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 the Motorcycle for Service |
| 2 | Remove seat. | Removing and installing seat |
| 3 | Purge and disconnect fuel supply line. | Fuel line |
| 4 | Remove side covers. | Side covers |
| 5 | Disconnect negative battery cable from frame stud. | Power disconnect |
| 6 | Remove front belt guard. | Belt guards |
| 7 | Remove fuel tank. | Fuel tank |
| 8 | Drain engine oil and discard filter. | Replace engine oil and filter |
| 9 | Disconnect jiffy stand sensor connector. | Jiffy stand sensor |
| 10 | Remove left side rider foot control. | Rider foot controls |
| 11 | Install oil drain plug after oil has drained. | Replace engine oil and filter |
| 12 | Drain cooling system. | Inspect radiator and coolant |
| 13 | Remove engine coolant hoses from engine. | Coolant hoses |
| 14 | Disconnect cooling fan connector. | Removing and installing cooling fan |
| 15 | Remove cooling fan and radiator. | Removing and installing radiator |
| 16 | Remove thermostat housing. | Thermostat housing |
| 17 | Disconnect engine wire harness. | Engine wire harness |
| 18 | Disconnect Vehicle Speed Sensor (VSS) connector. | Vehicle speed sensor (VSS) |
| 19 | Disconnect rear oxygen (02) sensor connector. | Oxygen (O2) sensor |
| 20 | Disconnect neutral indicator switch connector. | Neutral indicator switch |
| 21 | Disconnect oil pressure switch connector. | Oil pressure switch |
| 22 | Disconnect alternator and CKP sensor connectors. | Voltage regulator |
| 23 | Disconnect horn connector. | Removing and installing horn |
| 24 | Remove drive belt. | Drive belt |
| 25 | Remove upper front engine mount. | Front engine mount |
| 26 | Disconnect starter. | Removing and installing starter |
| 27 | Disconnect front oxygen (02) sensor connector. | Oxygen (O2) sensor |
| 28 | Remove right side rider foot control. | Rider foot controls |
| 29 | Remove exhaust system. | Exhaust system |
| 30 | Remove air cleaner assembly. | Exhaust system |
| 31 | Remove induction module asssembly. | Induction module |
| 32 | Disconnect engine to frame ground from engine stud. | Engine wire harness |
| 33 | Disconnect lower clutch cable. | Clutch control |
| 34 | Support engine. | Support engine using FAT JACK (Part No. HD-45968) or similar. |
| 35 | Remove lower front engine mount. | Front engine mount |
| 36 | Remove rear engine mount. | Rear engine mount |
| 37 | Remove engine from chassis. | Tilt top of engine toward the right side. Remove from chassis. |
Install
| PART NUMBER | TOOL NAME |
| HD-45968 | FAT JACK |
Follow all steps listed to install engine in frame. Refer to Table 4-23.
Table 4-23. Install Engine
| STEP NO. | COMPONENT | INSTRUCTIONS |
| 1 | Secure motorcycle on lift. | Motorcycle general maintenance, Secure the Motorcycle for Service |
| 2 | Install engine. | Lift engine as necessary. Install engine from right side. Align in chassis. Support engine using FAT JACK (Part No. HD-45968). |
| 3 | Install rear engine mount. | Rear engine mount |
| 4 | Install lower front engine mount. | Front engine mount |
| 5 | Install upper front engine mount. | Front engine mount |
| 6 | Connect lower clutch cable. | Clutch control |
| 7 | Adjust clutch cable. | Check and adjust clutch |
| 8 | Connect engine to frame ground to engine stud. | Engine wire harness |
| 9 | Install induction module. | Induction module |
| 10 | Install air cleaner assembly. | Air cleaner assembly |
| 11 | Adjust throttle and idle cables. | Check and adjust throttle cables |
| 12 | Connect purge line to induction module. | Induction module |
| 13 | Install exhaust system. | Exhaust system |
| 14 | Install right side rider foot control. | Rider foot controls |
| 15 | Connect front oxygen (02) sensor connector. | Oxygen (O2) sensor |
| 16 | Connect starter. | Removing and installing starter |
| 17 | Install drive belt. | Drive belt |
| 18 | Connect horn connector. | Removing and installing horn |
| 19 | Connect alternator and CKP sensor connectors. | Voltage regulator |
| 20 | Connect oil pressure switch connector. | Oil pressure switch |
| 21 | Connect neutral indicator switch connector. | Neutral indicator switch |
| 22 | Connect rear oxygen (02) sensor connector. | Oxygen (O2) sensor |
| 23 | Connect Vehicle Speed Sensor (VSS) connector. | Vehicle speed sensor (VSS) |
| 24 | Connect engine wire harness. | Engine wire harness |
| 25 | Install thermostat housing. | Rear brake master cylinder |
| 26 | Install cooling fan and radiator. | Removing and installing radiator |
| 27 | Connect cooling fan connector. | Removing and installing cooling fan |
| 28 | Install engine coolant hoses. | Coolant hoses |
| 29 | Fill cooling system with new coolant. | Inspect radiator and coolant |
| 30 | Pressure test cooling system. | Diagnose and test |
| 31 | Install left side rider foot control. | Rider foot controls |
| 32 | Connect jiffy stand switch connector. | Jiffy stand sensor |
| 33 | Install fuel tank. | Fuel tank |
| 34 | Connect fuel supply line. | Fuel line |
| 35 | Install engine oil drain plug. Install new oil filter. Fill engine with new oil. | Replace engine oil and filter |
| 36 | Install front belt guard. | Drive belt |
| 37 | Connect neagtive battery cable. | Power disconnect |
| 38 | Install side covers. | Side covers |
| 39 | Install seat. | Removing and installing seat |
| 40 | Run motorcycle. Perform engine oil level hot check. | Replace engine oil and filter |