHING INSTALLATION earlier in this section. Attach
BUSHING INSTALLATION earlier in this section.
gearcase cover to right crankcase (10), which has been
2. Identify the previously reamed rear intake cam gear
disassembled from left crankcase, securing with a mini-
bushing (13) in right crankcase (10), which has been dis-
mum of three mounting screws.
assembled from left crankcase. Insert the shank end of
2.
Insert a standard 11/16-in. diameter reamer through the
REAR INTAKE CAM GEAR BUSHING REAMER
previously reamed cam gear bushing (13) in right crank-
(through gearcase side of this bushing.
case, which is in line with one of the bushings to be
3. With reamer inserted into bushing in right crankcase,
reamed in gearcase cover.
attach gearcase cover to right crankcase, securing with a
3.
Turn reamer clockwise through bushing in cover until
minimum of three mounting screws.
reamer bottoms. Then give reamer one complete clock-
4. Turn reamer clockwise through bushing in gearcase
wise turn to size the bushing. Continue turning reamer
cover until reamer bottoms. Then give reamer one com-
clockwise while extracting reamer from bushing.
plete clockwise turn to size the bushing. Continue turning
4.
Repeat Steps 2. and 3. for remaining two cam gear
reamer clockwise while extracting reamer from bushing.
bushings (except rear intake bushing) in gearcase cover,
5. Separate gearcase cover from right crankcase. Inspect
if required.
bushing for proper cam gear shaft fit. Repeat line ream-
5.
Separate gearcase cover from right crankcase. Inspect
ing operation if necessary.
bushings for proper cam gear shaft fit. Repeat line ream-
ing operation if necessary.
1WARNING
Compressed air can pierce the skin and flying debris from
1WARNING
compressed air could cause serious eye injury. Wear
Compressed air can pierce the skin and flying debris from
safety glasses when working with compressed air. Never
compressed air could cause serious eye injury. Wear
use your hand to check for air leaks or to determine air
safety glasses when working with compressed air. Never
flow rates. (00061a)
use your hand to check for air leaks or to determine air
6. Thoroughly clean gearcase cover, removing all metal
flow rates. (00061a)
chips/shavings. Blow out all bushing bores and oil pas-
6.
Thoroughly clean gearcase cover, removing all metal
sages using low pressure compressed air.
chips/shavings. Blow out all bushing bores and oil pas-
sages using low pressure compressed air.
3-78
2006 Sportster: Engine
HOME
Pinion Shaft Bushing in Gearcase Cover
12090
NOTE
A newly installed pinion shaft bushing in the gearcase cover
must be line reamed, using both the right crankcase and Part
No. HD-94812-87 as pilots for the reamer, to establish correct
clearance and to ensure proper alignment. If crankcase
halves are not separated on your motorcycle, use a spare
right crankcase to perform the following line reaming proce-
dure.
1.
See Figure 3-83. Pinion shaft bushing (16) must be
installed in gearcase cover (17) as described in BUSH-
ING INSTALLATION earlier in this section. Attach gear-
case cover to right crankcase (10), which has been
disassembled from left crankcase, securing with a mini-
mum of three mounting screws.
2.
See Figure
3-89. Install PINION SHAFT BUSHING
REAMER PILOT into right crankcase roller race. Insert
PINION SHAFT BUSHING REAMER through the pilot.
3.
Turn reamer clockwise through bushing in gearcase
Figure 3-89. Line Reaming Pinion Shaft Bushing
cover until reamer bottoms. Then give reamer one com-
plete clockwise turn to size the bushing. Continue turning
reamer clockwise while extracting reamer from bushing.
1WARNING
4.
Separate gearcase cover from right crankcase. Inspect
Compressed air can pierce the skin and flying debris from
bushing for proper pinion shaft fit. Repeat line reaming
compressed air could cause serious eye injury. Wear
operation if necessary.
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
5. Remove pilot from right crankcase roller race. Thor-
oughly clean gearcase cover, removing all metal chips/
shavings. Blow out all bushing bores and oil passages
using low pressure compressed air.
ASSEMBLY/INSTALLATION
See CAM GEARS AND GEARCASE COVER under 3.24
BOTTOM END OVERHAUL: ASSEMBLY to install cam gears
and gearcase cover in engine.
2006 Sportster: Engine
3-79
HOME
OIL PUMP
3.21
GENERAL
x0160x3x
The oil pump seldom needs servicing. Before you disassem-
ble an oil pump suspected of not producing adequate oil pres-
sure, be absolutely certain that all possible related
15
malfunctions have been eliminated:
14
● Make sure all oil line clamps are tight and that lines are
not pinched or damaged.
● Check oil level and condition of oil in tank. Pressure will
12
be affected if oil is diluted. In freezing weather, proper cir-
culation of oil can be affected if the oil feed line becomes
clogged with ice and sludge.
● Check for a grounded oil pressure switch wire [120] or a
13
faulty switch if oil pressure indicator lamp fails to go out
with engine running.
See 3.6 ENGINE LUBRICATION SYSTEM, 3.25 OIL TANK
and 7.33 OIL PRESSURE SWITCH for additional informa-
tion.
REMOVAL
11
10
NOTE
9
The oil pump can be removed with engine in frame and with-
out removing gearcase cover.
8
1.
Drain oil from oil tank.
NOTE
7
See Figure 3-90. Do not remove oil pump feed fitting (2) from
the pump (1). Hold oil pump feed fitting and loosen large high
pressure hose fitting nut (3). Then remove high pressure hose
(4) from oil pump feed fitting.
6
2.
See Figure 3-90. Remove high pressure feed hose (4)
1
from oil pump (1).
10110
5
3
4
4
1
3
2
1.
Oil pump cover
2.
Screw w/washer (2)
3.
Torx screw (2)
4.
Connector
5.
Hose fitting
6.
Feed gerotor set
7.
Gerotor separator plate
8.
Scavenge gerotor set
2
9.
Retaining ring
1.
Oil pump
10. Thrust washer
2.
Oil pump feed fitting
11. O-ring
3.
High pressure hose fitting nut
12. Oil pump body
4.
High pressure feed hose (to oil filter)
13. Elbow fitting
14. Gear shaft
Figure 3-90. Oil Pump Feed Hose
15. Gasket
Figure 3-91. Oil Pump
3-80
2006 Sportster: Engine
HOME
NOTE
x0468x3x
See Figure 3-91. The oil pump is designed to be removed as
a complete assembly by unscrewing the two long screws (2)
1
at opposite corners of the pump. The other two screws (3)
2
hold the pump together so that it may be removed and
installed as a unit.
3.
See Figure 3-91. Carefully remove two screws (2) that
3
secure oil pump to crankcase. Pump will drop with
screws removed. Discard mounting gasket (15).
1.
Outer gerotor
4.
Disconnect and tag the two remaining oil hoses from the
2.
Inner gerotor
pump.
3.
Wear limit
Figure 3-92. Gerotor Wear Limits
DISASSEMBLY
1.
See Figure 3-91. Remove two Torx screws (3). Lift cover
ASSEMBLY
(1) off body (12). Remove and discard O-ring (11).
2.
Slide both pieces of feed gerotor set (6), separator plate
NOTE
(7) and both pieces of scavenge gerotor set (8) off gear
Liberally coat all moving parts with clean engine oil to ensure
shaft (14).
easy assembly and smooth operation at start-up.
3.
Remove and discard retaining ring (9). Remove thrust
1. See Figure 3-91. Install gear shaft (14) through oil pump
washer (10) and gear shaft.
body (12). Position thrust washer (10) over end of shaft.
Install new retaining ring (9) into groove in shaft.
CLEANING, INSPECTION
2. Insert inner gerotor of the scavenge gerotor set (8) over
gear shaft.
AND REPAIR
3. Place outer gerotor over inner to complete scavenge set.
4. Position separator plate (7) into case and line up slots on
1WARNING
perimeter with tabs inside oil pump body.
5. Place feed gerotor set (6) over gear shaft.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
6. Install a new O-ring (11) into groove in oil pump cover
safety glasses when working with compressed air. Never
(1). Place cover onto pump body. Install two Torx cover
use your hand to check for air leaks or to determine air
screws (3). Tighten to 70-80 in-lbs (7.9-9.0 Nm).
flow rates. (00061a)
1.
Clean all parts in cleaning solvent. Blow out holes and oil
INSTALLATION
passages with low pressure compressed air.
1. See Figure 3-91. Place new mounting gasket (15) in
2.
See Figure 3-92. Inspect both gerotor sets for wear.
position.
Mesh pieces of each set together as shown. Use a feeler
gauge to determine clearance.
2. Secure pump to crankcase with two screws (2). Tighten
to 125-150 in-lbs (14.1-16.9 Nm).
NOTE
The maximum allowable clearance between gerotors is
NOTE
0.004 in. (0.10 mm). Replace gerotors as a set if clearance
Use new hose clamps to secure oil tank feed hose and vent
exceeds this dimension.
hose to oil pump fittings. If fittings were removed, use
TEFLON® PIPE SEALANT or HYLOMAR® on fitting threads.
3.
Measure thickness of feed gerotors with a micrometer. If
they are not the same thickness, replace as a set.
3. Install hoses on oil pump. Attach oil tank feed hose to
hose fitting (5) with new clamp. Attach oil tank vent hose
4.
See Figure 3-91. Check gear shaft (14) teeth for damage
to elbow fitting (13) with new clamp.
or wear. Replace gear shaft if necessary.
4. See Figure 3-90. If oil pump feed fitting (2) was removed
for any reason, install fitting in oil pump (1) cover. Tighten
to 55-65 in-lbs (6.2-7.4 Nm).
5. If high pressure feed hose (4), was removed completely,
install end opposite high pressure fitting nut (3) in crank-
case. Tighten to 60-90 in-lbs (6.8-10.2 Nm).
6. Install high pressure feed hose fitting nut (3) onto feed fit-
ting on front of oil pump. Hold oil pump feed fitting with a
wrench and tighten high pressure hose fitting nut to 85-
105 in-lbs (9.6-11.8 Nm).
7. Fill oil tank with proper oil. See 1.5 ENGINE OIL AND
FILTER.
2006 Sportster: Engine
3-81
HOME
OIL FILTER MOUNT
3.22
GENERAL
11485
Oil is pressure-fed from the oil pump to the oil filter mount via
a hose connection. Oil travels through the filter mount into the
filter via outer filter holes.
Adequate oil pressure activates the oil pressure indicator
lamp switch in the filter mount, which turns off the oil pressure
indicator lamp.
1
The check ball in the filter adapter opens at 4-6 psi (28-41 kN/
m2) oil pressure. Filtered oil leaves the filter, flowing past the
check ball.
DISASSEMBLY
1.
Remove oil filter. See CHANGING OIL AND FILTER
under 1.5 ENGINE OIL AND FILTER.
2
2.
See Figure 3-93. Remove oil filter adapter (1) from oil fil-
ter mount (2). Remove check ball (3) and spring (4).
5
3.
Remove oil pressure indicator lamp switch (5).
x0469a3x
CLEANING AND INSPECTION
4
2
1WARNING
3
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
1
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
Thoroughly clean all parts in cleaning solvent. Blow out holes
and passages with compressed air.
1.
Oil filter adapter
2.
Oil filter mount (part of right crankcase)
ASSEMBLY
3.
Check ball
4.
Spring
5.
Oil pressure indicator lamp switch
NOTE
Use TEFLON® PIPE SEALANT or HYLOMAR® on all fittings
Figure 3-93. Oil Filter Mount
installed to oil filter mount.
1.
See Figure
3-93. Install oil pressure indicator lamp
3. Connect oil pressure switch wire [120] to oil pressure
switch (5). Tighten to 50-70 in-lbs (5.6-7.9 Nm).
indicator lamp switch.
4. Pour about 4 fl oz. (120 ml) of clean engine oil into new
NOTE
oil filter. Apply a light coat of oil to oil filter gasket. Install
The new oil filter adapter has one end coated with pre-
oil filter onto oil filter mount/adapter assembly; tighten fil-
applied LOCTITE on the threads; that end must be installed
ter an additional 1/2 to 3/4 turn after gasket contacts filter
into the oil filter mount.
mount surface.
2.
Place spring (4) and check ball (3) into threaded hole at
5. Fill oil tank with proper oil. See 1.5 ENGINE OIL AND
center of mount (2). Push oil filter adapter against ball to
FILTER.
compress spring. Install threaded end (with LOCTITE)
into threaded hole at center of mount. Tighten oil filter
adapter to 96-144 in-lbs (10.9-16.3 Nm).
3-82
2006 Sportster: Engine
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