Our digital service literature is excluded from any exchange! It is your responsibility to make sure and check if the service manual is for your bike, year, and model. If you are in doubt, please contact us before. This official service manual is for the following motorcycles. The latest Adobe Reader is required to work with this eBook.
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See Figure Following the sequence shown, alternately loosen the six rocker housing bolts. Remove rocker housing bolts and their captive washers. Remove rocker housing and gasket. Discard gasket. CAUTION To prevent distortion of the cylinder head, cylinder and cylinder studs, gradually loosen the cylinder head bolts in the specified sequence.
Remove cylinder head bolts. Continue turning the bolts in these increments until loose. Remove the cylinder head bolts. Remove cylinder head and head gasket 2. HDA when measuring, boring or honing of the cylinder is required. See 3. Figure Push Rod Locations. Raise the cylinder just enough to place clean shop towels under the piston.
This will prevent any dirt or debris, such as broken ring pieces, from falling into the crankcase bore. Even a slight bend or nick can cause a stress riser leading to stud failure. Carefully remove the cylinder. Exercise caution to avoid bending the cylinder studs. As the piston becomes free of the cylinder, hold it upright to prevent it from striking the studs or dragging across the stud thread area. Slide approximately 6. Use material with I.
Remove O-ring seal 4 from the bottom of the cylinder liner. Discard O-ring seal. Remove O-ring from ring dowel 4 on base of cylinder deck. Discard O-ring. Verify that clean shop towels are properly positioned over the crankcase bore to prevent the piston pin circlip from falling into the crankcase. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. Remove the piston pin circlip. HDA into the piston pin bore. Position claw on tool in slot of piston 2 directly under circlip.
Hold a shop towel over the piston pin bore in case a circlip should fly out during removal. Squeeze the handles of the tool together and pull from bore. Remove circlip from claw and discard. NOTE It is not necessary to remove both piston pin circlips during piston removal. Leave the second circlip in the pin bore.
Remove the piston pin. Remove acorn nut and spacer from rod end of tool. Slide rod end through piston pin. Install spacer and acorn nut 1 on end of rod. Position rubber-coated tips 2 of tool on flat each side of pin bore. Turn handle 3 in a clockwise direction until piston pin is pulled free of bore. Remove the piston. Be sure to hold the connecting rod shank upright to prevent it from striking the crankcase. Place a 3. Use material with an O. Turn the piston over. Service as needed.
See the following topics for inspection and repair information. Complete engine work. If performing a top end overhaul only, see 3. If performing a complete engine overhaul, see 3. This section provides a sequential process for engine reassembly after a complete 3.
If you reached this section after an inspection or repair procedure, start where necessary and continue to the end of the section. Apply clean H-D 20W50 engine oil to piston pin, piston bosses and upper connecting rod bushing.
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