Valve Lash

1.22

Part No.

Specialty Tool

HD-45314

Crankshaft rotating wrench

LASH MEASURMENT

1. Remove airbox assembly. See 1.4 AIRBOX AND AIR FILTER.

2. Remove battery. See 1.7 BATTERY MAINTENANCE.

Harley Rod Crank

IAC sensor connector [87B] Idle air control (IAC)

Throttle position (TP) sensor connector [88B] Air intakes (covered)

Figure 1-53. Fuel Line

3. See Figure 1-53. Remove fuel lines.

Figure 1-55. Intake Clamps, Throttle Body Removed

2003 Harley Rod Radiator Vent Hose

Ground strap Radiator hose P clamp Front cylinder breather hose Rear cylinder breather hose Cable straps

Part No.

Specialty Tool

HD-45314

Crankshaft rotating wrench

Ground strap Radiator hose P clamp Front cylinder breather hose Rear cylinder breather hose Cable straps

LASH MEASURMENT

IAC sensor connector [87B] Idle air control (IAC)

Throttle position (TP) sensor connector [88B] Air intakes (covered)

1. Remove airbox assembly. See 1.4 AIRBOX AND AIR FILTER.

2. Remove battery. See 1.7 BATTERY MAINTENANCE.

Figure 1-53. Fuel Line

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.

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

Figure 1-55. Intake Clamps, Throttle Body Removed

Vrod Remove Throttle Cable

Figure 1-59. Correct Engine Rotation

Figure 1 -57. Vapor Valve caution

7. See Figure 1-55. Loosen clamps at each intake and lift throttle body straight up.

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.

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.

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.).

NOTE

It may be necessary to loosen drive belt, and loosen exhaust at rear support bracket to allow the engine to drop sufficiently.

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.

Figure 1-59. Correct Engine Rotation

Figure 1 -57. Vapor Valve

Figure 1-58. Front Motor Mount Bolt

9102

Aultanator Figer

Figure 1-61. Rear Cylinder Cam Lobe Position

Derby Car Without Radiator

Figure 1-62. Measuring Valve Lash

CAUTION

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

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.

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.

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.

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. in Appendix D.

Table 1-6. Valve Lash Specifications

Figure 1-60. Front Cylinder Cam Lobe Position

Figure 1-61. Rear Cylinder Cam Lobe Position

Figure 1-62. Measuring Valve Lash

9074

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 disassembly/assembly must be retrieved or severe engine damage will result.

Figure 1-63. Top Dead Center Positioning Tool (HD-45653)

Figure 1-64. Crankshaft Locking Pin (HD-45306).

1. See Figure 1 -63. 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.

2. See Figure 1-64. Remove plug from timing hole.

CAUTION

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

3. Using CRANKSHAFT ROTATING WRENCH (HD-45314) rotate the engine counterclockwise (CCW) (direction of operation) and observe exhaust cam lobe. Note when exhaust valve is closing (TDC Tool will start to extend as valve closes) and engine is approaching TDC.

4. Verify that the TDC POSITIONING TOOL is fully extended and front piston is at TDC.

5. See Figure 1-64. Insert CRANKSHAFT LOCKING PIN (HD-45306). The CRANKSHAFT LOCKING PIN should insert flush with engine case. If necessary gently rock crankshaft using CRANKSHAFT ROTATING WRENCH (Part No. HD-45314) to lock engine at exact TDC.

6. See Figure 1-65. Engine is correctly timed with cam gear marks aligned and lobes positioned as shown.

7. If cam timing is not correct see 3.20 CAM DRIVE.

8. Remove CRANKSHAFT LOCKING PIN.

9. Install engine timing plug in timing hole. Tighten to 23 Nm (17 ft-lbs).

PART NO.

SPECIALTY TOOL

HD-45653

TDC positioning tool

HD-45306

Crankshaft locking pin

HD-45314

Crankshaft rotating wrench

1. Timing hole

2. Locking pin

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