Motorcycle engine repair Harley Street 750 (2014-2021)
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Fastener torque values
Fastener torque values in this chapter The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Alternator access cover screws 10.0-12.0 Nm 89-106 in·lbs Alternator cover , Assemble Alternator...
Fastener torque values in this chapter The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Alternator access cover screws 10.0-12.0 Nm 89-106 in·lbs Alternator cover , Assemble Alternator...
Specifications of engine
Engine Table 4-1. Engine ITEM XG500 XG750 Number of cylinders 2 Type 4-cycle, SOHC, 60 degree V-Туре, liquid cooled Bore 69 mm 2.72 in 85 mm 3.35 in Stroke 66 mm 2.6 in 66 mm 2.6 in Piston displacement 500 cc 30 in³ 749 cc 46 in³ Engine rev limiter...
Engine Table 4-1. Engine ITEM XG500 XG750 Number of cylinders 2 Type 4-cycle, SOHC, 60 degree V-Туре, liquid cooled Bore 69 mm 2.72 in 85 mm 3.35 in Stroke 66 mm 2.6 in 66 mm 2.6 in Piston displacement 500 cc 30 in³ 749 cc 46 in³ Engine rev limiter...
Engine oil flow
Operation Main Oil Distribution 1. See Figure 4-1. Engine oil flows to: a. Oil pickup (10). b. Oil pump (11). c. Oil filter (9). d. Right main bearing (13), left main bearing (6) and oil passage (7). 2. Oil switch (8) senses oil pressure at oil...
Operation Main Oil Distribution 1. See Figure 4-1. Engine oil flows to: a. Oil pickup (10). b. Oil pump (11). c. Oil filter (9). d. Right main bearing (13), left main bearing (6) and oil passage (7). 2. Oil switch (8) senses oil pressure at oil...
Breather operation
General Operation See Figure 4-2. The crankcase is vented to prevent a buildup of pressure caused by the downward force of the pistons. The breather system sends crankcase vapors, via the timing chain opening (5), to the induction module (1). The...
General Operation See Figure 4-2. The crankcase is vented to prevent a buildup of pressure caused by the downward force of the pistons. The breather system sends crankcase vapors, via the timing chain opening (5), to the induction module (1). The...
Oil pressure
Operation See Figure 4-3. The red OIL PRESSURE indicator lamp illuminates to indicate improper circulation of the engine oil. The indicator illuminates when the ignition is turned on (before the engine is started), but normally extinguishes once the...
Operation See Figure 4-3. The red OIL PRESSURE indicator lamp illuminates to indicate improper circulation of the engine oil. The indicator illuminates when the ignition is turned on (before the engine is started), but normally extinguishes once the...
Troubleshooting of engine
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. Note. Note gauge readings at the end of the...
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. Note. Note gauge readings at the end of the...
Front engine mount
Prepare 1. Remove main fuse. See Power disconnect . 2. Remove exhaust system. See Exhaust system . Remove PART NUMBER TOOL NAME HD-45968 FAT JACK Lower 1. See Figure 4-5. Remove lower front engine mount. a. Support engine (8) using FAT JACK (Part...
Prepare 1. Remove main fuse. See Power disconnect . 2. Remove exhaust system. See Exhaust system . Remove PART NUMBER TOOL NAME HD-45968 FAT JACK Lower 1. See Figure 4-5. Remove lower front engine mount. a. Support engine (8) using FAT JACK (Part...
Rear engine mount
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . Remove 1. See Figure 4-7. Remove rear engine mount. a. Support engine. b. Remove screws (4). c. Remove bolts (5). d. Remove rear...
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . Remove 1. See Figure 4-7. Remove rear engine mount. a. Support engine. b. Remove screws (4). c. Remove bolts (5). d. Remove rear...
Replace engine
Remove PART NUMBER TOOL NAME HD-45968 FAT JACK Follow all steps listed to remove engine from frame. Refer to Table 4-22. Table 4-22. Remove Engine STEP NO. COMPONENT INSTRUCTIONS 1 Secure motorcycle on lift. Motorcycle general maintenance , Secure...
Remove PART NUMBER TOOL NAME HD-45968 FAT JACK Follow all steps listed to remove engine from frame. Refer to Table 4-22. Table 4-22. Remove Engine STEP NO. COMPONENT INSTRUCTIONS 1 Secure motorcycle on lift. Motorcycle general maintenance , Secure...
Rebuild engine
Engine rotation and top dead center (tdc) Engine Rotation Notice: Rotate engine toward front cylinder only. Do not rotate engine toward rear cylinder, as engine damage can result. Cylinder is at TDC when arrow on cam sprocket is perpendicular to...
Engine rotation and top dead center (tdc) Engine Rotation Notice: Rotate engine toward front cylinder only. Do not rotate engine toward rear cylinder, as engine damage can result. Cylinder is at TDC when arrow on cam sprocket is perpendicular to...
Intake adapter
Prepare 1. Remove main fuse. See Power disconnect . 2. Lift rear of fuel tank. See Lift rear of fuel tank . 3. Remove air cleaner assembly. See Air cleaner assembly . 4. Remove breather hoses. See Breather hoses . 5. Remove induction module. See...
Prepare 1. Remove main fuse. See Power disconnect . 2. Lift rear of fuel tank. See Lift rear of fuel tank . 3. Remove air cleaner assembly. See Air cleaner assembly . 4. Remove breather hoses. See Breather hoses . 5. Remove induction module. See...
Cylinder head covers
Prepare 1. Disconnect negative battery cable. See Power disconnect . 2. Lift rear of fuel tank. See Lift rear of fuel tank . 3. Remove breather hoses. See Breather hoses . Remove 1. See Figure 4-9. Remove cylinder head cover. a. Discard fasteners (2...
Prepare 1. Disconnect negative battery cable. See Power disconnect . 2. Lift rear of fuel tank. See Lift rear of fuel tank . 3. Remove breather hoses. See Breather hoses . Remove 1. See Figure 4-9. Remove cylinder head cover. a. Discard fasteners (2...
Camshaft sprocket and timing chain
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Cylinder heads
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Remove fuel tank. See Fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly. See Air cleaner...
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Remove fuel tank. See Fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly. See Air cleaner...
Rocker arms
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Camshaft assembly
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Removing and installing valves
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Chain guide
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Removing and installing cylinders
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Removing and installing pistons
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Lift rear of fuel tank. See Lift rear of fuel tank . 4. Remove exhaust system. See Exhaust system . 5. Remove air cleaner assembly....
Alternator cover
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Disconnect stator and CKP connectors from regulator. See Voltage regulator . Remove 1. See Figure 4-30. Remove alternator cover. a....
Prepare 1. Remove front belt guard. See Belt guards . 2. Disconnect negative battery cable. See Power disconnect . 3. Disconnect stator and CKP connectors from regulator. See Voltage regulator . Remove 1. See Figure 4-30. Remove alternator cover. a....
Clutch cover
Prepare 1. Remove negative battery cable. Power disconnect . 2. Drain engine oil. See Replace engine oil and filter . 3. Remove exhaust. See Exhaust system . 4. Remove right footrest and rear brake pedal assembly. See Rider foot controls . 5. Detach...
Prepare 1. Remove negative battery cable. Power disconnect . 2. Drain engine oil. See Replace engine oil and filter . 3. Remove exhaust. See Exhaust system . 4. Remove right footrest and rear brake pedal assembly. See Rider foot controls . 5. Detach...
Removing and installing balancer
Prepare 1. Remove negative battery cable. See Power disconnect . 2. Remove alternator cover. See Alternator cover . 3. Remove alternator. See Removing and installing alternator . 4. Remove clutch cover. See Clutch cover . Remove 1. See Figure 4-38....
Prepare 1. Remove negative battery cable. See Power disconnect . 2. Remove alternator cover. See Alternator cover . 3. Remove alternator. See Removing and installing alternator . 4. Remove clutch cover. See Clutch cover . Remove 1. See Figure 4-38....
Crankshaft gear
Prepare 1. Remove negative battery cable. See Clutch cover . 2. Remove clutch cover. See Clutch cover . Remove PART NUMBER TOOL NAME HD-51281 LOCKING TOOL 1. Install LOCKING TOOL (Part No. HD-51281). 2. See Figure 4-41. Remove crankshaft gear. a....
Prepare 1. Remove negative battery cable. See Clutch cover . 2. Remove clutch cover. See Clutch cover . Remove PART NUMBER TOOL NAME HD-51281 LOCKING TOOL 1. Install LOCKING TOOL (Part No. HD-51281). 2. See Figure 4-41. Remove crankshaft gear. a....
Starter gear
Prepare 1. Remove alternator cover. See Alternator cover . 2. Remove alternator. See Removing and installing alternator . Remove 1. See Figure 4.43. Remove starter gear (2). 2. Remove shaft (1). Install 1. See Figure 4.43. Install shaft (1). 2....
Prepare 1. Remove alternator cover. See Alternator cover . 2. Remove alternator. See Removing and installing alternator . Remove 1. See Figure 4.43. Remove starter gear (2). 2. Remove shaft (1). Install 1. See Figure 4.43. Install shaft (1). 2....
Oil pump
Prepare 1. Remove exhaust system. See Exhaust system . 2. Remove clutch. See Removing and installing clutch . Remove Oil Pump Note: Oil pressure relief valve is located in oil pump. Oil pressure relief valve is not serviceable. Replace oil pump as...
Prepare 1. Remove exhaust system. See Exhaust system . 2. Remove clutch. See Removing and installing clutch . Remove Oil Pump Note: Oil pressure relief valve is located in oil pump. Oil pressure relief valve is not serviceable. Replace oil pump as...
Oil strainer
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Crankcase assembly
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Main bearings
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Crankcase oil nozzles
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Oil passage plugs
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Crankshaft and connecting rods
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
Prepare 1. Remove engine. See Replace engine . 2. Remove starter. See Removing and installing starter . 3. Remove clutch. See Removing and installing clutch . 4. Remove cylinder head covers. See Cylinder head covers . 5. Remove cylinder heads. See...
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