514
SUPPLEMENT
d. Slowly apply pressure and drive valve guide
33
onto the collar until the valve guide bottoms in
the installer sleeve.
e. Remove the valve guide/collar assembly (D,
Figure 32) from the installer sleeve.
5. Apply a thin coat of Vaseline to the entire outer
surface of the valve guide before installing it in the
cylinder head.
CAUTION
When installing oversize valve guides,
make sure to match each guide to its re-
spective bore in the cylinder head.
6.
Install the new valve guide as follows:
a.
Install the intake (A, Figure 30) or exhaust (B)
valve seat adapter into the tube at the top of the
support stand (C).
b.
Install the support stand on the hydraulic press
table.
c.
Install the cylinder head (A, Figure 33) onto the
support stand (B) centering the cylinder head
valve seat onto the seat adapter.
d.
On exhaust valves, position the valve guide
ceptacle until the installer sleeve (C, Figure 33)
with the collar end going in last. The intake
contacts the machined surface of the cylinder
valve guides are non-directional, either end can
head.
go in first.
l.
Remove the cylinder head and special tools
e.
Install the valve guide onto the cylinder head re-
from the press bed.
ceptacle.
m. Repeat sub-steps a-l for the remaining valve
f.
Install the valve guide installer sleeve (C, Fig-
guides.
ure 33) over the valve guide, and insert the ta-
7.
Replacement valve guides are sold with a smaller
pered end of the valve guide driver (D) into the
inside diameter than the valve stem. Ream the guide to
installer sleeve.
fit the valve stem as follows:
g.
Center the valve guide driver under the press
ram and make sure the driver is perpendicular to
a. Apply a liberal amount of reamer lubricant to
the press table.
the ream bit and to the valve guide bore.
h.
Support the cylinder head, slowly apply pres-
b. Start the reamer straight into the valve guide
sure and slowly start to drive the valve guide
bore.
into the cylinder head receptacle. Stop and back
off the press ram to allow the valve guide to
CAUTION
center itself.
Only apply pressure to the end of the
i.
Verify that the support stand (A, Figure 33) and
drive socket. If pressure is applied to the
valve guide driver (D) are square with the press
T-handle, the bore will be uneven,
table.
rough cut and tapered.
j.
Once again apply press pressure and continue
to drive the valve guide part way into the cylin-
c. Apply thumb pressure to the end of the drive
der head receptacle. Once again, stop and back
socket portion of the T-handle while rotating the
off the press ram to allow the valve guide to
T-handle clockwise. Only light pressure is re-
center itself.
quired. Apply additional lubricant to the
k.
Again apply press pressure and continue to
reamer and into the valve guide while rotating
drive the valve guide into the cylinder head re-
the reamer.
2002-2005 MODEL SERVICE INFORMATION
515
d. Start the drill and move the hone back and
34
forth in the valve guide bore for 10 to 12 com-
plete strokes to obtain a 60° crosshatch pat-
tern.
9. Repeat Steps 7 and 8 for each valve guide.
10. Soak the cylinder head in a container filled with
hot, soapy water. Then clean the valve guides with a
valve guide brush or an equivalent bristle brush. Do
not use a steel brush. Do not use cleaning solvent,
kerosene or gasoline as these chemicals will not re-
move all of the abrasive particles produced during
the honing operation. Repeat this step until all of the
valve guides are thoroughly cleaned. Then rinse the
cylinder head and valve guides in clear, cold water
35
and dry them with compressed air.
11. After cleaning and drying the valve guides, apply
clean engine oil to the guides to prevent rust.
12. Resurface the valve seats as described in Valve
Seat Reconditioning in this chapter.
PISTONS AND PISTON RINGS
Piston Clearance
Later model 2003 and the 2004-on models have a
d.
Continue to rotate the reamer until the entire bit
small oval-shaped opening on the piston skirt coat-
has traveled through the valve guide and the
ing. This opening is used to locate the micrometer
shank of the reamer rotates freely.
for an accurate outer diameter measurement. This
small oval-shaped opening is too small for the stan-
CAUTION
dard flat anvil micrometer to obtain an accurate
Never back the reamer out through the
measurement. Use a 3-4 in. blade or ball anvil style
valve guide as the guide will be dam-
micrometer, or a 4-5 in. micrometer with spherical
aged.
ball adapters to achieve a correct measurement.
1. Make sure the piston skirt and cylinder bore is
e.
Remove the T-handle from the reamer. Remove
clean and dry.
the reamer from the combustion chamber side
14
2. Measure the cylinder bore with a bore gauge
of the cylinder head.
(Figure 34) as described under Cylinder Block In-
f.
Apply low-pressure compressed air to remove
spection in Chapter Four.
the small shavings from the valve guide bore.
Then clean the valve guide bore with the small
NOTE
spiral brush.
Some early 2003 models were not
8.
Hone the valve guide as follows:
equipped with the bare aluminum
spots on the piston skirt coating.
a. Install the valve guide hone into a high-speed
electric drill.
3A. On early 2003 models, measure the piston di-
b. Lubricate the valve guide bore and hone
ameter with a micrometer as follows:
stones with the reamer lubricant—do not use
a. Hold the micrometer at the bottom of the pis-
motor oil.
ton skirt at a right angle to the piston pin bore
c. Carefully insert the hone stones into the valve
(Figure 35). Adjust the micrometer so the
guide bore.
spindle and anvil just touch the skirt.
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516
SUPPLEMENT
b. Start below the bottom ring and slowly move
36
the micrometer toward the bottom of the skirt.
c. The micrometer will be loose, then tight at
about 0.5 in. (12.7 mm) from the bottom and
then loose again.
d. Measure the piston skirt at the tightest point.
3B. On late 2003 and 2004-on models, measure the
piston diameter with a micrometer as follows:
a. Use the previously described special microm-
eter and correctly position it on the bare alu-
minum spot on each side of the piston as
shown in Figure 36.
1. Place the support tube with the A side facing up
b. Measure the piston at this location only.
on the press bed.
4. Subtract the piston diameter from the largest
2. Position the right side crankcase with the outer
bore diameter; the difference is piston-to-cylinder
surface facing up and position the bearing directly
clearance. If the clearance exceeds the specification
over the support tube on the press bed.
in Table 6, the pistons should be replaced and the
3. Install the pilot shaft through the bearing and
cylinders bored oversize and then honed. Purchase
into the support tube.
the new pistons first. Measure their diameter and
4. Center the press driver over the pilot shaft.
add the specified clearance to determine the proper
5. Hold the crankcase half parallel to the press bed
cylinder bore diameter.
and have an assistant slowly apply press pressure on
the pilot shaft until the bearing is free from the case
CAMSHAFT SUPPORT PLATE
half.
6. Remove the case half and special tools from the
Rear Camshaft Sprocket and
press bed.
Crankshaft Drive Sprocket Alignment
The procedure is identical to previous models.
Installation
Refer to Table 7 for sprocket spacer thickness and
1. Apply a light coat of clean engine oil to the outer
part numbers.
surface of the bearing and to the crankcase recepta-
cle.
CRANKCASE AND CRANKSHAFT
2. Place the support tube with the B side facing up
on the press bed.
Right Side Main Bearing Replacement
3. Position the right side crankcase with the outer
surface facing up on the press bed.
Refer to Figure 37.
4. Position the new bearing with the manufac-
The following tools or their equivalents are re-
turer’s marks facing up and place it over the crank-
quired to remove and install the right side main
case receptacle.
bearing:
5. Install the pilot/driver through the bearing and
1. Hydraulic press.
into the support tube.
2. Crankshaft bearing support tube: (HD-42720-5).
6. Center the press driver over the pilot driver.
3. Pilot/driver: (B-45655).
7. Slowly apply press pressure on the pilot driver,
pressing the bearing into the crankcase. Apply pres-
sure until resistance is felt and the bearing bottoms
Removal
in the support tube. This will correctly locate the
bearing within the crankcase. Remove the pilot
NOTE
driver.
The Harley-Davidson support tube is
marked with an A on one end and a B
8. Remove the crankcase and the support tube from
on the other.
the press bed.
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2002-2005 MODEL SERVICE INFORMATION
517
37
CRANKCASE ASSEMBLY
1. Connecting rod bushing
11. Retaining ring
2. Crankshaft assembly
12. Locating dowel
3. Oil hose fitting
13. O-ring
4. Crankshaft main bearing
14. O-ring
5. Needle bearing-camshaft
15. Locating dowel
6. Dowel pin
16. Medallion plate
7. Plug
17. Thrust washer
8. O-ring
18. Oil seal
9. Piston cooling jet
19. Sprocket shaft spacer
14
10. Screw
20. Bolt
9. Check on each side of the crankcase to make
The following tools or their equivalents are re-
sure the bearing is centered within the receptacle. If
quired to remove and install the right side main
not, reposition the bearing until it is centered
bearing:
correctly.
1. Hydraulic press.
10. Spin the bearing to make sure it rotates
2. Crankshaft bearing support tube: (HD-42720-5).
smoothly with no binding.
3. Pilot/driver: (B-45655).
Left Side Main Bearing Assembly
Bearing removal
Replacement
1. Place the crankcase on the workbench with the
Refer to Figure 37.
inboard surface facing up.
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518
SUPPLEMENT
2. If still in place, remove the crankshaft spacer
38
from the bearing bore.
3. Carefully pull the thrust washer from the outer
surface of the crankcase past the oil seal.
4. Place the support tube on the workbench with
the A side facing up.
5. Position the crankcase with the inner surface
facing up and place the bearing bore over the sup-
port tube.
6. Use a suitable size drift and tap the oil seal out of
the bearing bore. Discard the oil seal.
7. Turn the crankcase over with the inner surface
facing up.
39
CAUTION
Do not damage the crankcase retain-
ing ring groove with the screwdriver.
The groove must remain sharp to cor-
rectly seat the retaining ring.
8. The roller bearing (A, Figure 38) is secured in
the crankcase with a retaining ring (B) on the inner
surface of the bearing bore. Remove the retaining
ring (B, Figure 38) as follows:
a. Use a flat tip screwdriver and place it under
the retaining ring. Carefully lift the edge of
the retaining ring up and out of the crankcase
groove.
Bearing installation
b. Slide the tip of the screwdriver around the
edge of the bearing and continue to lift the re-
1. Apply clean engine oil, or press lube, to the bear-
taining ring out of the crankcase groove.
ing receptacle in the crankcase and to the outer race
c. Remove the retaining ring.
of the new bearing.
2. Position the support tube (A, Figure 40) on the
9. Position the support tube (A, Figure 39) on the
press bed with the A side facing up.
press bed with the A side facing up.
3. Position the crankcase half with the inner side
10. Position the crankcase half with the outer side
facing up and position the crankshaft’s bearing
facing up and position the crankshaft’s bearing bore
bore over the support tube. Correctly align the two
over the support tube. Correctly align the two parts.
parts.
11. Slide the pilot/driver (B, Figure 39) through
4. Correctly position the new bearing (B, Figure
the crankcase bearing and into the support.
40) over the crankcase bore with the manufacturer’s
12. Center the press ram (C, Figure 39) directly
marks facing down.
over the pilot/driver (B) and slowly press the bear-
5. Slide the pilot/driver (C, Figure 40) through the
ing out of the crankcase.
new bearing and the crankcase and into the support.
13. Remove the crankcase and special tools from
6. Center the press ram (D, Figure 40) directly
the press bed.
over the pilot/driver (C) and slowly press the bear-
14. Clean the crankcase half in solvent and dry it
ing into the crankcase until it lightly bottoms in the
with compressed air.
crankshaft bearing bore.
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2002-2005 MODEL SERVICE INFORMATION
519
CAUTION
40
Do not damage the crankcase retain-
ing ring groove with the screwdriver.
The groove must remain sharp to cor-
rectly seat the retaining ring.
NOTE
If the retaining ring will not correctly
seat in the crankcase groove, the
bearing is not correctly seated in the
crankcase bore. Repeat Steps 2-6
10. Install the bearing’s new retainer ring as fol-
lows:
a. Work the retaining ring into the crankcase
groove being careful not to damage the crank-
case groove.
b. Use a flat tip screwdriver and push the retain-
41
ing ring. Continue to push the retaining ring
into the crankcase groove and make sure it is
correctly seated in the groove.
Crankshaft End Play Inspection
All 2003-on models are equipped with assembled
roller bearings and this procedure is no longer nec-
essary.
Crankshaft Left Side Main Bearing Assembly
Inner Race Replacement
Removal
1. Support the crankshaft in a support fixture
(HD-44358), or an equivalent, with the bearing side
14
facing up (A, Figure 41).
2. Place a hardened plug (B, Figure 41) between the
bearing puller and the end of the crankshaft.
3. Install the bearing splitter under the bearing inner
race (C, Figure 41).
4. Apply graphite lubricant to the bearing puller
7.
Remove the crankcase and special tools from the
center screw, and attach a bearing puller (D, Figure
press.
41) to the splitter.
8. Make sure the bearing has been pressed in past
the retaining ring groove. If the groove is not visible
WARNING
above the bearing, repeat Steps 2-6 until the groove
In Step 5, never use the heat gun in
is visible.
conjunction with the penetrating oil.
9. Position the crankcase on the workbench with
The heat from the gun may ignite the
the inner surface facing up.
oil resulting in a fire.
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