Fastener torque values The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE Notes Axle, rear, nut 95-105 ft·lbs 129-142 Nm 3.11 INSTALLING ENGINE IN CHASSIS , Procedure: XL Models Axle, rear, nut 95-105 ft·lbs 129-142 Nm...
Specifications of engine Table 3-1. Engine ITEM XL 883 MODELS XL 1200 MODELS XR1200X Number of cylinders 2 Type 4-cycle, 45 degree, V-twin, air cooled Compression ratio 8.9-1 9.7-1 10.0-1 Bore 3.000 in 76.20 mm 3.500 in 88.90 mm 3.500 in 88.90 mm Stroke 3.812 in 96.82 mm...
Diagnosing valve train noise To diagnose and correct noisy hydraulic lifters and valve train components, use the following procedures: 1. With engine and oil at normal operating temperature, check oil pressure at 2000 rpm. If oil pressure is above 50 psi (345 kPa) or below 5...
Cylinder compression test PART NUMBER TOOL NAME HD-33223-1 CYLINDER COMPRESSION GAUGE Combustion chamber leakage may cause performance issues. A compression test can help determine the source of cylinder leakage. Test engine at normal operating temperature 1. Disconnect...
Cylinder leakage test PART NUMBER TOOL NAME HD-35667-A CYLINDER LEAKDOWN TESTER The cylinder leakage test pinpoints engine problems including leaking valves, worn, damaged or stuck piston rings and blown head gaskets. Use CYLINDER LEAKDOWN TESTER (Part No. HD-35667-A)....
Diagnosing smoking engine or high oil consumption Before removing the cylinder heads, check for compression and cylinder leakage. See 3.5 TROUBLESHOOTING, Compression Test or 3.5 TROUBLESHOOTING, Cylinder Leakage Test . Check prior to cylinder head removal 1. Oil tank overfilled. 2. Oil carryover....
How to use engine repair section Typical symptoms Always use all available symptoms to begin a diagnosis. Symptoms indicating a need for engine repair are often misleading. If more than one symptom is present, possible causes can be narrowed down to make a partial diagnosis. An...
Engine top end service Table 3-24. Engine in chassis SERVICE PROCEDURE COMPONENT REPAIR PROCEDURES Remove parts necessary to gain access to all components above cylinder deck. See 3.13 TOP END OVERHAUL: DISASSEMBLY , Stripping Motorcycle for Top End Repair. Continue with...
Engine bottom end service Table 3-26. Engine in chassis: cam compartment service SERVICE PROCEDURE COMPONENT REPAIR PROCEDURES Remove parts necessary to gain access to all components above cylinder deck. See 3.13 TOP END OVERHAUL: DISASSEMBLY , Stripping Motorcycle for Top...
Removing engine from chassis: XL models PART NUMBER TOOL NAME HD-45967 SHOP DOLLY HD-45968 FAT JACK HD-46284 ENGINE HOOK Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which...
Removing engine from chassis: XR 1200X models PART NUMBER TOOL NAME HD-45967 SHOP DOLLY HD-45968 FAT JACK HD-46284 ENGINE HOOK Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which...
Installing engine in chassis XL models PART NUMBER TOOL NAME HD-45967 SHOP DOLLY HD-45968 FAT JACK HD-46284 ENGINE HOOK FASTENER TORQUE VALUE Isolator mount, front, screw 25-35 ft·lbs 33.9-47.5 Nm Isolator mount, rear, screw 25-35 ft·lbs 33.9-47.5 Nm Fork, rear, pivot/engine mount bolt...
Installing engine in chassis XR 1200X models PART NUMBER TOOL NAME HD-45967 SHOP DOLLY HD-45968 FAT JACK HD-46284 ENGINE HOOK FASTENER TORQUE VALUE Isolator mount, front, screw 25-35 ft·lbs 33.9-47.5 Nm Isolator mount, rear, screw 25-35 ft·lbs 33.9-47.5 Nm Fork, rear, pivot/engine mount bolt...
Engine top end overhaul: disassembly This section describes disassembling the top end of the engine, from the cylinder deck up. To perform a complete top end overhaul, follow all steps listed in this section. Then follow all steps listed in the following sections, including inspection...
Cylinder head — disassembly PART NUMBER TOOL NAME HD-34736-B VALVE SPRING COMPRESSOR 1. See Figure 3-49. Clamp VALVE SPRING COMPRESSOR (Part No. HD-34736-B) in vise and compress valve spring. Figure 3-49. Valve spring compressor 2. See Figure 3-50. Remove valve collar...
Cylinder head — cleaning and inspection PART NUMBER TOOL NAME B-45525 VALVE GUIDE HONE HD-34751 VALVE GUIDE CLEANING BRUSH HD-96796-47 VALVE SPRING TESTER Cylinder heads Warning! Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear...
Cylinder head — replacing rocker arm bushings PART NUMBER TOOL NAME HD-94804-57 ROCKER ARM BUSHING REAMER 1. See Figure 3-58. To replace worn bushings, press or drive them from the rocker arm. If bushing is difficult to remove, turn a 9/16-18 tap into bushing. From opposite side of rocker arm,...
Cylinder head — replacing valve guides PART NUMBER TOOL NAME B-45523 VALVE GUIDE REAMER B-45524 VALVE GUIDE REMOVER/INSTALLER B-45525 VALVE GUIDE HONE HD-34751 VALVE GUIDE CLEANING BRUSH HD-39782-A CYLINDER HEAD SUPPORT STAND HD-39786 CYLINDER HEAD HOLDING FIXTURE HD-39847 REAMER...
Cylinder head — refacing valve seats PART NUMBER TOOL NAME B-35758-52A CUTTER PILOT HD-34751 VALVE GUIDE CLEANING BRUSH HD-35758-C NEWAY VALVE SEAT CUTTER SET HD-39786 CYLINDER HEAD HOLDING FIXTURE Notes: Check that valve stem to valve guide clearance is correct before refacing. Refer...
Cylinder head — assembly PART NUMBER TOOL NAME HD-34736-B VALVE SPRING COMPRESSOR 1. Apply a liberal amount of SCREAMIN' EAGLE ASSEMBLY LUBE to the valve stem. 2. See Figure 3-71. Insert valve (1) into valve guide (3) and bottom valve on valve seat (2). 3. See Figure 3-67....
Cylinder and piston — cleaning, inspection and repair PART NUMBER TOOL NAME HD-33446-86 TORQUE PLATE BOLTS HD-33446-B CYLINDER TORQUE PLATES 1. Soak cylinder and piston in an aluminum-compatible cleaner/solvent until deposits are soft. Clean with a brush. Blow off loosened carbon and dirt particles....
Cylinder and piston — connecting rod bushings PART NUMBER TOOL NAME HD-35102 WRIST PIN BUSHING HONE HD-39964 REAMER LUBRICANT HD-94800-26A CONNECTING ROD BUSHING REAMER HD-95952-33C CONNECTING ROD CLAMPING TOOL HD-95970-32D CONNECTING ROD BUSHING REMOVER/INSTALLER Removing upper connecting rod...
Engine top end overhaul: assembly This section describes assembling the top end of the engine, from the cylinder deck up. If the engine crankcase has been disassembled for repair, it must be assembled before assembling the top end of the engine. See 3.22 BOTTOM END OVERHAUL:...
Engine bottom end overhaul: disassembly This section describes disassembling the bottom end of the engine. If engine overhaul requires disassembly of crankcases, remove engine from vehicle. See 3.10 REMOVING ENGINE FROM CHASSIS. Then disassemble top end of engine. See 3.13 TOP END...
Gearcase: XL models Bushing inspection and removal: XL only PART NUMBER TOOL NAME HD-95760-69A BUSHING AND BEARING PULLER Note. The camshaft and pinion gear shafts are supported by bushings in both the cover and the crankcase. 1. See Figure 3-114. Measure each bushing...
Crankcase — disassembly and assembly When replacing the connecting rod and flywheel assembly, the pinion shaft bearing, or the sprocket shaft bearing, inspect and make repairs to the cylinder heads, the cylinders, the gear case and the transmission. Perform a complete engine overhaul....
Engine bottom end overhaul: assembly Crankcase PART NUMBER TOOL NAME B-45520 GEAR DETENT ASSEMBLY AID B-45655 CRANKCASE BEARING REMOVER/INSTALLER B-45676-A SPROCKET SHAFT SEAL/SPACER INSTALLER HD-42326-B CRANKSHAFT GUIDE TOOL HD-42579-6 SPROCKET SHAFT ADAPTER HD-42579-A SPROCKET SHAFT...