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 bushings
Notes:
- Replace the upper connecting rod bushing if the piston pin to rod bushing clearance exceeds 0.002 in (0.051 mm).
- Place clean shop towels in and around the crankcase bore. This prevents prevents chips and shavings from falling into the crankcase.
- If CONNECTING ROD CLAMPING TOOL (Part No. HD-95952-33C) holes are too small, enlarge the holes in the tool.
1. See Figure 3-82. Obtain the CONNECTING ROD CLAMPING TOOL and install as follows:
- a. Slide clamp (2) over connecting rod so that slots engage cylinder head studs. Exercise caution to avoid scratching or bending studs.
- b. With the knurled side up, screw threaded cylinders (1) onto studs to secure position of clamp.
- c. Alternately turn each clamp thumbscrew (3) a few turns to gradually fix position of connecting rod. Turning only one thumbscrew will move rod off-center, while tightening second thumbscrew can cause rod to flex or bend.
![](https://motoinstruction.ru/img/harley/12/117941.jpg)
Figure 3-82. Connecting rod clamping tool (part No. HD-95952-33C): 1. Threaded cylinder (2); 2. Clamp; 3. Thumb screw (2)
2. Install rubber hoses over remaining two cylinder studs.
3. See Figure 3-83. Obtain the CONNECTING ROD BUSHING REMOVER/INSTALLER (Part No. HD-95970-32D).
- a. Sparingly apply graphite lubricant to threads of bolt (6) to prolong service life and provide smooth operation.
- b. Slide receiver cup (5) onto bolt with the closed side facing bolt head.
- c. Insert bolt through upper connecting rod bushing.
![](https://motoinstruction.ru/img/harley/12/117942.jpg)
Figure 3-83. Connecting rod bushing remover/installer (part No. HD-95970-32D): 1. Nut; 2. Flat washer; 3. Bearing; 4. Remover/Installer; 5. Receiver cup; 6. Bolt
4. Remove bushing as follows:
- a. See Figure 3-84. Slide remover side of remover/installer onto bolt. The driver is stamped to verify proper orientation.
- b. See Figure 3-83. Slide bearing (3) and flat washer (2) onto bolt (6) until they contact remover/installer (4).
- c. Thread nut (1) onto bolt until assembly is snug.
- d. Using two box end wrenches, tighten nut on bolt until bushing is free.
- e. Remove nut from bolt. Remove flat washer, bearing and remover/installer. Remove bolt from bushing bore.
- f. Remove bushing from receiver cup and discard.
![](https://motoinstruction.ru/img/harley/12/117943.jpg)
Figure 3-84. Remover stackup. Use remover side of remover/installer
Installing upper connecting rod bushings
1. See Figure 3-83. Obtain the CONNECTING ROD BUSHING REMOVER/INSTALLER (Part No. HD-95970-32D).
- a. Sparingly apply graphite lubricant to threads of bolt (6) to prolong service life and provide smooth operation.
- b. Slide receiver cup (5) onto bolt with the closed side facing bolt head.
- c. Insert bolt through upper connecting rod bushing bore.
- d. See Figure 3-85. Slide new bushing onto bolt. Start bushing into bore. Be sure that bushing is square in bore and not cocked.
- e. Slide installer side of remover/installer onto bolt until shoulder contacts bushing. The remover/installer is stamped to verify proper orientation.
- f. Slide bearing and flat washer onto bolt until they contact remover/installer.
- g. Thread nut onto bolt until assembly is snug.
- h. See Figure 3-86. Using two box end wrenches, tighten nut on bolt until collar on remover/installer bottoms against connecting rod.
![](https://motoinstruction.ru/img/harley/12/117944.jpg)
Figure 3-85. Installer stackup
![](https://motoinstruction.ru/img/harley/12/117945.jpg)
Figure 3-86. Installing new piston pin bushing: 1. Piston bushing tool; 2. Rod clamping fixture
2. Remove nut from bolt and remove flat washer, bearing and remover/installer. Remove bolt from bushing bore, but exercise caution to avoid scratching or gouging bushing.
Note. Leave CONNECTING ROD CLAMPING TOOL installed during bushing reaming procedure which follows.
Reaming upper connecting rod bushings
Note. Sizing bushing with less than 0.00125in (0.0317mm) clearance can result in a bushing loosening and/or seized pin in rod.
1. Clean up and size bushing to 0.0010-0.0005 in (0.0250.013 mm) undersize using the CONNECTING ROD BUSHING REAMER (Part No. HD-94800-26A).
- a. Carefully insert bit of reamer into upper connecting rod bushing. Do not apply lubricant to reamer or bushing. Ream the bushing dry or cut will not be accurate.
- b. Install a 11/16 12-pt socket and T-handle on reamer lug.
- c. Placing thumb on drive socket, apply slight pressure on reamer while rotating handle/drive socket clockwise.
Note. For best results, do not push on reamer or apply pressure to the reamer handle. While excessive pressure results in a rough cut, bushing bore will be tapered if pressure is not centrally applied.
- d. Continue rotating handle/drive socket until entire bit has passed through bushing and shank of reamer rotates freely in the bore.
Note. Never back reamer out of connecting rod or bushing will be damaged.
2. Remove T-handle and socket, and carefully pulling on bit, draw shaft of reamer out of connecting rod bushing.
Note. Abrasive particles can damage machined surfaces and plug oil passageways possibly resulting in engine failure.
3. Using contact cleaner or cleaning solvent, thoroughly wipe upper connecting rod and bushing of any metal shavings or debris.
Note. Leave CONNECTING ROD CLAMPING TOOL installed during bushing honing procedure which follows.
Honing upper connecting rod bushings
1. Obtain the WRIST PIN BUSHING HONE (Part No. HD-35102) and REAMER LUBRICANT (Part No. HD-39964) to hone bushing to final size. Use a liberal amount of honing oil to prevent damage to hone or bushing. Use care to prevent foreign material from falling into the crankcase.
- a. Install hone in a high speed electric drill.
- b. Apply reamer lubricant to finishing stones of hone and inside of upper connecting rod bushing.
- c. Start finishing stones of hone into bushing.
- d. Activating the drill, move the entire length of the finishing stone arrangement forward and backward through the bushing bore for 10 to 12 complete strokes. Work for a crosshatch pattern of approximately 60 degrees.
Note. Abrasive particles can damage machined surfaces and plug oil passageways possibly resulting in engine failure.
2. Using contact cleaner or cleaning solvent, thoroughly wipe upper connecting rod and bushing of any metal shavings or debris. Continue wiping until a clean cloth shows no evidence of dirt or debris.
3. Lightly oil a good piston pin and insert it into the upper connecting rod bushing bore to feel for the proper interference fit. The pin should slide in and out of the bushing without binding, but also without pivoting or rocking.
4. Remove the connecting rod clamping tool.
5. Remove shop towels exercising caution that shavings, chips and other debris do not fall into crankcase.
Repair
If connecting rod is bent, do not attempt to straighten. Flywheel and connecting rod assembly must be replaced. Straightening connecting rods by bending will damage the bearing on the crank pin and the piston pin bushing.