Motorcycle engine repair Harley V-Rod VRSCA (2002-2006)

Engine specifications
Table 3-1. Engine general ITEM DATA Number of cylinders 2 Type 4-cycle, 60°, liquid cooled V-twin Torque (domestic model at crank) 100 Nm (74 ft-lbs) @ 7000 rpm Bore 100 mm (3.94 in.) Stroke 72 mm (2.835 in.) Piston displacement (approx.) 1130 cc...

Service wear limits
Wear limits are given here as a guideline for measuring used engine components. Replace components when they exceed values listed here. Table 3-21. Crankshaft/crankcase ITEM REPLACE IF WEAR EXCEEDS MM IN Main bearing journal 55.940 2.202 Axial end...

Engine torque values
ITEM TORQUE Notes: 5 mm head bolts 9.7 Nm 85 in-lbs page 3-94 Bypass fastener 35 Nm 25 ft-lbs page 3-37 Cam chain tensioner 100 Nm 78 ft-lbs page 3-97, 3-99 Cam cover 9.7 Nm 85 in-lbs page 3-99 Cam journal caps 9.7 Nm 85 in-lbs page 3-35, 3-97, 3-99...

Howto use this section
Top end repair Valve lash adjustment and secondary cam chain adjustment can be done with engine in chassis. Cam drive inspection and some part replacement can be done with the engine in chassis. For all other top end repairs, the engine must be...

Diagnosing valvetrain noise
To diagnose and correct noisy valve train components, use the following procedures: PART NO. SPECIALTY TOOL HD-45334 Secondary chain measurement tool 1. Visually inspect camshaft lobes for abnormal wear. 2. If there is noise and engine has low oil...

Compression test
Satisfactory engine performance depends upon a mechanically sound engine. In many cases, unsatisfactory performance is caused by combustion chamber leakage. A compression test can help determine the source of cylinder leakage. Use CYLINDER...

Cylinder leakage test
The cylinder leakage test will pinpoint engine problems including leaking valves, worn, broken or stuck piston rings and blown head gaskets. The cylinder leakage tester applies compressed air to the cylinder at a controlled pressure and volume and...

Diagnosing smoking engine or high oil consumption
Perform Compression test or Cylinder leakage test as described. If further testing is needed, remove suspect head(s) and inspect for the following: Check prior to cylinder head removal 1. Crankcase overfilled. 2. Oil carryover. 3. Breather hose...

Stripping motorcycle for service
Note. If cylinder head, crankcase, or transmission work needs to be performed, engine must be removed from chassis. See 2.9 Engine replacement . 1. If engine is to be removed, position motorcycle on a lift with side extensions. 2. See Figure 3-7....

Engine cradle and stand
See Figure 3-8. When the engine has been removed from the chassis, use HD-42310 BENCHTOP STAND or HD-43646 ROLLING STAND with HD-42310-40 ENGINE CRADLE. Threaded holes are provided in the upper engine half for attachment to the engine cradle. All...

Throttle body — removal and installation
Removal 1. Disconnect the idle speed control (IAC) connector. 2. Disconnect the throttle position (TP) sensor. 3. See Figure 3-11. Loosen throttle body clamps. Figure 3-11. Loosen throttle body clamps 4. Detach throttle body from rubber seals by...

Cam drive removal
PART NO. SPECIALTY TOOL HD-45314 Crankshaft rotating wrench HD-45653 TDC positioning tool HD-45306 Crankshaft locking pin HD-45491 Tappet compressing tool 1. Remove plug top coils and spark plugs. See 1.19 Spark plug/coil . 2. Remove cam cover. 3....

Cylinder head service — removal and disassembly
If TAPPET COMPRESSING TOOL (HD-45491) is in place from the cam drive removal process, remove it before proceeding. Removing the head with valves extended could result in damage. PART NO. SPECIALTY TOOL HD-39786 Cylinder head holding fixture HD-45333...

Procedure for using the Neway valve seat cutter
PART NO. NEWAY NO. SPECIALTY TOOL HD-45333 Cylinder head holder HD-39786 Cylinder head holding fixture HD-35758-51 6 mm pilot HD-35758-53 203 46731° Exhaust seat cutter HD-35758-54 271 70° Intake seat cutter HD-35758-A 622 46°/31° Intake seat cutter...

Cylinder head — assembly
PART NO. SPECIALTY TOOL HD-45322 Valve guide seal installer HD-34736-B Valve spring compressor 1. Thoroughly clean head before beginning assembly. 2. See Figure 3-61. Insert lower spring collar. Figure 3-61. Lower spring collar 3. Lubricate valve...

Upper and lower crankcase — disassembly
PART NO. SPECIALTY TOOL HD-45304 Alternator stator cover remover/installer tool HD-45340 Gasket alignment dowels HD-45301 Transmission assembly retainer tool 1. Remove inspection cover. Remove the 14 fasteners on the alternator cover. 2. See Figure...

Shift drum removal
PART NO. SPECIALTY TOOL HD-45339 Shift mechanism/detent retractor 1. See Figure 3-124. Remove input shaft bearing retainer to fully expose shifting fork shaft. Figure 3-124. Input shaft bearing retainer 2. See Figure 3-125. Remove neutral switch....

Upper and lower crankcase — assembly
PART NO. SPECIALTY TOOL HD-45339 Shift mechanism/detent retractor HD-45338 Shift lever substitute HD-45301 Transmission assembly retainer HD-45311 Counterbalance alignment pin HD-45316 Crankshaft assembly retainer HD-45306 Crankshaft locking pin...

Counterbalancer bearing replacement — removal and installation
Removal PART NO. SPECIALTY TOOL HD-45311 Counterbalancer alignment pin HD-45490 Balancer bearing remover/installer tools HD-34902 Big-twin mainshaft primary bearing remover and installer HD-95637 Wedge attachment 1. See Figure 3-154. Install...

Crankshaft bearing replacement
General Crankshaft bearings MUST be replaced every time the cases are split for service. If the cam drive is not being serviced, crankshaft bearings can be replaced without removing the cam drive chain. The alternator side and clutch side crankshaft...

Shift shaft and seal — removal and installation
General This procedure is shown with the engine removed. The shift shaft and seal may be replaced without removing the engine from the chassis. Removal Warning! Always wear proper eye protection when installing retaining rings. Use the correct...

Crankshaft, piston and cylinder liner
General Remove cam drive, rotor and cylinder heads. Split crankcases. Remove lower crankcase and set aside. PART NO. SPECIALTY TOOL HD-45316 Crankshaft assembly retainer HD-44358 Flywheel support fixture HD-45313 Cylinder liner remover/installer...

Cam drive — assembly
1. Rotate the front cylinder piston to TDC. Remove plug from timing hole on right side of engine and insert CRANKSHAFT LOCKING PIN (HD-45306).The CRANKSHAFT LOCKING PIN should insert flush with engine case. 2. See Figure 3-236. Insert water pump...

Cylinder heads — installation
Cylinder head removal is part of top end disassembly. See 3.10 Top end disassembly . Clean and examine heads carefully before installation. If heads, values, guides or springs require service, see 3.11 Cylinder head service . If heads have been...

Installing and timing the cams
PART NO. SPECIALTY TOOL HD-45314 Crankshaft rotating wrench HD-45653 TDC positioning tool HD-45306 Crankshaft locking pin HD-45491 Tappet compressing tool 1. Install TDC POSITIONING TOOL (HD-45653) in front spark plug hole. Caution! Never insert a...

Valve tappet shims
Table D-1. Case 1 valve tappet shims Part No. Shim Thickness H-D 18696-01К 1.825 mm H-D 18697-01К 1.850 mm H-D 18698-01К 1.875 mm H-D 18699-01К 1.900 mm H-D 18700-01К 1.925 mm H-D 18701-01К 1.950 mm H-D 18702-01К 1.975 mm H-D 18666-01К 2.000 mm H-D...

Valve lash calculation worksheet 1
V.I.N. Technician Date Intake lash 0.22 mm±0.025 (0.0087 in.±0.00098) Exhaust lash 0.32 mm±0.025 (0.0126 in.±0.00098) Important notes: Valve numbers correspond to the "cast-in " number in the cylinder head casting located at each valve tappet....

Valve lash calculation worksheet 2
VIN Technician Date Intake lash 0.22 mm±0.025 (0.0087 in.±0.00098) Exhaust lash 0.32 mm±0.025 (0.0126 in.±0.00098) Important notes: Valve numbers correspond to the "cast-in" number in the cylinder head casting located at each valve tappet. Always...