Harley Davidson 2018 softail models. Service manual — page 16
NOTE
Abrasive particles can damage machined surfaces or plug oil passageways. Clean parts before disassembly to prevent
component damage.
1. Use low-pressure compressed air to clean exterior
surfaces of engine.
2. Disconnect negative battery cable. See Main Fuse.
3. Remove seat. See Remove.
4. Remove fuel tank. See Prepare.
5. Remove spark plug cables. See Remove.
6. Remove coil. See Prepare.
7. Remove left side engine mount. See Prepare.
8. Remove air cleaner. See Remove.
9. Remove air cleaner backplate assembly. See Prepare.
10. Remove upper front engine mount. See Prepare.
11. Remove oil cooler cover and upper screw. See Prepare.
12. Remove upper cooling lines. See Prepare.
13. Remove induction module. See Prepare.
14. Disconnect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR.
15. Remove spark plugs. See Prepare.
16. Remove upper rocker covers. See Prepare.
17. Remove breathers. See Prepare.
18. Remove lower rocker covers. See Prepare.
19. Remove rocker arms. See Prepare.
20. Remove pushrods, lifters and covers. See Prepare.
21. Remove cylinder heads. See Prepare.
22. Remove cylinders. See Prepare.
NOTE
It is not necessary to remove both piston pin retaining rings for piston removal.
1. Place clean shop towels over crankcase bore to prevent the piston pin retaining ring from falling into the crankcase.
2. See Figure 1. Using HD-51069-2 (PISTON PIN RETAINING RING INSTALLER) with HD-51069-17 (NOSE
ADAPTER), remove and discard one piston pin retaining ring.
a. Insert tool (1) into piston pin bore with claw on tool in slot of piston (2) (directly under retaining ring).
b. Squeeze handles of tool together.
c. Pull retaining ring from bore. Discard retaining ring.
1
Piston pin retaining ring installer
2
Piston
3
Protective material over cylinder studs
Figure 1. Piston Pin Retaining Ring Removal
3. See Figure 2. Remove piston.
a. Remove the piston pin using HD-42320-8 (PISTON PIN EXTRACTOR) with HD-42320-D (PISTON PIN
REMOVER).
b. Hold the connecting rod to prevent it from striking the crankcase. Remove the piston.
c. Place a piece of foam-type water pipe insulation around connecting rod to prevent damage.
4. Identify piston location by marking piston pin boss underneath.
Figure 2. Remove Piston Pin
Special Tools
Description
Part Number
Qty.
NOSE ADAPTER
HD-51069-17
1
PISTON PIN RETAINING RING
HD-51069-2
1
INSTALLER
WARNING
Failure to properly install and inspect piston pin retaining rings will result in engine failure and possible rear wheel
lockup, which could result in death or serious injury. (03406a)
NOTE
Do not reuse piston pin retaining rings.
1. Install one new piston pin retaining ring using PISTON PIN RETAINING RING INSTALLER (Part
Number:HD-51069-2) with NOSE ADAPTER (Part Number:HD-51069-17).
a. See Figure 1. Slide retaining ring down nose of tool until it contacts claw.
b. Center retaining ring at top of tool. Lightly squeeze handles of tool to capture retaining ring in claw.
c. Tilt the retaining ring forward until the end gap contacts nose of tool.
d. See Figure 3. Insert the tool (2) into the piston pin bore until claw is aligned with slot (3) in piston.
e. Firmly push the tool into the piston pin bore until it bottoms.
f. Release handles, Remove tool.
g. See Figure 2. Verify that retaining ring end gap (3) is opposite from opening (2).
h. Inspect the retaining ring to verify that it is fully seated in the groove.
2. Install piston.
a. Verify that one retaining ring is installed in piston pin bore.
b. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to piston pin, piston pin bores and upper connecting rod
bore.
c. Remove water pipe insulation from connecting rod shank.
d. See Figure 3. Place piston over rod end with the arrow (1) pointing toward the front of the engine.
e. Insert piston pin through pin bore and upper connecting rod until it contacts retaining ring installed in
opposite pin boss.
f. Place clean shop towels over the cylinder and lifter bores.
3. See Figure 1. Install new retaining ring using PISTON PIN RETAINING RING INSTALLER (Part
Number:HD-51069-2) with NOSE ADAPTER (Part Number:HD-51069-17).
a. See Figure 2. Verify that retaining ring end gap (3) is opposite from opening (2).
b. Inspect the retaining ring to verify that it is fully seated in the groove.
Figure 1. Aligning Retaining Ring
1
Piston pin
2
Retaining ring opening
3
End gap location
Figure 2. Pre-Installed Retaining Ring
1
Arrow
2
Piston pin retaining ring installer
3
Slot
Figure 3. Install Pin Retaining Ring
1. Remove piston rings.
WARNING
Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety
glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates.
(00061a)
NOTE
Do not sandblast or glass bead blast pistons. Bead blasting rounds off ring lands.
Do not damage or enlarge the holes.
Do not use a wire brush to clean oil holes.
Avoid scratching the sides of the piston ring grooves.
1. Remove all combustion deposits.
a. Soak the pistons in hot water with dishwashing liquid or a cleaner designed to remove carbon and which
does not corrode aluminum.
b. Follow the manufacturer's instructions.
c. Thoroughly rinse the pistons.
d. Clean the oil drain holes in the oil control ring groove with a small bristle brush.
e. Dry parts with low-pressure, compressed air.
2. Verify that all oil holes are clean and open.
NOTE
A portion of a compression ring properly ground to a sharp chisel-like edge works well to clean piston ring grooves.
3. Thoroughly clean the three piston ring grooves of all carbon deposits.
NOTE
Always install new piston rings.
Always deglaze (or hone) the cylinder before installing new rings.
Insufficient ring gap may cause the ends to touch at operating temperatures. This causes ring breakage, cylinder
scuffing and/or piston seizure.
Excessive ring gap causes high oil consumption and blow-by of exhaust gases resulting in contaminated oil and
reduced engine efficiency.
1. See Figure 1. Check ring end gap of each ring before installing on piston.
a. Insert piston upside down into cylinder. Apply even downward force to align piston ring.
b. Measure the ring end gap with a feeler gauge. Refer to Piston.
Figure 1. Measuring Ring Gap
NOTE
Piston ring position is identical for both pistons.
1. See Figure 1. Install three-piece oil control ring.
a. Install expander ring (1) with ends facing up (see inset).
b. Install bottom oil rail (2).
c. Install top oil rail (3).
NOTE
Position the "N" marking on the compression rings to the top of the piston.
The top ring has chamfered corners on the ring face. The second ring has a sharp upper corner and a groove cut
around the lower edge.
2. Install second compression ring (4).
3. Install top compression ring (5).
4. Verify that all piston rings rotate freely.
5. See Figure 2. Arrange gaps as shown.
1
Expander ring
2
Bottom oil rail
3
Top oil rail
4
Second compression ring
5
Top compression ring
Figure 1. Piston Rings
1
Expander ring
2
Bottom oil rail
3
Top oil rail
4
Second compression ring
5
Top compression ring
Figure 2. Piston Ring Order of Assembly and Gap Alignment
1. Install cylinders. See Prepare.
2. Install cylinder heads. See Prepare.
3. Install pushrods, lifters and covers. See Prepare.
4. Install rocker arms. See Prepare.
5. Install lower rocker covers. See Prepare.
6. Install breathers. See Prepare.
7. Install upper rocker covers. See Prepare.
8. Install spark plugs. See Prepare.
9. Connect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR.
10. Install induction module. See Prepare.
11. Install upper cooling lines. See Prepare.
12. Install oil cooler upper screw and cover. See Prepare.
13.
NOTE
See Remove and Install: Upper Front Engine
Mount for proper tightening sequence.
Install left side engine mount. See Prepare.
14. Install upper front engine mount. See Prepare.
15. Install air cleaner backplate assembly. See Prepare.
16. Install air cleaner. See Remove.
17. Install coil. See Prepare.
18. Install spark plug cables. See Remove.
19. Install fuel tank. See Prepare.
20. Install seat. See Remove.
21. Connect negative battery cable. See Main Fuse.
NOTE
Abrasive particles can damage machined surfaces or plug oil passageways. Clean parts before disassembly to prevent
component damage.
1. Use low-pressure compressed air to clean exterior
surfaces of engine.
2. Disconnect negative battery cable. See Main Fuse.
3.
NOTE
Detach rider foot control bracket only if needed to
remove exhaust system.
Detach right side rider foot control bracket. See Remove
and Install: Forward Foot Controls.
4. Remove exhaust system. See Prepare.
5. Remove seat. See Remove.
6. Remove fuel tank. See Prepare.
7. Remove spark plug cables. Remove.
8. Remove upper front engine mount. See Prepare.
9. Remove oil cooler cover upper screw. See Prepare.
10. Remove upper cooling lines. See Prepare.
11. Disconnect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR
12. Remove upper rocker covers. See Prepare.
13. Loosen rocker arm screws to relieve tension on pushrods.
See Prepare.
Remove
1. See Figure 1. Remove camshaft cover.
a.
Remove screws (3).
b.
Remove camshaft cover (4).
c.
Discard gasket (5).
Install
1. See Figure 1. Install camshaft cover.
a. Install new gasket (5).
b. Install camshaft cover (4).
c. Install screws (3). Hand tighten.
d. See Figure 2. Tighten screws in the sequence
shown.
Torque: 10.2-13.6 N·m (90-120 in-lbs) Camshaft
cover screws
2. See Figure 1. Install timer cover, if removed.
a. Install timer cover (2).
b. Install screws (1). Tighten.
Torque: 2.8-4 N·m (25-35 in-lbs) Camshaft timer
cover screws
1
Screw (5)
2
Timer cover
3
Screw (9)
4
Camshaft cover
5
Gasket
Figure 1. Camshaft Cover
Figure 2. Cam Cover Tightening Sequence
Special Tools
Description
Part Number
Qty.
SCREAMIN' EAGLE MAGNETIC
93979-10
1
LIFTER HOLDERS
CRANKSHAFT/CAMSHAFT
HD-47941
1
SPROCKET LOCKING TOOL
1. See Figure 1. Remove chain and sprockets.
a. Mark one of the chain links with a colored marker.
b. Remove cam chain tensioner fasteners (2). Remove cam chain tensioner (1).
c. Install CRANKSHAFT/CAMSHAFT SPROCKET LOCKING TOOL (Part Number:HD-47941) between cam
sprocket (9) and crank sprocket (8).
d. Remove cam sprocket screw (4) and washer (3).
e. Remove crank sprocket screw (5) and washer (6).
f. Remove sprocket locking tool.
g. Remove both sprockets and chain.
h. Remove spacer (10).
1
Cam chain tensioner
2
Screw (2)
3
Washer
4
Screw, cam sprocket
5
Screw, crank sprocket
6
Washer
7
Chain
8
Crank sprocket
9
Cam sprocket
10
Spacer
Figure 1. Camshaft Drive
2. Remove camshaft.
a. See Figure 2. Support lifters using SCREAMIN' EAGLE MAGNETIC LIFTER HOLDERS (Part
Number:93979-10).
b. See Figure 3. Remove four screws (5).
c. Remove screws (1).
d. Remove cam support plate (2).
e. Remove camshaft (3).
f. Remove O-ring (4).
Figure 2. SCREAMIN' EAGLE Magnetic Lifter Holder
1
Support plate screw (6)
2
Cam support plate
3
Camshaft
4
O-ring
5
Oil pump screws (4)
Figure 3. Cam Support Plate
NOTE
See Engine for specifications.
Camshaft
1. Inspect lobes for abnormal wear or discoloration.
2. Inspect bearing surfaces for scoring or discoloration.
3. Measure bearing journals.
4. If desired, remove and inspect lifters.
a. Mark lifters so they can be installed in the same location and orientation as original.
b. Remove lifters through camshaft cavity.
c. Measure lifters.
Cam Support Plate
1. Measure the diameters of the camshaft and crankshaft bores.
2. Measure flatness of support plate.
3. Inspect gerotor area for excessive wear or deep grooves.
4. Verify that all oil passages are clean and open.
Cam Drive Components
1. Inspect sprockets and chain for wear.
Special Tools
Description
Part Number
Qty.
CRANKSHAFT/CAMSHAFT
HD-47941
1
SPROCKET LOCKING TOOL
1. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to all
bearing surfaces and bearings.
2. See Cam Support Plate. Install cam and cam support
plate.
a. Install camshaft in crankcase.
b. Install new O-ring (4) into the feed oil port of the
crankcase.
c. Apply a thin film of SCREAMIN' EAGLE ASSEMBLY
LUBE to the feed port spigot of cam support plate.
d. Slide cam support plate over shafts and mate to
crankcase.
e. Verify that cam support plate is fully seated.
f. Start all screws.
3. See Figure 1. Tighten screws in sequence.
a. Tighten screws (1, 2) to 1.4-6.8 N·m (12-60 in-lbs).
b. Rotate crankshaft one full revolution (360 degrees).
c. Tighten screws (3-8) in the sequence shown to 10.2-
13.6 N·m (90-120 in-lbs) in the sequence shown.
d. Final tighten four oil pump screws (1-2, 9-10) to
10.2-13.6 N·m (90-120 in-lbs) the same sequence.
Figure 1. Cam Support Plate Tightening Sequence
NOTE
Check sprocket alignment if any of the following parts are new:
Cam support plate
Camshaft
Cam sprocket
Crankshaft sprocket
Flywheel assembly
4.
Check sprocket alignment.
a. See . Install original cam sprocket spacer (10).
b. Install cam sprocket without chain using screw (4) and
washer (3).
c. Install crankshaft sprocket without chain using screw
(5) and a smaller diameter flat washer from bulk
inventory.
d. Position the CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL (Part Number:HD-47941) between
the sprockets. Tighten both sprocket screws to 20.3
N·m (15 ft-lbs). Remove the sprocket locking tool.
e. Push on crankshaft and camshaft to eliminate end
play.
f. Place a straightedge across the sprocket faces.
Alignment offset must be 0.23 mm (0.009 in) or less.
g. Remove cam sprocket.
h. Install the appropriate spacer (10) using Table 1 as a
guide.
i.
Check alignment with the new spacer installed.
j.
Remove both sprockets.
Table 1. Cam Sprocket Spacers
PART NO.
IN
MM
25729-06
0.100
2.54
25731-06
0.110
2.79
25734-06
0.120
3.05
25736-06
0.130
3.30
25737-06
0.140
3.56
25738-06
0.150
3.81
5. Install camshaft drive.
a. Apply a light film of SCREAMIN' EAGLE ASSEMBLY LUBE to camshaft and crankshaft.
b. Install cam sprocket spacer (10).
c. See Figure 2. Assemble sprockets and chain with timing marks aligned. Verify that the marked chain link is
on the same side as the timing marks.
d. Rotate camshaft until keyed spline is up.
e. Rotate crankshaft until flat is up.
f. Install sprockets and chain.
g. Verify that timing marks on the sprockets are aligned.
h. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (red) to screws.
i. Apply a film of oil to bottom of both sprocket screw heads and washers.
j. Loosely install screws and washers.
Figure 2. Timing Marks
5. Tighten sprocket screws.
a. Position the CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL (Part Number:HD-47941) between
the sprockets.
b. Tighten both sprocket screws to 20.3 N·m (15 ft-lbs).
c. Loosen both screws one revolution (360 degrees).
d. Final tighten the cam sprocket screw to 46.1 N·m
(34 ft-lbs).
e. Final tighten the crank sprocket screw to 32.5 N·m (24
ft-lbs).
f. Remove the sprocket locking tool.
6. Install primary cam chain tensioner. Tighten to 10.2-13.6
N·m (90-120 in-lbs).
7. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to chain
and sprockets.
1. Install rocker arms. See Prepare.
2. Install upper rocker covers. See Prepare.
3. Connect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR.
4. Install upper cooling lines. See Prepare.
5. Install oil cooler cover and upper screw. See Prepare.
6. Install upper front engine mount. See Prepare.
7. Install spark plug cables. Remove.
8. Install fuel tank. See Prepare.
9. Install seat. See Remove.
10. Install exhaust system. See Prepare.
11. Attach right side foot control bracket, if removed. See
Remove and Install: Forward Foot Controls.
12. Connect negative battery cable. See Main Fuse.
Special Tools
Description
Part Number
Qty.
CAMSHAFT NEEDLE BEARING
HD-42325-C
1
REMOVER/INSTALLER
Remove
1. See Figure 1. Remove camshaft bearing using components of CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER (Part Number:HD-42325-C).
2. Hold the flat on the HD-42325-12A (COLLET). Turn hex at end to expand collet.
3. Turn hex nut to remove bearing.
Figure 1. Remove Camshaft Needle Bearing
Install
1. Calculate bearing installed depth.
a. Measure thickness of HD-42325-4 (SUPPORT
PLATE).
b. Add support plate thickness to 3.737 in (94.92 mm).
Record this value.
2. See Figure 1. Install bearing using HD-42325-7A
(CAMSHAFT NEEDLE BEARING INSTALLER).
a. Place new needle bearing on installer with letters
facing installer (visible from cam chest when
installed).
b. Install support plate.
3. See Figure 2. Turn forcing screw to press needle
bearing to depth calculated earlier ± 0.020 in (0.54
mm).
a. Do not exceed torque specification during needle
bearing installation or damage to crankcase will
occur..
Torque: 33.9 N·m (25 ft-lbs) Cam needle bearing
installation maximum torque
Figure 2. Measure from Top of Support Plate to Edge of Needle Bearing
NOTE
Abrasive particles can damage machined surfaces or plug oil passageways. Clean parts before disassembly to prevent
component damage.
1. Use low-pressure compressed air to clean exterior
surfaces of engine.
2. Disconnect negative battery cable. See Main Fuse.
3.
NOTE
Detach rider foot control bracket only if needed to
remove exhaust system.
Detach right side rider foot control bracket. See Remove
and Install: Forward Foot Controls.
4. Remove exhaust system. See Prepare.
5. Remove seat. See Remove.
6. Remove fuel tank. See Prepare.
7. Remove spark plug cables. Remove.
8. Remove upper front engine mount. See Prepare.
9. Remove oil cooler cover and upper screw. See Prepare.
10. Remove upper cooling lines. See Prepare.
11. Disconnect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR.
12. Remove upper rocker covers. See Prepare.
13. Loosen rocker arm screws to relieve tension on pushrods.
See Prepare.
14. Remove camshaft cover and cam support plate. See
Prepare.
1. Remove oil pump assembly from crankshaft.
2. See Figure 1. Discard O-rings (5, 6).
3. Disassemble and inspect oil pump components.
1
Feed gerotor set
2
Oil pump housing
3
Scavenge gerotor set
4
Back housing
5
Scavenge port O-ring
6
Feed port O-ring
Figure 1. Oil Pump
1. See Oil Pump. Remove gerotors.
2. See Figure 1 and Figure 2. Remove pressure relief valve.
a. Hold spring (1) compressed.
b. Drive out roll pin (3).
c. Carefully release spring pressure.
d. Remove spring and piston (2).
3. Clean parts in a non-volatile cleaning solution.
4. Dry parts using low-pressure compressed air.
5. Inspect housing.
a. Verify that all oil holes are clean and open.
b. Inspect relief valve piston and seat for damage.
c. Inspect oil pump housing bores for scoring, gouging or cracking.
d. See Oil Pump. Inspect for grooves or scratches on the cam support plate and back housing (4).
6. See Figure 3. Check gerotor wear.
a. Check for damage on lobes of gerotors.
b. Mesh rotors of one gerotor set together.
c. Measure clearance between tips of lobes on inner and outer gerotors.
d. Maximum clearance is 0.1 mm (0.004 in). Inspect second gerotor set in the same manner.
e. Measure and compare thickness of each rotor in a gerotor set. Maximum difference is 0.025 mm (0.001 in).
Inspect second gerotor set in the same manner.
NOTE
See arrow in Figure 1 and Figure 2. Oil pump design changed as a running change. Early pumps have two passages
near the relief valve while late pumps have one passage.
7. See Oil Pump. Assemble the oil pump.
1
Spring
2
Piston
3
Roll pin
Figure 1. Oil Pressure Relief Valve: Early Production
1
Spring
2
Piston
3
Roll pin
Figure 2. Oil Pressure Relief Valve: Late Production
1
Outer gerotor
2
Inner gerotor
3
Wear limit
Figure 3. Measure Gerotor Sets for Wear
NOTE
Early and late production oil pump components are not interchangeable.
1. Install pressure relief valve.
a. See Oil Pressure Relief Valve: Early Production. Apply a film of SCREAMIN' EAGLE ASSEMBLY LUBE
to piston (2) and bore.
b. Install piston and spring (1).
c. Hold spring compressed and install roll pin (3).
1. Lubricate all parts with SCREAMIN' EAGLE ASSEMBLY LUBE during assembly.
2. See Oil Pump. Install back housing (4) and scavenge gerotor set (3) on crankshaft.
3. Install new O-ring (5) in scavenge port of crankcase.
4. Apply a film of SCREAMIN' EAGLE ASSEMBLY LUBE to scavenge port spigot.
5. Slide oil pump housing (4) onto crankshaft while fitting scavenge port into O-ring.
a. Firmly push on oil pump housing to verify that it is snug in bore.
6. Install the feed gerotor set (1).
7. Install new O-ring (6) in the feed port of crankcase.
1. Install cam support plate and camshaft cover. See
Prepare.
2. Install rocker arms. See Prepare.
3. Install upper rocker covers. See Prepare.
4. Connect electrical connectors.
a. Rear cylinder: Engine temperature sender, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR.
5. Install upper cooling lines. See Prepare.
6. Install oil cooler upper screw and cover. See Prepare.
7. Install upper front engine mount. See Prepare.
8. Install spark plug cables. Remove.
9. Install fuel tank. See Prepare.
10. Install seat. See Remove.
11. Install exhaust system. See Prepare.
12. Attach right side foot control bracket, if removed. See
Remove and Install: Forward Foot Controls.
13. Connect negative battery cable. See Main Fuse.
Prepare
1. Secure motorcycle on lift. See Servicing a Motorcycle.
2. Disconnect negative battery cable. See Main Fuse.
3. Remove saddlebags, if equipped. See Remove and
Install: Standard.
4. Remove seat. See Remove.
5. Remove fuel tank. See Prepare.
6. Remove battery. See Prepare.
7. Remove battery tray. See Prepare
8. Remove exhaust system. See Prepare.
9. Remove air cleaner. See Remove.
10. Remove air cleaner backplate assembly. See Prepare.
11. Disconnect front oil hose from oil cooler. See Prepare.
12. Drain engine oil and discard filter. See Check Engine
Oil Level.
13. Remove voltage regulator. See Prepare.
a. Release stator harness anchor.
14. Disconnect CKP sensor. See Prepare.
15. Disconnect jiffy stand sensor, if equipped. See Prepare.
16. Disconnect oil pressure sender. See Prepare.
17. Disconnect clutch cable. See Prepare.
18. Remove starter. See Prepare.
19. Remove primary chaincase. See Prepare.
20. Remove drive belt from transmission pulley. See
Prepare.
21. Remove rear splash guard. See Prepare.
22. Disconnect line from oil check valve. See Prepare.
23. Release main harness and brake line from lower frame
rail.
a.
Allow to hang below frame.
24. Remove right foot support bracket. See Remove and
Install: Forward Foot Controls.
25. Remove brake pedal master cylinder assembly. See
Prepare.
a. Place on work surface. Wrap rear master cylinder
with protective padding.
26. Disconnect VSS. See Prepare.
27. Disconnect ACRs. See Prepare.
28. Disconnect ground cable from transmission case. Do
this only if removing as one assembly or transmission
case separately.
29. Disconnect knock sensors. See Prepare.
30. Disconnect cylinder temperature sensor. See Prepare.
31. Remove USB caddy. See Prepare.
32. Disconnect spark plug cables. See Remove.
33. Remove ignition coil. See Prepare.
34. Remove left side engine mount (coil bracket). See
Prepare.
Remove
1. Wrap rocker covers and frame rails with protective
padding or tape.
2. Support powertrain.
a. Support engine using FAT JACK (PART NUMBER:
HD-45968) or similar.
b. Place support under crankcase.
c. Support transmission using FAT JACK (PART
NUMBER: HD-45968) or similar.
d. Place support under frame.
3. Remove pivot shaft. See Prepare
4. Remove front engine mount. See Prepare
5. Remove lower front engine mount bolt. See Prepare
6. Remove powertrain from chassis.
a. Slide transmission case as far back as possible.
b. Remove engine from right side.
7. Remove induction module assembly. See Prepare
Install
1. Make sure motorcycle is secure on lift.
2. Install induction module assembly. See Prepare
3. Install powertrain into chassis.
a.
Install engine from right side.
b.
Position in chassis.
4. Install lower front engine mount. See Prepare
5. Install front stabilizer link and bracket. See Prepare
6. Install pivot shaft. See Prepare
7. Remove powertrain supports.
8. Remove protective padding/tape from rear master
cylinder, rocker covers and frame rails.
Complete
1. Install left side engine mount (coil bracket). See
Prepare.
2. Install ignition coil. See Prepare.
3. Connect spark plug cables. See Remove.
4. Install USB caddy. See Prepare.
5. Connect cylinder temperature sensor. See Prepare.
6. Connect knock sensors. See Prepare.
7. Connect ground cable to transmission case.
8. Connect ACRs. See Prepare.
9. Connect VSS. See Prepare.
10. Install brake pedal master cylinder assembly. See
Prepare.
11. Install right foot support bracket. See Remove and
Install: Forward Foot Controls.
a. Secure main harness and brake line to lower frame
rail.
12. Connect line to oil check valve. See Prepare
13. Install rear splash guard. See Prepare
14. Install drive belt. See Prepare.
15. Install primary chaincase. See Prepare.
16. Install starter. See Prepare.
17. Install and adjust clutch cable. See Prepare.
18. Connect oil pressure sender. See Prepare.
19. Connect jiffy stand sensor, if equipped. See Prepare.
20. Connect CKP sensor. See Prepare.
21. Install voltage regulator. See Prepare.
22. Fill engine oil and install new filter. See Check Engine
Oil Level.
23. Connect upper cooling lines. See Prepare.
24. Install air cleaner backplate assembly. Prepare.
25. Install air cleaner. See Remove.
26. Install exhaust system. See Prepare.
27. Install battery tray. See Prepare.
28. Install battery. See Prepare.
29. Install fuel tank. See Prepare.
30. Install seat. See Remove.
31. Install saddlebags, if equipped. See Remove and
Install: Standard.
32. Connect negative battery cable. See Main Fuse.
33. Run motorcycle until engine is at normal operating
temperature.
a. Check clutch operation. Adjust if needed.
b. Check instrument lamps.
c. Check for leaks.
d. Check engine oil level (hot).
1. Remove engine. See Prepare.
2.
NOTE
Abrasive particles can damage machined surfaces or
plug oil passageways. Clean parts before
disassembly to prevent component damage.
Use low-pressure compressed air to clean exterior
surfaces of engine.
3. Remove spark plugs. See Prepare.
4. Remove upper rocker covers. See Prepare.
5. Remove breathers. See Prepare.
6. Remove lower rocker covers. See Prepare.
7. Remove rocker arms. See Prepare.
8. Remove pushrods, lifters and covers. See Prepare.
9. Remove cylinder heads. See Prepare.
10. Remove cylinders. See Prepare.
11. Remove pistons. See Prepare.
12. Remove cam cover and cam compartment components.
See Prepare.
13. Remove oil pump. See Prepare.
1.
Remove oil pump from crankshaft.
CAUTION
Do not rotate crankcase half in engine stand when
flywheel is installed. The flywheel assembly can fall
out, resulting in parts damage or moderate injury.
(00552c)
2.
Position crankcase with cam compartment facing down.
NOTE
Never move or lift the crankcase by grasping the
cylinder studs.
3.
NOTE
Use care to not allow the balancer gears to raise
when lifting off left crankcase. The balancer gears
can disengage the crankshaft gear, allowing the
balancer scissor gear to unload. Rotating the scissor
gear back into position is difficult.
Separate crankcase halves.
a. See Figure 1. Remove 12 crankcase screws in the
sequence shown.
b. Separate case halves.
c. See Figure 2. Lift left crankcase half (2) off end of
crankshaft.
4.
Remove two dowel pins in split line face of right case half.
NOTE
HD-52065 (Balancer Gear Alignment Tool) must be
installed before removing balancer.
5.
Remove balancers (4).
a. Rotate gear teeth slightly with a screwdriver to allow
tool installation.
b. Install HD-52065 (Balancer Gear Alignment Tool).
c. Lift balancer from crankcase.
6.
Remove flywheel assembly (3).
Figure 1. Crankcase Torque Sequence
1
Screw (14)
2
Left crankcase
3
Flywheel assembly
4
Balancer
Figure 2. Separate Crankcase Halves
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