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. See Air cleaner assembly.
6. Remove breather hoses. See Breather hoses.
7. Remove induction module. See Induction module.
8. Remove coolant hoses. See Coolant hoses.
9. Remove cylinder head covers. See Cylinder head covers.
10. Remove clutch cover. See Clutch cover.
11. Remove crankshaft gear. See Crankshaft gear.
12. Remove alternator. See Removing and installing alternator.
13. Remove cam sprocket and timing chain. See Camshaft sprocket and timing chain.
14. Remove cylinder head. See Cylinder head covers.
15. Remove chain guides. See Chain guide.
Remove
1. See Figure 4-23. Remove cylinder block assembly.
- a. Remove cylinder block assembly (1) from dowel pins (5).
- b. Discard cylinder gasket (2).
Figure 4-23. Cylinder Block Assembly: 1. Cylinder block assembly; 2. Cylinder gasket; 3. Piston; 4. Piston rings; 5. Dowel pins
Install
1. See Figure 4-23. Install cylinder gasket.
- a. Install new gasket (2) with the small center hole aligned with the oil passage in the crankcase.
2. Verify piston ring alignment. See Removing and installing pistons.
3. Install cylinder block assembly.
- a. Lubricate cylinder liner bore with new engine oil.
- b. Support piston (3).
- c. Slide cylinder block assembly (1) over piston and piston rings (4).
- d. Install cylinder block assembly onto dowel pins (5).
Disassemble
PART NUMBER | TOOL NAME |
HD-51459 | CYLINDER LINER REMOVER AND INSTALLER TC18 |
Note: Mark liner and cylinder before removal to aid placement during installation.
1. See Figure 4-24. Remove cylinder liner.
- a. Use CYLINDER LINER REMOVER AND INSTALLER TC18 (Part No. HD-51459) to remove cylinder liner (1) from cylinder (5).
- b. Discard cylinder liner O-rings (4).
2. Remove coolant sleeve.
- a. Remove screw (8).
- b. Remove coolant sleeve (7).
- c. Discard coolant sleeve O-ring (6).
Figure 4-24. Cylinder Block Assembly: 1. Cylinder liner; 2. О-ring groove (2); 3. Dowel pins (2); 4. Cylinder liner O-ring (2); 5. Cylinder; 6. Coolant sleeve O-ring; 7. Coolant sleeve; 8. Screw
Clean and inspect
1. Clean all parts thoroughly.
2. Inspect cylinder liner for wear. Replace as necessary.
3. Inspect cylinder block for corrosion or cracking. Clean or replace as necessary.
4. Inspect coolant sleeve for corrosion or damage. Replace as necessary.
Assemble
PART NUMBER | TOOL NAME |
HD-51459 | CYLINDER LINER REMOVER AND INSTALLER TC18 |
FASTENER | TORQUE VALUE | |
Coolant sleeve screw | 10.0-12.0 Nm | 89-106 in·lbs |
Notes: Cylinder liners and pistons are supplied as a matched set.
Replace both items.
Front and rear matched pistons and cylinder liners are not interchangeable.
1. See Figure 4-24. Install coolant sleeve.
- a. Install new O-ring (6).
- b. Install coolant sleeve (7).
- c. Install screw (8). Tighten to 10.0-12.0 Nm (89-106 in·lbs).
2. Install cylinder liner.
- a. Lubricate new cylinder liner O-rings (4) with new engine oil.
- b. Install new cylinder liner О-rings to grooves (2) in cylinder liner (1).
Note: Do not damage О-ring when installing liner.
- c. Use CYLINDER LINER REMOVER AND INSTALLER TC18 (Part No. HD-51459) to install cylinder liner in cylinder (5).
- d. Verify that the О-rings are not twisted.
Complete
1. Install chain guides. See Chain guide.
2. Install cylinder head. See Cylinder heads.
3. Install cam sprocket and timing chain. See Camshaft sprocket and timing chain.
4. Install alternator. See Removing and installing alternator.
5. Install crankshaft gear. See Crankshaft gear.
6. Install clutch cover. See Clutch cover.
7. Install cylinder head covers. See Cylinder head covers.
8. Install coolant hoses. See Coolant hoses.
9. Install induction module. See Induction module.
10. Install breather hoses. See Breather hoses.
11. Install air cleaner assembly. See Air cleaner assembly.
12. Install exhaust system. See Exhaust system.
13. Secure rear of fuel tank. See Lift rear of fuel tank.
14. Connect negative battery cable. See Power disconnect.
15. Install front belt guard. See Belt guards.