Piston and cylinder
PART NUMBER | TOOL NAME |
HD-34623-C | PISTON PIN LOCKRING REMOVER/INSTALLER |
HD-42322 | PISTON SUPPORT PLATE |
HD-96333-51E | PISTON RING COMPRESSOR |
1. Slide approximately 6.0 in (152 mm) of plastic tubing, rubber hose or conduit over each cylinder stud to protect cylinder studs and piston from damage.
Note. See Figure 3-87. Install XL pistons with the arrow on the top and the side of the piston point toward the front.
![](https://motoinstruction.ru/img/harley/12/117946.jpg)
Figure 3-87. Arrows on piston must point toward front of engine
2. Install piston assembly over connecting rod.
3. Install piston pin.
Note. You may wish to place clean shop towels over cylinder and lifter bores prior to the next step, to prevent the piston pin lock ring from falling into the crankcase.
4. See Figure 3-88. Install new piston pin lock rings with the PISTON PIN LOCK RING REMOVER/INSTALLER (Part No. HD-34623-C). Make sure the ring groove is clean and that the ring is fully seated in the groove with the gap away from the slot at the bottom.
![](https://motoinstruction.ru/img/harley/12/117947.jpg)
Figure 3-88. Installing piston lock rings
Note. Avoid damage to cylinder and piston. Always use new lock ring. Clean lock ring groove and seat lock ring firmly in groove. If it does not, discard the lock ring. Do not install a used lock ring or a new one that has been installed and removed. A loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair.
5. See Figure 3-89. Make sure the piston ring end gaps are properly positioned as shown.
![](https://motoinstruction.ru/img/harley/12/117948.jpg)
Figure 3-89. Position ring end gaps at arrows
6. Lubricate cylinder wall, piston, pin and rod bushing with engine oil.
7. Remove cylinder stud sleeves. Install a new cylinder base gasket. Make sure the piston does not bump the studs or crankcase.
8. See Figure 3-90. Install PISTON SUPPORT PLATE (Part No. HD-42322) as shown. Rotate crankshaft to rest piston on support plate.
![](https://motoinstruction.ru/img/harley/12/117949.jpg)
Figure 3-90. Piston support plate
9. See Figure 3-91. Compress the piston rings using PISTON RING COMPRESSOR (Part No. HD-96333-51E).
![](https://motoinstruction.ru/img/harley/12/117950.jpg)
Figure 3-91. Installing cylinder over piston
10. Gently slide cylinder over cylinder base studs and piston crown, resting it on the top of the ring compressor band as shown.
11. Push the cylinder down with a firm, quick motion until the bottom of the cylinder bore slides below the piston ring area.
12. Remove the piston ring compressor and piston support plate, and push the cylinder all the way down onto the crankcase cylinder deck.
13. Repeat for other piston and cylinder.
Tappet covers, pushrod covers and pushrods
FASTENER | TORQUE VALUE | |
Tappet cover fastener | 90-120 in·lbs | 10.2-13.6 Nm |
1. See Figure 3-93. If anti-rotation devices (10) and tappets (11) have been removed, install the tappets. See 3.22 BOTTOM END OVERHAUL: ASSEMBLY, Tappets.
2. See Figure 3-92. Orient tabs of the front (1) and rear (2) tappet covers to the front and rear cylinders.
![](https://motoinstruction.ru/img/harley/12/117951.jpg)
Figure 3-92. Tappet cover orientation: 1. Front cylinder; 2. Rear cylinder
3. See Figure 3-93. Install tappet covers (7) with new gaskets (8). Secure with screws (5) and washers (6). Tighten to 90-120 in·lbs (10.2-13.6 Nm).
![](https://motoinstruction.ru/img/harley/12/117952.jpg)
Figure 3-93. Middle valve train components: 1. O-ring (4); 2. Pushrod cover (4); 3. O-ring (4); 4. Pushrod (4); 5. Screw (8); 6. Washer (8); 7. Tappet cover (2); 8. Gasket (2); 9. Screw (2); 10. Anti-rotation device (2); 11. Tappet (4); 12. Right crankcase
4. Install new O-rings (3) in recesses in tappet covers. Press pushrod covers (2) into O-rings.
5. Identify pushrod location by its color and length. Refer to Table 3-33.
6. Slide intake and exhaust pushrods (4) down inside pushrod covers until they rest on seat at top of tappet (11).
Table 3-33. Pushrod specifications
POSITION | COLOR BAND | LENGTH | |
in | cm | ||
Intake | Orange | 10.746 | 27.295 |
Exhaust | Purple | 10.800 | 27.432 |
Cylinder head
FASTENER | TORQUE VALUE | |
Cylinder headbolts, 1sttorque | 96-120 in·lbs | 11-14 Nm |
Cylinder headbolts, final torque | 13-15 ft·lbs | 18-20 Nm |
Cylinder headbolts, 1sttorque | 96-120 in·lbs | 11-14 Nm |
Cylinder headbolts, final torque | 13-15 ft·lbs | 18-20 Nm |
Notes:
- Install the pushrod covers and lower cover retainers before installing cylinder heads. See 3.16 TOP END OVERHAUL: ASSEMBLY, Tappet Covers, Pushrod Covers and Pushrods.
- Thoroughly clean and lubricate threads of cylinder head screws before installation. Friction caused by dirt and grime will result in a false torque indication.
1. Coat mating surfaces of cylinder base studs and headbolts with parts cleaning solution.
2. Scrape old oil and any carbon deposits from threads by using a back-and-forth motion, threading each head screw onto its mating cylinder stud.
3. Remove headbolts from studs. Wipe or blow dry thread surfaces.
4. Thoroughly clean and dry gasket surfaces of cylinder and cylinder head.
Note. XR 1200X: See Figure 3-94. The cylinder head gasket has metal patches (2) that must be installed against the cylinder head. When installing the gasket on the cylinder, be sure the words "THIS SIDE UP" (1) and the metal patches (2) are visible.
![](https://motoinstruction.ru/img/harley/12/117953.jpg)
Figure 3-94. Cylinder head gasket: XR 1200X: 1. This side up; 2. Metal patches
5. See Figure 3-95. Install a new head gasket to cylinder.
![](https://motoinstruction.ru/img/harley/12/117954.jpg)
Figure 3-95. Cylinder head installation: 1. Cylinder head; 2. Gasket
6. Carefully lower cylinder head over studs and position on dowels. Use great care so as not to disturb head gasket.
Note. Only oil film must remain on the cylinder head screw surfaces. Too much oil will pool in the head screw sleeve preventing full thread engagement.
7. Lightly coat threads, underside of flange and bottom face of cylinder headbolts in clean Harley-Davidson 20W50 engine oil. Wipe off excess oil.
8. Start cylinder headbolts onto cylinder studs, two short bolts on left side of engine, two long bolts on right. Tighten all bolts only finger-tight at this time.
Note. The procedure for tightening the head screws is critical to proper distribution of pressure over gasket area. It prevents gasket leaks, stud failure and head and cylinder distortion.
9. See Figure 3-96 and Figure 3-97. In sequence, tighten headbolts in the following steps:
- a. Tighten each bolt to 96-120 in·lbs (11-14 Nm).
- b. Tighten each bolt to 13-15 ft·lbs (18-20 Nm).
- c. Loosen all bolts.
![](https://motoinstruction.ru/img/harley/12/117955.jpg)
Figure 3-96. Front cylinder headbolt torque sequence: 1. Short bolt; 2. Short bolt; 3. Long bolt; 4. Long bolt
![](https://motoinstruction.ru/img/harley/12/117956.jpg)
Figure 3-97. Rear cylinder headbolt torque sequence: 1. Short bolt; 2. Short bolt; 3. Long bolt; 4. Long bolt
10. After headbolts are loosened from initial torque, tighten bolts in three stages. Tighten in sequence:
- a. Tighten each bolt to 96-120 in·lbs (11-14 Nm).
- b. Tighten each bolt to 13-15 ft·lbs (18-20 Nm).
- c. See Figure 3-98. Mark cylinder head and headbolt shoulder with a line (1).
- d. Tighten each bolt an additional 85-95 degrees (2).
![](https://motoinstruction.ru/img/harley/12/117957.jpg)
Figure 3-98. Tighten headbolts: 1. Mark; 2. 85-95 degrees
11. XR 1200X: Install Precision Cooling oil lines. See 3.12 PRECISION COOLING SYSTEM: XR 1200X, Cylinder Head Oil Return Lines.
Rocker covers
FASTENER | TORQUE VALUE | |
Rocker cover, inner, large bolt | 18-22 ft·lbs | 24.4-29.8 Nm |
Rocker cover, inner, small bolt | 135-155 in·lbs | 15.3-17.5 Nm |
Rocker cover, inner, screw | 135-155 in·lbs | 15.3-17.5 Nm |
Breather screw: XL Models | 35-55 in·lbs | 4.0-6.2 Nm |
Rocker cover, outer, screw | 120-168 in·lbs | 13.5-19.0 Nm |
Inner cover
1. For each cylinder, rotate crankshaft so that the lifters are on the base circle of the cams.
2. Install new gasket (1) with FRONT HEAD facing up on the front head and REAR HEAD facing up on the rear head.
- a. XL Models: See Figure 3-101.
- b. XR 1200X: See Figure 3-102.
3. Install the inner rocker cover assembly (2) (with rocker arms and shafts). Fit the ends of the pushrods in the rocker arm sockets.
Note. To avoid damage to pushrods or rocker arms, do not rotate crankshaft until both pushrods can be turned with fingers.
4. Install and finger tighten all fasteners (3, 5, 4) one turn at a time.
5. See Figure 3-99. Tighten the fasteners in sequence:
- a. Tighten the four large bolts (1, 2, 3, 4) and then retighten the first fastener (5) to 18-22 ft·lbs (24.4-29.8 Nm).
- b. Tighten the three small bolts (6, 7, 8) to 135-155 in·lbs (15.3-17.5 Nm).
- c. Tighten the two screws (9, 10) to 135-155 in·lbs (15.3-17.5 Nm).
![](https://motoinstruction.ru/img/harley/12/117958.jpg)
Figure 3-99. Inner rocker cover torque sequence
![](https://motoinstruction.ru/img/harley/12/117959.jpg)
Figure 3-100. Outer cover torque sequence
Breather: XL models
1. Identify breather location for front and rear cylinders.
2. See Figure 3-101. Install breather (7) with new breather seal (6).
![](https://motoinstruction.ru/img/harley/12/117960.jpg)
Figure 3-101. Rocker cover: XL models: 1. Gasket; 2. Inner rocker cover; 3. Large bolts (4); 4. Small bolts (3); 5. Screws (2); 6. Breather seal; 7. Breather; 8. Screw; 9. Gasket; 10. Cover gasket; 11. Outer rocker cover; 12. Sealing washer (4); 13. Fastener (4)
3. Install screw (8). Tighten to 35-55 in·lbs (4.0-6.2 Nm).
Breather: XR 1200X
1. See Figure 3-102. Inspect and replace the umbrella check valve (8) if necessary.
![](https://motoinstruction.ru/img/harley/12/117961.jpg)
Figure 3-102. Rocker cover: XR 1200X: 1. Gasket; 2. Inner rocker cover; 3. Large bolts (4); 4. Screws (2); 5. Small bolts (3); 6. O-ring; 7. Breather; 8. Umbrella valve; 9. Gasket; 10. Gasket; 11. Outer rocker cover; 12. Sealing washer (4); 13. Fastener (4)
2. Install a new O-ring (6) on the breather assembly (7).
3. Install breather in cavity.
Outer cover
Notes:
- XL Models: See Figure 3-101.
- XR 1200X: See Figure 3-102.
1. Install new gaskets (9, 10) on the inner rocker cover.
2. Install outer rocker cover (11) on inner rocker cover. Install fasteners (13) with captive washers and new sealing washers (12).
3. See Figure 3-100. Tighten fasteners (1, 2, 3, 4) in sequence and then re-tighten the first fastener (5) to 120168 in·lbs (13.5-19.0 Nm).
Assembling motorcycle after top end repair
FASTENER | TORQUE VALUE | |
Stabilizer link, upper front, frame bracket mounting screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Stabilizer link, lower front, frame bracket mounting screw | 25-35 ft·lbs | 33.9-47.5 Nm |
Fuel tank mounting screw | 15-20 ft·lbs | 20.4-27.1 Nm |
1. See Figure 3-103. Install upper front stabilizer link and frame bracket:
- a. Install upper frame bracket (3) with upper stabilizer link (2), horn bracket (9) (models with front mounted horn), screws (5) and washers (8). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
- b. Install screw (4) securing stabilizer link to engine bracket (1). Tighten to 25-35 ft·lbs (33.9-47.5 Nm).
![](https://motoinstruction.ru/img/harley/12/117962.jpg)
Figure 3-103. Upper front stabilizer link assembly (typical): 1. Engine bracket; 2. Upper stabilizer link; 3. Upper frame bracket; 4. Screw; 5. Screw (2); 6. Screw (2); 7. Lockwasher (2); 8. Washer (2); 9. Horn bracket (models with front mounted horn)
2. Install induction module assembly. See 4.8 INDUCTION MODULE: XL MODELS or4.9 INDUCTION MODULE: XR 1200X.
3. Install the following connectors into the induction module:
- a. TPS [88].
- b. IAC [87].
- c. TMAP sensor [80].
- d. Fuel injector connectors [84], [85].
4. Install air cleaner assembly:
- a. XL Models except XL 1200V: Install backplate, air filter and air cleaner cover. See 4.3 AIR CLEANER ASSEMBLY, XL Models except XL 1200V.
- b. XL 1200V: Install backplate, air filter and air cleaner cover. See 4.3 AIR CLEANER ASSEMBLY, XL 1200V.
- c. XR 1200X: Install air box assembly and connect crankcase vent hoses. See 4.3 AIR CLEANER ASSEMBLY, XR 1200X.
- d. EVAP Controlled Models: Install EVAP purge hose on induction module. See 4.20 EVAPORATIVE EMISSIONS CONTROL.
5. Install horn.
- a. Front Mount: See 6.32 HORN, Replacement: Front Mount.
- b. Side Mount: See 6.32 HORN, Replacement: Side Mount.
Warning! When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
6. Install fuel tank.
- a. Tighten to 15-20 ft·lbs (20.4-27.1 Nm).
- b. Attach quick-connect fitting on fuel line to fuel tank fitting.
- c. Gently tug on quick-connect fitting to verify that it is securely locked in place. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
7. Install exhaust pipes and mufflers. Plug in O2 sensor connectors [137], [138]. See 4.13 EXHAUST SYSTEM: XL MODELS or 4.14 EXHAUST SYSTEM: XR 1200X.
8. Connect spark plug cables to spark plugs.
9. Install main fuse.
Warning! After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
10. Install seat.