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 cylinder head gasket surface.
Engine rebuild sequence
| PART NUMBER | TOOL NAME |
| HD-51460 | ENGINE STAND ADAPTER |
Disassemble
Follow all steps listed to disassemble engine before a complete rebuild. Refer to Table 4-24.
Table 4-24. Engine Rebuild Sequence: Disassemble
| STEP NO. | COMPONENT | INSTRUCTIONS |
| Prepare Engine | ||
| 1 | Mount engine in stand. | Use ENGINE STAND ADAPTER (Part No. HD-51460). |
| 2 | Remove spark plugs. | Replace spark plugs |
| 3 | Remove intake adapters. | Intake adapter |
| 4 | Remove cylinder head covers. | Cylinder head covers |
| 5 | Remove starter. | Removing and installing starter |
| 6 | Remove clutch cover. | Clutch cover |
| 7 | Discard oil filter. | Replace engine oil and filter |
| 8 | Remove alternator cover. | Alternator cover |
| Alternator Side | ||
| 9 | Remove alternator rotor and starter ring gear. | Removing and installing alternator. |
| Rear Cylinder | ||
| 10 | Rotate engine to rear cylinder TDC. | Rebuild engine |
| 11 | Remove rear cam sprocket, timing chain and tensioner assembly. | Camshaft sprocket and timing chain |
| 12 | Remove rear cylinder head assembly. | Cylinder heads |
| 13 | Remove rear cylinder assembly. | Removing and installing cylinders |
| 14 | Remove rear piston assembly. | Removing and installing pistons |
| Clutch Side | ||
| 15 | Rotate engine to front cylinder TDC. | Rebuild engine |
| 16 | Remove clutch. | Removing and installing clutch |
| 17 | Remove balancer. | Removing and installing balancer |
| 18 | Remove oil pump. | Oil pump |
| 19 | Remove crankshaft gear. | Crankshaft gear |
| Front Cylinder | ||
| 20 | Remove front cam sprocket, timing chain and tensioner assembly. | Camshaft sprocket and timing chain |
| 21 | Remove front cylinder head assembly. | Cylinder heads |
| 22 | Remove front cylinder assembly. | Removing and installing cylinders |
| 23 | Remove front piston. | Removing and installing pistons |
| Crankcases, Crankshaft and Connecting Rods | ||
| 1 | Remove engine from stand. | |
| 24 | Seperate the crankcase halves. | Crankcase assembly |
| 25 | Mount right crankcase half in stand. | Use ENGINE STAND ADAPTER (Part No. HD-51460). |
| 26 | Remove crankshaft assembly. | Crankshaft and connecting rods |
| 27 | Disassemble connecting rods. | Crankshaft and connecting rods |
| 28 | Remove crankcase oil nozzles. | Crankcase oil nozzles |
| Transmission | ||
| 29 | Remove shift forks and drum from crankcase. | Drum and forks. |
| 30 | Remove transmission from crankcase. | Removing and installing the transmission. |
| 31 | Disassemble transmission gears. | Removing and installing the transmission |
| Transmission Bearings | ||
| 32 | Remove right crankcase bearings. | Transmission right crankcase bearings |
| 33 | Remove left crankcase bearings. | Transmission left crankcase bearings |
| Main Bearings | ||
| 34 | Remove main bearings. | Main bearings |
Assemble
Follow all steps listed to assemble engine after a complete rebuild. Refer to Table 4-25.
Table 4-25. Engine Rebuild Sequence: Assemble
| STEP NO. | COMPONENT | INSTRUCTIONS |
| Prepare Engine | ||
| 1 | Mount right crankcase half in stand. | Use ENGINE STAND ADAPTER (Part No. HD-51460). |
| Main Bearings | ||
| 2 | Install main bearings. | Main bearings |
| Transmission Bearings | ||
| 3 | Install left crankcase bearings. | Transmission left crankcase bearings |
| 4 | Install right crankcase bearings. | Transmission right crankcase bearings |
| Transmission | ||
| 5 | Assemble transmission gears. | Removing and installing the transmission |
| 6 | Install transmission to crankcase. | Removing and installing the transmission. |
| 7 | Install shift forks and drum to crankcase. | Drum and forks. |
| Crankcases, Crankshaft and Connecting Rods | ||
| 8 | Install crankcase oil nozzles. | Crankcase oil nozzles |
| 9 | Assemble connecting rods. | Crankshaft and connecting rods |
| 10 | Install crankshaft assembly. | Crankshaft and connecting rods |
| 12 | Remove engine from stand. | |
| 13 | Join the crankcase halves. | Crankcase assembly |
| 14 | Mount engine in stand. | Use ENGINE STAND ADAPTER (Part No. HD-51460). |
| Rear Cylinder | ||
| 15 | Rotate engine to rear cylinder TDC. | Rebuild engine |
| 16 | Install rear piston assembly. | Rebuild engine |
| 17 | Install rear cylinder assembly. | Removing and installing cylinders |
| 18 | Install rear cylinder head assembly. | Cylinder heads |
| 19 | Install rear cam sprocket, timing chain and tensioner assembly. | Camshaft sprocket and timing chain |
| Clutch Side | ||
| 20 | Install oil pump. | Oil pump |
| 21 | Install crankshaft gear. | Crankshaft gear |
| 22 | Install balancer. | Removing and installing balancer |
| 23 | Install clutch. | Removing and installing clutch |
| Front Cylinder | ||
| 24 | Rotate engine to front cylinder TDC. | Rebuild engine |
| 25 | Install front piston assembly. | Removing and installing pistons |
| 26 | Install front cylinder assembly. | Removing and installing cylinders |
| 27 | Install front cylinder head assembly. | Cylinder heads |
| 28 | Install front cam sprocket, timing chain and tensioner assembly. | Camshaft sprocket and timing chain |
| Alternator Side | ||
| 29 | Install starter ring gear and alternator rotor. | Removing and installing alternator. |
| Finish Assembly | ||
| 30 | Install alternator cover. | Alternator cover |
| 31 | Install output pulley. | Output pulley |
| 32 | Install new oil filter. | Replace engine oil and filter |
| 33 | Install clutch cover. | Clutch cover |
| 34 | Install starter. | Removing and installing starter |
| 35 | Install cylinder head covers. | Cylinder head covers |
| 36 | Install intake adapters. | Intake adapter |
| 37 | Install spark plugs. | Replace spark plugs |
| 38 | Remove engine from stand. | |