Home

End Float

Contents

1. Early long 1967 1970 Has a 1 2 longer hole through the center for the dry clutch release rod Changed for electric start Late short 1971 e1984 No hole Main Clutch Gears Early short 1957 1969 Has a shoulder above the threads Early long 1967 1970 Longer has a groove below the splines Long short 1971 e1984 2 different both interchange No shoulder above the threads No groove at the base of the splines The needle bearing needs to be replaced occasionally Use a blind hole puller Don t use a Slide hammer Use a press When you feel the bearing move 1 8 stop and spread the puller Remove Use an old mainshaft to seat the new bearing The washer with 2 notches on top of the bearing is pressed in The notches let oil into the bearing Reinstall in the correct position NOT UPSIDE DOWN Always replace the bearing on the countershaft in the case when the transmission is being serviced Remove and install from the outside in Don t hit with a brass hammer Use a plastic hammer Shifter Shafts Old style 1957 1974 Pinned in and has a spot weld or stake on both sides Look for flat spots on the side of the ball Replace if it has flat spots Look for straightness Replace if twisted 1975 1976 Long 1977 Shift shaft ran through the primary cover 1977 1985 Long long 1986 1990 Short long evo 67 X
2. bulleti campaig bulletin engin odel year production elp you identit he crankcase number st To h 095 Davidson has become aware that on cer cam bolt his condition could caus without prior warning uld run erratically before quitting could lose its clamp th tain 1999 model ngin In some odel motorcycles eg were built hrough September 27 uipped with Twin Cam 88 from the start of 1999 1998 are tamped on t Davidson has voluntarily declared this a torcycles please r nc he left side of the fy mo fected 199 Twin Cam 88 engines must have a 99 stamped in n 3 and 4 and have numbers in position 5 through 7 from 035 through 270 related to motor vehicl to recall all potentially a Sal follow wi thin n containing complete n will in accordance with NHTSA regulations In the interest of OR DELIEV defect fety Campaign 095 and plans fFfected vehicles A service details concerning this 14 days Owner notification will follow the mutual customers DO NOT SELL customers you have sold any of to contact All regist ER any potent tially af until the recall service hasbeen performed fected motorcycles to your Tf tered owners of these motorcycles t the customers immediately to make them aware of
3. Generator is electromagnetic magnetism only when engine is running 36 Load Charge Indicator Idiot Light When Generator is charging it s not grounded amp light goes off A Post to light always has brown wire Light to switch Switch to battery Armature Testing Short Use Growler and hacksaw blade test for magnetism A short will still charge but at a decreased rate Ground Using 110 VAC w light test copper to bare metal Check for continuity If light comes on continuity Continuity is bad Infinity is good Open Copper to copper Light goes off Continuity is good Infinity is bad Use 110 VAC because electricity will jump a gap causing smoke and spark Mica cut on armature should be 025 or deeper Too shallow cut deeper w hacksaw blade Field Coils Can be checked for Shorts Post to post with meter 4 7 ohms Anything less than required resistance is bad Opens Post to post with meter if you get a reading there is no open Any reading on short test no open Grounds Post to base metal ground Infinity is good Continuity is bad Test Generator output out of bike by putting double nuts on end of shaft put in drill and run in reverse Do output test 3 7 VDC Good 37 3 Types of Relays See handout All are interchangeable and must be grounded Delco Remy Chevy Prestolite Round Bosch Small square 1966 1969 Pan Shovel Generator 1970 Ist Alternator on Big
4. on genuine H D goes to the back flat to front If installed wrong the transmission will be hard to get into gear and will pop out of gear easily Transmission will have to be disassembled to correct Mainshafts 3 types Shortest 1964 amp earlier kickstart only DC Generator Mid length 1965 1969 Electric start DC Generator Longest 1970 1984 Electric start AC Alternator Sprockets 1980 amp earlier Sprocket had concave Concave goes in 1981 amp later Flat Assisted by washer Left hand thread Assemble washer sprocket nut 21 5 Speed Transmissions 1 year 1980 Access door on the right side 1980 1986 Fork amp Arm 1987 Present Ball amp Ramp Can be worked on without removing from the bike Drain is on the bottom except on Softails On older Softails the drain is on the access door Gears right to left 4 1 3 2 5 1 amp last things to check Eccentric shifter pawl Must be in 3 gear to check Loosen the nut turn the adjusting screw to get equal space on both sides Customer s complaint if not in adjustment Shifts good one way not good the other way Eccentric has 2 springs When spring breaks shifting lever won t return Transmission must be disassembled to fix On Softails since the oil tank is on top of the lid feel the stops with an allen wrench and set half way between the stops 1988 amp earlier Starter had t
5. always reinstall in same position amp location Solid Lifters Ironhead XL 1957 1985 To adjust opposite push rod should be at the highest point Push rod should spin freely with zero lash up amp down Better off a little too loose than too tight If push rod moves from side to side at top of travel tappet blocks are worn To remove push rod loosen locknut amp adjust until push rod will come out Hydraulic Lifters Shovelheads 1966 1984 1 2 Each cylinder is adjusted individually Push rods to be adjusted are adjusted on the compression stroke valves closed Turn rear wheel until push rod rises valve open then falls valve closed then bump wheel 1 4 turn Intake amp exhaust pushrods to be adjusted should spin freely or engine is not on compression stroke These pushrods and lifters are rebuildable Remove lifter hold check ball in to empty oil push in amp turn 1 4 turn left to disassemble Reinstall lifter then push rods amp adjust push rods by turning the nuts 1 4 turn at a time until the distance from the shoulder of the lifter to the top of the lifter is 520 Lifter can be preloaded by putting in clean oil pushing in on check ball amp letting out to get the 520 23 Adjustable Evo Aftermarket Adjust 1 cylinder at a time Turn rear wheel until push rod rises valve open then falls valve closed then bump wheel 1 4 turn Zero lash Use a pitch gauge to determine the number
6. earlier 1 advance TDC 1981 1 2 amp later advance 1 TDC Timing hole 7 degrees 1991 XL amp Later Hole on right side Dot toward rear advance Dot toward front retard Rear cylinder piston rises first Front cylinder runs hotter Engine runs clockwise cam runs counterclockwise 1 2 engine speed Timing hole Left side except Sportster 1991 moved to right Some Harleys had 3 timing marks 1984 amp earlier amp 1991 amp later Ist mark is always rear cylinder advance 2nd mark is Front Cylinder full advance amp TDC for Rear 3rd is Front Cylinder TDC 2 marks first is front cylinder advance second is front cylinder TDC When looking in timing hole left side if dot is towards front timing is retarded If towards rear timing is advanced Runs better more advanced Retarded timing sounds like carb problems Turn backing plate clockwise to advance timing Counterclockwise to retard timing 28 1969 amp earlier Big Twins had distributor 1970 amp earlier XLs had distributor 1970 amp later Big Twin got nose cone ignitions are interchangeable Set plug gap based on type of ignition 1971 amp later XLs went to nose cone Distributor Clockwise retards Counterclockwise advances Advance mechanism is fully open 1700 2000 rpm Always runs fully advanced Timing is always done on front cylinder full advance Parts of Advance Mechanism Timing screw Big head small body Ho
7. 1971 54 cubic inch 900 cc 3 X 3 13 16 stroke Directional piston with a full skirt Cylinder part number is 57 The front fin is cut away on the front cylinder and the rear fin is cut away on the rear cylinder for the exhaust Front and rear cylinders don t interchange 1972 mid 1973 61 cubic inch 1000 cc Bigger bore diameter 3 3 16 Headbolt threads to the top of the hole Cylinder walls are thin NOT GOOD Smaller bolt pattern Late 1973 1985 Much thicker cylinder walls Headbolt threads start 12 down in the hole Headbolt pattern is bigger 72A part number if it has a part number Most head gaskets for Ironheads are copper and will eventually weep oil Spray the gasket with Copper Coat Don t reuse Thich head gaskets were used in 1982 to lower the compression ratio Torque headbolts to 60 65 ft lb 7 16 X 24 TPI 4 Early 1973 and earlier had 6 point headbolts with separate washers Late 1973 and later had 12 point headbolts with separate washers 2 longer Don t mix headbolts The cylinder has a spigot Make sure it s not taller than the counterbore in the head If necessary use a thicker head gasket 72 piston was used from 1972 1985 and is directional Pistons require 003 piston to wall clearance no matter what the manual says The wear limit is 007 Karl Schmidt pistons were used the last year of production They have a beveled end wrist
8. 1986 Thrust plates have been used since 1958 when H D went to needle bearings Cams should measure 3 030 to 3 035 from gear face to shoulder 1987 amp later Cam is longer 3 070 to 3 080 apx End play washer was eliminated Use end play washer on any cam whether short or long if needed Cam Endplay Remove tappet block amp measure between the end of the cam amp the thrust plate On assembly start with the thrust washer if used Install the cam cover with a new gasket Torque to spec Then measure the endplay with a feeler gauge It should be 001 to 016 Never let a bike leave with less than 005 Long cam with no washer 001 to 050 It s not advisable to NOT torque the timing cover before measuring end play The gasket thickness WILL change end play Cam thrust washers interchange on all Evos 11 Tappet Rollers In early engines the rollers are replaceable 3 Reasons to replace Radial clearance Surface damage on roller Roller end clearance 015 to 020 The cam turns at 1 2 of pinion gear rpm The timing cover has bushings for cam and pinion shaft Condition of pinion shaft bushing is important because all oil in the lower end goes down the pinion shaft There are drillways in the flywheel pinion shaft and crankshaft to get oil to the rod bearings There is an oil passage in the timing cover that comes out in the pinion shaft and feeds the bottom end
9. If there is too much clearance between the pinion shaft and the bushing oil will spray out New pinion shaft to bushing clearance is 001 or less Wear limit is 004 apx Excessive pinion shaft to bushing clearance results in not enough oil going to the bottom end The ignition drives off the end of the cam Excessive clearance between the cam and bushing results in Erratic ignition timing Erratic idle Oil in the ignition cavity of the nosecone Cam to bushing clearance should be 004 apx Always measure bushings before reassembly Always pin the cam bushing when changing it whether originally pinned or not and ream after pinning because pinning distorts the bushing Install order Remove Install Pin Ream 12 Gears on Cams amp Pinion Gears There are a variety of sizes color coded Biggest Black Smallest Orange 003 difference Too tight mesh between cam and pinion whine Too lose mesh between cam and pinion rattle The easiest way to sidestep these problems is to press the gear off the old cam and install on the new one OR Measure the gear on the old cam and the gear on the new cam and compare Use gauge pins to measure Put rubber band around the gear teeth Put gauge pins 180 degrees apart Zero the micrometer Measure across the pins Compare the measurements with the manual to get within specifications Use 105 gauge pins for no groove or 1 groove cams Use 108
10. Twin 1984 1 2 Ist Alternator on Sportster All Alternator Charging Systems are interchangeable 1970 1975 Day Night Charging System Better rotor Magnets were screwed in cages splined deeper Checking Stator Always check before installing Check Battery First Regulator should have no voltage in plug going to Stator or there is a bad diode Don t connect or disconnect stator with bike running Zero meter Set on Ohms If digital meter hold leads together until the number goes down Always subtract that number from any reading Short test Pin to pin Anything less than required resistance is no good Ground Any pin to base metal Infinity is good Continuity is bad Infinity is good Ground Trash it 38 Output Test Meter on 500 VDC Pin to pin Run at 2000 rpm Reading as below If no reading bad Big Twins 70 75 4 pins 40 Volts 1000 RPM 13 Amps Day Nite Charging 76 81E 2 male pins 19 26 VAC 1000 RPM 17 22 Amp ___ 2 4 ohms SIL 88 2 female pins 19 26 VAC 1000 RPM 17 22 Amp _ 2 4 ohms 89 95 2 female pins 16 20 VAC 1000 RPM 32 Amp 1 2 ohms 95 98 2 female pins 16 20 VAC 1000 RPM _ 38 Amp lt 5 ohms Low Output 97 99 2 female pins 19 26 VAC 1000 RPM 45 Amp lt 5 ohms High Output EFI Sportsters 84 1 2 90 2 female pins under tranny 12 18 VAC 1000 RPM 19 23 Amp 2 4 Ohms 91 Present_2 female pins right down tube 19 26 VAC 1000 RPM 19 23
11. XL 5 Speed Oil Pump 2 versions Early 1991 1998 Late 1999 Present A little deeper with an extra hole that leads into the Scavenge Both interchange 4 Bolts 2 hold the pump on 2 hold the pump together 004 wear limit on rotor tip The bottom plate is directional The Pressure Relief is cast into the crankcase 58 Priming Oil Pumps Big Twin Single Cam Manually pump Remove the spring and the feed check ball Sportster Take out the feed check ball and spring Fill the oil tank When oil runs out it s primed Twin Cam Use assembly lube on all parts Fill the oil filter Spin the engine with the plugs out put plugs in the wires and ground to the case or you ll blow the electronic ignition module There should be oil pressure within 30 40 seconds If in doubt remove the return from the oil pump put it in a bucket and turn the engine over If oil comes out you have pressure Rotor Tip Wear limit 004 Feed Rotor Protrusion 001 011 59 Twin Cam Cam side 1 model The drive cam longer of the 2 cams has a woodruff keyway and ran in a ball bearing The cam drive sprocket had a key made into it The bolt that held it on was made wrong The head nut should be 90 degrees to the shank but wasn t on many models It would sometimes back off The first warranty was simply 2 bolts and 2 washers Sometimes the drive cam ball bearing would fail The c
12. a bad wheel bearing in a car If any check fails disassemble the lower end If everything is within wear limits check to see if the connecting rods are straight Checking Connecting Rods For Straightness Rods can be bent twisted or both Use a Rod Checking Tool from JIMS It is a piece of rod with 001 to 002 clearance in the wrist pin bushing long enough to rest on both sides of the case Put strips of paper under both sides of the tool at the front and at the rear position in the cylinder If twisted the paper will be tight on opposite corners and loose on opposite corners If the rod is bent and twisted the paper will be tight on 3 corners and loose on 1 Take the bend out first Tricks Don t yank apply the load carefully The small end of the rod needs to be parallel with the case mouth If you can see that the rod is bent replace the rod Bent connecting rods can cause Rapid ring wear Wrist pin to blow out and ruin cylinder Change and size wrist pin bushings before checking rods for bend Check rods for straightness AFTER installing 34 Installing and Reaming Wrist Pin Bushings Clamp the middle of the rod in a vise Use JIMS tool to remove and install Ream with a 25 32 expansion reamer Use a piece of tubing over the reamer and on the rod to press on Ball honing isn t required unless it s necessary for final fit 34 Ball Hone for anything except Twin Cam Wrist pin 790 Clearance 0005
13. and facing away from you Hold the bit down and against the cylinder Tighten the center screw The Drive Pin goes in the center hole which is the one closest to the middle Make a pass by hand and tap the cylinder with brass or aluminum to center the cylinder Controls are Fast Off and Slow 75 Down is Counterclockwise Up is clockwise Always leave in the Down Counterclockwise position with motorcycle cylinders Never start with the bit touching the cylinder Turn on Fast ALWAYS hold onto the switch Don t take a bigger cut than 007 008 The finishing cut should never be more than 005 and preferably 003 When finished with the first cut take the drive pin out and put in the other hole for Rapid Travel to bring the quill back to the top Take the pin out and unplug the machine and clean the bit Use a boring bar micrometer but never assume that they are accurate Measure the cylinder after every cut with the same micrometer that the piston was measured with Put the Boring Bar micrometer over the quill Snug the screw up with your fingers Move it in until it touches the end of the bit Loosen the 2 end screws Put your thumb behind the bit with the forefinger on the top Move it until you get the reading that you want Turn it beyond the measurement that you want and then back it up for accuracy Run the quill down until it almost touches the cylinder but not quite Put the pin back in the Bo
14. bearings Front ends used motor oil 20W 50 1973 1999 Timken bearings Have end play but no running clearance Has a spacer on the inside most bikes If the spacer is too long there will be too much end play If the spacer is too short the bearing could weld itself into the axle Shim to correct Big Twin had disc brakes front and rear Until 1978 XLs had disc brakes on the front and drum brakes on the rear On drum brakes if the spacer is left out between the bearings the backing plate will cut into the drum Anything with a disc brake has Timken bearings Anything with disc on the front is Japanese This started in 1973 End play Sport bike 004 012 End play Big bike 002 006 1973 to present front ends use Fork Oil 2000 up Went back to ball bearings These are supposed to be 100 000 mile bearings No running clearance no end play Wheel Seals On 19 amp 21 wheels the seal is flush On 16 wheels countersink the seal 14 NEVER PUSH THE SEAL IN TO THE BEARING Repack bearings whenever tires are changed On 21 wheels always inflate the tires to 40 44 psi to prevent rim damage Anti Dive In 1984 anti dive was introduced Applying the front brake caused a solenoid to keep air from leaking From 1984 1987 the fill valve was located on the safety bar From 1988 1996 last year of the anti dive the fill valve was located on the end of the left handlebar Sch
15. can be turned with your fingers before starting the engine Oil pump bolts through 1977 X 24 TPI 1978 amp later 1 4 X 20 TPI 27 Lapping Connecting Rods in a Lathe Use a tapered expandable lap This enables us to recondition connecting rods that are in pretty good shape The lap head is changed with lapping compound Use Clover brand because it is oil base not water base Compound is available in 36 grit to 1200 grit Use 180 220 grit Clover Brand is available from Goodson 1 800 533 8010 or www goodson com Don t use valve grinding compound Put the lap in the lathe and charge with compound enough to get a thin even surface Then put the rod on and snug the lap Tighten right loosen left makes the lap bigger Tighten enough to where you can tap the rod with a finger to move it Run the lathe at 150 220 rpm Move the rod back and forth on the lap holding the rod by the big end Use the full length of the lap Count the strokes Every 25 strokes turn the rod over and go in the other direction After 25 or so in each direction wipe the compound out and inspect the inside of the rod Look for good crosshatch Do the other rod in the same way then measure Don t leave the tool loaded To measure use a T gauge and a micrometer and check the X and the Y axis The rod hole must be round to within 0002 5 major problems in lapping rods Too much compound causes bellmout
16. has no Timken bearing on the left side It uses a big roller bearing that is self aligning It is retrofit plug in Super Blend Bearing On Evo and Twin Cam valve guides there is no shoulder Take metal off the bottom of the guide Sink the guide that much further in the head Adapt the guide tool to seat deeper Compression Ratio Useable upper limit 10 1 Higher compression needs a sophisticated ignition system and won t run well on pump gas 9 5 1 is okay 9 1 is high for ironheads To determine the compression ratio get the difference in cylinder capacity wet from piston BDC to the spark plug hole and from piston TDC to the spark plug hole The difference is the ratio 79 1948 1965 Panhead 61 1948 1952 or 1953 74 1948 1965 61 3 5 16 X 3 1 2 74 3 7 16 X 3 31 32 1948 1954 Straight bearings 1955 1957 Timken bearings amp o ring heads 1958 1962 Different heads 1963 1965 Outside oiler Heads 1948 1954 Plumber intake 1958 Increased the diameter of the head 4 1958 1962 O ring manifold 1963 1965 Outside oiler lugs on the heads Exhaust spigots are problematic The steel exhaust pipes wore out the aluminum Intake and exhaust valves are 1 34 Bronze valve seats that aren t compatible with unleaded fuel Machine the old seats out 006 007 interference fit with the heads Cast in steel
17. in first The notch goes on the roll pin in the pump body to keep the washer from spinning in the pump The flat side goes in first The wave plate goes in next feet facing in The washer with the seal and the shoulder goes in last with the flat side facing out It fits in the counterbore of the other washer The pump should spin with an even drag Torque to 95 120 in Ib Feed out and oil pressure switch are on the same side of the pump The rotors need to be for the particular pump 1977 E1982 Beveled edge pump rotors L1982 E1984 Square edge pump rotors 57 XL Oil Pump 1984 1 1990 The 1984 and 1985 ironheads are similar to the 1986 1990 but have no pressure relief This pump is a filter pump It has an oil filter housing The oil filter housing contains The pressure relief sending unit The feed check The pressure relief valve The oil filter is on the pressure side of the pump like the Twin Cam The filter is between the pump and the engine The pressure relief consists of a piston and a spring Oil is pumped into the timing chest The feedcheck is under the filter adaptor It consists of a rubber ball and a spring The filter has a bypass built in in case it becomes plugged The filter needs to be for motorcycle applications DON T USE EMGO BRAND The pump has bigger feed rotors than earlier pumps and the housing is different to accept bigger rotors The rotors must be for the particular pump
18. is 1 1 If you shim under the countershaft 1 gear it will affect countershaft endplay Mainshaft endplay is controlled by a teardrop washer Check countershaft endplay after the transmission is installed The mainshaft endplay should be 003 020 Excessive endplay causes hard noisy shifting Inadequate endplay burns down the shaft washer and ruins the bearing or gear 69 XL Kickstart Mechanism Through 1966 Kick only Through 1979 Available with kick Primary kickstart Drives through the clutch and primary drive and not through the gearbox The bushing in the gear wears out or gets loose Sometimes the sleeve clutch basket spacer gets loose The shaft has a thrust plate and a little square o ring on it This goes in the hole first When replacing the shaft use an old shaft from the other side to locate the thrust plate The notch on the shaft should be in the 11 30 position Check aftermarket kick shafts for Shoulder that is too thick Shoulder that is too thin Squares on each end that aren t lined up in relation to each other The big gear has a u shaped groove on the back that runs on a pin in the primary Shaft play should be 015 020 Shim if too much Use a lockplate with tab behind the nut and use red loctite The shoulder on the nut MUST face out Torque to 45 50 ft lbs Check the big spring for damage Make sure it s installed with the end behind the gear and in the 12 00 position If the teeth on
19. is correct 5 16 from the face of the gear to the gasket surface 53 XL Oil Pumps 2 styles of Gear oil pumps from 1957 1976 1952 1971 K model and Sportster Smaller gears Smaller breather gear 52 part 1972 1976 Bigger gears Bigger breather gear 72 part Pump assemblies are interchangeable To disassemble the engine must be removed from the bike The timing cover must be removed Gear protrusion is 001 to 004 No pressure relief Pull the pin to remove the breather gear Check the bottom plate for damage Check gear protrusion Check the check ball and spring Torque the cap of the check ball to 12 14 ft lb Torque the oil pump bolts to 90 100 in lb unless using the brown paper gasket then torque to 50 60 in Ib Gasket materials Brown paper not good use High Tack White paper Better Light paper Don t use Black paper Best Aftermarket oil pumps are available from V Twin for about 400 Normal operating oil pressure Hot idle 5 6 lbs good 3000 rpm 7 10 lb Average 54 To check with engine hot and at idle loosen the top nut of the top end oiler If oil spurts out it s good The feed line fitting is on the back of the oil pump The scavenge is on the crankcase Most oil pump gaskets should about 010 uncompressed 59 XL Oil Pump 1977 E1984 Trachoidal Gerotor pump Feed on end scavenge on the other No
20. is going to be removed 14 AC Clutch 1984 4 1990 Sportsters with Alternators The rear wheel must be raised to find the tight spot in the Primary Chain on XLs Disconnect the negative lead of the battery before working on any clutch Get maximum freeplay in the cable Take the covers out of the primary The spring comes out first Take the locknut out next It has to come out before taking the primary cover off On 1984 to present back out the adjusting screw until it lightly seats then go in turn If the lever won t hit the grip the adjusting screw is bad If the locknut won t drop in the slot turn it to the right until it drops in This is a Reverse Action Clutch Ball amp Ramp It pulls apart instead of pushing apart Use H D tool 34761 the hockey puck clutch tool It goes on hollow end first Tighten only enough to get the clip out Inspect the spring plate for movement There should be no movement To remove the hub and basket remove the snap ring Remove the sprocket and basket with the primary chain Check inside the basket before reassembly for metal parts on the magnets The spacer must be on before the snap ring Check the hub for bad bearings etc On 1990 amp earlier Sportsters the sprocket has to come off to remove the transmission 15 Fuji Clutch 1990 to Present Observe the 4 rules for working on the clutch The Fuji clutch was changed in 1998 so that special tools wouldn t have to be use
21. of nut flats to adjust depending on manufacturer Mark flat on nut with marker to make it easier to count NEVER TURN ENGINE OVER UNTIL PUSHRODS ARE ADJUSTED amp LIFTERS BLED IN THAT CYLINDER If not sure of engine position put air in spark plug hole amp listen to determine where it is escaping from If from the carb the intake valve is still open if from the exhaust the exhaust valve is open Adjust pushrod until air won t blow out Adjust 1 4 turn at a time or turn the nut the total turns needed but allow time for lifters to bleed YOU MUST BE ABLE TO SPIN THE PUSHRODS W FINGERS OR ENGINE DAMAGE WILL OCCUR Always start adjustment with zero lash 26 Evo amp Twin Cam Stock Non adjustable Must remove rocker boxes On rubber mounted FXR engine must be jacked up front motor mount removed amp engine lowered to get rear rocker bolt out 9 bolts hold the rocker boxes on Remove by loosening 1 4 turn at a time from outside in Otherwise bolts may snap Reassemble by tightening from inside out 1 4 turn at a time Push rods will adjust themselves to within 01 Each cylinder is done individually Turn rear wheel until engine is on compression stroke valves closed Evos have 3 o rings per push rod tube Lifter blocks have a thrust washer that goes on under the o ring Stock push rods are good and are light 2d Ignitions and Timing From right side the engine turns clockwise 1981 1 2 amp
22. on either side of the cam but are easier to put on the outside Stock shims have to go on the inside of 2 cam but aftermarket has shims to fit on the outside Cam endplay 005 025 Most engines will be in spec without the shims They either tend to be in spec or way out of spec Check cam endplay with a new gasket cover on Check through the tappet block hole The Generator Drive Gear has a big hole that faces out 44 Evo XL Timing Side Cams and Timing Covers 4 different cams for Evo XLs 2 for the 4 speed 1986 1990 C or T won t interchange with 5 speed 2 for the 5 speed 1991 to Present D or W won t interchange with 4 speed longer 4 speed cams 1986 amp 1987 T any displacement no longer available replace with C cam 1988 1990 C any displacement T or D interchange so long as exhaust are the same or intake are the same 5 speed cams D 883 or 1200 W Sport model A little better than the D but not much Evo XL doesn t use cam shims The 4 speed uses the same dogbone plates as the ironhead but no shims Evo 5 speeds don t use dogbone plates or needle bearings Instead it uses bushings Evo XL Timing Covers 89 part number has a waffle pattern inside and no crankcase vent 5 speed cover won t fit 4 speed 84A part number is a 4 speed cover and won t fit ironheads No waffle pattern Has a big blac
23. pattern works better better bottom end Check ball in float ball can stick open or closed Notch in choke plate fuel must shoot through it If Accelerator pump isn t working bike dies on acceleration 42 Late model best of the 3 1983 1987 XL 1984 1989 Big Twin First year of VOES on both bikes Non adjustable fuel screw Push pull throttle linkage Double linkage choke with high idle cam Tall skinny sprayer 5 midrange holes 5 CV Carb Keihen Constant velocity 1988 Present No accelerator pump on 1988 XLs 1989 XL got CV with accelerator pump 1990 Big Twin got CV with accelerator pump Carb is made by Honda Very good carb Only 1 adjustment Idle adjustment screw If the diaphragm has a hole in it top speed will be about 70 mph 6 Dellorto Carb 1979 1985 XL Covered in the section of the Service Manual for the XR 1000 1983 amp 1984 43 The bottom of a carburetor and the top of the float should be at the same level The best way to know how a carb is doing is to read the spark plugs Slow jet or Pilot jet center of plug electrode Main jet outside part of plug Turning the fuel screw in slows fuel delivery Spray contact cleaner on the intake to check for leaks If the idle drops slowly there is a big leak If the idle goes up there is a small leak To put a newer CV on an Ironhead or Shovelhead take out the pilot jet fit the hole with a snug fitting jet drill bit the
24. pin and use a round wire c clip wrist pin lock 1957 1985 XL Cylinder Heads 5 different 57 part number 900 cc Head bolt measurement is apx 3 440 from the inside of one hole to the inside of another hole 1972 1000 cc Head bolt measurement is apx 3 540 from the inside of one hole to the inside of another hole Don t go by the part number 1973 Late The head bolt pattern changed Don t go by the part number Measures 3 640 from the inside of one hole to the inside of another hole 1978 and later All heads got an air cleaner mount hole 1982 Late 1985 The head is thicker where the rocker arm bolts down It uses special upper and lower retainers Check valve stem protrusion Ironhead XL Spark Plugs All XL Ironheads used short reach spark plugs Champion H8 or J12 Harley 4 42 1957 1985 XL Valve Guides 1957 1982 The valve guides are different heights and different diameters Intake 309 3095 Exhaust 339 3395 The valve guides had shoulders 1983 1985 Shoulderless They will fit and work in any ironhead but won t work well with old valve guides Pay attention to the valve spring installed height Standard intake 1 15 16 Standard exhaust 1 9 16 available in 1 5 8 amp 1 4 Use 80 or equivalent 1957 1985 Valves Aftermarket valves Many are long stem valves R valves XLR are 08
25. pinion shaft and make sure the oil passage is clear Make sure the oil passage in the flywheel is clear Make sure the crankpin oil passage is clear Put the woodruff key in the pinion shaft and make sure it s seated Use red loctite then torque the pinion shaft Make sure there is a space between the pinion shaft and the flywheel Put the woodruff key in the crankpin Put the crankpin in the right flywheel Use red loctite Then torque Blow in the oil passage holes to make sure they are clean and line up Put the rod bearings and cages together and on the crankpin Use Vaseline on the bearings but clean it off the taper with lacquer thinner Set the left flywheel on red loctite and torque Check the rod side clearance Side shake is NOT side clearance Side clearance is measured between the flywheel thrust washer and the side of the female rod Side shake is wobble Rod side clearance should be 005 to 025 A little more is okay On S amp S engines it is 035 to 040 If there is too much rod side clearance change the flywheel thrust washer Standard is 065 They are available in 005 and 010 As much as 020 can be taken up 30 Reasons for inadequate rod side clearance Oil or grease on the crankpin tapers It s critical to clean before assembly Worn out taper The shoulder should not be flush with the flywheel Improperly seated thrust washer Should be flush and uniform Thicker than s
26. stage gear type pump since 1936 4 types of aluminum pumps since 1968 All have a vertical slot and a tower 68 1968 1972 Big round hole at the top of the slot 68A 1973 1980 No big round hole at top of slot Hole is pressure relief outlet 68B 1981 1991 Extra hole above the slot pressure relief The hole is for the oil pressure relief valve 92 1992 up Different bolt pattern Won t bolt to earlier crankcases The only parts that pressurized oil goes to are Rod Bearings Wrist Pin Bushings Hydraulic Lifters Everything else is splash fed The feed check ball amp spring in top of the oil pump keeps oil from filling up the crankcase by gravity Keep the check ball cavity clean When changing the ball use the old ball and place a bolt on top of it Rap twice with a ball peen hammer to clean the seat Under the tall tower is the pressure relief bypass valve plunger and stiff spring The function is to keep excess oil pressure from getting to the engine 1981 amp up The top cap is smaller and there is an o ring Earlier models had a big top cap and a gasket Oil pump bolt torque is critical The torque is determined by the gasket material White Plastic Torque to 40 to 50 in lb White Paper Torque to 60 to 70 in Ib Black Paper Torque to 95 to 120 in Ib Bolt torque directly affects oil pump gear protrusion 26 Always use the same gasket material
27. the engine it s no good amp the springs on the inside are worn if it spins Check the Primary Chain adjustment Using a socket turn the engine over a couple times Put a straight edge across the top and bottom of the inner primary just in front of the clutch hub and take a reading off the primary chain with a dial caliper Then put the straight edge across the top and bottom of the inner primary just in front of the clutch hub and take another reading off the primary chain If the difference is more than 030 shim behind the sprocket shaft extension to get the correct alignment To adjust the primary chain find the tight spot The primary chain gets tighter when it gets hot The adjusting shoe is tapered in front and wider in the back Dry Clutch 1941 1984 2 Only clutch that is safety wired Rear wheel does not have to be off the ground to work on the clutch Improper adjustment and the clutch will drag 1 8 freeplay on spring clutch There is a thrust washer on the Bendix of the starter There are 2 types of primary chain oilers Drip type Total loss system Lube fell off chain amp ran out inner primary onto the ground Primary wasn t sealed Spray type Uses engine vacuum to suck the oil back into the oil tank 20 25 hg 2000rpm Sealed primary To check take the top left inspection cover screw out and use a vacuum gauge there while running the engine Dry clutches from 1965 and l
28. the plate are rounded replace Make sure the teeth on the new gear match the teeth on the old gear 2 styles of kickstart Early 1957 1970 Dry Late 1971 1979 Wet These don t interchange The teeth need to mesh good or it won t work 70 Clutch Main Bearing Removal There is an inner and an outer snap ring Knock out the shaft with a plastic hammer Knock the old bearing out If there is too much play where the bearing rides use the oil ring rail off an XL Clip apx 1 off To press in the new bearing use an old 45 piston or something 2 34 in diameter Use a sleeve for the Big Twin Timken bearing tool Press the shaft in but never load the bearing 1980 and later has a different snap ring XL Motor Mounts Always tighten the rear motor mounts first then the front The rear motor mount is mounted on studs It won t come off with the cases together without cutting A Motorsport mount should be reinstalled The engine will still have to be removed but the cases won t have to be split 71 Vibration Primary causes Loose or broken motor mounts Worn out compensating sprocket Bad primary chain Bad clutch basket bearing Loose transmission mounts Broken rubber motor mounts Bent transmission mainshaft dropped on left side To balance the engine use a combination of rotating and reciprocating mass Rotating Bottom half of connecting rods Crankpin nuts Rod bear
29. this recall we urge you a by Harley Davidson to bring the vehicle in cted vehicles will be notified for recall service 61 Twin Cam Removal Replacement To convert ball bearing to needle bearing Mark the cam drive chain before removal Install with the same side facing out Unload cam chain tension using a short piece of welding rod to hold the tensioner off the chain Remove the retaining plate screws and remove the plate Put the cam plate on the press and press the cams out Put the cam in BRASS jaws of the vise Using a harmonic puller and a guillotine puller remove the bearing Mark the teeth on the cam at the timing marks for reassembly The drive cam goes in the hole OPPOSITE the 2 shoulders that protrude from the front of the cam cover Install the bearings in the plate one at a time Put the cams in the chain and line up the timing marks with each other Put the cam plate with cams on the press Press in the driven cam while insuring that the drive cam drops into the needle bearing DON T PRESS THE DRIVE CAM IN Make sure the timing marks line up Put the retaining plate back It is directional Use Blue Loctite on the retaining plate screws Put the snap ring back in the groove on the cam Don t take out the pin holding the tensioner until the cams are reinstalled in the engine 62 Removing and Installing Pinion and Cam Shaft Bushings Take an old motor spr
30. to 001 Don t leave the reamer loaded Removing and Installing Wrist Pin Bushings in the Engine Use a connecting rod clamping tool available from V Twin or HD Cover the hole with dry rags and cover the dry rags with oily rags to keep chips out of the bottom end Aftermarket wrist pin bushings vary in dimension H D isn t too variable Make the 1 pass with an expansion reamer Then use a lpass reamer Get a square socket from Sears to drive the reamer BETTER Use a Ram Jet Wrist Pin Reamer from Ram Jet Enterprises V Twin It has a hex head instead of a square head Put the new bushing in and size before checking the rods for straightness Bushings are available in 001 and 002 oversize OD but if needed make sure the rod isn t bad 35 Lapping Pinion Side Main Bearing Race Put the crankcase together with alignment studs Use tool and a new Timken bearing on the motor sprocket side Slide the lap tool in from the gearcase side Snug the lap Turn using the full length Check the case race Lap until it s gray all the way around and within 0002 Then do the formula to get the bearing size Keep lapping compound off of the shaft of the tool and out of the bearing assembly Use 180 to 220 grit compound Running And Installing Timken Bearing In The Left Crankcase 1989 amp Earlier Knock out the bearing and the spacer from the inside shoulder against the bearing Use the bearing removal tool to re
31. top is bigger The 82A won t bolt into an earlier Evo flywheel There isn t enough clearance on the flywheel Grind 1 back and 1 8 deep Flywheels The difference between communized and non commonized tapered flywheels Commonized The dot is advance amp the line is TDC front cylinder 3 81 amp later Non Commonized Line is advance amp dot is TDC front cylinder On the right flywheel the oil hole and keyway location is how to identify Commonized 90 Degrees Non Commonized 130 Degrees 23 Drive side Sprocket side bearing Timken bearing 6 Parts 2 Bearings 2 Races 2 Spacers Inner amp Outer Early 55 68 Round or C shaped later Late 69 Present DON T INTERCHANGE Bearings are normally changed anytime the flywheel is pressed out of the case Bearings are sold as a matched assembly The only thing that can be changed is the inner spacer to adjust the clearance Outer races are pressed into the left crankcase The bearing is pressed onto the motor sprocket shaft A bigger thicker spacer moves the bearing out and increases clearance endplay 001 004 of endplay is desired Spacers range from 095 to 120 in increments of 002 Always keep spacers from overhauls for reuse Don t put the spacer and the seal in until ready to assemble Lube with motor oil Endplay specs are the same on all models Early and late spacers WON T inter
32. 0 longer Valve Guide Seals Ironheads never used valve guide seals Oiling System Different oiling system Most of the oil goes to the bottom end Valve Clearance 001 0015 Intake 0015 002 Exhaust Use different size reamers for intake and exhaust They don t have to be ball honed 43 1957 1985 XL Timing Side Ironhead Camshafts 4 different sets Arranged and numbered back to front from 1 4 1957 1970 2 cam has gear to drive the magneto on the circuit breaker 4 cam is shorter than the later models with no tach drive Won t fit anything else because of 2 and 4 cam 1971 1980 Tach drive on 4 cam can be pressed off to use on 1981 to E1984 1981 E1984 Interchanges with 1971 1980 if tach gear is pressed off 1984 1 2 1985 4 cam changed 3 short cams and 1 big cam No generator drive 4 Different XL Lobe Profiles 1957 1958 XL 1959 1979 P 1966 PB Factory Performance Option not a very good cam 1980 1985 Q These were color coded gears There is a chart in the manual Check Lobe surface condition and dimension Bearing surface condition and dimension The Dogbone cam thrust plate is directional The bevel faces away from the case They are not variable thickness H D endplay shims come in 005 and 007 sizes Multiples can be used to get correct endplay Aftermarket shims are available in 005 and 020 sizes Shims can go
33. 84 1 2 86 Single groove in gear face Letter V on front lobe 87 89 Single groove in gear face Letter L on front lobe 90 e92 2 grooves on face Changed gear tooth shape Letter L on front lobe Won t work on earlier evo Noise reduction change L92 Present Final change Letter N on front lobe 2 grooves in gear face 2 other Evo cams that weren t common O Cam 1995 Factory Fuel Injection 2 grooves in the gearface C Cam California cam Single groove or double groove versions V L C 2 groove L O N 10 Things to check on a cam Lobe condition Lobe dimension measure heel to toe Look for shorter lobes 005 006 wear Bearing surface condition Bearing surface dimension 95 of catastrophic engine failures are caused by tappet roller failure or cam failure Cams are usually damaged because of not enough endplay The result is that the thrust plate is burned down and the bearing is ruined and sometimes welded The cam thrust plate is not variable thickness but aftermarket thrust washers are available in various thicknesses They can t be ordered in various thicknesses They have to be measured H D part is always 1 16 Look for some that are 045 The cam thrust plate goes beside the bearing but was not intended to allow adjusting endplay Cam shims are used to adjust end play Cam shims are variable thickness 1936
34. Amp 2 4 Ohms Last test Test Regulator Use test light Clip wire on fin Pierce Battery Charging Lead as close to the Regulator as possible If tester lights Regulator is Bad Ground test Clip wire on fin Go to positive side of battery Tester should light If not broken wire or bad ground 39 Alternators are better than Generators because Less maintenance Less moving parts Higher output Less noise Better ground clearance If battery goes dead on Points ignition system problem could be that kill switch or diode allowed current to drain to ground when engine isn t running Milliamp test Done with key off Dressers w radios etc Hook up meter Unhook all components by 1 at fuse block is okay to isolate circuits Look for current drop If the Stator has output but not enough check the compensator nut Some models had no crankshaft spline and could spin Starter Draw Test Last thing to do to determine if starter needs to be removed Use VAT 40 Load Tester Put green lead on starter cable with arrow of green lead pointing away from starter Use Red scale zero meter Hit starter button needle will spike and then level out Take level reading 1988 and earlier Round starter If it draws more than 120 amps starter must be removed 1989 and later Big Twins amp 1981 and later XLs Square starter If it draws more than 150 amps starter must be removed 40 1 Carburetors Linkert M
35. End Float Load the axle and tighten the nut Use a dial indicator that is set to zero Rotate the axle to seat the washers The end play should be set to 004 012 for sport bikes and 002 006 for dressers The spacer in the middle of the hub determines end float Shorter Less Longer More If there is too much end float use a shorter spacer Not enough end float will cook the bearings and cause the wheel to lock up Too much end float will cause the wheel to wobble If using shims the first shim should have a shoulder that goes toward the bearing Spin to set the bearing before pulling up to measure Swingarms Pre 1982 or 1983 The pivot bolt should be torqued to 50 ft lbs The big nut loads the bearings The swingarm must be weighed Set it for 2 lbs heavier than the free weight Look for a ratcheting effect or side to side movement Swingarm movement should be smooth with no ratcheting or side play Adjust the chain on the tight spot Compensate for the weight of the bike amp rider On old bikes visually align the chain Adjust the chain or belt first then make all other adjustments on the opposite side of the bike Models 1936 1984 FL FLH 4 speed 16 Front wheel 16 Rear wheel Solid mount 1971 1986 FX 4 speed 19 or 21 Front wheel 16 Rear wheel Solid mount Both of these models are covered by one manual 1980 FLT 5 speed 16 Front wheel 16 Rear wh
36. L Transmission Disassembly and Reassembly The only snap ring is on the main shaft 3 gear Knock out the countershaft oiler with an extension or deep socket The tube lets oil into the countershaft 1 gear bushing Clean the oiler carefully The hole on the side faces up Inspect the countershaft bearing surfaces and splines Inspect the gears and dogs and doghouses If rounded more than 25 replace On the mainshaft inspect the 3 bearing surfaces Upon reassembly the transmission can be set up and tested on the bench There are 8 gears 2 sliding Countershaft Assembly Start with the thrust washer Then freewheeling gear 4 dog gear 5 dog on mainshaft Spacer 4 dog sliding gear Variable thickness washer Countershaft 1 gear smallest gear Mainshaft Assembly 3 gear Non variable washer Last gear groove faces away from the access door 68 Shift Forks Cam plate has a bolt with retainer for the pawl carrier assembly detent with lockplate In neutral the sliding gears should be centered relative to the gears on either side 3 things that affect centering Shift fork length Variable thickness washer under the countershaft 1 gear Pawl carrier shims Pawl carrier shims move both shift forks away from the access door Shift through the gears on the bench and look for a minimum of 50 engagement If not enough engagement at 1 gear change the washer All drive is on the dogs Direct drive transmission 4 gear ratio
37. Needle Bearing Page 37 Twin Cam Oil Pump Page 38 XL Upper End 1957 1985 Page 39 XL Tappet Blocks Page 40 XL Tappets Page 40 XL Cylinders Pistons 57 85 Page 41 XL Cylinder Heads 57 85 Page 42 XL Spark Plugs Page 42 XL Valves 57 85 Page 43 XL Valve Guide Seals Page 43 XL Oiling System Page 43 XL Valve Clearance Page 43 XL Timing Side Page 44 XL Cams Page 44 Evo XL Timing Side Cams Page 45 Evo XL Timing Covers Page 45 Evo XL Cams Page 45 Flow Bench Page 46 Ironhead XL Timing Covers Page 47 XL Primary Drive Page 47 XL Primary Chains Page 48 XL Motorsprocket Page 48 XL Clutch amp Primary Drive Page 49 1971 Early 1984 Wet Clutch Page 51 XL Lower End Page 52 XL Pinion Shaft Page 53 Timing XL Oil Pump Page 53 Installing XL Pinion Gear Page 53 XL Oil Pumps Page 54 XL Oil Pump 77 84 Page 56 XL Oil Pump 84 90 Page 58 XL 5 Speed Oil Pump Page 58 Priming Oil Pumps Page 59 Twin Cam Cam Side Page 60 Twin Cam Recall Notice Page 61 Twin Cam Removal Replacement Page 62 Pinion amp Cam Shaft Bushing R amp R Page 63 XL Transmissions Page 64 XL Mainshafts Page 67 XL Main Clutch Gears Page 67 XL Shifter Shafts Page 67 XL Tranny Disassemble Reassemble Page 68 XL Countershaft Assembly Page 68 XL Mainshaft Assembly Page 68 XL Shift Forks Page 69 XL Kickstart Mechanism Page 70 XL Clutch Main Bearing Removal Page 71 XL Motor Mounts Page 71 Vibration Page 72 Static Balancing Page 73 Mainshaft Endplay 4 Spd XL Page 74 Co
38. Push rod tubes Same 6 parts as the Big Twin XL Pushrods 1957 1985 All 4 are the same but should be reinstalled in the same location to prevent noise Pushrods are aluminum with pressed in steel ends If bent replace 39 XL Tappet Blocks 1957 1966 apx Cast iron 1967 1976 Aluminum with puller groove 1977 1985 Aluminum without puller groove All are the same front to rear All interchange Worn tappet blocks cause noise Wear limit 008 Not repairable Bad tappets will damage new tappet blocks New clearance 001 When installing tappet and block don t allow tappet to drop down out of the block Hold by the top of the tappet and tap the block down with a plastic hammer The o ring needs to be in place on the outside of the tappet block or it will leak XL Tappets 3 different types 1957 1970 3 holes in each side to reduce weight and reciprocating mass in the valve train 1971 1976 No holes but weight is the same as earlier 1977 1985 2 holes in the top due to different oiling system oil drainback All interchange but must have holes drilled for 1977 and later The roller assembly is replaceable all pre evos Standard tappet OD is 730 They are available oversize in 005 and 010 Ball hone with a 750 hone if necessary 40 XL Cylinders and Pistons 1957 1985 3 different cylinders 3 different types of pistons that are likely to be seen 1957
39. The valve seal installation tool registers against the lower retainer Every time the valve comes out a new valve seal must be installed 3 Critical Things for Assembly Clean Lubricate Torque For Evo amp Twin Cam exhaust valve protrusion measurement use the long end of the dial caliper Rocker Arm Bushings 2 types Steel Brass Either will work equally well Remove install and ream one bushing at time to avoid loss of alignment between the 2 bushings Take an old 5 8 X 11 tap amp thread into the rocker arm bushing to be replaced 4 or 5 turns Turn the rocker arm over amp knock the bushing amp tap out at the same time On non Evo or Twin Cams line up the oil hole in the bushing with the oil hole in the rocker arm or if there is no hole in the bushing drill a 3 32 hole Evo amp Twin Cam oil holes don t go into bushing Use a solid pilot reamer to ream the rocker arm bushing Use cutting oil Don t ream dry turn backwards or force Seat the new bushing flush then ream then use ball hone It s important to change the rocker arm bushing if worn Excessive rocker arm shaft to bushing clearance causes overoiling of the top end and smoke Valve Guides Use the special JIMS tool to change in Evo amp Twin Cam engines Order apx 6 extra shafts Put Anti Seize on the bottom of the guide so it won t seize or gall on installation Oil the threads on the tool and on the wafer bearing Heat the head
40. XLs VOES Vaccuum operated electrical switch 1984 Big Twins VOES VOES has 1 job to retard timing 10 degrees under heavy load to prevent detonation If not using plug up vacuum line amp ground wire from module to the frame A VOES hose leak will cause the bike to run lean To Check VOES For light bike 3 1 2 4 1 2 hg inches of mercury large bike 6 hg Using digital multimeter red lead to brain lead audible setting black lead to ground wire vacuum pump to VOES pump slowly watch gauge VOES is adjustable screw on top 2 things to check with vacuum pump 1 VOES 2 Vacuum of inner primary on shovelhead with dry clutch 3 things that contribute to detonation 1 Octane 2 Heat 3 Too high compression If lean in only 1 cylinder air leak Low compression in 1 cylinder push rods too tight 32 Batteries 32 Amp Hour 1965 1984 FLH 1967 1978 XL 22 Amp Hour FLT 30 Amp Hour Fuel Injected 19 Amp Hour 1979 amp up XL FX FXR FXD amp Softails Sun Vat 40 Load Tester Black to negative red to positive green around negative Set at 3 times the amp hour rating of the battery to be tested for no more than 15 seconds or until voltage drops to 9 6 VDC Use Blue Scale to zero amp set voltage Watch bottom scale for reading Remove battery from bike it could explode Harley Plugs Lower number hotter plug Higher number colder plug When checking coil infinite reading open Points Front cyli
41. am would lock up briefly and the engine would strip the key out of the gear The second warranty was a new cam plate cams oil pump and 4 tappets H D then went to a splined end cam that has a master spline that is wider than the others It will only go on one way When the bearing failed the engine kept running BAD In late 2000 H D went to a needle bearing The needle bearing made it much easier to change the cams There was no need to press a cam into the needle bearing The big end of the cam case end always used needle bearings No dogbones no thrust plates and no alignment reaming is necessary No bushings The tool for cam removal is the JIMS 1277 3 piece The bearings are pressed on with one of the pieces That tool Bears on the outer edge of the bearing to prevent damage Insures alignment Seats the bearing to the proper depth One piece of the tool presses the cam into the plate REMOVE THE CAM BEARING RETAINING PLATE BEFORE REMOVING THE CAMS 4 screws Later models had longer cam sprocket retaining bolts 60 1999 TC88 CAM BOLT RECALL NOTICE January 8 1999 SAF ETY R ECALL CAMPAIGN Dear Harley Dealer Distributor motorcycl loading and or break to quit runnin i s th ngin T g with or th NStances Certain 1999 m ngine co s which ngines fFfected m a t engine A positio stamped Harley
42. ame as on the Big Twin 001 004 The rod side clearance is the same as on the Big Twin 005 025 Evo bore and stroke 3 X 3 13 16 Ironhead bore and stroke 3 3 16 X 3 13 16 52 XL Pinion Shafts 1957 1976 4 splines 1 wider than the others Pinion gear only goes on way 1977 E1981 Pressed on inner race 6 splines 2 longer Threaded protion for the nut to hold the timing gears Notch on 1 spline lines up with the pinion gear 3 81 1985 Commonized taper pinion shaft Bearing inner race is made as part of the shaft The oil hole is 180 degrees from the keyway Smaller woodruff keyway The pinion shaft nut is torqued to 120 ft lbs All Evo XL pinion and motor sprockets are made 1 piece with the flywheel and must be OD ground Timing the XL Oil Pump Breather Gear 1976 and earlier 1977 and later doesn t have a breather gear so there s no need to time Rotate the engine to the advance mark in the timing hole Push the oil pump drive gear onto the pinion shaft and back against the shoulder making sure that the hole in the oil pump gear lines up with the notch in the oil pump upper housing Installing the Pinion Gear There is a left hand thread hole in the end of the pinion shaft the only left hand thread on XLs Put the tool in the hole and crank on the nut until the pinion gear is pressed onto the shaft The gear should fit tight When the tool bottoms the space
43. and the small end Torque the nut that holds the pinion shaft to the flywheel to 140 170 ft lbs Always use Red Loctite 21 Crankpin Between the flywheel halves Non commonized 1941 E81 Large keyway oil hole is 130 degrees from keyway Commonized 3 81 to Present Smaller keyway oil hole is 90 degrees from the keyway Different thread pitch Torque crankpin nut to 185 210 ft lb Use Red Loctite The crankpin is usually replaced if the engine is bad enough to need repair or if the rods are loose enough to tear down further Motor Sprocket Shaft 1970 Bigger and longer due to the alternator 1970 1971 Small taper big keyway Torque to 140 170 ft lbs 1972 E81 Large taper amp nut No key Torque to 360 440 ft lbs Use a 1 5 8 socket with the taper faced off 3 81 1985 Commonized taper motor sprocket shaft Looks like earlier Measure the fat part of the taper to distinguish 1 320 Commonized 1 420 Non Commonized 72 e81 Torque the communized taper motor sprocket shaft to 290 320 ft lbs 2 reasons to replace the Motor Sprocket Shaft Threads or splines damaged Big tapered roller bearing isn t a tight press fit Late 1985 The Motor Sprocket Shaft was cast as part of the flywheel Aftermarket engines may have any type of motor sprocket shaft and should be inspected to determine which shaft it has S amp S has a number on the f
44. ange and 9 fins Early amp late ARE interchangeable 80 OHV was introduced in 1978 74 has 3 7 16 bore amp 3 31 32 stroke 80 has 3 2 bore amp 4 1 4 stroke Pistons are different between 74 amp 80 To use an 80 cylinder on a 74 engine use a 060 over 74 piston The 80 piston is shorter on the top and bottom and will cause extremely low compression if used in a 74 engine Base Nuts Shovel Early 7 16 X 20 w 5 8 hex head high nut Later Same threads but has 9 16 hex head and integral washer Uses a triangular washer Only use the early nut on early jugs The late nut can be used on early or late jugs 1948 e1978 Same headbolt with a separate washer Later Integral washer All interchange 60 65 ft lbs Torque 14 mm S wrench needed to remove rounded shovel headbolts Use 9 16 Dogbone to torque Shovels all have a spigot on top of the jug that fits into the head The head has a corresponding counter bore If the spigot is too high it will leak oil Use a file or belt sander to lower Big Twin Single Cam Evo Cams won t work in a Shovel Shovel 70 e77 Cam has smooth gear face amp the letter H on the front lobe L77 e82 Shape of teeth changed to reduce noise Big groove machined in gear face Letter H on front lobe L82 end of prod Big groove on gear face Letter S on front lobe Evo
45. angle Degrees of crankshaft rotation that points are closed Saturation When points are closed amp building up voltage in coil When points open plugs fire When voltage jumps a gap voltage increases Open points decrease dwell Close points increase dwell When gap is too narrow points will burn When gap is too wide high speed miss On dual fire ignition trigger side is whatever side you want it to be 30 Prestolite Ignition 1978 1 2 amp 1979 Electronic ignition w mechanical advance Air gap 006 002 Small cam lobe front Wide cam lobe rear Set air gap with plastic or brass feeler gauge due to magnetism Plug gap 032 2 white wires Pink tach wire Blue trigger wire If bike won t start no spark try disconnecting tach wire To replace use Dyna S ignition Works on magnetism no air gap ground VOES to frame if not using 1980 amp later V Fire Automatic Works on magnetism starts retarded can t static time 3 parts Rotor Notch goes into cam Pickup Turn to advance or retard timing Preset air gap Brain Rev limiter so bike won t blow up Causes engine to misfire every other time Evo 5200 5300 rpm Twin Cam 5500 rpm Twin Cam B 5300 rpm 0 800 rpm 5 degrees BTDC spark 800 1700 rpm 25 degrees BTDC spark 1700 amp up Full advance 35 degrees 31 1991 From White White Pink Blue to White White Pink Pink Module went to 7 pin connector 1983
46. ater use a sealed primary 1964 and earlier kick start use a total loss system 10 Don t start the engine without the primary cover in place It can damage the bendix A damaged primary cover can be cut so that the bendix can be covered To adjust the clutch use the clutch adjustment screw in the center of the clutch hub The handle should be out all the way with no tension on the cable maximum freeplay Fork amp Arm adjustment Turn the clutch adjustment screw in until it lightly seats then back it out 4 to 1 2 turns Hold the screw while tightening the lock nut To remove the chain adjuster only take the top bolt off Take the clamp off the hose Remove the hose Use an impact wrench to take the compensator nut off If torquing use Red Loctite If using the impact wrench don t use red loctite The Compensator nut uses regular threads Inspect the compensator fingers for pitting On the clutch hub there are 10 springs Measure 1 from the back of the pressure plate to the front of the clutch release disc to preload the springs To adjust the springs loosen or tighten the nuts The clutch release disc must come out straight no matter if the pressure plate is straight or not Check for warpage and bad springs There should be minimal freeplay at the lever on any spring clutch after it s adjusted The lever should contact the grip Check spring preload Adjust the set screw Adjust the cable Check that the relea
47. bearings are available in 0004 increments Running clearance is 0005 001 3 Different Countershafts 1936 1977 mid Threaded on right O ring groove on left amp uses loose roller bearings Mid 1977 1978 Threaded on right 2 O ring grooves one on right is for ID purposes only 005 smaller in diameter than earlier Uses cage bearings 1979 1986 Slot on right O ring groove on left uses cage bearings Main Drive Gear Has 44 bearings Mid 77 amp earlier Loose After Mid 77 Cage bearings Mid 1977 amp earlier Spacer on main drive gear for L shaped key Keeps bearings amp spacer going at same speed amp keeps the bearings from tilting Held on by the sprocket To loosen any nuts on the transmission move the clutches to lock up the transmission All Harley transmissions There is a seal on the outside on the Maingear side Drill holes to remove To reinstall put a spacer into the seal and reinstall as a unit using special tool To Disassemble the Transmission Take off the bearing carrier Hit the end of the mainshaft 1 gear takes the bearing out 2 gear takes the carrier out On 2 45 1 gear 1 gear takes out both The clips in front of 3 gear must come out Never reuse the clips 20 Shifter Clutches 2 different 1 is between 1 amp 2 Large amp Non Directional 1 is between 3 amp 4 Small amp Directional Taper word High
48. both inside and outside Normal oil pump gear protrusion is 001 to 004 with no gasket New pumps may have 006 The oil pump scavenge pickup is directly beneath the cam Always clean the oil tank lines and oil cooler if there were any problems involving the oil pump The oil pump seal separates the feed side from the scavenge side of the oil pump Replace the seal when working on the oil pump It is included in the gasket set A c clip goes in the oil pump and a snap ring goes inside the timing cover due to clearance The scavenge gear is bigger than the feed gear If scavenge isn t working the bottom end will fill with oil and oil will blow out leak and the engine will smoke If the feed gear doesn t work the rocker arm bushings will squeak and the pistons will stick If there is an oil indicator lamp it will come on To check for oil pressure remove the scavenge line at the oil pump and see if oil shoots out The engine should have 6 7 psi at idle minimum and 12 35 psi at 2000 rpm hot Priming a Dry Oil Pump It is unlikely that the oil pump will prime itself Take feed check ball amp spring out amp put the cap back on Run engine for apx 1 minute OR Pump manually into the feed side There must be oil pressure within 30 40 seconds of startup When assembling the oil pump don t use gasket sealer Spray the gasket with High Tach or Copper Coat or something sticky Make sure the pump
49. change 24 Lower End Pinion Side Main Bearings and Rod Bearings Pinion shaft Bearing 1958 1986 and aftermarket to present 2 washers 2 cages and bearings and 1 spiral lock The cages are reuseable and the rollers are replaceable 28 Bearings 14 per cage 250 is standard Available in 0002 0004 0006 0008 001 and in some applications 002 oversize The washer goes on first The first bearing sits open end up The next bearing sits open end up Then the washer is installed and the spiral lock goes on last 1987 1991 Obsolete Can t purchase Replace with either the newer or the older Had Black Bearing Closed cages Retained with a flat C clip Bearing was 2 piece 1992 Present 1 piece bought as a complete assembly 2 oversizes available color coded All races can be lapped and sized The late race 1992 amp later has oil holes that are 90 degrees from each other Rod Bearings 1941 1972 4 identical steel cages Loose bearings Male 2 cages over long bearings 54 rollers 1973 1986 3 piece Will fit Big Twins from 1941 to present 2003 51 rollers 1987 Present Black Comes as an assembly Components can t be purchased individually No oversizes Uses different sizes of crankpins The standard size is 1 249 since 1941 Replace as a unit Normal rod clearance is 0005 to 001 23 Oil Pump Single Cam 2
50. clearance If the rotors look good and the clearance is good the pump will work The scavenge rotors are bigger They go in first Then the washer The feed rotors go on top The Cam Plate is the front of the pump housing To reassemble put the pump on the cam plate with 2 bolts and 2 tappet block alignment tools Rotate snug rotate torque The tappet block alignment tool insures alignment on the pinion shaft 38 XL Upper End 1957 1985 2 styles of XL rocker boxes Early 1957 1970 No notch Late 1971 1985 Has notch Interchangeable but not front to back Rocker boxes are held on with 5 16 X 24 cap screws Torque to 15 16 ft lb Rocker arms are smaller than shovelhead but use the same bushings end caps nuts and washers Bushing clearance 004 005 Rocker arms are spring loaded Intake amp Exhaust rocker arms are different The exhaust has an oil hole near the pad Interchanging the exhaust and the intake will cause Overoiling the top end Smoke There are 4 different part numbers for XL rocker arms Ironheads have solid lifters Zero lash Early and late XL rocker arms interchange Excessive valve stem protrusion causes upper spring retainer to be hit by the rocker arm and causes the valve stem to fatigue and break out of the keeper groove Cure Bigger valve or new seat Rocker boxes don t interchange front to back The oil line fitting goes on the intake side
51. d There are 2 Snap Rings an inner and an outer Never reuse the snap rings Install sharp side out When using the Fuji tool don t remove the inner snap ring Remove the inner snap ring only to take off the stator If removing the clutch as a whole remove the inner snap ring The center will come out Don t remove the outer snap ring without using the tool YOU MUST REMOVE THE OUTER SNAP RING WITH THE TOOL ON NEVER REMOVE BOTH SNAP RINGS AT THE SAME TIME Start with a fiber disk and end with a fiber disk Turn the nut on the tool 4 turn at a time until the outer snap ring will come out with a screwdriver Unload the tool after removing Remove the clutch plates A magnet makes removal easier The manual shows the shoulder up but it should be installed with the shoulder down in There is a spring plate in the middle of the clutch pack Inspect it for movement There should be none The first indication of a worn spring plate is having to constantly adjust the clutch Loosen the compensator Take off the clutch hub nut Take off the Primary Chain Tensioner Remove the clutch hub amp front sprocket with the primary chain all together 16 DC Clutch 1971 1984 2 Must be in 4 gear to work on It s called the DC clutch because it s only found on Sportsters with generators It is a wet clutch The rear wheel must be raised to find the tight spot in the primary chain on XLs Review the rules for working on clutches Scre
52. e 1970 1976 Middle offset Used a sleeve nut Don t use an air wrench and don t red loctite Torque to 125 ft lbs 1977 Present Long offset Uses a sleeve nut Don t use an air wrench and don t red loctite Torque to 125 ft lbs 4 speed or 210 ft lbs 5 speed None of these motorsprockets interchange Splines are the same in each All 4 speed motorsprockets have 34 teeth All 5 speed motorsprockets have 35 teeth All have 5 16 X 18 tapped holes for a puller 48 XL Clutch and Primary Drive 1957 1970 Dry multi plate standard action clutch Uses a traverse screw release mechanism The cover helps keep oil out It uses a gasket It s held on by 12 10 screws with small lockwashers It doesn t require any special tools to work on it The wave plate acts as a spring retainer 3 of the nuts take a 7 16 socket and 3 of the nuts take a 1 2 socket The 1 2 nuts are sleevenuts The 7 16 nuts and the 1 2 nuts are 180 degrees apart They will only go on 1 way The nuts have a groove on the bottom to keep them from backing off Always back the nuts off evenly The spring retainer plate retains the springs It serves as an adjuster block There are 6 clutch springs This clutch doesn t need Barnett heavy springs The springs go in sheet metal buckets The releasing disc pressure plate should be replaced if warped or if the hole in the middle is cracked The end of the clutch rel
53. e or if the throttle is twisted more than once or twice DON T CHECK COIL It can explode If a Scanalyzer isn t available the key can be turned on then off then on again 46 The Check Engine light should blink fast then blink slow to give the Trouble Code The Breakout Box plugs into the top of the ECM amp diagnoses circuits without having to probe or remove parts The fuel pump on a fuel injected bike is mounted on an isopod in the fuel tank so it can be easily removed and installed Unused fuel is pumped back into the tank at apx 3 psi Barometric sensor Can be tested with a vacuum guage test the diaphragm All EFI bikes have single fire ignition The sensor plate can t be turned to do the timing 1999 amp later No timing hole everything is done with Scanalyzer The Cam Sensor Plate has a small switch Vehicle Attitude Sensor VAS shuts bike off if leaned over to 80 degrees Carb bikes have a Bank Angle Sensor BAS on the left side of the bike that shuts the bike off if leaned over to 55 degrees 3 Main Sensors Crank Position Sensor Monitors the flywheel 32 teeth 2 teeth missing at TDC Cam Position Sensor After 2000 no more cam position sensor Throttle Position Sensor Fuel Injected bikes use the High Output Charging System 45 amps 30 amp hour battery earth magnets charges at idle 47 Valve Spring Tester Valve Springs Valve Stem Valve Guide Seals Rocker Arm Bushings Valve Guides Wr
54. e the crossover shaft was Has the crankcase vent on top Uses a different gasket with a new location for the top end oil feed passage L1984 1985 Smooth hole for the crossover 84 part number No generator gear Uses a different gasket with a new location for the top end oil feed passage XL Primary Drive Primary Chain Tensioner Early 1957 1970 1971 1976 Has a piece that bolts over the chain The lug can be cut off to use on earlier models Has a short bolt and a special lock washer Attaching bolts should have a lockwasher and a hardened flat washer If too long they will hit the flywheel There should be no clearance between the tensioner or the pad 1977 1979 The flat tensioner mounts on the stud in the case It has a flat spring Replace it with the model for 1977 1990 1980 Has a coil spring The shoe is held on with screws This tensioner works from 1977 1990 There should be 2 34 freeplay at the tight spot 47 XL Primary Chains All interchange from 1957 to present 1957 1980 have figure 8 side plates 1981 Present is heavier and better It has flat side plates Diamond Chains and Duckworth Chains are the best and are OEM When the chain is out of adjustment or has a bad tight spot REPLACE IT Freeplay at the tight spot should be 2 to 34 XL Motorsprocket 1957 1969 Shortest offset shortest shoulder Used a hex nut Use Red Loctit
55. econe use a junk cam with the gear turned down to fit inside the nosecone Dress up the cam and or the pinion bushing with a ball hone if needed 001 clearance Removing and Replacing the Cam Needle Bearing To remove the cam needle bearing put collet fingers through the bearing Put the large part over the shaft then the brass washer and then the nut Tighten and pull the bearing out To replace make sure the letters on the bearing face out Always replace the camshaft bearing on 1993 amp later Evos Use a tool to support the shoulder and tap in until it bottoms Make sure it will spin freely 37 Twin Cam Oil Pump 3 types All interchange but the parts don t interchange between the 3 types 99 Earliest 99A Different body and different rotor dimensions 2 additional parts 2 thin washers and a wave plate The wave washer puts a spring load on the pump 99B Latest The part that goes in the tube in the crankcase is longer There was a change in the cam doors They have an extra oil passage for balancers on Twin Cam B engines This hole can be plugged for use on earlier engines with no blockoff casting The Twin Cam Oil Pump is a Gerotor Oil Pump or Truncoidal It contains 2 feed rotors 2 scavenge rotors and separate washer It runs off the pinion Always inspect the rotors and body for damage and check rotor tip clearance Use a feeler gauge between the rotors in several places Wear limit 004
56. edure first to see if that cures the problem 51 XL Lower End Motor Sprocket Shaft 1957 1976 1 where the Timken bearing presses on It has a keyway 1977 E1981 1 1 16 1 062 where the Timken bearing presses on Has keyway L1981 1985 Commonized No woodruff keyway in the taper Has ID groove at the base of the spline Torque the nut to 120 ft lb and use red loctite Replace if the splines and threads are damaged or the bearing fit is loose There is a space between the shoulder of the motor sprocket shaft and the flywheel Evo XLs 1986 Present The motor sprocket shaft and the pinion shaft is made 1 piece with the flywheels Crankpins Commonized 3 81 99 Oil hole and keyway are 90 degrees apart The thread pitch is different Non communized 1957 e1981 The oil hole and the keyway are 130 degrees apart It has a bigger keyway and different thread pitch Connecting Rods The ironhead 1957 1985 used 1 type of connecting rod It had a 52 part number if it has a part number It uses the same rod lap and the same bushing reamer as Big Twins Evo rods have a 83 part number The front rod is directional 2000 and later uses a different crankpin pressed into the flywheel Flywheel assembly is not rebuildable and won t work in an Ironhead The rods are too short Torque crankpin nut to 150 175 ft lb The bearing clearance is the s
57. eel Rubber mount 1982 1994 FXR 5 speed 19 or 21 Front wheel 16 Rear wheel Rubber mount Both of these models are covered by one manual FLT Fairing mounted to the frame FLHT Fairing turns with the bars R Rubber In 1995 the Dynaglide replaced the FXR After 1995 each bike had a separate manual The first Softail was in 1984 1984 amp 1985 were 4 speeds with kick amp electric 1986 5 speed electric start only Softail Only Big Twin with a solid mount On T Models the VIN number is on the left side of the neck On all others it s on the right When adjusting the stabilizers there should be an equal amount of threads on each side of the center nut Drive train Engine Transmission Swing Arm 3 Types of Final Drive Belt Chain and Enclosed Chain Harley Wheels All Harley wheels 1 spoke crosses 4 Mid 1977 amp earlier are laced in the early style pattern Inside spokes go in the same direction Inside holes inside spokes Outside hole to the left Late style Inside spokes cross each other Outside hole to the right Sportsters changed in 1998 to the late style laced in the early style pattern VIN Numbers 3 styles 1969 amp Earlier First 2 numbers are the year only on the case not on the frame Second letters are the model Last numbers are the serial numbers 1970 First 2 digits are the model Next 5 digits are the serial number Last 2 digits are the year The
58. exhaust valve guides were knurled internally to hold oil in the guide and lubricate the valve stem The function of the bevel on top of the guides is to deflect oil old valve guides didn t use seals Always use assembly lube on valve stems NEVER USE GREASE AS AN ASSEMBLY LUBE If you need something to hold a part in place use Vaseline SGCC amp SCCD are good oils to use Twin Cam Rocker Boxes The Rocker Box gasket is directional The covers aren t stressed on Twin Cams won t leak The Rocker Arm carrier is held on with 4 5 16X18 cap screws Long black pushrods are exhaust Both are the same Both intake are the same Rocker arm cover is held on with 6 double hex nuts Big Twin Upper End Shovelhead cylinder is one piece cast iron It s not sleeved but can be sleeved Shovelhead cylinders always have an oil drainback passage hole in the bottom of the cylinder Use an interference fit to sleeve Shovel cylinders 001 0015 It s cheaper to just get new cylinders Shovelhead front and rear cylinders are different Rear 2 wide gasket surfaces and 2 narrow gasket surfaces Front 4 narrow gasket surfaces The notches on the bottom of the shovel cylinders face each other Early Cylinder 1966 to early 1978 Late Cylinder Late 1978 to 1984 1 2 1985 Early has 66 part number on the base a thin base flange and 10 fins Late has 78 part number on the base a much thicker base fl
59. faces the front Torque Plates must be used on Evos and Twin Cams to Bore Measure Hone Use old head or base gaskets with torque plates 3 reasons why pistons are directional One valve relief is bigger than the other The bigger relief goes towards the intake valve Skirt shape The notch goes towards the other piston Wrist pin location It is sometimes offset towards the thrust side to reduce the tendency of the piston to rock in the bore at TDC and at BDC If the word MAHLE is inside the piston look for a direction lug The lug goes to the left or clutch side If there is a letter on an EVO piston it indicates the wrist pin If there is a number on an EVO piston it indicates the grade Wrist Pin Lock Styles There were 4 different wrist pin lock styles since 1930 Horse collar lock Fits in wrist pin Used in HD through 1972 Spiral Lock 1973 1977 Snap Ring 1977 1982 Directional sharp edge faces out towards you and away from the wrist pin A spiral lock can be used in any piston that originally used a snap ring but a snap ring can t be used in a spiral lock piston The open ends of snap rings must be at 6 or 12 o clock Round Wire C clip Used when H D went to moly pistons 1983 Present Can t interchange with any other lock because of the shape of the groove Twin Cams use a larger C Clip Piston Rings Normal ring side clearance is 001 or less If 005 006 rep
60. g is on the torque wrench double it for the actual reading Check valve springs for Free Length Spring Pressure Valve Spring installed height doesn t depend on the spring Changing the spring doesn t affect the installed height Installed Height Top of the bottom retainer to bottom of top retainer To correct for Excessive Installed Height Shim the lower spring retainer if the valve stem protrusion is within limit Valve Stem Protrusion How far the valve protrudes from the cylinder head surface to the top of the valve stem Wear limit The point beyond which the component is no longer serviceable If valve stem protrusion is out of the wear limit it may be because of a worn out valve seat or the head or valve has been refaced too many times Sometimes a new valve can get valve protrusion back into spec Another option is a valve with a larger head A sunk valve seat is bad To correct Valve Stem Protrusion Use a valve with a bigger head bigger valve New seat Use a service valve 030 shorter EVO engines only To correct excessive spring installed height Use shims Bigger valves New seats Service valve The Valve Seat is not a part of the head It has 006 007 cold interference fit Twin Cam Exhaust Valve has a dimple in the center of the valve to distinguish from an Evo valve Valve Guide Seals The last thing to do on a Valve job Lube the valve stem Put plastic tube on the stem
61. gauge pins for 2 groove cams To insure removal amp installation of the gear in the same position on the cam mark around the shaft cutout with a Magic Marker or Prussian Blue Scratch 2 lines for realignment Timing Cover Remove with a special tool from V Twin Jims etc Breather Gear End Play Install a variable thickness washer Use a new gasket Lay a straightedge horizontally across the new gasket and measure between the straightedge and the washer with a feeler gauge Subtract 006 for gasket compression 001 016 is spec 13 To Remove Pinion Gear 1954 1992 Must have a 2 sided left hand thread nut Late 1992 amp up Regular right hand thread hex nut Use a Pinion Gear Puller to pull the pinion gear Tap the back of the woodruff key to get the front of the key up then pull the key spacer and oil pump drive gear Oil Pump Drive Gear The oil pump drive gear is directional One side is beveled The bevel faces in towards the crankcase Pinion Shaft Installation The pinion shaft must be clean dry and free of grease when reassembling Pinion Shaft Assembly Oil pump drive gear 2 types 5 tooth 6 tooth Each had a different corresponding gear on the oil pump Pre 73 5 teeth on drive 25 teeth on driven 5 1 ratio 1973 amp later Shovels amp Evos 6 teeth on drive 24 teeth on driven 4 1 ratio When installing aftermarket or late style oil pump on early engine instal
62. hake is measured with a dial caliper The clearance is measured with a feeler gauge The Front Rod has a wear limit of 125 The Rear Rod has a wear limit of 090 Push the rod to one side and measure from the cylinder stud to the rod Then push the rod to the other side and measure from the cylinder stud to the rod Radial Movement Rod moves straight up and down ANY radial movement is too much Pinion Shaft Runout Check with a dial indicator using a 4 bolt and nut in a timing cover hole to hold the dial indicator Put the end of the dial indicator on the pinion shaft and rotate the flywheel The maximum runout is 003 Pinion Shaft Runout is caused by Flywheel misalignment the primary cause End of the pinion shaft worn out of round Bent pinion shaft Unusual on 89 amp earlier Common on 90 amp later Pinion Shaft Deflection Check by lightly prying up and down on the pinion shaft to see if the bearing is worn out Pinion Shaft Deflection is caused by Wear in bearings Wear in pinion shaft Wear in race All 3 Pinion Shaft Deflection causes Noise Vibration Damage to main bearing Damage to Pinion Shaft Not enough oil to the bottom end 33 Flywheel End Play Use a dial indicator on the end of the pinion shaft Push and pull hard on the motor sprocket shaft Endplay should be 001 to 004 if new 007 if used and the bearing is quiet If the bearing is bad it will sound like
63. he access cover 5 Speed Gear Ratios 1 3 24 1 Andrews makes a 2 94 1 gear taller m22 3 1 60 1 4 1 25 1 Saket The difference between the 4 speed and the 5 speed is that the 4 speed 1 gear is lower Always replace clips thrust washers and bearings on any rebuild Split bearings are interchangeable early or late model There are 2 slider gears on the mainshaft The slots face towards the access door On a5 speed 2 gear amp 3 gear are the same gear The transmission mainshaft is the longest shaft The dish shape on the conical washer faces out towards the access door The conical washer with the lip goes on the mainshaft If the remaining gear needs to be removed from the case it can be driven out but the bearing will need to be replaced Main Drive Gear Nut screws onto 5 gear Left hand thread If the nut loosens oil will leak out The Inner Race slides onto the mainshaft If the bearing freezes up only the inner race is damaged and not the mainshaft The back of the Inner Race to the front of the Main Drive Gear should be 100 If it s in too far or out too far the bearing won t be entirely on the race The numbers in the Inner Race should face out JIMS Inner Race Remover amp Installer Tool is necessary for getting into the transmission 24 Pushrods Always adjust with transmission in high gear rear wheel off ground to turn engine over Unless replacing
64. hing Running the rod too loose on the lap causes bellmouthing Holding the rod by the small end causes bellmouthing Use the full length of the lap or a low spot will wear on the lap and will ruin the lap Turn the rod over every so many strokes or you ll taper the rod Use this 4 step formula to determine rod bearing roller size Race ID 1 625 minus shaft OD 1 249 376 minus 001 clearance divided by 2 the actual roller size The dry running clearance should be 0005 to 001 Crankpin standard is 1 249 Oversizes available 001 amp 002 28 Rod Rollers 1875 is standard Oversizes available 0002 0004 0006 0008 001 002 003 Pinion Rollers 250 is standard Oversizes available 0002 0004 0006 0008 001 002 some applications 29 Flywheel Assembly Procedures Lay out everything and clean all parts with lacquer thinner Have Brake Kleen red Loctite and all tools Assemble right to left with one exception If the motor sprocket shaft was removed install it first Clean the tapers with lacquer thinner Use red loctite and torque to spec If the flywheel nut has a retainer it can be used It doesn t matter either way If the retainer doesn t line up with the nut tighten the nut to line it up never loosen Make sure there is a space between the motor sprocket shaft and the flywheel Take the
65. ief rod has a small head that can damage the release disc Pick up the clutch inner hub and the race to take it out The studs are 4 X 20 on one end and 1 4 X 28 on the other end Make sure the seal is good or it will leak The clutch runs on needle bearings The inner race falls out easily DON T LOSE IT The Torrington bearing presses on from the back The inner and outer hubs don t wear much The clutch runs on the main clutch gear 49 There is a rubber seal in the main clutch gear shaft Make sure it s replaced out of the dry clutch Start with 2 steel plates The first is thicker with a step The step faces out towards you The regular steel plate is next Fiber plates are raybestos Barnett plates are best Alternate fiber and steel Don t leave the derby cover off and run wet The sharp edges of the steel plates need to face in the same direction On reassembly the studs need to be in the center of the spring buckets It keeps oil The release plate has a big dot in it at 12 00 position and a small dot at the 6 00 Line up the big dot with the mark on the tooth on the inner hub Clutch adjustment There should be 3 16 190 200 from the top of the wave plate to the lip of the spring bucket Check with a dial caliper along the lower part of the wave plate 50 1971 E1984 Wet clutch Wet Multi plate reverse action clutch Uses a ball amp ramp release mechanism Not very g
66. ignment line up the wheels The 4 points of the wheels must be lined up The front stabilizer moves the rear wheel left to right The top stabilizer moves the engine left to right Use an inclinometer on the front and rear rotors and read If within 1 2 degree of each it s in spec An inclinometer is a protractor that gives angles Do the front rotor first and then the rear since the front can t be moved Positive caster The tubes are at a greater angle than the steering head All T models have trailing fork tubes 30 36 degrees Trailing fork tubes are self centering Push the wheel to one side and let go It should swing 3 times and then back to center On other fork tubes the fall away is 1 1 2 to 2 An enclosed chain rides in a rubber boot in oil Wheel Hub Assembly 1936 1966 Running clearance is 001 0015 End play is 003 010 Shims are 002 Oversize bearings available in 0002 increments from 2502 to 251 Oversize means running clearance Measure the shaft with the bearings on it Then measure the inside of the hub The difference is the clearance End play or end float is changed by shims Starhub got its name from the dust cover It has 14 bearings on the left drive side and 12 bearings on the right side All Big Twins drive from the left All XLs drive from the right and never had the star hub The hub is the same front and rear 1967 1972 Sealed ball
67. imensions Pan Pushrods 1948 1952 Hydraulic 1953 amp later Pans amp Shovels Hydraulic tappets and adjustable pushrods Steel with no oil hole Adjustment on the bottom using a split lock nut Generator engine front exhaust push rod is 1 4 longer 20 Pushrod Tubes Parts of Pushrod Covers Clip Bottom tube Top tube Cup Spring Puts load on clip Washer Keeps seal from being damaged by end of spring 1978 and earlier Cork Seals 1979 to Present O rings The function of the shoulder on pushrod tubes is to support the O ring Anything with a shoulder can use either the O ring or the cork seal There are 3 seals on each tube Damaged seals will cause leaks The 5 speed Evo Sportster has 1 piece pushrod tubes Pinion Shaft also called Gear Shaft 1958 1972 Oil feed hole on the side Side Oiler Pinion Shaft 1973 E81 No oil feed hole on the side Oil hole through the center End Align Pinion Shaft 3 81 1989 Commonized Taper Shaft Used on many aftermarket engines To identify Much smaller woodruff key amp taper the size of the others Oil hole is 90 degrees from the keyway instead of 130 degrees 1990 amp Later Part of the flywheel None interchange The thread pitch on the nut between the communized and earlier is not the same Replace the pinion shaft if there is 0002 0003 wear or any noticeable wear Check the big bearing surface
68. ings Bearing Cages Reciprocating Balance factor or Top half of rod Pistons Wrist Pins Wrist Pin Locks 72 Static Balancing Total weight of connecting rods then weigh each end separately Total should be within 1 gram of total rod weight Weigh the crankpin nuts rod bearings cages pistons rings wrist pins and wrist pin locks After getting the rotating weight hang a weight with exactly that weight on the flywheel in the crankpin hole Put the flywheel assembly on LEVEL balance stand Check the assembly in 3 places Don t drill around the crankpin hole Use lead to weight the flywheel Thread the inside of the hole and pour molten lead in Holes 7 16 max in XL YY max in BT Never drill more than 1 2 way through the flywheel Don t use wheel weights or body lead Use pure lead if possible Plumbers lead is good 73 Checking Mainshaft Endplay on 4 Speed XL Use a dial indicator and bolt with 2 nuts Put the bolt with one nut into the crankcase hole above the transmission mainshaft Put the second nut on Mount a dial indicator on the stud Put the end of the indicator on the transmission mainshaft Move back and forth to read the endplay Endplay should be 003 020 Checking Countershaft Endplay on 4 Speed XL Put a 4 bolt with a nut in the lower rear primary cover hole Mount a dial indicator on it Fix the dial indicator to bear on the countershaft end Use a bent spoke t
69. inserts for the head bolts and spark plugs It s not unusual for hairline cracks to develop between the spark plug hole and the head bolts caused by overtorquing the spark plugs Short plug 3 8 H8 or J2 Harley 4 or 3 4 Most pan covers were aluminum The D ring is on the outside to prevent distortion They are usually thin steel or thick aluminum 80 Rocker arm cover screws are 10 24 thread Tighten until the gasket just bulges There are 12 in each head Always use cork gaskets with aviation permatex on both sides Pan always has a felt pad glued in the rocker arm cover with JB Weld There isn t much room for valve stem protrusion Rocker Arms Top bearing half is bronze The bottom bearing half is cast iron Wear limit is 003 The 61 engine has a smaller bore and a shorter cylinder The earliest 74 engines have an oil feed passage and a drainback in the cylinder In 1955 1962 engines the feed passage and drainback comes in under the piston like a shovelhead In 1963 1965 engines the drainback is inside but no feed passage It has outside oil lines The base bolt pattern is the same for knuckles pans and shovels The headbolt pattern is different on all 3 The 74 pan uses the same pistons as the 74 shovel and the same headbolts and base nuts as the early shovels Panhead Cams amp Breather Gears 1948 1969 4 different cams 61 Marked on gear on the front lobe 61 and
70. is hollow billet for weight reduction 1948 FL The FL cam isn t marked 1955 H cam small bearing surface on each end 1958 Dimensional cam change went to a needle bearing in the case from a bushing Color coding started in the mid 50s to reduce noise 81 Panheads had hydraulic lifters Knuckles and Ironheads had solid lifters Oil fed out of the rocker arm The lifter was in the top of the push rod on early models Panheads can t use Knucklehead rocker arms They are a different ratio and will cause damage Knuckle 1 1 Pan 1 5 1 Before 1958 there was no cam thrust plate There was a shoulder on the bushing that did the same thing Breather Gear Pan 1950 Same as knucklehead had a built in washer Breather gear with a big hole works in knuckles and pans Andrews J cam is good for stock Panheads S amp S sells breather gears for all models 82 High Performance for 45 Flatheads Use K model cylinders heads and intake not KH or KHK One cylinder stud will need to be relocated Use KH KHK or KK cams but not K cams Install 1 42 carb or 36mm Mikuni If using stock heads stone around the valve seats to break the top angle Relieve the area from the valves to the cylinder to a depth of 003 83 Dynomometer Horsepower calculations HP RPM X TQ divided by 5252 CHP Crankshaft HP 5 7 Parasitic loss BHP Output shaft HP 10 15 Parasitic loss dependi
71. ist Pin Removal Wrist Pin Locks Piston Rings Cyl Studs Headbolts Nuts Torquing Heads Evo TC Cylinders Rocker Arms Valves amp Guides TC Rocker Boxes BT Upper End Shovel Base Nuts BT Single Cam Cam Endplay Tappet Rollers Cam amp Pinion Gears Timing Cover Breather Gear End Play Pinion Gear Removal Oil Pump Drive Gear Pinion Shaft Installation Pinion Shaft Assembly Pinion Shaft Gear Sets Breather Gears Cylinder Parallel Hone Tappet Blocks Shovel Tappets Shovel Tappet Blocks Evo Tappets Evo Pushrods Pushrod Tubes Pinion Shaft Crankpin Motor Sprocket Shaft Connecting Rods Flywheels Sprocket Bearings Main Bearings Rod Bearings Oil Pump Single Cam Priming Oil Pump Page 1 Page 1 Page 1 Page 2 Page 2 Page 3 Page 3 Page 4 Page 5 Page 5 Page 6 Page 6 Page 7 Page 8 Page 9 Page 9 Page 10 Page 10 Page 11 Page 12 Page 13 Page 13 Page 13 Page 14 Page 14 Page 14 Page 14 Page 15 Page 16 Page 17 Page 18 Page 18 Page 19 Page 19 Page 20 Page 21 Page 21 Page 22 Page 22 Page 23 Page 23 Page 24 Page 25 Page 25 Page 26 Page 27 Lapping Connecting Rods Rod amp Pinion Rollers Flywheel Assembly Pinion Bearing RaceR amp R Lower End Check Wrist Pin Bushing Install amp Ream Lapping Pinion Main Bearing Race Installing Bearing in Left Crankcase Page 28 Page 29 Page 30 Page 32 Page 33 Page 35 Page 36 Page 36 Reaming Timing Cvr Bushings Page 37 R amp R Cam
72. k knob inside which is part of the crankcase vent separator Has an umbrella valve since 1984 2 If the cap part of the black knob is missing oil will leak Wear limit in bushings is 003 004 In 4 speed covers the 1 and the 4 cam bushings are relieved to clear the 2 cam gear When changing the bushing they must be notched 45 Flow Bench Super Flow 110 The Flow Bench is like a giant vacuum cleaner The purpose is to see how much air goes through the port Polishing the port doesn t help except in the exhaust port where it keeps carbon buildup down and keeps heat up The exhaust port should flow apx 75 of the intake port 46 Ironhead XL Timing Covers Always check all bushings for any in or out movement 1957 1967 Single bar cover 52 part number inside cover Magneto mount 1968 1970 Replaced the bar with 6 fins Otherwise identical to 52 1971 1976 Has a 71 part number inside the cover First nosecone cover 1977 1978 Much lower pinion shaft bushing Won t work on earlier models Can be replaced with 79 81 cover Vent tube on the bottom Can use a Chevy PCV valve if necessary Has a PCV valve under the generator part of the cover for the breather vent tube to screw into It will leak without the PCV valve 1979 E1981 Has a crankcase vent on top that goes to the air filter 1981 E1984 Has a threaded hole wher
73. l the 4 1 drive gear set To count the teeth on a worm gear count where they begin or end DON T INTERCHANGE BETWEEN DRIVES Install the drive gear with the bevel towards the crankcase Then install the spacer then the pinion gear and then the left hand thread nut After torquing insure that the spacer will still move The taper must be clean and dry or the gear WILL crack when torquing Use Blue Loctite On early engines the pinion gear was changed Late 77 89 Short teeth 54 Early 77 Long teeth 14 The taper on the shafts is the same but the teeth must be matched to the cam No groove cams use long tooth gear 54 to E77 One groove cams use short tooth gear L77 to 89 The late pinion shaft isn t hardened IT WILL BEND If bent a new flywheel half will have to be bought Pinion Shaft Gear Sets Evo engines had 2 styles Through 89 Tapered pinion shaft 90 and later Pinion shaft is cast into the flywheel The bearing race is pressed on If the race is bad send the flywheel half to Harley 1 piece shaft 1 woodruff key 1990 E92 Oil pump drive then woodruff key then spacer then pinion gear then left hand thread nut No taper on 1990 and later An early style nut cannot be used on 90 92 Evos L 92 Present Longer shoulder on the oil pump drive gear and the pinion gear No spacer Right hand thread nut Can t interchange with earlier models 15 B
74. lace The purpose of the 3 piece oil control ring is to let oil back into the bottom end The 2 ring is usually directional If the top ring has a bevel the bevel faces up The top ring is the compression ring If the 2 ring has a bevel the bevel usually faces down Ring End Gap 010 to 020 030 max 003 to 004 of ring gap per inch of cylinder bore Cylinder Studs Head Bolts and Nuts Everything on the top end is hardened on EVOs and Twin Cams Several styles of cylinder studs in EVOs 84 85 Male thread on bottom female on top 3 8 X 16 TPI L 85 E87 Double male stud short end goes down uses head nut amp washer M87 90 Double male thread with shoulder on top 91 Double male thread shoulder on bottom The only style cylinder stud available now is the 85C used in all Evos and Twin Cams Late studs can be used on any case that used double male threads If replacing 84 85 studs that had female ends heads must be drilled out to fit and head nuts must be used On 2 Generation Head Nuts a washer is part of it Late 92 Head casting is thicker on the shoulder side amp the nut is longer The head is marked 92 The same fasteners are used on Evos and on Twin Cams If later style heads are used on early evos longer head nuts must be used Torquing Heads To torque heads on Evos amp Twin Cams torque in an N pattern in 3 stages 7 ft lb
75. lds advance mechanism to cam On bottom back of advance mechanism small roll pin that engages notch on end of cam Points cam Small lobe front cylinder Wide lobe rear cylinder Flat spot on 1 side goes to another roll pin If put in correctly it will click flat spot will be on roll pin front cylinder compression small lobe will be pointing towards front of bike If put in backwards 180 degrees out engine won t run Use dielectric grease on advance mechanism to prevent rust They usually rust in the open position Advanced timing is the biggest killer of the starter Bendix All bikes start in retard position because of slow piston speed When setting timing hit starter listen for banging If none is heard take for test ride Listen for pinging If there is none everything is fine 29 To Set Points Front cylinder compression small lobe facing front set points for 018 when in middle of lobe Turn engine over to wide lobe and set for 018 002 If gap is too wide advanced timing On distributor if it won t advance to put mark in window 1 Widen point gap 2 Move 1 tooth If timing screw is bent points gap may stay out of spec Use small punch and brass hammer amp tap back to close gap between front amp rear cylinders Points Ignitions Blue wire trigger side of coil White wire always hot Plug gap 028 Magneto 022 Dwell time When points are closed changes with rpm Dwell
76. loat level too low Atmospheric vents on carb amp tank clogged Elevation change Modified air filter Push rods too tight Retarded timing Harleys have unique carb problems because of Erratic Intake Signal the same amount of fuel is not delivered to each cylinder Worst thing with high fuel level Fire amp Death Worst thing with low fuel level Seized engine causing rear wheel lockup Death 45 Fuel Injection First year 1995 1995 amp 1996 Couldn t adjust 1997 Adjustable 2000 Softails went to Delphi System Uses a laptop computer amp phone link to H D 2001 Everything else went to Delphi System Scanalyzer Plugs into Data Link Gray Only place to plug it in When key is turned on you hear the fuel pump pressurize to apx 43 psi The Check Engine light will come on for about 4 seconds and then go off If the light comes back on there is a problem Don t run out of fuel while hooked up Scanalyzer Functions System ID Tells what chip is installed Trouble Codes Menu Display current Display Historic Clear History Data Monitor RPM Idle Speed Control ISC Engine Temperature ET Intake Air Temperature IAT Throttle Position Sensor TPS Injector Pulse Width in milliseconds INJPW Advance Barometric Sensor Baro Sensor Active Diagnostics Fuel Pump Front Injector Rear Injector Front Coil Rear Coil Tachometer If the front injector is checked and run for a long tim
77. lywheel to determine which shaft is used Check the rod sideplay and then put the rod in the middle and pull up and down to check for radial movement 22 The wear limit side to side is 0018 Any radial movement is too much To remove the bearing from the motor sprocket shaft use a guillotine puller and a harmonic balancer puller Disassemble the flywheel assembly from left to right and reassemble from right to left Hit the flywheel with a brass hammer 90 degrees to the crankpin to break free Bearing cage on crankpin is narrow on top and bottom and wide in the middle Use a bearing installer tool to install the crankpin bearings Don t load the flywheels Connecting Rods Harleys used 3 or 4 different sets XA Rods 1941 1973 Says XA705 amp XA706 on the side 74 Rods Began in 1974 The part number 74 is on the rod ends It is a direct replacement for the XA rods Will fit any Knuckle Pan or Shovel The XA rod is 030 longer but this presents no problem Late Shovels amp Evos use 82 Rods They are heavier and thicker The front rod is offset directional When assembled the V is more narrow If the V is wide they are assembled wrong When assembled correctly the part number on the front rod is on the right and the part number on the rear rod is on the left 82A Late Has more metal around the small hole amp the oil hole in the
78. move the case race Support the case and press from the inside Turn the case over and do the same from the other side Move the center snap ring to where it doesn t line up with the oil hole Knock out To reinstall make sure the open end of the snap ring lines up with the oil hole 1990 amp Later The race is aluminum Use JIMS tool to remove the snap ring Reinstall in reverse order Make sure the race is against the snap ring Heat the crankcase or you will destroy it Heat case freeze race 36 Reaming The Cam And Pinion Shaft Bushings In The Timing Cover Bushings must be reamed anytime they are replaced and before installing cam seal Necessary equipment Cam Right crankcase JIMS makes a tool so you don t need Cam Bushing Remover Fixed solid fits into camshaft bearing like a cam to insure alignment JIMS Plate Put the reamer into the cam bearing from the gear side Put on the timing cover without the gasket Bolt securely with at least 4 screws Put the JIMS plate on the nosecone so that it can be held in a vise without damaging Put the entire assembly in the vise Ream using cutting oil When the reamer drops through remove it Pinion Bushing Use a different reamer with an adapter that fits in the plug that fits the pinion side main bearing Ream making sure it goes all the way through the bushing Make one turn and pull it out Don t pull backwards To put the seal back in the nos
79. n drill out the jet with the next bigger drill bit Continue to drill bigger one size at a time until the bike stops sneezing The reason is that the CV carb runs leaner Use a pin vise to hold the jet drill bit and use a Mikuni adapter to mount to the manifold Signs that the bike is running lean at low throttle opening Surging sneezing through carb popping running hot running better with the choke out backfire on deceleration cold natured Signs that the bike is running lean at wide open throttle Picks up speed when letting off throttle runs better with choke out runs hot Signs that the bike is running rich at low throttle opening Fouled plugs black smoke starts easy without the choke runs bad when warm 44 Signs that the bike is running rich at wide open throttle Fouled plugs poor gas mileage runs cold Causes of rich condition at Low Throttle Opening Slow jet too big Fuel screw out too far Enrichener not in all the way Float level too high Causes of rich condition at Wide Open Throttle Main jet too big Restricted air filter Partially closed choke Elevation change Causes of lean condition at Low Throttle Opening Air Leak Fuel screw turned in too far Plugged passageways Midrange too small Push rods too tight Retarded timing Causes of lean condition at Wide Open Throttle Main jet clogged or too small Clogged petcock Pinched fuel line Clogged fuel filter F
80. nder compression Remove backing plate Set point gap for 018 Go to back lobe and set for 018 002 Use modified pliers to turn points cam to left full advance Go to opposite side amp check timing mark Should be slightly advanced on front cylinder 33 Dyna S Test light hooked to trigger side of coil front cylinder compression Put timing mark where it needs to be in window hold rotor to left to advance Anywhere from center to back of hole is OK Crane Hi 4 1983 rotor must be used because of VOES To static time red LED lights up TDC compression front cylinder Turn clockwise until LED goes off Anytime there are 2 pickups it s single fire 1 pickup dual fire To bypass VOES set to RACE ONLY Red wire center lug on coil w white wires from orig coil White wire Rear cylinder on coil Black wire Front cylinder on coil Brown Tach Green VOES If not used just tape wire up V Fire Hook up tach must be timed Dynamically Idle 1700 2000 rpm Using inductive timing light clamp on front plug wire amp holding light at angle to avoid glare loosen backing plate and turn until mark is in window 34 Electrics 1965 Ist year of electric start on Big Twin 1967 Ist year of electric start on XL 1981 Sportster got square starter Nippon Denso 1989 Big Twin got square starter Nippon Denso amp inner primary design was changed On 1989 amp up Big Twins Solid mount bikes are rotor frie
81. ndly All rubber mounted bikes are rotor friendly 1988 amp earlier Inner primary had to be removed on solid mount bikes to change rotor Starter Systems Battery is power Starter motor 1 post for wire Starter relay Necessary for stepped down wire size Solenoid 3 posts Longest Battery Next Starter motor Shortest Relay On older bikes pulling out the Bendix energizes the solenoid The copper washer that energizes can weld itself amp keep the starter motor turning if the battery is weak 2 Functions of Solenoid Electrical To connect battery to starter Mechanical To throw Bendix into ring gear 35 Starter Relay has 3 posts Battery Standing voltage Starter Button Message in from the switch Solenoid Message out to Starter 2 Posts on Generator Armature amp Field If battery isn t charging Generator Residual magnetism Test Check battery standing voltage Remove wires from generator Red lead to A post Black lead to Ground At 2000 rpm should have 1 3 VDC If no residual magnetism Add jumper to F post from any ground Run at 2000 rpm Should have 25 30 VDC or until 10 seconds have passed whichever comes first After 10 seconds coil turns to magnet and burns out Polarizing Generator In bike Positive lead to A terminal Flash with jumper from ground to F terminal Out of bike Positive to A terminal Flash F post with ground When rebuilding Generator don t have to polarize unless needed
82. ng on final drive WHP Rear wheel HP 10 15 Parasitic loss depending on final drive Factors that influence parasitic loss Oil viscosity 1 factor Chain or belt tension and gear lash Metal combinations ie mild steel hard steel aluminum Chain avg 98 efficient 9 PL Belt avg 92 efficient 18 PL alignment is critical Shaft avg 84 efficient 26 PL Rod tangency 90 of rod tangency gives the greatest mechanical advantage commonly between 59 and 78 The crank stroke vs rod length 90 delivers the most efficient engine leverage for power production depending on degree of E V O 1 Confirm mechanical condition before dyno testing 2 Confirm electrical system condition before Dyno Testing Coil saturation Rise time and spark timing must all be identical Heat range of plugs determined by ceramic insulator Spark gap tuning Hotter plug develops heat closer to the piston Colder plug develops heat closer to the head If running lean widen the gap If running rich narrow the gap High heat plug throws flame front further away from the cylinder head Low heat plug throws flame front closer to the cylinder head 84 3 Confirm air fuel management No air leaks No fuel leaks or stuck needle valve assembly Uniform fuel height in the float bowl Uniform jetting in the pilot needle and main jets Be consistent with fuel types and fasteners The specific gravity of fuel and compounds
83. o come out to get to lid round starter 1989 amp later Starter doesn t have to be removed square starter 22 2 thing to check Positioning on shift drum 1980 mid 1991 Check for positioning After mid 1991 Not necessary Has dowel pin for neutral indicator instead of casting Must be done in neutral To find neutral look for 3 detents in a row on the shifter drum 1 Neutral 2 Also look for neutral indicator The shift drum is the only thing to shim in 5 speed transmissions and only for positioning and end float Measure with a dial caliper from the edge of the bearing carrier to the center of the shift fork groove resting on top of the edge of the shims but not measuring shim Should be 1 992 to 2 002 To adjust take off the clip amp use variable thickness washers 3 thing to check Shift drum end float 003 to 007 Check between the bearing carrier and the shim Use a variable thickness washer to change the end float There are 3 shifter forks in 5 speed transmissions for each 2 gears All face towards the front a 45 degree angle To disassemble loosen the shifter fork nuts and slide the gears to lock up the transmission To take out shift shaft remove pipe plug on right side NOT pipe plug on the left side 23 Slide the shift shaft out NEVER remove from the left side In 1987 the pipe plug was discontinued The shifter shaft was held in place by a casting on t
84. o move the countershaft Endplay should be 003 012 When assembling the transmission use the thinnest washers to check the play Torque the transmission mounting bolts to 12 14 ft lbs Use Blue Loctite and a star lockwasher 74 Boring Bar Bore Master Made by Precision Mfg in Clearwater FL Apx 3000 Another good brand is Kwik Way but it cost twice as much Bore Master Mdl CT 175 1 75 Shaft quill diameter Use for cylinders up to 4 in diameter there are 3 sizes available To Use Clean the Bore Master table the cylinder registers on the table upside down The cylinder head gasket surface must be clean and flat Use parallel bars on the shovel or ironhead cylinder because of the spigots Lube the machine and the threads of the clamps Use the centering core that comes with the Bore Master It almost centers the cylinder Make sure the clamps are tall enough to do Evo and Twin Cam cylinders with torque plates attached Make sure the clamps don t touch the cylinder sleeve If the clamps won t bear on the cylinder use jack bars for the clamp to bear on Position so that the jack bar is 1 or 2 notches higher on the clamp side than on the cylinder side 2 types of bits both are interchangeable and replaceable The best is solid They have to be replaced or recut When facing the switches the 3 screws on the quill should face you The cutting edge will be on your right
85. o simulate neutral amp get equal space on each side of the shifter forks There are 2 different ones Round w slots Fits drum top 78 amp earlier Square w dowels Fits ratchet top 79 amp later 18 2 thing to check Countershaft End Float Harley Specs 003 012 Check between the variable thickness washer and the end of the countershaft gear Change the end float by different variable thickness washers Never use 2 variable thickness washers Never exceed 100 Finger Rollers Sit on top of shift forks and go into the drum They should be replaced whenever the transmission is worked on Shift Shaft 1975 amp earlier Held in by a set screw on the right side 1976 amp later A retaining clip on the inside keeps the shift shaft from sliding out This shaft will fit earlier transmissions To adjust shifter forks shim one side or the other There are 2 shim thicknesses 007 and 014 Shim the forks so the clutches will have equal engagement Early Shifter Fork Nuts face out 1979 amp later Shifter Fork Nuts face inside Out with old in with new Shifter Forks are NOT identical and will not interchange among different models 1974 amp earlier Transmission Push Rod can be pulled 1975 amp later Pulling the Push Rod will pop off the spring clip on the kicker side 19 Countershaft has 22 bearings on each end for a total of 44 Standard bearing size is 125 Oversize
86. ocket shaft and use to knock the old cam bushing out of the timing cover Use the tool from the backside of the cover to remove the pinion bushing Don t lose the old pins They will be reused The flat on the bushing faces the oil hole To pin use the installation tool The installation tool has a drill guide hole in it Use a 31 drill bit 120 Don t use the old hole The pin is 125 Drill through the guide making sure of the depth Seat the pin flush or just below flush Make sure the oil passage is clean Drill the oil hole if necessary Ream 63 XL Transmissions Must have vents due to created pressure and to prevent leaks 76 Transmission vent is in the primary case like feed check valve in a 1977 XL Also has a hole in the inspection cover of the primary 1977 1980 Vent hole in the left top of the crankcase 1981 Hole in the same place but not threaded 1986 1990 Evo 4 speed Vent close to the same location behind the starter in the center of the crankcase 1991 Present Evo 5 speed Big tube On the mainshaft the first gear has a relief to clear the roll pin From outside in c clip round washer bearing teardrop washer Mainshaft bearing race The washer goes next to the c clip Shifter Pawl Carrier Mechanism Snap Ring Washer Shifter Cam Plate The Shifter Cam Plate has cam slots cut in The function is to tell the shift fork what to do Finger Roller
87. odel M Used on Harleys amp Indians No jets Has holes that dump gas Vertical throttle disc Last yr 1964 Better carb than model DC Model DC Used on Big Twins amp XLs Used on last Panhead 1965 and first 2 3 Shovelhead 1966 Not as good as the Model M Tillotson 1967 1st carb with an accelerator pump 1967 1970 Big Twin 1967 1971 XL XR 1000 had 2 carbs Synchronize with vacuum test No float bowl Diaphragm works on vacuum Wall of Death riders use Do a vacuum test to check the diaphragm Nicknamed Pumper Bendix 1971 1978 1 2 Big Twin 1972 1976 1 2 XL Rubber O ring on the main jet If the O ring is bad or missing the bike will idle but will die upon acceleration Used a leather plunger for an accelerator pump Lube with Vaseline Some plungers are adjustable they have 3 holes instead of 1 to shoot more or less gas The Bendix has a lot of flat spots not a very good carb 41 4 Keihen Fixed Venturi 1976 1 2 1987 XL 3 models 1978 1 2 1989 Big Twin 2 models How To Identify Early model 1976 1 2 1978 1 2 Adjustable fuel screw One choke mechanism Single pull throttle lever 4 midrange holes in straight line Rubber diaphragm No plunger Accelerator pump Mid model 1978 1 2 1982 XL 1978 1 2 1983 Big Twin Non adjustable fuel screw Single pull throttle linkage Double linkage choke with high idle cam 4 midrange holes in diamond
88. on If broken shifter won t return to position 65 Inspect the housing for Cracks Loose cam plate stops tighten rivet heads if loose There were 2 versions of housings Early 1957 1976 Shaft protrudes above housing Late 1977 1990 Shaft doesn t protrude above housing Housings and cam plates don t interchange between early and late The pawl carrier assembly interchanges with any 4 speed XL Shift Forks 4 speed Same part from 1957 1990 9 different lengths Standard is 1 440 from side of pin to side of fork or 005 010 020 and 030 1972 amp earlier steel 1973 amp later brass The letter C on the shift forks designates standard Good aftermarket shift forks can be obtained from V Twin or Custom Chrome ALWAYS MEASURE 3 things to look for with aftermarket shifter forks Flat place on the shaft to clear the countershaft 1 gear If not there the transmission will lock up when assembled Shoulder on the end of the shaft In 3 or 4 gear position the shoulder clears the transmission access door and allows the transmission to clear 4 gear Check the bore for smoothness and ease of movement on the shaft Always replace shifter forks if they are bent or damaged 66 XL Mainshafts Always inspect for wear or damage to the 3 bearing surfaces Early short 1957 1969 Has a hole through the center for the dry clutch release rod
89. ood Requires a clutch spring compressor to disassemble Replacement springs are usually 1 spring instead of the original inner and outer springs The spring plate contains the clutch release bearing If it feels crunchy replace it The inner hub and basket don t usually wear out The inner hub has 2 tapped holes for a harmonic balancer puller The holes are 14 X 20 The clutch basket has a ball bearing that usually needs to be replaced It s held in with a snapring Press the new bearing in with a socket that fits on the outside bearing race The pressure plate is on the bottom If it s damaged or has loose studs replace it Sleeves go over the pressure plate studs and adjust the clutch spring preload Shorter More Longer Less Standard length is 1 525 040 to 080 A big snap ring holds the clutch together When it has notches in it replace it The clutch ends in a half plate The half plate is the last plate in and the first plate out It s function is to hold the clutch together The lined side faces in towards the clutch The steel plates should be checked for warpage damage or funny colors from overheating The holes and slots in the plates are thermal slots Install the sharp edge of the clutch plates in the same direction either all facing in or all facing out Look at the grooves on the friction plates to determine wear Anytime there are problems with the clutch do the clutch adjustment proc
90. osens tighten 120 strokes per minute apx Keep hone snug but not so tight that you can t hang onto the drill To avoid taper alternate cylinder ends after every 25 30 strokes Use Torque Plates with Evo and Twin Cam cylinders Make a plate to use with Shovels etc to enable you to put the cylinder in a vise Don t clamp onto the cylinder base A piece can be fabricated to prevent the hone from going out the opposite end too far Use a 280 320 stone then a 240 ball hone This makes for easier ring seating Faster rotation isn t necessary and only wears out the stones faster Use a slower speed 17 Tappet Blocks Shovelheads 2 styles Mid 50s to 1977 Uses countersunk head screws Usually marked Front or Rear Not interchangeable front to rear Most are cast iron Oil passage feeds oil to the hydraulic lifters Use 1 4 X 24 TPI screws through 1977 1978 to Early 1984 Flat base not countersunk 14 X 20 TPI screws Aftermarket tappet blocks come with 2 sets of screws Tappet blocks wear out If they look bad they are Clearance is 008 max between the tappet and the block Tappets Shovelhead Tappets are directional the flat and the hole face towards each other across the center of the tappet block If installed wrong they won t pump up The roller assembly can be replaced Always inspect tappets If any are bad they can be replaced individually without replacing them all Late 82 Q
91. r Don t let the puller contact the push rod The clutch hub is rebuildable Check the plate on the back for movement it shouldn t move Peen the rivets to tighten The studs can be replaced Look for indentions on the studs Replace if necessary Grease the bearings before reinstalling A new clutch hub costs about 70 2003 Check the Primary Chain tension before installing the Outer Primary Cover 12 Big Twin Wet Clutch 1984 1 1989 A B C Clutch First wet clutch used on Big Twins not very good always breaking These years were the only years for the tapered transmission mainshaft There are 3 settings on the retainer A B amp C The Diaphragm spring should be flat 010 Check with a straight edge and a feeler gauge B is the tightest setting A is medium setting C is the weakest setting Tighten the bolts 4 turn at a time in a cross pattern Start at the A setting Too tight 010 Too loose rocks If it still rocks on all settings add an extra steel clutch plate in the middle of the clutch pack next to another steel plate Start at the A setting then the B setting If it still rocks replace the clutch pack This clutch starts with a steel plate and ends with steel plate Install with the sharp side out Review the rules before working on the clutch Remove the plugs to make it easier to turn the engine over Don t use an impact wrench on the clutch hub nut Remove the compensator nu
92. raeder valve 5 20 psi dressers road kings some FXRs In 1997 dressers got air shocks and heavier springs Changing Fork Oil First step in changing the fork oil on dressers is to relieve the air pressure Drain the fluid from one side amp then pump Repeat procedure on the other side Replace with the same amount of fluid in each side 8mm bolt fits the drain hole threads The ride can be stiffened by adding more fork oil 1949 was the last year of the springer front end 1949 1957 used the Hydra Glide telescopic front end and rigid rear 1958 1964 was the Duo Glide It was the first swingarm and used telescopic front forks with shocks in the rear 1965 Present Electra Glide First year of electric start Telescopic front forks and rear shocks On Softtails extend the shocks to compress The 2 shocks are under the transmission Tire Change Demo Break the bead Use wood block if necessary to keep rotor off floor Wire brush to clean wheel For tube tires use a rim band or duct tape To install tire look for the yellow spot and put it near the valve hole Make sure the arrow on the tire points in the direction of rotation Soap up the tire push over wheel If using a manual tire changer always pull and never push the bar Clutches Rules Before Working on Clutch Disconnect the negative lead of the battery Get maximum freeplay in the cable Try to turn the compensator If it spins without turning
93. reather Gears Knuckles amp early Pans Washer made as part of the gear Late Pans through early 77 Steel endplay washer Straight timing mark Late 77 79 Timing mark in shape of a T with a small center pin T indicates late style tooth shape 1980 E 82 Bigger center pin and the T shape timing mark L82 E86 Plastic 14 slots 2 holes Mid 86 E92 12 slot 2 holes Interchangeable with 14 slot gear L92 to present 12 slot no holes Will only work in umbrella valve engines All can use high quality plastic washers but plastic gear can t use the metal washer The metal gear can use the plastic washer Excessive Breather Gear Endplay causes Overoiling of the bottom end Improper scavenging Oil blowing out of the crankcase vent 16 Cylinder Parallel Hone Also called Rigid Hone Sunnen amp Aamco are 2 manufacturers There are 4 parts to the assembly When they are used or worn out throw them away and replace all 4 parts as an assembly Teeth on the shaft face the center so the pinion gear can drive The assembly consists of 2 stones on 2 sides and 2 guides on 2 sides There is a coarse and a fine adjustment Start at the base of the cylinder Honing is hard on drill motors Use a good one Lube the cylinder with parts cleaner or WD40 Don t use oil Rotate slow and stroke fast This determines the crosshatch 45 60 degrees is desired As the hone lo
94. ring Bar Plug in the machine and hold the switch On the final bore don t run the quill back up Take the cylinder off the machine 76 Piston Fitting Non Evo Anything except Evo Bore to the size of the piston with no clearance or 001 under Then hone the cylinder to size The piston to wall clearance should be 001 003 Usually you must bore 001 002 to get the boring bar marks out You must have the piston that you are going to use in your hand MEASURE CORRECTLY Measure the cylinder at the bottom Deduct the width of the piston The difference is how much to bore Piston Fitting Evo The piston can t be measured Check the chart in the manual for Bore Diameter Specs Dimensions 77 High Lift Cam Cylinder Head Setup To determine you must know Cam lift at the valve Rocker Arm ratio it affects the lift at the valve Valve travel How far the valve moves before anything hits Usually the upper retainer hits the top of the guide To measure valve travel measure from the head to the top of the retainer Using a carb spring push down the valve until something hits The difference is valve travel Take the cam lift at the valve amp add 040 minimum at full length 060 is better To increase valve travel the most common way is to shorten the top of the valve guide When the valve guide is shorter guide life expectancy is shortened but this is usually no big deal If not r
95. s Bearing between shift fork pin and cam slot Clearance between finger rollers and cam plate 003 009 Wear limit 015 Check with a feeler gauge and new finger rollers between the points of the cam plate and the finger rollers If the finger rollers are bad it will start out with hard noisy shifting Then it will jump out of gear Then the finger rollers will break up Then the transmission will come apart and break the case 64 The Cam Plate locates the shift fork The Shift Fork moves the sliding gear The back angle on gear dogs holds the transmission in gear The shift fork gets bent because the transmission jumps out of gear The problem is probably the cam plate and or the sliding gear Bad cam plate symptoms Hard noisy shifting Jumps out of gear Countershaft falls out Always replace whenever inside the transmission Finger rollers Pawl carrier springs Under the cam plate Shifter pawls Shifter pawl spring Shifter pawl carrier Replace the shifter pawl springs when you can see the light through it When it s worn out it won t shift correctly The pawls don t wear out often When they do they wear round on the corners Replace the pawl carrier if it s damaged Don t attempt to repair it The pawl carrier housing contains Pawl carrier springs Cam plate steps Replace pawl carrier springs if bent or if they have shiny flat spots Always replace anytime you re inside the transmissi
96. s 14 ft lbs 14 turns 90 degrees Per Bruce 43 ft Ibs Make sure threads are clean Oil the threads and the washer shoulder of head bolts nuts DO NOT OVER TORQUE If overtorqued studs WILL come out of the cases Replace studs if they have any marks dings etc To remove old studs that are stuck spot heat the case around the stud with a propane torch To install use a 5 16 steel ball as an installation tool Put the ball into the head nut and thread the nut onto the stud Thread the stud into the case DON T BEND Torque to 10 ft Ibs Evo amp Twin Cam Cylinders Both are cast aluminum with cast in liner Cylinders are interchangeable front to rear Mark the cylinder to put back in the same place Twin Cam uses an O ring instead of base gaskets The blue ring on Evo gaskets faces down on base cylinder gaskets All H D cylinders are parallel bored with 280 320 grit stone Then use 240 ball hone Rocker Arms Mirror image Must use 2 of each part number Evos and Twin Cams use the same rocker assembly Rocker Arm ratios 1 43 1 Ironheads amp Shovels 1 6 1 Evos amp Twin Cams Rocker arms wear out mostly on the pad where it contacts the valve stem In Shovels make sure the oil hole in the bushing and the oil hole in the rocker arms are aligned or drill the oil hole out 3 32 Evos amp Twin Cams oil the top end through the pushrods In Shovels oil drains through the push rods Evo amp T
97. se are on the right side of the case VIN number is on the frame and the engine on the right side of the neck HO 1970 H1 1971 H2 1972 through H9 1979 JO 1980 Only year for the letter J The VIN description is found in the Chassis section of the manual In 1981 Harley Davidson started using the 17 digit code 1 HD 1 model engine type factory numbers year where made serial number On the engine is the model engine type year and serial number The 1981 year starts with a B From 1981 and later Harley doesn t use the letters I O U or Q In 1984 the numbers moved back to the left side of the case Sportster numbers were always on the left until 1991 when most changes in Sportsters occurred The timing hole was moved from the left to the right side 5 Speed Transmission Belt Drive Fuji Clutch 1 piece push rod tubes Tappet blocks became part of the case Bigger charging system B 88B Fuel Injection L Big Twin Evo K Shovelhead M 883 Y 88B Carb N 1100 P 1200 H Ironhead R Fuel Injection Evo V Twin Cam Carb W Twin Cam Fuel Injection 1986 1 Evo Sportster 1986 1987 883 or 1100 1988 883 or 1200 883 to 1200 Conversion Bore cylinders 1 2 from 3 to 3 1 2 removes 7 lbs of metal from each cylinder Cut chambers on the head bigger and use Wiseco pistons On rubber mounted bikes the components are hanging For vehicle al
98. sing disc is coming out straight To Disassemble the Clutch Take the nut off the adjusting screw Put large washer on Put nut back on Tighten nut to remove the 3 pressure plate adjusting nuts After the nuts are removed the plate and springs come out as one unit 11 The first plate is a fiber plate All Harleys start with fiber and end with fiber except for the wet clutch found in 1984 1 2 to 1989 models On Dry Clutches always clean the plates for 30 minutes in lacquer thinner Rough the fiber plates with coarse sandpaper Blow off with air Steel plates Install with the sharp edges out Stagger so that the large and small cutouts on the edge are staggered Check for loose pillar blocks in the clutch basket The large gear on the clutch basket is the Ring Gear It is engaged by the Bendix to start the engine All rubber mounted bikes are rotor friendly meaning that the inner primary doesn t have to be removed to remove the stator 1980 Present Solid mounts from 1989 and later FXST The clutch hub has 3 main studs All Clutch Hub nuts have left hand threads except the Sportster DC clutch Clutch hub nuts should have locking tab behind it Put 2 seals in the clutch hub nut even though the manual only shows one Use a puller to get the clutch hub off if the bike is a5 speed If the bike is a4 speed use a jiffy tool a large punch about 8 long threaded on one end Screw it on and hit with a hamme
99. t and the compensator Loosen the primary chain to take the tension out Loosen the clutch adjusting screw Take off the bolts 14 turn at a time in a cross pattern Put in 1 gear hold the brake and use a breaker bar and socket Left hand thread 13 Use a puller and the 4 clutch retainer nuts to attach the puller Remove the clutch basket and the compensator sprocket at the same time Remove the diaphragm spring pressure plate and clutch plates Always lay the clutch plates flat to prevent warpage Inspect the fiber plates for wear check the manual for specs Inspect the steel plates for warpage by holding them together and looking to see if light can be seen between them This clutch has a 3 piece pushrod with a flat spot on the last piece The clutch vents through the flat spot through the main shaft into the transmission and into the atmosphere All transmissions are vented to prevent seals from blowing If it has a gold ring on the back of the hub it is a Zipper ring made by Zipper It is pressed onto the shaft It isn t stock It strengthens the hub The 1984 model gets one ring the 1984A gets a different ring To reassemble Super Glue the key into the mainshaft keyway key should be on top slide the hub on put the nut on put the transmission in first gear with the brake on and torque to 50 60 ft lbs DON T IMPACT BECAUSE IT HAS A TAPERED SHAFT The key doesn t have to be removed unless the Inner Primary
100. t timed Engine doesn t need to be removed from the frame to disassemble Replace the rotors in sets because they are matched Driven by a drive pin in the pump shaft The inner rotor has 2 notches 1 square and 1 round The Square fits the drive pin Check for rotor tip clearance with a 004 feeler gauge Check rotor protrusion of the feed rotors in the lower housing 001 011 For inadequate protrusion replace the lower housing and or rotors No gasket It has an o ring Most protrude above the surface slightly for a good seal The small o ring in the counterbore seals around the feed check The only gasket goes between the pump body and the crankcase The snap ring is special It s round on the outside with ears on the inside The scavenge rotors are much larger than the feed rotors Remove the drive pin and the shaft with gear 1 piece will fall out To remove the feed check valve use a bolt to push it out Don t use a tool so small that it will enter the feed check or it will cause damage Don t disassemble It s only held in with an o ring The arrow points up Oil pressure At idle 7 9 psi normal At 3000 rpm 15 18 psi Check the scavenge rotors for tip clearance To reassemble Put the shaft in the body 56 Put the drive pin in Put the inner rotor in with the square notch over the pin Put on the outer rotor Spin Put the washer with the lip on one side and the notch but no seal
101. tandard thrust washer Overtorque on crankpin nuts 185 210 ft lbs Short crankpin Happens when the taper is down too far or the taper is undersize Most common reasons why flywheels are impossible to align Aligning Flywheels 3 Things That Can Be Wrong Pinched Flywheels are closer opposite the crankpin Bowed Flywheels are further apart opposite the crankpin Misaligned Indicators move together like windshield wipers If it takes a while to true retorque the nut Put indicators as close to the flywheels as possible 31 Removing amp Installing The Pinion Side Main Bearing Race 1976 amp Earlier Set screw in the case must be removed Use a 1 or a 3 Sportster cam in the timing side Support the case and press the XL cam to press the bearing out HEAT FIRST When reinstalling the oil hole in the bearing race must line up with the oil holes in the case Dowels on the case must be supported Seat the race fully making sure that it s seated flush Races are made in standard 002 005 and 010 2 varieties of case races Early 1958 1992 Late 1992 to present Late has holes through it and an oil groove Late works on 1958 present Early only works in the early case The race must be lapped anytime it s replaced because it distorts when pressed 32 How To Determine If The Lower End Is Capable Of Further Service Rod Side Shake not the same as Rod Side Clearance Side s
102. to 250 degrees F before knocking the old valve guide out Install the new guide until it stops Ironhead amp shovelhead guides are shouldered and don t use the same tool to install If the new guide snags when installing remove and go down size The valve guide should be 002 to 004 bigger than the hole that it s going into at room temperature Never change valve guides cold Always heat the head up Valve guides should be marked for size but some aren t If there are grooves in the guide each groove is 001 Too much valve stem to guide clearance causes oil to run into the head The engine will smoke Valve guides wear mostly on bottom or top If the guide is tight in the middle loose on the ends replace the guides Valve guides are Bronze or Cast Iron Valves are either hard chrome carbonized or titanium nitride On pre Evos freeze the guides to help installation When using the valve guide reamer use cutting oil Always use a ball hone on Evo amp Twin Cam engines to finish size the valve guides after reaming Wrist Pin Removal Tool All thread with a nut on the end ground to fit into the wrist pin hole on the piston Put PVC on the other side to avoid damage to the piston Tighten the nut against the PVC to pull the wrist pin out Don t drive it out An arrow on a Piston indicates that it is a directional piston Always mark pistons and reinstall in the same position The arrow always
103. u to zero the degree wheel properly Superflow SF 250 Dyno Most sophisticated Dyno available and the hardest to run The sensor box is the heart and soul It holds all the intelligence gathering devices 6 computers synchronized Eddy brake current 360 Ib 500 HP How much pressure to apply When to apply When to shut off the pressure Weather station processor Air pressure Vapor pressure Humidity Source for correction factors In Sensor Box Keyboard amp Display Remote PC for printing and display Processed 400 times per second Fuel Injection 200 times per second Closest competition is the Land N Sea Dynomometer 86
104. uick fill lifter Identified by heavier spring Interchanges Lifters can be cleaned and tested buy only do 1 at a time Wash out with brake cleaner so it can be shaken and you can hear the check ball Once clean and dry hold it down for 10 seconds It should pop back up but on new lifters it won t Use motor oil or assembly lube when reassembling Don t use metal to push on the check ball Use a plastic straw etc To reassemble push in until the spring clicks and then turn 1 4 turn The lifter function is to maintain zero valve clearance regardless of engine temperature 18 All the lifters can do is get longer or shorter The most common mistake is to adjust the pushrods on 1 cylinder and then turn the engine over and bend valves Always adjust at TDC Adjustment on shovelheads and earlier is Zero lash plus 3 or 4 turns or use the 520 tool Dirt will hold the check ball off the seat causing the lifter to function improperly If lifters aren t working properly Check for oil and pressure Check tappet oil filter screen clean or replace at every oil change Remove lifters for cleaning and inspection Evo Tappet Blocks 3 Varieties of Evo Tappet Blocks Early Cast iron Late 1 Aluminum with an oil passage plug Late 2 Aluminum without an oil passage plug They interchange but not front to rear They must be measured for wear and clearance 004 0045 in Evo Too much clearance causes noise Tappets Two t
105. unning the valve guide seal put a sharp taper on the valve guide for oil deflection If running a valve guide seal add 125 for height of the seal to the length of the guide This is problematic in iron head sportsters but everything else is okay If the valve guide is too short for the seal to seat fully the lower retainer must be machined so that the seal goes down into it some OR In instances where a valve with a long stem is used or the upper retainer is not as deep the clearance is between the upper retainer and the guide seal Don t ever thin out the upper retainer The keepers will pull through Don t use aluminum retainers on the street Spring travel is how far the spring will move from installed height to coil bind To check spring bind take the spring s put in a vise put paper between the coils and tighten the vise until the paper pulls apart Deduct that measurement from the installed height 78 You need as much spring travel as you have valve lift Minimum of 040 060 is better and 080 is better still and has twice the life To get more spring travel cut the spring seat out in the head Kurt isn t fond of this method you can go into the port if not careful Last resort The best method is to call the cam manufacturer s tech dept and order springs from them Check spring travel on each spring and valve 6200 rpm is max on Evo 7000 rpm is max on Twin Cam The 2003 103 Twin Cam engine
106. untershaft Endplay 4 Spd XL Page 74 Cylinder Boring Page 75 Piston Fitting Page 77 Cylinder Head Setup High Lift Cam Page 78 Panheads Page 80 High Performance 45 Flatheads Page 83 Dynamometer Page 84 Superflow SF 250 Dyno Page 86 End Float Swingarms Models Wheels Page 3 VIN 883 Conv Wheel Hub Wheel Seals Anti DIve Fork Oil Tire Change Clutches Dry Clutch BT Wet Clutch XL AC Clutch Fuji Clutch XL DC Clutch 4 Spd Trans 5 Spd Trans Pushrods Lifters Ign amp Timing Batteries Spark Plugs Points Dyna S Crane Hi 4 Electrics Starters Solenoid Starter Relay Generator Armature Testing Field Coil Testing Relays Output Test Regulator Test Milliamp Test Starter Draw Test Carbs Fuel Injection Page 1 Page 1 Page 2 Page 4 Page 6 Page 7 Page 8 Page 8 Page 9 Page 9 Page 10 Page 10 Page 13 Page 15 Page 16 Page 17 Page 18 Page 22 Page 25 Page 25 Page 28 Page 33 Page 33 Page 33 Page 34 Page 34 Page 35 Page 35 Page 35 Page 36 Page 36 Page 37 Page 37 Page 38 Page 39 Page 39 Page 40 Page 40 Page 41 Page 46 Valve Spring Tester Checks for Pressure at Installed Height Measure Valve Spring Free Length off the tips of the spring not right on the tips On the Spring Tester 4 turn 1 64 16 TPI Start with Zero pointing at the 1 mark The clicker goes off at actual height Set for desired height put the spring on and use the torque wrench Whatever the readin
107. w the tool on tight so the threads won t strip out of the case Remove the 6 retainer nuts Back the tool center out Take out the springs and clip Impact off torque on This clutch hub nut has regular threads It is the only clutch hub nut with right hand threads On installation fully tighten the retainer nuts It starts with a fiber plate and ends with a fiber plate The plate that is 1 2 fiber and 2 steel goes in first Remove the clutch basket with the primary chain and the sprocket A small thrust washer should be on the shifter shaft A gasket should be on the foot peg mount shaft 17 4 Speed Transmissions They must come out of the bike to work on 1936 1964 was a kick start total loss system with a tin primary The first 4 speeds had a jockey shift In 1952 the first foot shift was introduced 1978 amp earlier lids are interchangeable Foot shifts could be made jockey shifts and vice versa by changing the lid 1979 1986 Ratchet top 1936 1978 Drum top 4 speed gears left to right are 4 3 2 1 On FLH 1 gear ratio is 3 1 On Superglide 1 gear ratio is 2 45 1 Taller gear Has a groove around center of gear Interchangeable with FLH 2 gear ratio is 1 82 1 3 gear ratio is 1 23 1 Ae gear ratio is 1 1 Andrews makes a 2 44 1 gear 1 and last thing to do when servicing transmission Check Shift Fork Alignment The Shift Fork Alignment Tool must be used The purpose of the tool is t
108. will determine the burn time of the fuel How long and how efficiently the fuel will be able to be burned in the combustion chamber is the burn time Burn time is 15 1 stolki Avg 064 980 Measure in 001 of a second From lean to rich short to long burn time More oxygen Shorter burn time Less oxygen Longer burn time 4 Confirm test conditions Calculate correction factors including atmospheric conditions The bore and flow of the head determine HP The stroke determines TQ Oversquare HP Bore is bigger than stroke Undersquare TQ Stroke is bigger than the bore Other influences Compression Affects HP amp TQ Octane Number at which compressed fuel self detonates Air fuel spark amp free radicals gives greatest amount of power The faster the heat rise the faster power is made BMEP Brake Mean Effective Pressure Measured at the output shaft XIR Oil Additive is the BEST It s a friction eliminator 85 Reasons to change oil Heat shearing of oil acid buildup in oil Rod length and stroke changes the angle of the rod tangency Set exhaust valves by temperature With a degree wheel on the crank set TDC at zero Put a dial indicator on the valve When the indicator comes off zero mark it on the wheel this is the degree that the valve is open Add to zero 180 degrees of closure Add valve close to get the total valve duration Use TDC stop to determine TDC to enable yo
109. win Cam rocker shafts are a piece of drill rod Rocker Arm endplay Evo 003 035 If end play is excessive replace the rocker arm or the carrier Shovels 005 025 Can be repaired Use 7 8 X 45 degree router countersink Bore to get the endplay into spec 010 to 012 is desired Rocker Arm Shafts Shovelheads Early End cap had 2 bearing surfaces Late End cap had 3 bearing surfaces Field expedient repair for a leaky shovel rocker arm shaft Cut a spiral lock in half put on the shaft put an O ring over it and tighten it up On a Shovel put the rocker shaft in first then the o ring then the cap Valves amp Guides Harley used steel guides up to 1979 in Big Twins and up to 1982 in XLs carpenter steel valve guides You can t use steel valve guides anymore due to unleaded gas Bronze and cast iron are used now and require a different valve stem material You must use valves that are Hard Chrome Carbonized a form of case hardening Titanium Nitride coated If hard valve guides are to be used use soft stem valves If hard stem valves are to be used use soft valve guides When inspecting valves check stem condition for wear damage at the keeper grooves Check the valve stem tips 5 major parts of the valve Head Margin Face Neck Stem 2 minor parts of the valve Keeper grooves Stem tip Valve stem should be straight to within 002 H D used valve seals since 1981 Old
110. ypes of tappets Early 84 87 3 dots 120 degrees apart in push rod cup Late L87 Present 2 square dots 180 degrees apart in push rod cup Built in hydraulic unit is not repairable must be replaced Tappets aren t directional in Evos Don t disassemble tappets because Harley Davidson said don t Easily damaged if disassembled 4 Large flat washers 1 under each bottom o ring This is the most commonly lost part Without the washer it will leak 19 Evo Tappet Blocks must be installed with the alignment tool Put the tool in the hole closest to the center of the engine Torque the tool to 30 in Ibs Snug the other screws remove the tool insert the 4 screw torque to 95 120 in Ibs in a cross pattern There are no nuts on the crankpin of the Twin Cam No servicing The entire flywheel assembly must be replaced Evo Pushrods One piece non adjustable Oil hole 4 different lengths color coded don t mix Longest Front exhaust Next longest Rear exhaust Then Front intake Shortest Rear intake Make sure aftermarket Evo amp Twin Cam pushrods have the oil hole If in doubt on adjusting aftermarket pushrods try zero lash 2 turns Coarser threads more adjustment per turn Don t try to straighten bent pushrods Pushrods don t usually wear out but they can Chrome moly is better than aluminum Shovel Pushrods Won t fit Twin Cams or Evos Same parts but different d

Download Pdf Manuals

Related Search

Related Contents

Orion Luft Bedienungsanleitung  Hitachi DV 20VB Drill User Manual  Denon DHT-588BA User's Manual  Samsung S27E310H 簡約至極 用戶手冊  Hotpoint HS2321L refrigerator  SAVE VSR 300/500 User Manual  Stamina Products , Inc Exercise Bike 15-0135 User's Manual  Prova - Calcule Mais  PDF - 1,49 MB  ÉCOLE MANAGEMENT ET SOCIÉTÉ 2015 - 2016 - Ipst-Cnam  

Copyright © All rights reserved. Failed to retrieve file