Cam Drive Removal

1. Remove plug top coils and spark plugs. See 1.19 SPARK PLUG/COIL.

2. Remove cam cover.

3. See Figure 3-18. Install TDC POSITIONING TOOL (HD-45653) in front spark plug hole.

CAUTION

Never insert a foreign object, such as a screwdriver, in the spark plug hole. Engine damage can result.

CAUTION

DO NOT ROTATE ENGINE CLOCKWISE. This is opposite the normal engine operation. Engine damage can result.

4. Using CRANKSHAFT ROTATING WRENCH (HD-45314) rotate the engine counter-clockwise (direction of operation). Note when exhaust valve is closing (TDC positioning tool will start to extend as valve closes) and engine is approaching TDC.

5. See Figure 3-19. When the TDC reference tool is fully extended, remove plug from timing hole on right side of engine and insert CRANKSHAFT LOCKING PIN (HD-45306).

6. The crankshaft locking pin should insert flush with engine case. It may be necessary to gently rock the crankshaft using the CRANKSHAFT ROTATING WRENCH (HD-45314) to lock engine at exact TDC.

7. Remove TDC POSITIONING TOOL (HD-45653) from front spark plug hole.

Rod Porsche Cam
Figure 3-18. Top Dead Center Positioning Tool
Figure 3-19. Crankshaft Locking Pin

PART NO.

SPECIALTY TOOL

HD-45314

Crankshaft rotating wrench

HD-45653

TDC positioning tool

HD-45306

Crankshaft locking pin

HD-45491

Tappet compressing tool

Harley Davidson Rod Engine Designed

2. Primary chain fixed guide

3. Secondary chain tensioner

4. Front cylinder fixed guide

5. Rear cylinder fixed guide

6. Front secondary cam chain

7. Rear secondary cam chain

8. Primary cam chain

Figure 3-20. Cam Drive

8. See Figure 3-21. Holding 36 mm rotor nut with CRANKSHAFT ROTATING WRENCH (HD-45314), loosen rotor fastener. Air impact tool may be used for REMOVAL ONLY.

9. See Figure 3-22. Holding 36 mm rotor nut with CRANKSHAFT ROTATING WRENCH (HD-45314), loosen starter limiter fastener.

10. See Figure 3-23. Loosen triple sprocket fastener.

11. See Figure 3-24. Remove rotor shell.

Figure 3-21. Rotor Fastener

9127

Figure 3-25. Starter Limiter Gear Assembly ikwarning

12. See Figure 3-25. Remove starter limiter fastener and starter limiter gear assembly.

Figure 3-26. Snap Ring ikwarning

Figure 3-22. Starter Limiter Fastener

Figure 3-23. Triple Sprocket Fastener

Figure 3-24. Rotor Shell

Figure 3-25. Starter Limiter Gear Assembly

12. See Figure 3-25. Remove starter limiter fastener and starter limiter gear assembly.

Always wear proper eye protection when removing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not excessively worn or damaged. Slippage may propel the ring with enough force to cause an accident. This could result in death or serious injury.

Figure 3-26. Snap Ring

13. See Figure 3-26. Remove snap ring from crankshaft.

14. See Figure 3-27. Slide snap ring, washer, and gear ball clutch with needle roller and cage assembly off of crankshaft.

15. See Figure 3-28. For this procedure, the front cylinder cams are pre-loaded. Install TAPPET COMPRESSING TOOL (HD-45491) on front cylinder to aid in disassembly.

a. Loosen 19 mm nut on tappet compressing tool.

b. Tools are marked intake and exhaust. Position them accordingly.

c. Use M6x25 fasteners to secure tools to head.

d. Tighten 19 mm nut to compress tappets.

16. See Figure 3-29. Remove secondary cam chain ten-sioner.

Figure 3-27. Snap Ring Removal
Harley Cam Ring Removal Tool
Figure 3-28. Tappet Compressing Tools (HD-45491)
Harley Secondary Cam Chain
Figure 3-29. Remove Secondary Cam Chain Tensioner
Figure 3-30. Cam Bearing Cap Removal
Harley Davidson Cam Chain
Figure 3-31. Cam Drive Chain

17. See Figure 3-30. Remove cam bearing caps.

18. See Figure 3-31. Roll chain over cam drive gear. Lift cam and drive gear from head.

19. In this position the rear cams are not preloaded. Remove rear cylinder bearing caps. Disconnect cams from chain.

20. Remove chains.

21. Remove water pump cover.

22. See Figure 3-32. Remove water pump housing. Using a soft face hammer, GENTLY tap around edge of housing while exerting outward pressure.

Harley Davidson Water Pump
Figure 3-32. Removing Water Pump Housing
Harley Cam Chain Tensioner 12962
Figure 3-35. Primary Chain Tensioner Retainer (HD-45326)

23. See Figure 3-35. Retract primary cam chain tensioner and insert PRIMARY CAM CHAIN TENSIONER RETAINER (HD-45326). Remove primary cam chain tensioner.

23. See Figure 3-35. Retract primary cam chain tensioner and insert PRIMARY CAM CHAIN TENSIONER RETAINER (HD-45326). Remove primary cam chain tensioner.

Rod Transmission Side Cover Removal

Figure 3-36. Primary Chain Fixed Guide

24. See Figure 3-36. Remove primary cam chain fixed guide.

25. See Figure 3-37. Remove the triple sprocket fastener.

Figure 3-34.

Figure 3-37. Triple Sprocket Fastener

Figure 3-36. Primary Chain Fixed Guide

24. See Figure 3-36. Remove primary cam chain fixed guide.

25. See Figure 3-37. Remove the triple sprocket fastener.

Harley Davidson Water Pump
Figure 3-38. Triple Sprocket/Water Pump Shaft

26. See Figure 3-38. Push triple sprocket/water pump shaft through engine toward the clutch side.

27. See Figure 3-39. Remove triple sprocket and primary cam chain.

Figure 3-39. Triple Sprocket and Primary Cam Chain Removed
Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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