Adjustment

PART NO.

SPECIALTY TOOL

HD-45314

Crankshaft rotating wrench

HD-45334

Secondary cam chain measurement tool

1. Support engine with a scissors jack under the frame at the fuel tank.

2. Remove the right side cover and maxi-fuse. See 8.5 MAXI-FUSE.

3. Unlock and open seat.

4. Remove airbox cover. See 1.4 AIRBOX AND AIR FILTER.

AwARNING

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

5. Disconnect negative battery cable.

6. Remove air filter top and air filter. See 1.4 AIRBOX AND AIR FILTER.

7. Remove the horn. See 8.20 HORN.

8. Remove the derby cover from the left side crankcase cover.

CAUTION

Turn the engine crankshaft counterclockwise only. Turning it clockwise could cause the cam chain to jump over the cam sprocket.

9. To position the front piston to adjust the secondary cam chain:

a. See Figure 1-82. Install CRANKSHAFT ROTATING WRENCH (HD-45314).

b. Hold the throttle wide open and watch front cylinder intake valve through intake port.

c. Turn crankshaft counterclockwise to open valve fully and then to close the valve.

d. When the front cylinder intake valve is seated, turn crankshaft an additional 1/4 turn (90°) clockwise (CW).

Figure 1-82. Positioning Piston

CAUTION

Never rotate the engine without the secondary cam chain tensioner installed. Cam timing could be changed, causing engine damage.

NOTE

Do not use the sealing washer from the secondary cam chain tensioner when installing the SECONDARY CAM CHAIN MEASUREMENT TOOL (HD-45334).

10. Remove the secondary cam chain tensioner.

11. See Figure 1-83. install SECONDARY CHAM CHAIN MEASUREMENT TOOL. Thread-in the tool until it is seated against the cylinder head.

12. Note the number of grooves showing on the tool.

13. Remove the SECONDARY CAM CHAIN MEASUREMENT TOOL.

14. From the table, select the number of shims necessary for correct secondary cam chain tension. See Table 1-7.

Table 1-7. Tensioner Shims

Grooves

Shims Required

4

1*

3

2*

2

3

1

4

* Do not add shims if start-up rattle is not heard.

NOTE

If a start-up rattle was noticed, 1 or 2 shims are added to the tensioner. If there was no start-up rattle, do not add 1 or 2

shims to the tensioner.

15. See Figure 1-84. Wrap cardboard or heavy cloth around thick shaft on plunger (1). Gently twist while pulling to remove plunger (1) from tensioner (3).

16. Apply a thin film of Harley-Davidson Motorcycle Oil 20W50 to selected shims (2) and plunger (1).

17. Seat number of selected shims (2) and plunger (1) in tensioner (3).

18. Lubricate tensioner seal (4) with Harley-Davidson Motorcycle Oil 20W50.

19. Install front cylinder secondary cam chain tensioner. Tighten to 100 Nm (74 ft-lbs).

CAUTION

Turn the engine crankshaft counterclockwise only. Turning it clockwise could cause the cam chain to jump over the cam sprocket.

20. To position rear cylinder to adjust secondary cam chain:

a. See Figure 1-82. Install CRANKSHAFT ROTATING WRENCH (HD-45314).

b. Hold throttle wide open and watch rear cylinder intake valve through intake port.

c. Turn crankshaft counterclockwise to open valve fully and then close intake valve.

Installed in Front Cylinder

¡04412

1. Plunger

2. Shims (as required)

3. Secondary cam chain tensioner

4. Seal

Figure 1-84. Secondary Cam Chain Tensioner

21. When rear cylinder intake valve is seated, turn crankshaft an additional 1/4 turn (90°) clockwise (CW).

NOTE

Do not use the sealing washer from the secondary cam chain tensioner when installing the SECONDARY CAM CHAIN MEASUREMENT TOOL (HD-45334).

22. See Figure 1-83. Remove rear cylinder secondary cam chain tensioner and install SECONDARY CHAM CHAIN MEASUREMENT TOOL Thread-in the tool until it is seated against cylinder head.

23. Note the number of grooves showing on tool.

24. Remove SECONDARY CAM CHAIN MEASUREMENT TOOL.

25. See Table 1-7. From the table, select the number of shims necessary for correct secondary cam chain tension.

NOTE

If a start-up rattle was noticed, 1 or 2 shims are added to the tensioner. If there was no start-up rattle, do not add 1 or 2 shims to the tensioner.

26. See Figure 1-84. Wrap cardboard or heavy cloth around thick shaft on plunger (1). Gently twist while pulling to remove plunger (1) from tensioner (3).

27. Apply a thin film of Harley-Davidson Motorcycle Oil 20W50 to selected shims (2) and plunger (1).

28. Seat number of selected shims (2) and plunger (1) in tensioner (3).

29. Lubricate tensioner seal (4) with Harley-Davidson Motorcycle Oil 20W50.

30. Install rear cylinder secondary cam chain tensioner. Tighten to 100 Nm (74 ft-lbs).

31. Install the horn. See 8.20 HORN.

32. Connect negative battery cable.

33. Install air filter and air filter top. See 1.4 AIRBOX AND AIR FILTER.

34. Install airbox cover.

35. Install the right side cover and maxi-fuse.

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

Don't pay hundreds of dollars to find out what is wrong with your car. This book is dedicated to helping the do it yourself home and independent technician understand and use OBD-II technology to diagnose and repair their own vehicles.

Get My Free Ebook


Responses

  • crispus
    How to measure secondary cam chain tensioner vrod?
    3 years ago

Post a comment