1. | Set motorcycle upright. | |
2. | Disarm security system. | |
3. | Remove seat. | |
4. | Remove main fuse. | |
5. | Remove fuel tank. | |
6. | Twin-Cooled: Drain coolant system. |
1. | Remove air cleaner assembly. | |
2. | Remove exhaust system. | |
3. | Remove induction module. | |
4. | Disconnect harness connections from cylinder head. | |
5. | Remove oil coolant lines and manifolds from engine. | |
6. | Remove rocker covers, rocker arms, pushrods and pushrod tubes. | |
7. | Remove cylinder heads, cylinder and pistons. | |
8. | Remove lifter covers, anti-rotation devices and lifters. | |
9. | Remove cam cover, cam plate and camshaft. | |
10. | Remove oil pump. | |
11. | Remove inner cam bearing. | |
12. | Remove existing clutch spring. |
1. | See Figure 3. Install camshaft needle bearing (4). | |
2. | Install the oil pump (5). See installation requirements. | |
3. | Install camshaft (3). | |
4. | Verify camshaft to crankshaft timing marks are properly aligned. | |
5. | See Figure 2. Install lifters (5), anti-rotation device, lifter cover gaskets (4) and lifter covers. | |
6. | See Figure 1. Install pistons (1) and cylinders (2). Follow instructions provided with piston and cylinder kit. NOTE This kit uses a special head torque sequence. | |
7. | Install cylinder heads using new flange nuts (4). a. Apply engine oil to new cylinder flange nuts only. b. Verify that only bottom of flange nuts receives lubrication. Do not allow lubrication on cylinder stud or internal threads of flange nuts. | |
8. | Torque flange nuts (4). a. Torque. Torque: 27.1–40.6 N·m (20–30 ft-lbs) b. Loosen one turn. Angle: -360° c. Torque. Torque: 12.2–14.9 N·m (9–11 ft-lbs) d. Torque. Torque: 24.2–27.1 N·m (18–20 ft-lbs) e. Final torque, tighten additional 90°. | |
9. | Install pushrod tubes and pushrods. | |
10. | With piston at approximately BDC on power stroke, install rocker arms. Alternately tighten screws to pull rocker shaft down evenly. | |
11. | Install rocker covers onto engine. | |
12. | Install cam cover. a. Verify camshaft to crankshaft timing marks are properly aligned. | |
13. | Install induction module. | |
14. | Connect wire harness connections to engine and induction module. | |
15. | Install manifolds and coolant lines to cylinder heads. | |
16. | Install exhaust system. | |
17. | Install air cleaner assembly. | |
18. | Install new emissions label. a. Locate emissions label on frame tube below the handlebars. b. Place new partial label from kit over top portion of emissions label on frame tube. |
1. | Install fuel tank. | |
2. | Install main fuse. | |
3. | Twin-Cooled: Fill coolant system and purge air per service manual instructions. | |
4. | Install seat. After installing seat, pull up on the seat to verify that it is secure. | |
5. | Recalibrate ECM with proper configuration. |
Item | Description | Quantity | Part Number |
---|---|---|---|
1 | Piston Kit, 119 in³ | 1 | 21900129 |
Piston Kit, 122 in³ | 1 | 21900130 | |
2 | Cylinder Kit (HOG Black) | 1 | 16800330 |
Cylinder Kit (Black Granite) | 1 | 16800331 | |
Cylinder Kit (HOG Black Non-Highlight) | 1 | 16800332 | |
3 | O-ring, Coolant Manifold | 4 | 11900090 |
4 | Flange Nut | 8 | 10200303 |
5 | Exhaust Gasket | 2 | 65324-83B |
Notes:
|
Item | Description | Quantity | Part Number |
---|---|---|---|
1 | O-ring | 4 | 11293 |
2 | O-ring | 4 | 11132A |
3 | O-ring | 4 | 11145A |
4 | Gasket, Lifter Cover | 2 | 25700362 |
5 | Lifter Kit, High Capacity | 1 | 18572-13 |
6 | Gasket, Lower Rocker Cover | 2 | 25700425 |
7 | O-ring, Breather | 2 | 11900116 |
8 | Gasket, Upper Rocker Cover | 2 | 25700372 |
Item | Description | Quantity | Part Number |
---|---|---|---|
1 | Gasket, Cam Cover | 1 | 25700370 |
2 | Camshaft drive sprocket retention kit | 1 | 25566-06 |
3 | Camshaft, SE8-447 | 1 | 25400199 |
4 | Needle bearing, camshaft | 1 | 9215 |
5 | Oil pump assembly (must be purchased separately, if needed) | 1 | 62400247 or 62400248 |
6 | Partial Emissions Tune-up Label (Not Shown) | 1 | Not sold separately |