Lash Adjustment

1. See Figure 1-66. Using CRANKSHAFT ROTATING WRENCH (HD-45314), rotate the engine counter-clockwise (direction of operation) to position front cylinder cam lobes at 10 o'clock and 2 o'clock.

2. See Figure 1-67. Clean oil from cam drive gear and chain link. Make a reference mark on chain and cam drive gear, both intake and exhaust, as shown.

NOTE

Copper colored links are for initial assembly of complete cam drive system.

3. See Figure 1-68. Remove secondary cam chain tension er.

caution

NEVER rotate engine with secondary cam chain ten-sioner removed. Engine damage and/or loss of correct timing will occur.

caution

Do not remove cam drive gear bolts. It is not necessary for the lash adjustment.

Zzr1100 Double Camshaft Timing
Figure 1-66. Front Cylinder 10 and 2 O'clock Cam Lobe Position
Zzr1100 Double Camshaft Timing
Figure 1-67. Reference Mark Cam Gear and Chain Link

Figure 1-68. Secondary Cam Chain Tensioner

PART NO.

SPECIALTY TOOL

HD-45314

Crankshaft rotating wrench

HD-45340

Gasket alignment tool

Figure 1-68. Secondary Cam Chain Tensioner

4. See Figure 1-69. Remove cam journal fasteners and caps from the cam needing adjustment.

NOTE

Remove and adjust only one camshaft at a time.

5. See Figure 1-70. Carefully move cam and drive gear aside. Keep cam drive gear and chain engaged.

NOTE

Handle chain and cam assembly carefully so as not to remove reference marks.

6. Carefully remove tappet. Oil film will usually cause shim to adhere to the under side of the tappet. Take care that shim does not dislodge and fall into engine. To remove tappet, use of a strong magnet is suggested. This will keep shim and tappet together during removal.

Figure 1-71. Tappet And Shim

Figure 1-72. Cam, Tappet, Shim Relationship

1. Camshaft

2. Tappet

3. Shim

Figure 1-69. Cam Journal Caps

Figure 1-72. Cam, Tappet, Shim Relationship

1. Camshaft

2. Tappet

3. Shim

Figure 1-70. Move Cam Aside With Chain Engaged

Figure 1-75. Cam Journal Cap Reference Numbers

Valve Lash Calculation Sheet

Figure 1-74. Position Shim

Figure 1-73. Measure Shim caution caution

7. Use a micrometer to measure the thickness of the removed shim. Record measurement in the "Installed Shim Measurement" column on valve lash calculation worksheet. See D.2 VALVE LASH CALCULATION WORKSHEET 1.

Figure 1-73. Measure Shim

Figure 1-74. Position Shim

Figure 1-75. Cam Journal Cap Reference Numbers

Do not use shim stock to adjust valve lash. Shim stock may dislodge and cause severe engine damage.

8. Calculate and record on the valve lash calculation worksheet the "New Shim Lower Limit" and the "New Shim Upper Limit."

9. Calculate and record "Desired Shim Size."

10. Select and record the "Closest Shim Size" replacement shim. See Table D-1. Case 1 Valve Tappet Shims and Table D-2. Case 2 Valve Tappet Shims.

11. Always confirm new shim thickness with micrometer. Record for reference.

12. See Figure 1-74. Position new shim in spring retainer pocket. Use a magnet to position the shim and carefully push into place with finger.

13. Replace tappet.

14. If the initial lash measurement of the remaining valve exceeds the upper or lower valve lash limits, preform the lash adjustment on the remaining valve.

15. See Figure 1-67. Install cam in alignment with new reference marks on drive chain and cam drive gear. Note new reference marks from step 2.

16. See Figure 1-75. Cam journal caps are numbered. Install cam journal caps with corresponding number on head, arrow pointing to center of head. Lubricate cam journal and journal cap with oil before placing in position.

17. Tighten cam bearing caps to 10 Nm (89 in-lbs).

18. Review the valve lash calculation worksheet and make adjustments to the valves activated by the opposite cam if necessary.

NEVER rotate engine with secondary cam chain ten-sioner removed. Engine damage and/or loss of correct timing will occur.

19. When second cam has been set aside, the valve lash adjusted, and the cam reinstalled, install secondary cam chain tensioner.

Figure 1-77. Spark Plug Hole Gasket (double lipped side)

Figure 1-76. Cam Cover Gaskets

20. Rotate engine two complete revolutions (counter-clockwise, direction of rotation) until cam lobes return to 10 o'clock and 2 o'clock position.

21. Re-measure valve lash of all front cylinder cams and record "Final Lash Reading" on the worksheet.

22. Review the worksheet for the rear cylinder valves and make adjustments as needed.

23. See Figure 1-61. Turn engine over to position rear cylinder cams at the 2 o'clock and 10 o'clock position and repeat the procedures for the rear cylinder.

24. After lash adjustment is complete, verify cam timing on both cylinders. See VERIFY CAM TIMING in 1.22 VALVE LASH.

25. When lash adjustment is verified install and tighten spark plugs to 23 Nm (17 ft-lbs).

26. Clean cam cover and install new gasket.

27. See Figure 1-76. Use cable straps (1) to help retain gasket as shown.

28. See Figure 1-78. Apply a thin bead of silicone along both half-moon shaped recesses in cylinder head. Cam cover gasket must stay in place, a small amount of sealer, lightly applied will help.

29. Carefully install cam cover and gasket. Cable straps will allow the cam bore plug to be moved horizontally to clear cam drive gears.

30. Visually check to ensure spark plug hole gasket (2) is in place.

NOTE

See Figure 1 -77. The seal of the spark plug hole gasket is correct when the tapered edge of the gasket is in the cam cover and the double lipped side of the rings is facing out to mate with the flat of the cylinder head.

31. Remove cable straps.

32. Place small cam cover in position.

33. See Figure 1-79. Insert GASKET ALIGNMENT TOOL (HD-45340).

Figure 1-76. Cam Cover Gaskets

Figure 1-77. Spark Plug Hole Gasket (double lipped side)

Cable strap

Spark plug hole gasket

Figure 1-78. Silicone Bead Pattern in Head Recesses

â– ISsBiSQ

Figure 1-79. Gasket Alignment Tool (H-D-45340)

34. See Figure 1-80. Insert fasteners in cam cover and tighten to 9.7 Nm (86 in-lbs) in sequence shown.

35. See Figure 1-58. Tighten front motor mount fastener to 38 Nm (28 ft-lbs).

36. Position the main harness along the left side of the frame and install cable straps.

37. Install front cylinder and rear cylinder breather hoses.

38. Install p-clamp around the right side radiator hoses and tighten fastener to 9.7 Nm (86 in-lbs).

39. Connect ground strap to cam cover. Tighten to 9.7 Nm (86 in-lbs).

40. See Figure 1 -81. Orient intake clamps as shown.

41. Install throttle body and tighten clamps.

42. See 1.19 SPARK PLUG/COIL. Install coils.

43. Attach the idle speed control (IAC) connector.

44. Attach the throttle position (TP) sensor.

45. Attach fuel lines.

a. Insert fuel lines from injector back under frame and connect to fuel tank.

b. Push connector onto fuel tank elbow until a "click" is heard.

c. Install right angle connectors on rigid lines from injector. Push until a "click" is heard.

46. Install battery. See 1.7 BATTERY MAINTENANCE.

47. Install airbox assembly. See 1.4 AIRBOX AND AIR FILTER.

Figure 1-79. Gasket Alignment Tool (H-D-45340)

Figure 1-80. Cam Cover Torque Sequence
Figure 1-81. Intake Clamps, Throttle Body Removed
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

  • MARCEL
    HOW TO DO A HARLEY VROD VALVE ADJUSTEMNT?
    3 years ago
  • HANA
    When do valves get adjusted on vrod?
    2 years ago
  • hiwet aatifa
    What size shim are in a vrscdx 1250cc?
    12 months ago
  • DAVID
    Does harley davidson vrod 1250cc need valve shim changed?
    9 months ago
  • Viljo Saariaho
    How do i know when harley v rod needs new valve shims?
    9 months ago

Post a comment