Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams — page 10
180
CHAPTER FOUR
295
296
295 for the inner bearing race. Also, check the roller
bearings for wear or damage. The bearings must
297
turn smoothly with no roughness. If any of these
parts are worn, replace the bearing assembly as de-
scribed under Left Side Main Bearing Assembly Re-
placement in this chapter.
6. Inspect the right side main needle bearing (Fig-
ure 296) for wear or damage. The bearing must
turn smoothly with no roughness. If damaged, re-
place the bearing assembly as described under
Right Side Main Bearing Replacement in this
chapter.
7. Inspect the camshaft needle bearings (Figure
297) in the right side crankcase for damage. To re-
place this bearing, refer to Camshaft Support Plate
298
in this chapter.
8. Inspect the valve lifter bore receptacles (Figure
298) for wear or damage. Refer to Valve Lifters in
this chapter.
NOTE
If the original piston cooling jets are
being reinstalled, apply Loctite No.
222
(purple) or an equivalent
threadlocking compound to the screw
threads prior to installation.
9. Make sure the piston cooling jets (Figure 299)
299
are clear. If necessary, remove the T20 Torx mount-
ing screws, remove the cooling jets and O-rings.
Clean the oil jets with compressed air. Install new
O-rings and tighten the screws securely.
Crankshaft and Connecting Rods
Cleaning and Inspection
If any portion of the crankshaft and/or connecting
rods are worn or damaged, they must be replaced as
ENGINE
181
300
304
4
301
305
one assembly. If necessary, have the crankshaft
302
overhauled by a Harley-Davidson dealership.
1. Clean the crankshaft assembly in solvent and dry
thoroughly with compressed air.
2. Hold the shank portion of each connecting rod
where it attaches to the crankshaft (Figure 300).
Pull up and down on each connecting rod. Any
slight amount of up and down movement indicates
excessive lower bearing wear. If there is movement,
the crankshaft must be overhauled.
3. Measure connecting rod sideplay with a feeler
gauge (Figure 301) and check against the service
limit in Table 2.
4. Inspect the right side (pinion shaft) (Figure 302)
303
and the left side (sprocket shaft) (Figure 303) for
excessive wear or damage.
5. Support the crankshaft on a truing stand or in a
lathe and check runout at the flywheel outer rim (A,
Figure 304) and at the pinion shaft (B) with a dial
indicator. If the runout exceeds the service limit in
Table 2, have the crankshaft trued or overhauled.
6. Inspect the crankshaft position sensor timing
teeth (Figure 305) on the left side flywheel for dam-
aged or missing teeth.
182
CHAPTER FOUR
7. On 2001 models only, make sure the retaining
ring (Figure 306) is secure on the right side of the
306
crankshaft.
Right Side Main Bearing
Replacement
A hydraulic press and a crankshaft bearing re-
mover and installer (JIMS part No. 1275) are re-
quired for the following procedure.
Removal
307
1. Remove the main bearing retaining ring (Figure
307) from one side of the bearing as follows:
a. Insert a small screwdriver under one end of
the retaining ring.
b. Push the end toward the bearing bore.
c. Raise the end of the ring up and out of the
crankcase groove.
d. Work around the circumference of the ring
and pull it out of the groove.
e. Discard the retaining ring as it cannot be re-
used.
2. Turn the crankcase half over and repeat Step 1
308
and remove the remaining retaining ring (A, Figure
308). Discard the retaining ring as it cannot be re-
used.
NOTE
The JIMS support tube is marked with
either REMOVER or INSTALLER
side.
3. Place the support tube with the side marked
REMOVER facing up on the press bed.
4. Position the right side crankcase with the outer
Installation
surface facing up and position the bearing directly
over the support tube on the press bed.
1. Apply a light coat of clean engine oil to the outer
5. Install the pilot shaft (Figure 309) through the
surface of the bearing and to the crankcase receptacle.
bearing and into the support tube.
2. Position the right side crankcase with the outer
6. Center the press driver over the pilot shaft.
surface facing up on the press bed.
7. Hold the crankcase half parallel to the press bed
3. Position the new bearing with the manufac-
and have an assistant slowly apply press pressure on
turer’s marks facing up (B, Figure 308) and place it
the pilot shaft until the bearing is free from the case
over the crankcase receptacle.
half.
4. Place the JIMS support tube with the side
8. Remove the case half and special tools from the
marked INSTALLER facing up (Figure 310) on top
press bed.
of the new bearing.
ENGINE
183
side of the bearing. If not, reposition the bearing un-
309
til it is centered correctly.
WARNING
The edges of the new retaining rings
are sharp. Wear shop gloves.
CAUTION
Both new retaining rings must be in-
stalled correctly to properly secure
4
the bearing in the crankcase half.
9. Install a new retaining ring (Figure 307) onto
each side of the new bearing as follows:
a. Position the new retaining ring with the cen-
310
ter of the closed end going into the ring
groove.
b. Press the center of the closed end into the
groove and hold it there to keep it within the
ring groove.
c. Alternating from side-to-side, using a small
screwdriver, press the retaining ring into the
ring groove, working with a small section at a
time.
d. Continue to work around the circumference
until the retaining ring is completely installed
within the ring groove. Make sure the retain-
ing ring is correctly seated in the ring groove.
311
10. Turn the crankcase half over and repeat Step 8
for the other retaining ring (A, Figure 308).
11. Spin the bearing to make sure it rotates
smoothly with no binding.
Left Side Main Bearing
Assembly Replacement
The left main bearing assembly must be replaced
as a complete set even if one bearing or race is dam-
aged.
5.
Center the press driver over the support tube.
6.
Slowly apply press pressure on the support tube,
Tools
pressing the bearing into the crankcase. Apply pres-
sure until the support tube contacts the crankcase
The following tools or their equivalents are re-
surface. This will correctly locate the bearing
quired to remove and install the left side main bear-
within the crankcase (A, Figure 311). Remove the
ing:
support tube (B).
1. Hydraulic press.
7. Remove the crankcase from the press bed.
2. Sprocket shaft bearing race tool (JIMS part No.
8. Check on each side of the crankcase to make
94547-80A)
sure the bearing is centered within the receptacle.
3. Race and bearing installation tool handle (JIMS
The retaining ring groove must be visible on each
part No. 33416-80).
184
CHAPTER FOUR
4. Snap ring removal and installation tool (JIMS
part No. 1710).
312
5. Sprocket bearing race installation tool (JIMS
part No. 2246).
Inner and outer bearing race replacement
NOTE
When replacing the bearing races in
the following steps, do not remove the
lock ring installed between the inner
and outer bearing races. This ring is
under heavy tension and will damage
the bearing bore as it passes through
it.
313
1. Place the crankcase on the workbench with the
inboard surface facing up.
2. Install one half of the bearing race remover tool
into the crankcase and push it against the inner bear-
ing race (A, Figure 312).
3. Install the other half of the bearing race remover
tool into the crankcase and push it against the inner
bearing race (B, Figure 312).
4. Hold the bearing race remover tools in place and
turn the crankcase over.
5. Insert the tool handle into the center of both race
remover tools. Press it into place until the ring (Fig-
314
ure 313) is locked into both bearing race remover
tools (Figure 314).
6. Support the left crankcase half on wooden blocks
on the press bed with the tool handle facing up.
7. Center the press ram directly over the tool han-
dle and slowly press the inner bearing race out the
crankcase.
8. Remove the crankcase and special tools from the
press bed.
9. Place the crankcase on the workbench with the
outboard surface facing up.
10. Install one half of the bearing race remover tool
into the crankcase and push it against the outer bear-
315
ing race (A, Figure 315).
11. Install the other half of the bearing race re-
mover tool into the crankcase and push it against the
outer bearing race (B, Figure 315).
12. Hold the bearing race remover tools in place
and turn the crankcase over.
13. Insert the tool handle into the race remover
tools. Press it into place until the ring (Figure 313)
is locked into both bearing race remover tools (Fig-
ure 316).
ENGINE
185
14. Support the left crankcase half on wooden blocks
316
on the press bed with the tool handle facing up.
15. Center the press ram directly over the tool han-
dle and slowly press the outer bearing race out of
the crankcase.
16. Remove the crankcase and special tools from
the press bed.
17. Clean the crankcase half in solvent and dry
with compressed air.
4
18. Check the lock ring (Figure 317) for looseness
or damage. If the lock ring is loose or damaged, per-
form the following:
a. Place the crankcase on a workbench with the
outboard side facing up.
317
b. With the gap of the lock ring at the 12 o’clock
position, install the special tool clamps onto
each side of the lock ring at the 10 o’clock and
2 o’clock positions.
c. Securely tighten the 9/16 in. Allen screws se-
curing the clamps to the lock ring.
d. Use snap ring pliers with straight tips and in-
stall them in one of the holes in each clamp.
e. Squeeze the pliers, compress the lock ring
and withdraw it from the crankcase groove.
f. Remove the clamps from the old lock ring
and install them onto the new lock ring.
g. Squeeze the pliers (Figure 318) and insert the
318
lock ring into the crankcase groove.
h. Check that the lock ring gap is centered with
the crankcase oil hole as shown in Figure 317.
NOTE
Install both races with their larger di-
ameter side facing out. Install the
bearing races with the same tool used
to remove the old ones.
19. Apply clean engine oil, or press lube, to the
bearing receptacles in the crankcase and to the outer
surface of the inner bearing races.
20. Position the installer base with the large end
319
facing up and place it on the press bed.
21. Position the crankcase with the outboard sur-
face facing up.
22. Install the crankcase onto the installer base
(Figure 319) until the crankcase retaining ring rests
on top of the installer base.
23. Install the outboard outer race into position on
the crankcase receptacle.
24. Apply clean engine oil, or press lube, to the
shaft of the pressing plug and install the pressing
186
CHAPTER FOUR
plug into the installer base (Figure 320). Push it
down onto the bearing outer race.
320
25. Center the press ram directly over the pressing
plug and slowly press the outer bearing race into the
outboard surface of the crankcase until it touches
the retaining ring (Figure 321).
26. Remove the crankcase and special tools from
the press.
27. Turn the crankcase over and repeat Steps 23-26
for the inboard outer bearing race.
Crankshaft inner sprocket
shaft bearing replacement
321
A sprocket shaft bearing cone installer (part No.
HD-997225-55B) is required to install the sprocket
shaft bearing (Figure 322).
1. Support the crankshaft with the bearing side fac-
ing up.
2. Install the bearing splitter under the bearing
(Figure 323) and tighten securely.
3. Attach a bearing puller onto the splitter (Figure
324).
4. Slowly tighten the center screw and withdraw
the bearing off the crankshaft shoulder.
5. Remove the bearing remover, splitter and bear-
ing from the crankshaft.
322
6. Clean the sprocket shaft with contact cleaner.
Check the sprocket shaft for cracks or other dam-
age. If damaged, refer service to a Harley-Davidson
dealership.
7. Slide the new bearing over the sprocket shaft.
8. Refer to Figure 325 and press the new bearing as
follows:
a. Apply clean graphite lubricant to the in-
staller’s pilot shaft threads, flat washer and
the bearing.
b. Thread the pilot shaft (A) onto the crank-
shaft until it contacts the crankshaft shoul-
der.
323
c. Slide the sleeve (B) over the pilot shaft until it
contacts the bearing inner race.
d. Install the tool’s bearing (C) and washer (D)
over pilot shaft and onto the top of the sleeve.
e. Thread the handle (E) onto the pilot shaft (A).
f. Slowly tighten the handle clockwise until
the bearing bottoms on the crankshaft
shoulder.
g. Unscrew and remove all parts of the bearing
installer.
ENGINE
187
are reinstalled, then the same size shim can be rein-
324
stalled as a starting point.
Carefully measure the end play as described in
Step 11. If there is any doubt about your abilities to
properly set up the crankshaft end play, refer this
procedure to a H-D dealership.
Tools
4
The following tools or their equivalents are re-
quired assemble the crankcase halves:
1. Sprocket shaft bearing installation tool (JIMS
part No. 97225-55).
325
2. Crankshaft guide (JIMS part No. 1288).
3. Engine stand (JIMS part No. 1022).
Procedure
Refer to Figure 326.
1. Position the crankshaft with the left side facing
up.
2. Apply clean engine oil or assembly lube to the
inner bearing (Figure 321) and to the left side
crankcase inner bearing race.
3. Install the shim of the specified thickness (see
Crankshaft End Play Inspection) onto the inner
bearing inner race.
4. Place the left crankcase half over the crankshaft
sprocket and onto the inner bearing.
5. Make sure the connecting rods are correctly po-
sitioned within the crankcase openings as shown in
Figure 327.
6. Make sure the crankcase is located correctly
onto the crankshaft inner bearing.
7. Install the outer roller bearing onto the crank-
shaft (Figure 328) and push it into the outer bearing
race.
Crankshaft End Play Inspection
8. Install the sprocket shaft bearing installation tool
onto the crankshaft following the manufacturer’s
Correct crankshaft end play is critical. The end
instructions.
play must be between 0.001-0.005 in. (0.025-0.127
9. Hold onto the handle
(A, Figure
329) and
mm). End play is determined by the thickness of the
tighten the large nut with a wrench (B). Tighten the
shim between the inner and outer bearings on the
large nut until the outer bearing is seated correctly
left side. Table 6 lists the shim part numbers and
and makes firm contact with the shim installed in
thickness.
Step 3.
If the end play was measured before disassembly
10. Remove the special tools and make sure the
and within specification, and the same components
outer bearing is seated correctly (Figure 330).
188
CHAPTER FOUR
326
CRANKCASE ASSEMBLY
1. Connecting rod bushing
12
Bolt
2. Crankshaft assembly
13. Plug
3. Oil hose fitting
14. Bearing
4. Retaining ring
15. Bearing race
5. Right side main bearing
16. Lock ring
6. Needle bearing-camshaft
17. Spacer ring
7. Crankcase assembly
18. Oil seal
8. O-ring
19. Sprocket shaft spacer
9. Piston cooling jet
20. Left side main bearing
10. Screw
(sprocket shaft) assembly
11. Locating dowel
21. Locating dowel
ENGINE
189
327
331
4
NOTE
328
The double check of the end play
check is important to ensure correct
crankshaft end play.
11. Check crankshaft end play as follows:
a. Securely attach a dial indicator to the left
crankcase half (A, Figure 331).
b. Position the dial indicator contact pointer
on the end of the crankshaft (B, Figure
331).
c. Push down hard on the crankcase (C, Figure
331) while turning it back and forth.
d. Hold the crankcase down and zero the dial
329
gauge.
e. Pull up on the crankcase as far as it will go
while turning it back and forth. Note the dial
indicator reading.
f. Repeat this step several times and note the
readings. They should all be the same.
g. The end play must be within 0.001-0.005 in.
(0.025-0.127 mm). If the end play is incor-
rect, the shim must be replaced using a shim
of a different thickness. Table 6 lists the
various thickness shims and their part num-
bers.
h. Remove the dial indicator.
330
12. Turn the crankcase assembly over and place it
on wooden blocks (Figure 332) thick enough so the
left side of the crankshaft clears the workbench sur-
face.
13. Install the locating dowels and new O-rings
(Figure 333) into both locations (Figure 334) in the
right crankcase half. Apply clean engine oil to the
O-rings.
14. Install the crankshaft guide (Figure 335) over
the crankshaft.
190
CHAPTER FOUR
332
333
15. Thoroughly clean and dry both crankcase gas-
ket surfaces before applying the gasket sealer in
334
Step 16.
16. Apply a thin coat of a non-hardening gasket
sealer to the crankcase mating surfaces. Use one of
the following gasket sealers:
a. Harley-Davidson crankcase sealant (part No.
HD-99650-81).
b. 3M #800 sealant.
c. ThreeBond Liquid Gasket 1104.
17. Align the crankcase halves and carefully lower
the right crankcase half onto the crankshaft and left
crankcase half (Figure 336). Press it down until it is
seated correctly on the locating dowels. If neces-
sary, carefully tap the perimeter of the right crank-
335
case half until it is seated around the entire
perimeter (Figure 337).
CAUTION
When properly aligned, the crankcase
halves will fit snugly against each
other around the entire perimeter. If
they do not meet correctly, do not at-
tempt to pull the case halves together
with the mounting bolts. Separate the
crankcase assembly and investigate
the cause of the interference.
18. Place the crankcase assembly in an engine
336
stand (A, Figure 338). Secure the engine stand to
the workbench so it cannot move.
19. Install the nine crankcase bolts into the left
crankcase half (B, Figure 338) and tighten as fol-
lows:
a. Alternately tighten the nine bolts finger-tight.
b. Using the torque pattern shown in Figure
339, tighten the bolts to 10 ft.-lb. (14 N•m).
c. Using the same sequence tighten the bolts to
15-19 ft.-lb. (20-26 N•m).
ENGINE
191
337
340
4
20. Install the left crankcase oil seal as described in
338
the following procedure.
21. Apply clean engine oil to the outer surface of
the sprocket shaft spacer and install it onto the
crankshaft and into the oil seal (Figure 340).
22. Install the following components as described
in this chapter:
a. Alternator rotor and stator assembly (Chapter
Eight).
b. Oil pump.
c. Camshaft assembly.
d. Pushrods and valve lifters.
e. Pistons.
f. Cylinder heads and cylinders.
339
23. Install the engine into the frame as described in
this chapter.
Crankcase Left Side Oil Seal Replacement
A sprocket shaft seal installer tool (JIMS part No.
39361-69 or equivalent) is required to install the oil
seal.
1. Remove the sprocket shaft spacer (Figure 340)
from the crankshaft and the oil seal.
2. Carefully pry the old oil seal (Figure 341) out of
the bearing bore.
3. Position the new oil seal with the open side fac-
ing out.
4. Install the oil seal onto the crankshaft (A, Figure
342) and center it within the bearing bore.
5. Apply clean engine oil or press lube to the spe-
cial tool threads, both washers and the radial bear-
ing.
6. Install the main body onto the crankshaft and
screw it on until it stops (B, Figure 342).
7. Install the shaft seal installer tool following the
manufacturer’s instructions.
192
CHAPTER FOUR
8. Hold onto the handle (A, Figure 343) of the
main body and tighten the large nut (B) with a
341
wrench. Tighten the large nut slowly and check that
the oil seal (Figure 344) is entering straight into the
bearing bore.
9. Tighten the large nut slowly until the shaft seal
installer tool makes contact with the crankcase sur-
face (Figure 345).
10. Remove the special tools.
11. Apply clean engine oil to the outer surface of
the sprocket shaft spacer and install it onto the
crankshaft and into the oil seal (Figure 340).
342
Cylinder Stud Replacement
Replace bent or otherwise damaged cylinder
studs (Figure 346) to prevent cylinder block and
cylinder head leaks.
1. If the engine lower end is assembled, block off
the lower crankcase opening with clean shop cloths.
2A. If the stud has broken off with the top surface of
the crankcase, remove it with a stud remover. Refer
to Chapter One.
2B. If the stud is still in place, perform the following:
a. Thread a 3/8 in.-16 nut onto the top of the stud.
b. Thread an additional nut onto the stud and
343
tighten it against the first nut so that they are
locked.
c. Turn the bottom nut counterclockwise and
unscrew the stud.
3. Clean the stud threads in the crankcase with a
spiral brush, then clean with an aerosol parts
cleaner. If necessary, clean the threads with an ap-
propriate size tap.
NOTE
New studs may have a threadlocking
compound patch already applied to
the lower stud threads. If so, do not
344
apply any additional locking com-
pound to these studs.
4. If the new stud does not have the threadlocking
compound patch, apply ThreeBond TB1360 or an
equivalent to the lower stud threads.
NOTE
The cylinder studs have a shoulder on
one end and this end must be installed
next to the crankcase surface.
ENGINE
193
345
347
4
pact wrench until the stud shoulder (Figure 347)
346
contacts the top surface of the crankcase.
8. Use a torque wrench and hand-tighten the stud to
the torque specification listed in Table 4.
9. Remove the cylinder head bolt and steel ball
from the cylinder stud.
10. Repeat for any additional studs.
ENGINE BREAK-IN
Following cylinder service (boring, honing, new
rings) and major lower end work, the engine must
5. Place a 0.313 in. diameter steel ball (H-D part
be broken in just as though it were new. The service
No. 8860) into a cylinder head bolt, then thread the
and performance life of the engine depends on a
bolt onto the end of the new stud without the collar.
careful and sensible break-in.
6. Position the stud with the shoulder end going in
1. For the first 50 mi. (80 km), maintain engine
first and hand-thread the new stud into the crank-
speed below 2500 rpm in any gear. However, do not
case.
lug the engine. Do not exceed 50 mph during this
period.
CAUTION
2. From 50-500 mi. (80-804 km), vary the engine
Do not use a breaker bar, ratchet or
speed. Avoid prolonged steady running at one en-
similar tool to install the studs. These
gine speed. During this period, increase engine
tools may bend the stud and cause the
speed to 3000 rpm. Do not exceed 55 mph during
engine to leak oil.
this period.
7. Hold the air impact wrench directly in-line with
3. After the first 500 mi. (804 km), the engine
the stud. Slowly tighten the new stud with an air im-
break-in is complete.
Table 1 GENERAL ENGINE SPECIFICATIONS
Item
Specifications
Engine type
Four-stroke, 45° OHV V twin, Twin Cam 88
Bore and stroke
3.75 x 4.00 in. (95.25 x 101.6 mm)
Displacement
88 cubic inch (1450 cc)
Compression ratio
8.9 to 1
Torque
82 ft. lb. (111 N·m) @ 3500 rpm
Maximum sustained engine speed
5600 rpm
194
CHAPTER FOUR
Table 1 GENERAL ENGINE SPECIFICATIONS (continued)
Item
Specifications
Engine weight
165 lbs. (74.8 kg)
Cooling system
Air cooled
Table 2 ENGINE SERVICE SPECIFICATIONS
Item
New in. (mm)
Service limit in. (mm)
Cylinder head
Flatness limit
-
0.006
(0.15)
Valve guide fit in head
0.0020-0.0033
0.002
(0.051-0.084)
(0.051)
Valve seat fit in head
0.003-0.0045
0.002
(0.076-0.114)
(0.051)
Rocker arm
Shaft fit in bushing
0.0005-0.0020
0.0035
(0.013-0.051)
(0.089)
Bushing fit in rocker arm
0.002-0.004
-
(0.051-0.102)
End clearance
0.003-0.013
0.025
(0.08-0.033)
(0.635)
Rocker arm shaft
Shaft fit in rocker arm support
0.0007-0.0022
0.0035
(0.018-0.056)
(0.089)
Valves
Valve stem-to-guide clearance
Intake
0.0008-0.0026
-
(0.020-0.066)
Exhaust
0.0015-0.0033
-
(0.038-0.084)
Seat width
0.040-0.062
-
(1.02-1.58)
Valve stem protrusion
1.990-2.024
-
(50.55-51.41)
Valve springs
Free length
Outer
2.105-2.177
-
(53.47-55.3)
Inner
1.926-1.996
-
(48.9-50.7)
Piston-to-cylinder clearance
0.0006-0.0016
0.0016
(0.015-0.041)
(0.041)
Piston pin fit in piston
0.0001-0.0004
0.001
(0.003-0.010)
(0.025)
Piston rings
Compression ring end gap
Top ring
0.007-0.020
0.020
(0.178-0.508)
(0.508)
Second ring
0.007-0.020
0.024
(0.178-0.508)
(0.610)
(continued)
ENGINE
195
Table 2 ENGINE SERVICE SPECIFICATIONS (continued)
Item
New in. (mm)
Service limit in. (mm)
Oil control ring end gap
0.009-0.052
0.050
(0.23-1.32)
(1.27)
Compression ring side clearance
Top ring
0.002-0.0045
0.0037
(0.051-0.114)
(0.09)
Second ring
0.0016-0.0041
0.0037
(0.041-0.104)
(0.09)
Oil control ring
4
side clearance
0.0016-0.0076
0.0072
(0.041-0.193)
(0.18)
Cylinder
Taper
-
0.002
–
(0.05)
Cylinder
Out of round
-
0.003
–
(0.08)
Warpage
At top (cylinder head)
-
0.006
(0.15)
At base (crankcase)
-
0.008
(0.20)
Cylinder bore
Standard
-
3.753
(95.326)
Oversize 0.005 in.
-
3.758
(95.453)
Oversize 0.010 in.
-
3.763
(95.580)
Oversize 0.020 in.
-
3.773
(95.834)
Oversize 0.030 in.
-
3.783
(96.088)
Connecting rod
Connecting rod-to-crankpin
clearance
0.0004-0.0012
0.002
(0.0102-0.0305)
(0.05)
Piston pin clearance
in connecting rod
0.0003-0.0007
0.002
(0.008-0.018)
(0.05)
Connecting rod side play
0.005-0.015
0.020
(0.13-0.38)
(0.51)
Hydraulic lifters
Fit in guide
0.0008-0.0020
0.003
(0.02-0.05)
(0.076)
Roller fit
-
0.0015
-
(0.038)
Roller end clearance
-
0.026
–
(0.660)
Camshaft support plate
Camshaft chain
tensioner shoe
See text
Camshaft support
plate warpage
0.010
(0.25)
Camshaft bushing fit
0.0008-0.001
(0.0203-0.0254)
(continued)
196
CHAPTER FOUR
Table 2 ENGINE SERVICE SPECIFICATIONS (continued)
Item
New in. (mm)
Service limit in. (mm)
Oil pump rotor
tip clearance
-
0.004
(0.10)
Sprocket shaft Timken bearing
Cup fit in crankcase
0.003-0.005
-
(0.08-0.13)
Cone fit on shaft
0.0005-0.0015
-
(0.013-0.038)
Crankshaft
Runout (at flywheel rim)
0.000-0.010
0.015
(0.0-0.25)
(0.38)
Runout (at pinion shaft)
0.000-0.002
0.003
(0.0-0.05)
(0.08)
End play
0.001-0.005
0.002
(0.03-0.13)
(0.05)
Table 3 PUSH ROD AND LIFTER LOCATION
Cylinder head/rocker
Cylinder
Lifter bore
housing bore
Front
Intake
Inside
Rear
Exhaust
Outside
Front
Rear
Intake
Inside
Front
Exhaust
Outside
Rear
Table 4 ENGINE TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N·m
Bearing retainer
plate screws
-
20-30
2-3
Breather cover bolts
-
90-120
10-14
Camshaft cover screws
-
90-120
10-14
Camshaft support plate
Allen bolt
-
90-120
10-14
Crankshaft position
sensor screw
-
90-120
10-14
Crankshaft sprocket
bolt
Refer to text
Crankcase bolts
15-19
-
20-26
Cylinder head bolts
Refer to text
Cylinder head
bracket bolts
28-35
-
38-47
Cylinder stud
10-20
-
14-27
Engine oil drain plug
14-21
-
19-28
Front isolator
mounting bolts
21-27
-
28-37
Left side footpeg
bracket screws
25-30
-
34-41
Lifter cover bolts
-
90-120
10-14
Oil filter mount bolts
-
90-120
10-14
(continued)
ENGINE
197
Table 4 ENGINE TORQUE SPECIFICATIONS (continued)
Item
ft.-lb.
in.-lb.
N·m
Oil fitting
-
120-144
14-16
Oil line cover bolts
-
84-108
9-12
Oil pump screws
-
90-120
10-14
Pipe plug
-
120-144
14-16
Piston oil jet screw
-
20-30
2-3
Rear camshaft
sprocket bolt
Refer to procedure
in text
4
Rear footpeg
bracket screws
25-30
-
34-41
Rocker arm
Support bolts
15-18
-
20-24
Housing bolts
-
124-168
14-19
Arm cover bolts
15-18
-
20-24
Shift lever pinch bolt
18-22
-
24-30
Sprocket shaft nut
150-165
-
203-224
Stabilizer link bolt
18-22
-
24-30
Horn bracket-to-
cylinder head bolt
28-35
-
38-48
Transmission
Mounting bolts
Preliminary
15
-
20
Final
30-35
-
41-47
Drain plug
14-21
-
19-29
Table 5 REAR CAMSHAFT SPROCKET SPACERS
Part No.
in.
mm
25722-99
0.230
5.84
25723-99
0.240
6.10
25721-99
0.250
6.35
25719-99
0.260
6.60
25717-99
0.270
6.86
Table 6 CRANKSHAFT LEFT SIDE BEARING SPACER SHIM
Shim Part No.
in.
mm
9110
0.0905-0.0895
2.299-2.273
9120
0.0925-0.0915
2.350-2.324
9121
0.0945-0.0935
2.400-2.375
9122
0.0965-0.0955
2.451-2.426
9123
0.0985-0.0975
2.502-2.476
9124
0.1005-0.0995
2.553-2.527
9125
0.1025-0.1015
2.602-2.578
9126
0.1045-0.1035
2.654-2.629
9127
0.1065-0.1055
2.705-2.680
9128
0.1085-0.1075
2.756-2.731
9129
0.1105-0.1095
2.807-2.781
9130
0.1125-0.1115
2.858-2.932
9131
0.1145-0.1135
2.908-2.883
(continued)
198
CHAPTER FOUR
Table 6 CRANKSHAFT LEFT SIDE BEARING SPACER SHIM (continued)
Shim Part No.
in.
mm
9132
0.1165-0.1155
2.959-2.934
9133
0.1185-0.1175
3.010-2.985
9134
0.1205-0.1195
3.061-3.035
CHAPTER FIVE
CLUTCH AND PRIMARY DRIVE
5
This chapter describes service procedures for the
WARNING
clutch and primary drive assemblies.
Disconnect the negative battery cable
before working on the clutch or any
Tables 1-3 are at the end of the chapter.
primary drive component to avoid ac-
Table 1 lists the clutch general specifications and
cidentally activating the starter mo-
sprocket sizes
tor.
Table 2 lists clutch torque specifications.
Table 3 lists sprocket alignment spacers.
2. Remove the bolts securing the left side footpeg
assembly (Figure 2) and remove the assembly.
3. Drain the primary chain oil as described in
PRIMARY CHAINCASE OUTER COVER
Chapter Three.
Removal
NOTE
Note the location of the inspection
Refer to Figure 1.
cover bolts. There are two different
length bolts and they must be rein-
NOTE
stalled in the correct location.
On models so equipped, always dis-
arm the optional TSSM security sys-
4A. On all models except FXDWG, perform the fol-
tem prior to disconnecting the battery
lowing:
or the siren will sound.
a. Make an alignment mark (A, Figure 3) on the
1. Disconnect the negative battery cable as de-
outer shift lever and the end of the inner shift
scribed in Chapter Eight.
lever shaft.
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