| Part No. | Specialty Tool |
| HD-45314 | Crankshaft rotating wrench |
1. Remove airbox assembly. See 1.4 Airbox and air filter.
2. Remove battery. See 1.7 Battery maintenance.
3. See Figure 1-53. Remove fuel lines.
- a. At the fuel rail, disconnect pressure fuel line and return fuel line by pressing blue buttons with thumb and first finger.
- b. Remove fittings at the fuel tank.
- c. Pull fuel lines away from the throttle body.
- d. Remove ground wires.
Figure 1-53. Fuel line
4. Remove front and rear coils. See 1.19 Spark plug/coil.
5. Disconnect idle air control (IAC) connector [87B] from throttle body.
6. Disconnect throttle position (TP) sensor connector [88B] from throttle body.
Figure 9-54. Throttle body electrical connectors: 1. IAC sensor connector [87B]; 2. Idle air control (IAC); 3. Throttle position (TP) sensor connector [88B]; 4. Air intakes (covered)
7. See Figure 1-55. Loosen clamps at each intake and lift throttle body straight up.
Figure 1-55. Intake clamps, throttle body removed
Note. Observe the position of the clamps for reassembly.
8. With throttle cables attached, wrap a shop towel around body for protection and secure away from engine.
9. Cover intake openings to prevent objects from falling into intake bore.
10. See Figure 1-56. Remove ground strap at cam cover.
Figure 1-56. Upper engine: 1. Ground strap; 2. Radiator hose P clamp; 3. Front cylinder breather hose; 4. Rear cylinder breather hose; 5. Cable straps
11. Remove p-clamp (2) retaining radiator hoses.
12. Remove front (3) and rear (4) breather hoses.
13. Remove main harness cable straps (5) along left side of frame.
14. See Figure 1-57. Remove vapor valve from t-stud.
Figure 1-57. Vapor valve
15. Loosen all cam cover fasteners.
Note. There are holes and openings in the frame and battery box area that, with the use of a ball end hex tool, will allow access to the cam cover fasteners. Suggest using Snap-on Tool #FABLM5E.
16. Support motor with jack under oil pan.
17. See Figure 1-58. Loosen front motor mount bolt and retract jack to allow the engine to drop down approximately 13 mm (1/2 in.).
Figure 1-58. Front motor mount bolt
Note. It may be necessary to loosen drive belt, and loosen exhaust at rear support bracket to allow the engine to drop sufficiently.
Caution! Do not allow dowels from cam cover to drop into the engine. If this should occur, they must be retrieved or serious engine damage will result.
18. Remove fasteners from small cam cover. Lift cover to clear dowels and remove from left side.
Note. The VRSCA has been manufactured with and without four cam-cover dowels. Do not drop any dowels into the open cylinder head.
19. Remove all remaining fasteners from cam cover.
20. Gently pry up cover and gasket. Remove cam cover by lifting up and over cam drive sprockets and removing from right side of motorcycle.
Note. It may be necessary to manipulate or move radiator hoses to allow front cam cover removal.
21. Remove spark plugs. See 1.19 Spark plug/coil.
Note. Spark plugs are only removed to allow the engine to be rotated easily. Spark plugs should be re-installed and torqued immediately after lash is set and before assembly begins.
22. Remove alternator derby cover to access 36 mm rotor nut.
Figure 1-59. Correct engine rotation
23. Using CRANKSHAFT ROTATING WRENCH (HD-45314) rotate the engine counter-clockwise (direction of operation) until nose of camshaft intake and exhaust are at the 10 o'clock and 2 o'clock position as shown in Figure 1-60.
- a. When adjusting the front cylinder the cam lobes will be at the base circle position on the tappet as shown in Figure 1-60.
- b. When adjusting the rear cylinder the cam lobes will be at the base circle position on the tappet as shown in Figure 1-61.
Figure 1-60. Front cylinder cam lobe position
Figure 1-61. Rear cylinder cam lobe position
Caution! DO NOT ROTATE ENGINE CLOCKWISE. This is opposite the normal engine operation. Cam chain tension is not maintained and cams can get out of time. Engine damage may result.
24. See Figure 1-62. Use blade style metric feeler gages to measure the gap (lash) between the cam and tappet.
Figure 1-62. Measuring valve lash
Notes:
- An angle blade feeler gage may increase the reliability of the readings.
- A valve lash calculation worksheet is provided in Appendix D to record the valve lash data. Use this sheet to determine the correct shim selection. Incorrect lash adjustment can cause serious engine damage.
25. Copy the D.2 Valve lash calculation worksheet 1.
Table 1-6. Valve lash specifications
| MM | IN. | ||
| Intake | Max | 0.245 | 0.0096 |
| Min | 0.195 | 0.0078 | |
| Exhaust | Max | 0.345 | 0.0135 |
| Min | 0.295 | 0.0117 |
26. Gage the lash for exhaust and intake valves and record selected blade thickness in the "Initial Lash Measurement" column of the valve lash calculation worksheet.
27. Repeat valve lash measurements on other cylinder head and record initial lash measurements.
28. Compare measurements to "Valve Lash Upper Limit" column and "Valve Lash Lower Limit" column. A valve requires lash adjustment if:
- a. Measurement is larger than "Valve Lash Upper Limit".
- b. Measurement is smaller than "Valve Lash Lower Limit".
29. If all valves are within specification, verify cam timing before reassembly. See Verify cam timing in 1.22 Valve lash.
30. If cam timing is correct, install spark plugs, install cam covers and front motor mount according to the instructions in the following procedure. See Lash adjustment in 1.22 Valve lash.
31. If valve lash must be adjusted, verify cam timing before disassembly. See Verify cam timing in 1.22 Valve lash.
Caution! Fasteners or objects dropped into engine during disas-sembly/assembly must be retrieved or severe engine damage will result.