Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams — page 9
160
CHAPTER FOUR
20. If necessary, disassemble and remove the cam-
shafts as described in this chapter.
214
Installation
NOTE
It is necessary to release the second-
ary chain tension in order to install
the camshaft inner ends into the
crankcase bearings (D, Figure 213).
If the tension is not released, the inner
ends of the camshafts are pulled to-
gether and out of alignment with the
bearings, making installation difficult
if not impossible.
215
1. Release the tension on the camshaft secondary
chain tension as follows:
a. Install the camshaft chain tensioner tool
onto the camshaft secondary chain
tensioner.
b. Using a wrench, rotate the tool counterclock-
wise and insert the hold pin (Figure 214)
through the hole in the outer surface of the
support plate and into the hole in the
tensioner. Push the hold pin all the way in un-
til it bottoms.
c. Remove the wrench and tensioner tool from
216
the tensioner.
2. Push on the oil pump assembly to make sure it is
correctly seated against the crankcase.
3. Install a new O-ring (A, Figure 213) onto the oil
pump assembly and a new O-ring (B) onto the lower
location. Apply a light coat of clean engine oil to the
O-rings.
4. On 2000-on models, install a new upper O-ring
(C, Figure 213). Apply a light coat of clean engine
oil to the O-ring.
5. Lubricate the camshaft needle bearing (Figure
215) in the crankcase and the camshaft bearing sur-
During
installation,
the
camshaft
faces (Figure 216) with clean engine oil.
ends may not be correctly aligned
6. If the camshafts were removed from the support
with the needle bearings. If force is
plate, check that the timing mark (Figure 217) on
applied, the needle bearing(s) will
each camshaft is aligned with each other. If not, re-
be damaged.
position the camshafts prior to installing the assem-
bly into the crankcase.
8.
Slowly install the camshaft support plate
as-
7. If removed, install the two locating dowels (E,
sembly into the crankcase. Guide the camshaft
Figure 213) onto the crankcase.
ends into the crankcase needle bearings. If neces-
CAUTION
sary, slightly rotate and/or wiggle the end of the
Do not force the camshaft support
rear cylinder camshaft (Figure 218) to assist in the
plate assembly into the crankcase.
alignment.
ENGINE
161
CAUTION
217
When properly aligned, the camshaft
support plate assembly will fit snugly
against the crankcase mating surface.
If they do not meet correctly, do not
attempt to pull the parts together with
the mounting bolts. Separate the cam-
shaft support plate assembly and in-
vestigate the cause of the interference.
4
9. Push the camshaft support plate assembly onto
the crankcase until it bottoms on the two locating
dowels and the crankcase mating surface.
10. Once again, check that the timing marks (Fig-
ure 219) on each camshaft are still aligned with
218
each other. If not, correct the problem at this time.
11. Tighten the six camshaft support plate to crank-
case Allen bolts in the following sequence:
a. Install and loosely tighten the Allen bolts (B,
Figure 211).
b. Using a crisscross pattern, tighten the Allen
bolts to the specification in Table 4.
12. Tighten the four camshaft support plate-to-oil
pump Allen bolts in the following sequence:
a. Install the Allen bolts
(A, Figure
211).
Tighten the bolts until they just contact the
support plate and then back them out 1/4 turn.
b. Rotate the engine until the oil pump is in neu-
219
tral center with no load on it.
c. Tighten the bolts until they are snug against
the support plate. Then, using a crisscross
pattern, tighten the Allen bolts to the specifi-
cation in Table 4.
13. After all ten Allen bolts are tightened, check
around the perimeter of the support plate to make
sure it is seated against the crankcase mating surface.
14. Install an angled pick into the opening and
against the secondary camshaft chain tensioner
shoe (A, Figure 220). Slowly release the hold pin
(B) and allow the tensioner shoe to gradually make
220
contact with the chain surface. If released too fast,
the shoe surface will slam against the chain and be
damaged.
15. Squeeze the tabs and install the camshaft chain
guide (Figure 210) onto the two posts.
NOTE
Step 16 is not necessary if the original
camshaft support plate, both cam-
shafts, the rear camshaft sprocket, the
crankshaft drive sprocket, and the
162
CHAPTER FOUR
crankshaft assembly are being reused
and installed. If any one of these com-
221
ponents have been replaced, Step 16
is necessary to ensure correct align-
ment between the rear camshaft
sprocket and the crankshaft drive
sprocket. If this alignment is incor-
rect, the primary drive chain and both
sprockets will bind and cause prema-
ture wear.
16. If new parts have been installed, check the
alignment of the rear camshaft sprocket and the
crankshaft drive sprocket as described under Rear
Camshaft Sprocket and Crankshaft Drive Sprocket
222
Alignment in the following procedure. If all original
parts have been installed, proceed to Step 17.
17. Relieve the tension on the camshaft primary
drive chain as follows:
a. Install the camshaft chain tensioner tool (Fig-
ure 221) onto the camshaft primary chain
tensioner.
b. Using a wrench (A, Figure 222), rotate the
tool counterclockwise and insert the hold pin
(B) through the hole in the tensioner and into
the hole in the support plate. Push the hold pin
all the way in until it bottoms.
c. Remove the wrench and tensioner tool from
223
the tensioner.
18. Position the sprocket spacer with the manufac-
turer’s mark side going on first, and install the
sprocket spacer (Figure 209) onto the rear camshaft.
NOTE
Refer to the mark made prior to re-
moval and position the camshaft pri-
mary drive chain so it will be
traveling in the same direction. If in-
stalled incorrectly, the drive chain
will wear prematurely.
19. Correctly assemble the rear camshaft sprocket,
224
the crankshaft drive sprocket and the primary drive
chain together as an assembly. Align the index mark
on both sprockets so they face each other as shown
in Figure 223.
20. On models so equipped, install the Woodruff
key onto the rear camshaft.
21. Install the rear camshaft drive sprocket (A, Fig-
ure 208), the crankshaft sprocket (B), and the pri-
mary camshaft drive chain (C) as an assembly onto
the crankshaft and rear camshaft. Align the flat on
ENGINE
163
24. Install a new camshaft sprocket bolt (A, Figure
225
207) and new crankshaft sprocket bolt and washer
(B). Tighten the bolts finger-tight at this time.
25. Install and mesh the camshaft and crankshaft
sprocket lock (Figure 225) between the camshaft
and crankshaft sprockets.
26. Place a flat blade screwdriver (A, Figure 226)
between the primary camshaft drive chain and the
tensioner. Slowly release the hold pin (B), then
4
slowly withdraw the screwdriver and allow the
tensioner to gradually make contact with the chain
surface. If released too fast, the shoe surface will
slam against the chain and be damaged.
27. Tighten both bolts in the following steps:
226
a. Tighten both bolts to 15 ft.-lb. (20 N•m).
b. Loosen both bolts one complete revolution
(360°).
c. Tighten the rear camshaft bolt to 34 ft.-lb. (46
N•m).
d. Tighten the crankshaft bolt to 24 ft.-lb. (33
N•m).
28. Remove the tool installed in Step 25.
29. Install the crankshaft position sensor (Figure
204) into the crankcase and tighten the bolt securely.
30. Install a new camshaft cover gasket (Figure
227) onto the crankcase.
227
NOTE
On 1999-2000 models, do not damage
the cam position sensor wiring (Fig-
ure 202) during cover installation.
31. Install the camshaft cover onto the crankcase.
Install the bolts and tighten them securely in a criss-
cross pattern.
32. Install the lifter covers, lifters and pushrods as
described in this chapter.
33. Install the exhaust system as described in
Chapter Seven.
the crankshaft sprocket with the flat on the crank-
shaft (A, Figure 224). Check the alignment of the
Rear Camshaft Sprocket and
index mark on both sprockets, and make sure they
Crankshaft Drive Sprocket Alignment
face each other as shown in B, Figure 224. Realign
the sprocket index marks if necessary.
This procedure is required if any of the following
parts have been replaced: the camshaft support
22. Apply clean engine oil to the underside of both
plate, either or both camshafts, the rear camshaft
new sprocket bolts prior to installation.
sprocket, the crankshaft drive sprocket and the
23. Apply a small amount of ThreeBond TB1360,
crankshaft assembly.
or an equivalent, threadlocking compound to the
If any of these components have been replaced,
threads of the new rear camshaft sprocket bolt. Do
the procedure is necessary to ensure correct align-
not apply the locking agent to the crankshaft bolt.
ment between the rear camshaft sprocket and the
164
CHAPTER FOUR
crankshaft drive sprocket. If this alignment is incor-
rect, the primary drive chain and both sprockets will
228
bind and cause premature wear.
For the correct relationship between the two
sprocket faces, the rear camshaft sprocket must be
0.005 in. (0.127 mm) below the surface of the
crankshaft sprocket.
1. Position the sprocket spacer with the manufac-
turer’s-mark side going on first. Install the sprocket
spacer (Figure 209) onto the rear camshaft and
push it on until it bottoms.
2. On models so equipped, install the Woodruff key
onto the rear camshaft.
3. Apply clean engine oil to the camshaft splines (or
229
Woodruff key) and rear camshaft sprocket splines.
4. Install the rear camshaft sprocket onto the cam-
shaft. Install the used mounting bolt and flat washer
(A, Figure 228). Tighten the bolt finger-tight.
5. Install the crankshaft sprocket (B, Figure 228)
onto the crankshaft. Install the used mounting bolt
and a washer with a smaller outer diameter (C).
Tighten the bolt finger-tight at this time.
6. Install and mesh the camshaft and crankshaft
sprocket lock (Figure 225) between the camshaft
and crankshaft sprockets.
7. Tighten both bolts in the following steps:
a. Tighten both bolts to 15 ft.-lb. (20 N•m).
230
b. Loosen both bolts one complete revolution
(360 degrees).
c. Tighten the rear camshaft bolt to 34 ft.-lb. (46
N•m).
d. Tighten the crankshaft bolt to 24 ft.-lb. (33
N•m).
8. Remove the special tool from the sprockets.
9. Place a straightedge (A, Figure 229) against the
face of both sprockets. Push the straightedge
against the crankshaft sprocket and hold it there.
10. Try to insert a 0.005 in. (0.127 mm) feeler
gauge (B, Figure 229) between the straightedge and
the camshaft sprocket face.
231
11A. If the 0.005 in. (0.127 mm) thickness flat
feeler gauge can be inserted, the sprockets are cor-
rectly aligned to each other. Remove both sprockets
and proceed with Step 17 of Camshaft Support
Plate Installation in the previous procedure.
11B. If a different thickness feeler gauge can be in-
serted indicating a height difference other than
0.005 in. (0.127 mm) the rear camshaft spacer must
be changed. Continue to insert the feeler gauge of a
different thickness until the dimension difference is
ENGINE
165
14B. If the crankshaft sprocket is less than 0.005 in.
232
(0.127 mm) above the camshaft sprocket, install the
next thinner size spacer under the camshaft
sprocket.
15. Install a new spacer and repeat this procedure
until the correct amount of height difference of
0.005 in. (0.127mm). is obtained.
16. After the correct thickness spacer is estab-
lished, proceed with Step 17 of Camshaft Support
4
Plate Installation in the previous procedure.
Camshaft Support Plate and Camshafts
233
A hydraulic press, camshaft chain tensioner tool
(JIMS part No. 1283) and camshaft remover and in-
staller (JIMS part No. 1277) are required to perform
the following procedure.
Disassembly
1. Remove the camshaft support plate as previ-
ously described.
2. Remove the snap ring (Figure 230) from the
front cylinder camshaft.
3. Release the tension on the camshaft secondary
chain tensioner as follows:
234
a. Install the camshaft chain tensioner tool onto
the camshaft secondary chain tensioner.
b. Using a wrench, rotate the tool counterclock-
wise and insert the hold pin (Figure 231)
through the hole in the outer surface of the
support plate and into the hole in the
tensioner. Push the hold pin all the way in un-
til it bottoms.
c. Remove the wrench and tensioner tool from
the tensioner.
4. Loosen and remove the four T20 Torx screws
(Figure 232) securing the bearing retainer plate.
noted. Write down this dimension as it will be used
Remove the bearing retainer plate (Figure 233).
to choose a new spacer.
5. Press the camshafts and secondary drive chain
12. Remove the rear camshaft sprocket
bolt,
out of the camshaft support plate as follows:
washer and sprocket.
a. Turn the camshaft support cover face up on
13. Remove the existing sprocket spacer (Figure
two support blocks in a press bed. Make sure
208) from the rear camshaft. Compare the part num-
the support blocks are tall enough to allow the
ber stamped on the spacer with the parts numbers in
complete removal of the camshafts from the
Table 5 to determine the thickness.
cover.
14A. If the crankshaft sprocket is more than 0.005 in.
b. Install the cups of the camshaft remover and in-
(0.127 mm) above the camshaft sprocket, install the
staller onto the top of the camshafts (Figure
next thicker size spacer under the camshaft sprocket.
234) following the manufacturer’s instructions.
166
CHAPTER FOUR
235
236
c. Center the press ram over the center of the
tool (Figure 235).
237
d. Slowly apply pressure and press the assembly
out of the support cover.
e. Remove the assembly, cover, and special tool
from the press bed.
6. To ensure that the camshaft secondary drive
chain is reinstalled in the same direction of travel,
mark one of the link plates on the bearing side with
a permanent marking pen (Figure 236) or scribe.
7. Separate the camshafts from the secondary drive
chain.
Inspection
238
There are no manufacturer’s specifications avail-
able for the camshaft. The following procedure is a
visual inspection to determine if the camshafts re-
quire replacement.
1. Check the camshaft lobes (Figure 237) for wear.
The lobes should not be scored and the edges should
be square.
2. Inspect the drive chain sprocket (Figure 238) for
broken or chipped teeth. Also check the teeth for
cracking or rounding. If the sprocket is damaged or
severely worn, replace the camshaft.
3. If the camshaft sprockets are worn, check the cam-
239
shaft secondary drive chain (Figure 239) for damage.
4A. On early models, inspect the Woodruff key and
key slot in the rear cylinder camshaft for wear or
damage.
4B. On later models, inspect the external splines (A,
Figure 240) on the rear cylinder camshaft and the
internal splines (B, Figure 240) on the sprocket.
Check for worn or damaged splines and replace ei-
ther or both parts if necessary. The sprocket must be
a tight fit on the camshaft.
ENGINE
167
240
244
4
241
245
5. Check the snap ring groove (Figure 241) on the
242
front cylinder camshaft for wear or damage.
6. Inspect the ball bearing (Figure 242) on each
camshaft and rotate it. It must rotate smoothly with
no roughness. If damaged, replace the ball bearing
as described in this section.
Assembly
NOTE
This procedure is shown with the ball
bearings in place on the camshafts
since they did not require replacement.
243
1. Prior to installing the camshaft assembly, the
tension must be relieved on the secondary cam
chain tensioner. Perform the following :
a. Install the camshaft chain tensioner tool (Fig-
ure 243) onto the camshaft secondary chain
tensioner.
b. Using a wrench, rotate the tool counterclock-
wise (Figure 244) and insert the hold pin
through the hole in the tensioner and into the
hole in the support plate. Push the hold pin all
the way in until it bottoms (Figure 245).
168
CHAPTER FOUR
c. Remove the wrench and tensioner tool from
the tensioner.
246
2. Assemble the camshafts and the secondary drive
chain as follows:
a.
Locate the index marks on the front of the
camshafts (Figure 246). Transfer these marks
to the backside of the sprockets, in the exact
same location, with a permanent marking pen
or scribe (Figure 247). These marks are used
later to observe proper alignment of the cam-
shaft as they are pressed into the camshaft
support plate.
NOTE
247
Refer to the mark made on one of the
link plates in Disassembly Step 6 and
position the camshaft secondary drive
chain so it will be traveling in the
same direction as noted prior to re-
moval. If installed incorrectly, the
drive chain will wear prematurely.
b.
Position the camshafts with the index marks
facing directly opposite each other (Figure
248).
c.
Correctly position the secondary chain with
the marked link plate facing up (Figure 236)
and assemble the secondary chain onto both
248
camshafts.
d.
Rotate the camshafts in either direction sev-
eral times and recheck the alignment of the
index marks. If necessary, readjust one of the
camshafts to achieve correct alignment (Fig-
ure 248).
3.
Apply a light coat of clean engine oil, or press
lube, to the camshaft ends and to the bearing recep-
tacles in the camshaft support plate.
4. Place the camshaft support plate on the press
bed with the bearing receptacles facing up (Figure
249).
249
5. Correctly position the camshaft assembly onto
the camshaft support plate with the rear cylinder
camshaft (Figure 250) located toward the back of the
support plate. Align the bearings with the support
plate receptacles and hold the assembly in place.
NOTE
Prior to pressing the camshaft assem-
bly into place, check the alignment of
the camshaft index marks on the back-
side of the sprockets (Figure 251). If
ENGINE
169
250
254
4
out of alignment, remove the assem-
251
bly and correct this alignment.
6. Install the cups of the camshaft remover and in-
staller onto the top of the camshafts (Figure 252),
following the manufacturer’s instructions.
7. Center the press ram over the center of the tool
(Figure 253).
8. Slowly apply pressure and press the assembly
into the support cover until it bottoms.
9. Remove the assembly and special tool from the
press bed.
10. Turn the assembly over and double check that
252
the camshaft index marks are still correctly aligned
as shown in Figure 254.
11. Rotate the camshafts several complete revolu-
tions and check for binding.
12. Install the retainer plate (Figure 233) into posi-
tion.
13. Apply a small amount of ThreeBond TB1342
or an equivalent threadlocking compound to the
Torx screw threads. Install the four T20 Torx screws
(Figure 232) and tighten securely.
14. Place a flat blade screwdriver between the sec-
ondary camshaft drive chain and the tensioner.
253
Slowly release the hold pin (Figure 231), then
slowly withdraw the screwdriver and allow the
tensioner to gradually make contact with the chain
surface. If released too fast, the shoe surface will
slam against the chain and be damaged.
15. Install the circlip (Figure 255) onto the front
cylinder camshaft. Make sure the snap ring is cor-
rectly seated in the camshaft groove.
16. Install the camshaft support plate as previously
described.
170
CHAPTER FOUR
Bushing replacement
255
A crankshaft bushing tool (JIMS part No. 1281) is
required to remove and install the crankshaft bush-
ing.
1. Place the bushing support tool on the press bed.
NOTE
The crankshaft bushing edge is
knurled on the side that faces the pri-
mary chain side.
2. Position the camshaft support plate with the pri-
mary chain side facing up. Place the camshaft sup-
port plate onto the bushing support tool and center
the bushing over the tool (Figure 256).
256
3. Install the remove side of the driver (Figure 257)
through the bushing and into the support tool until
the shoulder of the driver contacts the edge of the
bushing.
4. Apply pressure and press the bushing out of the
support plate until the driver collar contacts the sup-
port plate.
5. If removed, place the bushing support tool on the
press bed.
6. Position the camshaft support plate with the sec-
ondary chain side facing up. Place the camshaft
support plate onto the bushing support tool.
7. Apply a light coat of clean engine oil, or press
257
lube, to the outer surface of the bushing and to the
support plate bushing receptacle.
8. Position the bushing into the receptacle with the
knurled side facing up and align it.
9. Install the install side of the driver (Figure 258)
through the bushing and into the support tool until
the driver contacts the edge of the bushing.
10. Press the bushing into the support plate until
the driver collar contacts the support plate.
11. Remove the special tools and the support plate
from the press bed.
258
Camshaft Bearing Replacement
Ball bearings
A hydraulic press, camshaft bearing puller (JIMS
part No 1280) and camshaft remover and installer
(JIMS part No. 1277) are required to remove and in-
stall the camshaft ball bearings.
1. Install the camshaft bearing puller tool onto the
camshaft ball bearing (Figure 259) and remove it
following the manufacturer’s instructions.
ENGINE
171
b. Place the camshaft support plate (A, Figure
259
260) onto a support block. Make sure the sup-
port plate is indexed correctly into the support
block.
c. Apply a light coat of clean engine oil or
press lube to the outer surface of the ball
bearing and to the support plate bearing re-
ceptacle.
4
d. Place the ball bearing onto the support plate
(B, Figure 260).
e. Install the bearing pilot (Figure 261) into the
260
ball bearing.
f. Apply pressure and press the bearing straight
into the support plate until it bottoms.
g. Remove the pilot from the bearing and re-
move the support plate from the press bed.
Needle bearings
NOTE
The camshaft needle bearings can be
removed with the engine mounted in
the frame and the camshaft support
261
plate removed. This procedure is
shown with the engine removed and
partially disassembled to better illus-
trate the steps.
NOTE
Replace both needle bearings as a set
even though only one requires re-
placement.
A twin cam 88 engine stand (JIMS part No. 1022)
and flywheel press (JIMS part No. 1047-TP) were
2.
Repeat for the other camshaft bearing.
used in the following procedure.
NOTE
1. Remove the camshaft support plate assembly
The ball bearing is installed into the
from the engine as described in this chapter.
camshaft support plate, not onto the
camshaft(s).
2. Install the puller portion of the tool set (A, Fig-
ure 262) part way into the needle bearing. Install a
small hose clamp (B) onto the end closer to the nee-
3.
Install the ball bearing(s) into the camshaft sup-
dle bearing and tighten. This will close the end of
port plate using the camshaft remover and installer
the tool so it can pass through the needle bearing.
as follows:
Push the puller all the way through the needle bear-
a. Place the support block on the press bed.
ing and remove the hose clamp.
172
CHAPTER FOUR
3. Assemble the remainder of the tool components
onto the puller portion (Figure 263), following the
262
manufacturer’s instructions.
4. Place a 5/8 in. wrench on the flats of the puller
(A, Figure 264).
5. Place a
1 1/8
in. wrench, or an adjustable
wrench, on the large nut (B, Figure 264).
CAUTION
Do not turn the 5/8 in. wrench as this
will damage the special tool and the
crankcase receptacle.
6. Hold onto the 5/8 in. wrench to keep the puller
from rotating. Turn the 1 1/8 in. wrench clockwise
263
on the large nut. Tighten the large nut and pull the
needle bearing out of the crankcase receptacle.
7. Disassemble the special tool and remove the
needle bearing from it.
8. Repeat Steps 2-7 for the other needle bearing.
9. Apply a light coat of clean engine oil, or press
lube, to the outer surface of the ball bearings and to
the crankcase needle bearing receptacles (Figure
265).
NOTE
The following photographs are shown
with the crankcase disassembled to
better illustrate the steps.
264
10. Apply a light coat of clean engine oil to the
threads of the screw portion and to the installer
plate.
11. Insert the screw portion of the special tool part
way into the installer plate.
12. Install the installer onto the screw and push it
on until it locks into place.
13. Position the new bearing with the manufacturer’s
marks facing out on the installer (Figure 266).
14. Install the installer plate onto the crankcase,
aligning the tool to the bearing receptacle (A, Fig-
ure 267).
265
15. Install the thumb screws through the installer
plate
(B, Figure
267) and onto the crankcase
threaded holes. Tighten the thumb screws securely.
16. Slowly tighten the screw until the bearing starts
to enter the crankcase receptacle. Continue to
tighten until the installer contacts the crankcase sur-
face. This will correctly locate the needle bearing
within the crankcase.
17. Remove the special tools.
18. Repeat Steps 10-17 for the other needle bearing.
ENGINE
173
266
270
4
Oil Pressure Relief Valve
267
Removal/Installation
NOTE
This procedure is shown with the cam-
shaft assembly removed to better il-
lustrate these steps.
1. Remove the camshaft support plate assembly
from the engine as described in this chapter.
2A. If the camshaft assembly is still in place, secure
the camshaft support plate in a vise with soft jaws.
2B. If the camshaft assembly is removed, place the
268
camshaft support plate on a piece of soft wood.
3. Use a 1/8 in. punch and drive out the roll pin
(Figure 268) securing the valve body and spring in
place. Discard the roll pin (A, Figure 269).
4. Remove the valve body (B, Figure 269) and
spring (C) from the bypass port of the camshaft sup-
port plate.
5. Inspect the valve body, spring and bypass port
(Figure 270) for wear or damage. Replace as neces-
sary.
6. Apply a light coat of clean engine oil to the by-
269
pass port and to the valve body.
7. Position the valve body (A, Figure 271) with the
closed end going into the bypass port first.
8. Install the spring (B, Figure 271) into the valve
body.
9. Push the valve body and spring into the bypass
port, hold them in place and install a new roll pin
(Figure 272). Tap the roll pin in until it bottoms
(Figure 268).
174
CHAPTER FOUR
Cleaning Plug
Removal/Installation
271
NOTE
This procedure is shown with the cam-
shaft assembly removed to better il-
lustrate these steps.
1. Remove the camshaft support plate assembly
from the engine as described in this chapter.
2A. If the camshaft assembly is still in place, secure
the camshaft support plate in a vise with soft jaws.
2B. If the camshaft assembly is removed, place the
camshaft support plate on piece of soft wood.
3. Use a pair of pliers and carefully remove the
272
cleaning plug (Figure 273) from the camshaft sup-
port plate. Remove the O-ring.
4. Thoroughly clean the cleaning plug receptacle
and support plate in solvent. Dry with compressed
air.
5. Apply low-pressure compressed air to the clean-
ing plug receptacle (Figure 274) and blow out any
debris. Make sure the oil hole is clear.
6. Install a new O-ring onto the cleaning plug and
install the cleaning plug. Press it in until it bot-
toms.
273
Camshaft Primary and
Secondary Chain Tensioner
Removal/Inspection/Installation
NOTE
This procedure is shown on the pri-
mary chain tensioner and also ap-
plies to the secondary chain
tensioner.
1. Remove the camshaft primary and/or secondary
chain as described in this chapter.
2. Remove the snap ring (Figure 275) securing the
274
chain tensioner to the mounting post. Discard the
snap ring.
3. Slide the chain tensioner (A, Figure 276) off the
mounting post.
4. Inspect the chain tensioner shoe (A, Figure 277)
for wear. If the pad surface is worn halfway through
(A, Figure 278) or chipped (B), replace the assem-
bly.
5. Check the spring (B, Figure 277) for sagging or
damage. Replace the assembly if necessary.
ENGINE
175
275
279
4
6. Install the chain tensioner onto the mounting
276
post and insert the spring end into the receptacle in
the cover (B, Figure 276). Push the chain tension on
until it bottoms.
7. Install a new snap ring and press it into place
(Figure 279). Make sure it is correctly seated in the
mounting post groove.
CRANKCASE AND CRANKSHAFT
Disassembly
A twin cam 88 engine stand (JIMS part No. 1022)
277
and flywheel press (JIMS part No. 1047-TP) were
used in the following procedure.
CAUTION
Prior to disassembling the crankcase,
measure the crankshaft end play as
described in Crankcase Assembly.
Refer to Figure 280.
1. Remove the engine from the frame as described
in this chapter.
CAUTION
Do not lift the crankcase assembly by
278
the cylinder studs. Bent or damaged
cylinder studs may cause the engine to
leak oil.
2. Remove the following components as described
in this chapter:
a. Cylinder heads and cylinders.
b. Pistons.
c. Pushrods and valve lifters.
d. Camshaft assembly.
e. Oil pump.
176
CHAPTER FOUR
280
CRANKCASE ASSEMBLY
1. Connecting rod bushing
2. Crankshaft assembly
3. Oil hose fitting
4. Retaining ring
5. Right side main bearing
6. Needle bearing-camshaft
7. Crankcase assembly
8. O-ring
9. Piston cooling jet
10. Screw
11. Locating dowel
12. Bolt
13. Plug
14. Bearing
15. Bearing race
16. Lock ring
17. Spacer ring
18. Oil seal
19. Sprocket shaft spacer
20. Left side main bearing
(sprocket shaft) assembly
21. Locating dowel
f. Alternator rotor and stator assembly (Chapter
Eight).
281
NOTE
The bolts for the left side are to be left
off so the case halves can be sepa-
rated in the following steps.
3. Attach the crankcase assembly to an engine
stand (Figure 281), following the manufacturer’s
instructions. Make sure that the stand is attached
ENGINE
177
282
285
4
286
so the case can be separated in the following
283
steps.
4. Secure the engine stand to the workbench so it
cannot move.
5. Using the torque pattern shown in Figure 282,
loosen in two to three stages, then remove the
bolts from the left side of the crankcase (Figure
283).
6. Place the crankcase assembly on wooden blocks
with the camshaft cover (left side) facing up. Use
wooden blocks thick enough so the right side of the
crankshaft clears the workbench surface (Figure
284).
7. Tap around the perimeter of the crankcase with a
284
plastic mallet and remove the left crankcase half
(Figure 285).
8. If the crankcase halves will not separate easily,
perform the following:
a. Install a flywheel press (A, Figure 286) onto
the left side of the crankcase, following the
manufacturer’s instructions.
b. Make sure the right side engine stand bolts
(A, Figure 287) are not installed onto the
crankcase half.
178
CHAPTER FOUR
c.
Apply clean engine oil, or press lube, to the
end of the center screw and install it into the
287
tool.
CAUTION
Do not use a hand impact driver or air
impact wrench on the center screw, as
they will damage the crankcase
halves, as well as the tool.
d.
Slowly turn the center screw with a wrench
(B, Figure 286) 1/2 turn at a time. After each
turn, tap on the end of the center screw with a
brass mallet to relieve the stress on the center
screw and the tool.
288
e.
Repeat substep d until the center screw turns
freely and the crankcase halves begin to sepa-
rate (B, Figure 287).
f.
Remove the crankcase from the engine
stand.
g.
Remove the right side crankcase half (Figure
288).
h.
Remove the special tool from the left side
crankcase unless the crankshaft is going to be
removed in Step 10.
9. Remove the locating dowels and O-rings (Fig-
ure 289) from the right side crankcase.
289
WARNING
Wear safety glasses when pressing out
the crankshaft.
CAUTION
Do not remove the crankshaft by us-
ing a hammer to drive it out of the
crankcase half.
10A. If a hydraulic press is available, press the
crankshaft out of the right crankcase half as fol-
lows:
a. Support the right crankcase half in a press on
290
wooden blocks with the outer surface facing up.
b. Center the press ram onto the end of the crank-
shaft, then press the crankshaft out of the right
crankcase half. Have an assistant support the
crankshaft as it is being pressed out.
c. Remove the crankshaft.
d. Remove the right crankcase half from the press
bed and take to workbench for further service.
10B. If a hydraulic press is not available, perform
the following:
ENGINE
179
a.
Install a flywheel press onto the left side of
291
the crankcase, following the manufacturer’s
instructions (A, Figure 290).
b.
Apply clean engine oil, or press lube, to the end
of the center screw and install it into the tool.
CAUTION
Do not use a hand impact driver or air
impact wrench on the center screw, as
they will damage the crankcase as
4
well as the tool.
c.
Secure the right side of the crankshaft with a
wrench (B, Figure 290) to prevent it from ro-
tating in the following step.
292
d.
Slowly turn the center screw with a wrench
(C, Figure 290) 1/2 turn at a time. After each
turn, tap on the end of the center screw with a
brass mallet to relieve the stress on the center
screw and the tool.
e.
Repeat substep d until the center screw
pushes the crankshaft out of the left side
crankcase half.
f.
Remove the special tool from the left side
crankcase half.
11. To remove the left side crankshaft outer roller
bearing and oil seal assembly, perform the following:
a. Place the left side crankcase on the work-
293
bench with the outer surface facing up.
b. Carefully pry the sprocket shaft spacer out of
the oil seal.
c. Carefully pry the oil seal out of the crankcase
using a wide-blade screwdriver. Support the
screwdriver with a rag to prevent damaging
the crankcase.
d. Lift the outer roller bearing from the crank-
case.
Crankcase Cleaning
and Inspection
294
1. Clean both case halves in solvent and dry with
compressed air.
2. Apply a light coat of oil to the races to prevent rust.
3. Inspect the right side (Figure 291) and left side
(Figure 292) case halves for cracks or other damage.
4. Inspect the case studs (Figure 293) for damage.
If necessary, replace studs as described under Cylin-
der Stud Replacement in this chapter.
5. Inspect the left side main bearing races. Refer to
Figure 294 for the outer bearing race and Figure
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