Engine bottom end overhaul: assembly (Harley Sportster XL1200)

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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 BEARING/SEAL INSTALLATION TOOL
HD-42720-2	CRANKCASE BEARING REMOVER/INSTALLER BASE
J-5586-A	TRANSMISSION SHAFT RETAINING RING PLIERS

FASTENER	TORQUE VALUE
Piston oil jet screw	38-48 in·lbs	4.3-5.4 Nm
Oil deflector plate screw: XR 1200X	38-48 in·lbs	4.3-5.4 Nm
Crankcase fastener	15-19 ft·lbs	20.3-25.8 Nm
Cylinder stud	120-240 in·lbs	13.6-27.1 Nm

Installing piston oil jets

Notes:

• Damaged gaskets will result in either oil leakage or low oil pressure.
• See Figure 3-144. Gasket (4) is part of piston oil jet (2) assembly and is not sold separately.

1. See Figure 3-144. With oil jet pointed upward, install new piston oil jet assemblies (2) with gaskets (4) in right crankcase.

2. Apply LOCTITE 222 LOW STRENGTH THREADLOCKER AND SEALANT (purple) to TORX screws (3) and screws (6).


3. Install TORX screws to secure piston oil jet assembly to crankcase. Tighten to 38-48 in·lbs (4.3-5.4 Nm).

4. XR 1200X: Install oil deflector plate (5) using three screws (6). Tighten to 38-48 in·lbs (4.3-5.4 Nm).

Installing pinion shaft bearings

1. See Figure 3-145. Lubricate pinion shaft and pinion shaft bearing (2) with SCREAMIN' EAGLE ASSEMBLY LUBE.



2. Slip bearing on pinion shaft.

3. See Figure 3-146. Using TRANSMISSION SHAFT RETAINING RING PLIERS (Part No. J-5586-A), install new retaining ring in groove of pinion shaft bearing inner race. Make sure retaining ring is fully seated in groove.

Installing left main bearing

Note. When installing the left main bearing, the bearing presses from the inside of the left crankcase toward the outside. A shoulder is incorporated into the left crankcase which allows the bearing to be installed in one direction only.

1. See Figure 3-147. Using CRANKCASE BEARING REMOVER/INSTALLER (Part No. B-45655) and CRANKCASE BEARING REMOVER/INSTALLER BASE (Part No. HD-42720-2), press left main bearing into the left crankcase.



a. Place support tube (1) on press bed with recessed cup end facing up.

b. With the inboard side of the left crankcase (2) facing upward, position crankshaft bearing bore (3) over support tube.

c. Place left main bearing (4) over bearing bore. Insert pilot/driver (5) through left main bearing, through crankshaft bearing bore and into support tube.

d. Apply pressure with press ram (6) until left main bearing bottoms out in bearing bore.


2. See Figure 3-148. Install new retaining ring from the inside of the left crankcase.

Assembling crankcase halves

1. Install transmission assembly in left crankcase. See 5.14 TRANSMISSION INSTALLATION.

Note. See Figure 3-149. The gear detent assembly Aid is used to move the gear detent lever clear of the shifter drum for assembly.

2. Retract detent assembly in right case half and install GEAR DETENT ASSEMBLY AID (Part No. B-45520) until it bottoms in right case half.

3. Shift transmission to 1st gear.

4. Lubricate left main bearing with SCREAMIN' EAGLE ASSEMBLY LUBE.


5. Assemble crankcase halves together.

• a. See Figure 3-150. Install flywheel assembly in right crankcase. Slide pinion shaft through outer race in right crankcase.
• b. Slide CRANKSHAFT GUIDE TOOL (Part No. HD-42326-B) onto flywheel sprocket shaft.
• c. Apply a thin coat of HARLEY-DAVIDSON HIGH-PERFORMANCE SEALANT - GRAY to crankcase joint faces.
• d. See Figure 3-151. Carefully fit crankcases together.

Note. XR 1200X: See Figure 3-152. Install the double-ended bolt in position 8 to secure the front cylinder head oil return line.

e. Apply a drop of LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (red) to last few threads of each crankcase fastener and install fasteners (thirteen long and four short) in crankcase assembly.

f. In sequence, tighten fasteners to 15-19 ft·lbs (20.325.8 Nm).

6. Remove transmission gear detent assembly aid.

7. See Figure 3-153 and Figure 3-154. Install spacer in ID of new seal. With the open (lipped) side of seal facing outward, center seal/spacer assembly over bearing bore.

Notes:

• Removing spacer after installation requires seal procedure to be repeated.
• The XR 1200X requires the use of the SPROCKET SHAFT ADAPTER (Part No. HD-42579-6).

8. See Figure 3-155. Install bearing seal and spacer.

• a. Center seal/spacer driver (2) over seal, so that the sleeve (smaller O.D.) seats between seal wall and garter spring.
• b. Assemble SPROCKET SHAFT BEARING/SEAL INSTALLATION TOOL (Part No. HD-42579-A) (1) and SPROCKET SHAFT SEAL/SPACER INSTALLER (Part No. B-45676-A) onto sprocket shaft.
• c. Rotate handle clockwise until the spacer makes contact with the bearing. Remove tool from sprocket shaft.

9. Install retaining ring into groove in sprocket shaft bearing bore.

Installing cylinder base studs

See Figure 3-156. If cylinder studs were removed, install them as follows:



1. Pack clean towels into crankcase opening.

2. Place a steel ball into a head screw (1).

3. The cylinder studs (2) have a shoulder (3) at the lower end. Place the end of the studs without the shoulder into the head screw.

4. Install the studs in the crankcase with the shoulder end down. Use an air gun (4) to drive the stud until the shoulder reaches the crankcase.

5. Remove air gun. Use a torque wrench to tighten studs to 120-240 in·lbs (13.6-27.1 Nm).

Cam and pinion gear identification

Note. Prior to changing any cam gears, check gear shaft fit within corresponding bushings. Worn bushings can cause excessive backlash.

See Figure 3-157. Cam lobes are stamped with a number (1, 2, 3, or 4) followed by a letter. The number identifies the cam location/function. The letter identifies the cam lobe profile. Refer to Table 3-42.

Table 3-42. Cam identification

CAM LOCATION	XL	XR
Rear exhaust	1W	1S
Rear intake	2W	2S
Front intake	3W	3S
Front exhaust	4W	4S

Cam gears and gearcase cover: xl models

PART NUMBER	TOOL NAME
HD-43984	CRANKSHAFT LOCKING TOOL

FASTENER	TORQUE VALUE
Pinion shaft locking nut: XR 1200X	19-21 ft·lbs	26-29 Nm
Gearcase cover fastener	90-120 in·lbs	10.2-13.6 Nm

1. See Figure 3-158. Make sure shaft key (1) is installed on flywheel pinion shaft. Install oil pump drive gear (10) and pinion gear (9) on pinion shaft.

Note. See Figure 3-159. Timing mark on pinion gear tooth is aligned with keyway in ID of pinion gear. The timing mark will allow you to easily position pinion gear over shaft key and against oil pump drive gear on pinion shaft.

2. See Figure 3-158. Clean threads on pinion shaft and nut (8). Apply several drops of LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (red) to threads of nut.

Note. When using CRANKSHAFT LOCKING TOOL, do NOT use impact wrench to drive nut onto pinion shaft.

3. See Figure 3-161. Install pinion shaft nut.

• a. Install CRANKSHAFT LOCKING TOOL (Part No. HD-43984) over pinion shaft.
• b. Install nut on pinion shaft.
• c. Tighten to 19-21 ft·lbs (26-29 Nm).
• d. Tighten an additional 15-19 degrees of rotation.
• e. Remove CRANKSHAFT LOCKING TOOL (Part No. HD-43984).

Note. See Figure 3-162. Install rear exhaust and front intake cam gears before rear intake cam gear. This prevents an alignment problem with the pinion gear.

4. Lubricate all cams and all cam bushings in right crankcase with SCREAMIN' EAGLE ASSEMBLY LUBE.

5. See Figure 3-162. Rotate crankshaft until timing mark on pinion gear points exactly at centerline of rear intake cam bushing.

6. See Figure 3-158. Install rear exhaust cam (4). Rotate cam until timing mark (a slot) points exactly at center line of rear intake cam bushing.

7. Install front intake cam (6). Rotate cam until slotted timing mark points exactly at center line of rear intake cam bushing.

Note. See Figure 3-162. "V" marks on rear intake cam are not used for timing of Sportster model engines.

8. See Figure 3-158. Install rear intake cam (5). As you install this cam, rotate it so that the three timing marks (dots) line up exactly with timing marks on the pinion gear, rear exhaust cam and front intake cam.

9. Install front exhaust cam (7). Rotate the cam to line up the timing mark with the timing mark of the front intake cam.

10. See Figure 3-162. Verify timing marks. If necessary, remove a cam, rotate it slightly, and install. If timing marks are off even one tooth, engine will not run correctly.

11. See Figure 3-158. Install a new dry gasket (3) on gearcase cover (2).

12. Lubricate all cam bushings in gearcase cover with SCREAMIN' EAGLE ASSEMBLY LUBE.

13. Install gearcase cover. Secure coverto crankcase with 11 fasteners.

14. See Figure 3-163. Tighten in sequence to 90-120 in·lbs (10.2-13.6 Nm).



15. Gauge cam gear end play. See 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Cam Gear End Play.

Cam gears and gearcase cover: XR 1200X

PART NUMBER	TOOL NAME
HD-43984	CRANKSHAFT LOCKING TOOL

FASTENER	TORQUE VALUE
Pinion shaft locking nut: XR 1200X	19-21 ft·lbs	26-29 Nm
Gearcase cover fastener	90-120 in·lbs	10.2-13.6 Nm
Oil pump rotor cover screw: XR 1200X	90-120 in·lbs	10.2-13.6 Nm
Checkvalve housing fastener: XR 1200X	90-120 in·lbs	10.3-13.6 Nm
Gearcase cover fastener	90-120 in·lbs	10.2-13.6 Nm

1. See Figure 3-164. Make sure t-key (9) is installed on flywheel pinion shaft. Install spacer (6) and pinion gear (5) on pinion shaft.

Note. See Figure 3-165. Timing mark on pinion gear tooth is aligned with keyway in ID of pinion gear. The timing mark will allow you to easily position pinion gear over t-key and against oil pump drive gear on pinion shaft.

2. See Figure 3-164. Clean threads on pinion shaft and nut (4). Apply several drops of LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (red) to threads of nut.

Note. When using CRANKSHAFT LOCKING TOOL, do NOT use impact wrench to drive nut onto pinion shaft.

3. See Figure 3-166. Install CRANKSHAFT LOCKING TOOL (Part No. HD-43984) over pinion shaft. Install nut on pinion shaft. Tighten to 19-21 ft·lbs (26-29 Nm). Then tighten nut 15-19 degrees of rotation. Remove CRANKSHAFT LOCKING TOOL (Part No. HD-43984).

Note. Because of the larger diameter gear on the outboard end of the rear intake cam gear, install the rear exhaust and front intake cam gears before the rear intake cam gear.

4. Lubricate all cams and all cam bores in right crankcase with SCREAMIN' EAGLE ASSEMBLY LUBE.

5. See Figure 3-167. Rotate crankshaft until timing mark on pinion gear points exactly at centerline of rear intake cam bore.



6. Install rear exhaust cam. Rotate cam until timing mark (a slot) points exactly at centerline of rear intake cam bore.

7. Install front intake cam. Rotate cam until slotted timing mark points exactly at centerline of rear intake cam bore.

Note. V marks on rear intake cam are not used for timing of Sportster model engines.

8. Install rear intake cam. Rotate the cam to line up the three timing marks (dots) exactly with timing marks on the pinion gear, rear exhaust cam and front intake cam.

9. Install front exhaust cam. Rotate the cam to line up its timing mark (a dot) with timing mark (dot) of front intake cam.

10. Verify timing marks. If necessary, remove a cam, rotate it slightly and replace it. If timing marks are off even one tooth, engine will not run correctly.

11. Lubricate all cam bores in gearcase cover with engine oil.

12. See Figure 3-168. Install gearcase coverwith new gasket and secure with three fasteners (6). Tighten fasteners to 90-120 in·lbs (10.2-13.6 Nm).



13. Install oil pump rotors. Orient the rotors as removed.

14. Install new O-rings in oil pump cover and install using six fasteners (4). Tighten to 90-120 in·lbs (10.2-13.6 Nm).

15. Install check valve housing using a new base O-ring. Tighten fasteners (3) to 90-120 in·lbs (10.3-13.6 Nm).

16. Connect rigid lines (1) and vent hose (2). See 3.12 PRECISION COOLING SYSTEM: XR 1200X, Oil Pump Lines.

17. See Figure 3-169. Install gearcase and oil pump cover. Secure with 9 socket fasteners. Tighten in the sequence shown to 90-120 in·lbs (10.2-13.6 Nm).



18. Gauge cam gear end play. See 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Cam Gear End Play.

Tappets

FASTENER	TORQUE VALUE
Tappet cover, anti-rotation mounting screw	90-120 in·lbs	10.2-13.6 Nm

See Figure 3-170. The tappet and roller (4), under compression force from valve spring, follow the surface of the revolving cam. The up-and-down motion is transmitted to the valve by the pushrod and rocker arm. The tappet contains a piston (2) and cylinder. The check valve (3) allows the unit to fill with engine oil (1) reducing clearance in the valve train. The unit automatically compensates for heat expansion to maintain minimal clearances between the cam and the pushrod.



It is normal for tappets to click when engine is started after standing for some time. Tappets have a definite leakdown rate which permits the oil in the tappets to escape. This allows units to compensate for various expansion conditions of parts and still maintain minimal clearances. Tappets are functioning properly if they become quiet after a few minutes of engine operation.

Cleaning and inspection

Warning! Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates.

1. Clean all parts, except roller/tappet assembly, in solvent. Blow dry with compressed air.

2. Measure valve tappet OD and crankcase bore ID to calculate clearance. If guide clearance exceeds specification, replace the tappets and/or crankcases. Refer to Table 3-43.

3. Measure tappet roller free play. Recommended service practice is tappet replacement.

4. Measure tappet roller end clearance.

5. Soak tappets in clean engine oil and kept covered until assembly.

6. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to rollers and OD of tappet before installation.

Table 3-43. Valve tappet specifications

ITEM	SERVICE WEAR LIMIT
	in	mm
Tappet clearance in guide	0.0030	0.076
Tappet roller free play (clearance on pin)	0.0015	0.038
Tappet roller end clearance	0.026	0.660

Installation

1. See Figure 3-171. Rotate engine so that both tappets (3) from the cylinder being serviced will be installed on the base circle (lowest position) of the cam.



2. Apply a liberal amount of engine oil to tappet assembly (especially roller needles) for smooth initial operation.

Note. Face the flats of the tappets front and rear when installed in the engine and with the oil feed hole toward the gear cover.

3. Insert the intake and exhaust tappets into the anti-rotation blocks (2).

4. Install anti-rotation blocks with tappets into bore in right crankcase (4). Secure with screw (1). Tighten to 90-120 in·lbs (10.2-13.6 Nm).

Note. The front tappet cover has a tab on the front or right side. The rear tappet cover has a tab on the rear or left side.

5. Install the tappet covers, pushrod covers, and pushrods. See 3.16 TOP END OVERHAUL: ASSEMBLY, Tappet Covers, Pushrod Covers and Pushrods.

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Article about repair motorcycles «Harley Sportster XL1200» (2012-2023): «Engine bottom end overhaul: assembly»: https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113065 <a href="https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113065">Engine bottom end overhaul: assembly</a> - article about repair motorcycles «Harley Sportster XL1200» (2012-2023) from section «Engine repair». [url=https://motoinstruction.ru/en/Harley/Sportster/XL_2012/engine/repair/113065]Engine bottom end overhaul: assembly[/url] - article about repair motorcycles «Harley Sportster XL1200» (2012-2023) from section «Engine repair».