Engine specifications (Harley-Davidson V-Rod, 2002-2006) [Engine and systems: Engine repair]

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 (69 cubic in.)
Max. sustained engine speed	9000 rpm
Idle speed	1200 rpm±50
Engine & transmission weight	89.4 kg (197 lbs)

Table 3-2. Oil pump

ITEM	DATA
Type	Gerotor, internal oil pump, wet sump
Pressure	3-6.5 bar (43-94 psi) at 3000 rpm and normal operating temperature of 70°C (158°F)
Filtration	10 micron media between pump & engine

Table 3-3. Water pump

ITEM	DATA
Type	Impeller type, thermostat controlled bypass

Table 3-4. Valve diameters

ITEM	MM	IN
Intake	40.0	1.575
Exhaust	34.5	1.358

Table 3-5. Valve lash

ITEM		MM	IN
Intake	Max	0.245	0.0096
Intake	Min	0.195	0.0078
Exhaust	Max	0.345	0.0135
Exhaust	Min	0.295	0.0117

Table 3-6. Cylinder heads

ITEM	MM	IN
Valve guide in head (tight)	Max 0.051	0.002
Valve guide in head (tight)	Min 0.022	0.0009
Valve seat in head (tight)	Max 0.100	0.0039
Valve seat in head (tight)	Min 0.059	0.002
Head gasket surface (flatness)	0.020	0.0008
Valve-to-guide running clearance - intake	Max 0.0585	0.0023
Valve-to-guide running clearance - intake	Min 0.0285	0.0011
Valve-to-guide running clearance - exhaust	Max 0.0685	0.0026
Valve-to-guide running clearance - exhaust	Min 0.0385	0.0015
Valve guide I.D.	Max 6.015	0.2368
Valve guide I.D.	Min 6.000	0.2362
Valve stem diameter	Intake
	Max 5.9715	0.2351
	Min 5.9565	0.2345
	Exhaust
	Max 5.9615	0.2347
	Min 5.9465	0.2341
Valve to guide running clearance	Intake
	Max 0.0585	0.0023
	Min 0.0285	0.0011
	Exhaust
	Max 0.0685	0.0027
	Min 0.0385	0.0015
Valve seat to cylinder head press	Max 0.0100	0.0004
Valve seat to cylinder head press	Min 0.0590	0.0023
Valve seat run-out	Max 0.0050	0.0002
Valve seat to guide run-out	Max 0.0200	0.0008
Valve spring free length	Outer
	Max 45.630	1.797
	Inner
	Max 43.770	1.723
Valve spring installed height	Outer
	Max 39.000	1.535
	Inner
	Max 37.000	1.457
Cylinder head flatness	Max 0.0200	0.0008

Table 3-11. Cylinder heads (continued)

ITEM	KG	LB
Spring force installed	Outer @ 39 mm (1.535 in.) max
	Max 20.80	45.86
	Min 18.97	41.88
	Inner @37 mm (1.457 in.) max
	Max 11.31	24.95
	Min 10.10	22.26
Maximally compressed (intake and exhaust)	Outer
	Max 66.58	146.80
	Min 60.87	134.22
	Inner
	Max 34.15	75.31
	Min 31.10	68.57

Table 3-12. Cam drive

Chain guide wear	Pittings to be smaller than 16 mm in length, Maximum depth of tensioner show wear 0.8 mm.
Sprocket wear	Visual check, no pittings allowed lateral wear caused by chain is allowed

Table 3-13. Cam timing

Intake	106±1°
Exhaust	105±1°
Total intake lift	10.9 mm (0.4291 in.)
Duration intake @1 mm	248°
Total exhaust Lift	9.98 mm (0.3929 in.)
Duration exhaust @ 1 mm	206°

Table 3-14. Piston ring gap

ITEM	MM	IN
Top ring gap	Max 0.550	0.022
Top ring gap	Min 0.350	0.014
2nd ring gap	Max 0.600	0.024
2nd ring gap	Min 0.400	0.016
Oil control ring gap	Max 0.890	0.035
Oil control ring gap	Min 0.380	0.015
Top ring side clearance	Max 0.075	0.003
Top ring side clearance	Min 0.020	0.001
2nd ring side clearance	Max 0.055	0.002
2nd ring side clearance	Min 0.010	0.000

Table 3-15. Connecting rod/piston

ITEM	MM	IN
Rod small end bore dia.	Max 22.028	0.8672
Rod small end bore dia.	Min 22.018	0.8669
Piston pin diameter	Max 22.000	0.8661
Piston pin diameter	Min 21.995	0.8659
Running clearance	Max 0.033	0.0013
Running clearance	Min 0.018	0.0007

Table 3-16. Connecting rod journals

ITEM	MM	IN
Rod bearing journal	Red
	Max 47.991	1.8894
	Min 47.983	1.8891
	Blue
	Max 47.983	1.8891
	Min 47.975	1.8888
Rod bearing bore with-out bearing	Max 51.616	2.0321
Rod bearing bore with-out bearing	Min 51.600	2.0315
Rod bearing bore with bearing	Red
	Max 48.052	1.8918
	Min 48.020	1.8906
	Blue
	Max 48.044	1.8915
	Min 48.012	1.890
Running clearance	Max 0.069	0.0027
Running clearance	Min 0.029	0.0011
Axial ground play	Max 0.290	0.0114
Axial ground play	Min 0.140	0.0055

Table 3-17. Balance shaft/crankcase

ITEM	MM	IN
Balance shaft journal	Max 17.012	0.6698
Balance shaft journal	Min 17.001	0.6693
Press fit inner race to journal	Max -0.020	-0.0008
Press fit inner race to journal	Min -0.001	-0.0000
Crankcase balance shaft bearing bore	Max 39.971	1.5737
Crankcase balance shaft bearing bore	Min 39.955	1.5730
Bearing outer race to bearing bore press fit	Max -0.045	-0.0018
Bearing outer race to bearing bore press fit	Min -0.018	-0.0007

Table 3-18. Crankcase/cylinder liner

ITEM	MM	IN
Cylinder liner cover over stand	Max 0.130	0.0051
Cylinder liner cover over stand	Min 0.090	0.0035
Cylinder head deck flat-ness	Max 0.020	0.0008
Cylinder head deck flat-ness	Min 0.000	0.0000

Table 3-19. Piston/cylinder liner

ITEM		MM	IN
Cylinder liner I.D. out of round installed		Max 0.020	0.0008
Piston major diameter
Class I		Max 99.953	3.9352
		Min 99.949	3.9350
Class X		Max 99.961	3.9355
		Min 99.953	3.9352
Class II		Max 99.965	3.9365
		Min 99.961	3.9355
Running Clearance
Class cylinder liner	Class piston
I	X	Max 0.047	0.0019
		Min 0.026	0.0010
II	X	Max 0.060	0.0024
		Min 0.039	0.0015
I	I	Max 0.051	0.0020
		Min 0.034	0.0013
II	II	Max 0.052	0.0020
		Min 0.035	0.0014

Table 3-20. Crankshaft/crankcase

ITEM	ALTERNATOR SIDE		CLUTCH SIDE
ITEM	MM	IN	MM	IN
Main bearing journal	Blue
	Max 55.977	2.20382	Max 55.952	2.20283
	Min 55.971	2.20358	Min 55.946	2.20260
	Green
	Max 55.984	2.20409	Max 55.959	2.20311
	Min 55.977	2.20382	Min 55.952	2.20283
	Red
	Max 55.990	2.20433	Max 55.965	2.20334
	Min 55.984	2.20410	Min 55.959	2.20312
Main bearing bore	Max 61.019	2.40232
Main bearing bore	Min 61.000	2.40158
Running clearance	Blue
	Max 0.059	0.00232	Max 0.059	0.00232
	Min 0.026	0.00103	Min 0.026	0.00103
	Green
	Max 0.061	0.00240	Max 0.061	0.00240
	Min 0.027	0.00107	Min 0.027	0.00107
	Red
	Max 0.062	0.00244	Max 0.062	0.00244
	Min 0.029	0.00115	Min 0.029	0.00115
Axial end play	Max 0.060	0.00236
Axial end play	Min 0.050	0.00197

Engine specifications (Harley V-Rod VRSCA)

Table 3-1. Engine general

Table 3-2. Oil pump

Table 3-3. Water pump

Table 3-4. Valve diameters

Table 3-5. Valve lash

Table 3-6. Cylinder heads

Table 3-11. Cylinder heads (continued)

Table 3-12. Cam drive

Table 3-13. Cam timing

Table 3-14. Piston ring gap

Table 3-15. Connecting rod/piston

Table 3-16. Connecting rod journals

Table 3-17. Balance shaft/crankcase

Table 3-18. Crankcase/cylinder liner

Table 3-19. Piston/cylinder liner

Table 3-20. Crankshaft/crankcase