Harley Davidson FLHRC 2006. Maintenance & Repair Manual

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Apply a small dab of Loctite Medium Strength Thread-

locker 243 (blue) to threads of four bearing retainer plate

Roller Bearing

Ball Bearing

Rear Cam

Front Cam

screws. Using a T20 TORX drive head, secure bearing

retainer plate to cam support plate. Tighten screws to

20-30 in-lbs (2.3-3.4 Nm) in a crosswise pattern. Verify

that hole in retainer plate is properly aligned with sec-

ondary cam chain oiler.

Place cam support plate back on support block, if

removed. Block properly supports inner races of bear-

ings as camshafts are installed.

Align pin stamped timing lines on teeth of secondary

cam sprockets

(outboard faces). See Figure

3-111.

f1804x3x

Using a colored marker, carefully mark the timing line

locations on the inboard side of the sprocket teeth.

Figure 3-110. Cam Bearings

These marks are needed to observe proper orientation

of the camshafts when they are pressed into the bear-

Verify that the thrust washer is locked in place and

ings.

cannot be rotated. If necessary, install shaft in vise

using brass jaw inserts, and further tighten flange

10.

Place the secondary cam chain around the sprockets of

bolt until the desired result is achieved.

both the front and rear camshafts. To maintain the origi-

nal direction of rotation, be sure that the colored mark

g. Remove flange bolt, flat washer, sprocket and

placed on the chain link during disassembly is facing

spacer.

opposite the cam support plate during installation.

CAUTION

11.

Orient the camshafts so that they are positioned on

opposite ends of the chain, and then verify that the col-

Always install new bearings. Only use genuine Harley-

ored marks placed on the inboard side of the sprocket

Davidson bearings. Reusing old bearings or using bear-

teeth are still in alignment.

ings from a supplier other than Harley-Davidson will

result in engine damage.

12.

Maintaining the position of the camshafts on the chain

with the colored marks in alignment, place the sprocket

Obtain the CAMSHAFT/CAMSHAFT BEARING RE-

ends of the camshafts into the bearings.

MOVER/INSTALLER (HD-43644).

With the secondary cam chain side facing upward, place

cam support plate on support block, so that outer races

of bearings are properly supported. Note that one corner

Front

of the support block is contoured to accommodate the

Camshaft

chain guide blocks cast into the front of the support

Rear

plate.

Camshaft

Center new bearing over bearing bore with the lettered

side up. Slide pilot shaft of bearing driver through

bearing into hole of support block.

NOTE

Be aware that the front and rear cam bearings are not inter-

changeable. The rear bearing is the roller type, while the front

is the ball bearing kind. See Figure 3-110.

Center bearing driver under ram of arbor press. Press

on driver until bearing makes firm contact with counter-

bore in cam support plate. See upper frame of Figure 3-

112. Repeat steps to install second bearing.

NOTE

Pin Stamped

Timing Lines

f2067x3x

Bearings may be a press to loose fit. If deemed necessary,

clean bearing OD and apply Loctite Low Strength Thread-

Figure 3-111. Align Timing Lines on Teeth

locker 243 (Blue) before installation, but exercise caution to

of Camshaft Sprockets

avoid getting compound on rollers or bearing ID.

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NOTE

Press bearings into cam support plate.

Do not mix camshafts during the press procedure. The rear

Bearing

camshaft, which can be identified by the splined shaft, must

Pilot/Driver

go into the roller bearing at the rear of the cam support plate.

Bearing

13. Place cup of camshaft driver over end of front camshaft

only.

Support

CAUTION

Block

Verify that splined end of rear camshaft has been started

into support block. Damage to the camshaft and/or sup-

port block can occur if end of camshaft catches top of

block during the press procedure.

NOTE

f1618x3x

To reduce the likelihood of such contact occuring, use 7/8

Center front camshaft under ram. Start front cam-

inch drill bit to enlarge rear cam bore in support block. For

shaft into cam bearing.

best results, radius top inside edge of bore after drilling.

Ram

Camshaft

CAUTION

Driver

Be sure that the tensioner shoe is clear of the secondary

cam chain during the press procedure. Contact can

Front

result in damage that requires replacement of the ten-

Support

Camshaft

sioner assembly.

Block

14. Center end of front camshaft under ram and slowly apply

pressure to driver just to start front camshaft into bear-

ing ID. See center frame of Figure 3-112.

CAUTION

If rear camshaft is not properly aligned, edge of installed

f1822x3x

inner race can catch on bearing rollers. Bearing damage

can result if contact occurs during the press procedure.

While applying pressure to front camshaft, wiggle

rear camshaft to guide inner race between bearing

15. Slowly apply pressure to driver on front camshaft, while

rollers.

wiggling rear camshaft as necessary to guide inner race

between bearing rollers. See lower frame of Figure 3-

Rear

112.

Camshaft

16. When inner race on rear cam is started into roller bear-

ing, apply pressure to driver until front camshaft is fully

seated. If necessary, keep finger pressure at top of rear

camshaft to ensure that assembly remains square and

inner race moves to installed position in roller bearing.

17. Since the pin stamped timing lines on the secondary

sprockets cannot be observed once the camshafts are

pressed into the bearings, note that the outboard ends of

the shafts have a second set of timing lines (although

they may be somewhat difficult to see). Using a straight-

edge, verify that these timing lines are in alignment. See

Figure 3-113. If they are not, then the camshafts must be

removed and reinstalled (with a new bearing set).

f1821x3x

Figure 3-112. Install Cam Bearings/Camshafts

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Cam Chain Tensioners

Rear

Front

Camshaft

Removal

1CAUTION

Do not pull the retention pins from the primary or sec-

ondary cam chain tensioners with the chains and

sprockets removed. With 35-40 pounds of spring pres-

sure behind the tensioner, allowing it to accelerate

through its full length of travel will cause spring stretch-

ing and/or cracking of the tensioner shoe, damage which

requires replacement of the assembly. Furthermore, if

the tensioner should contact fingers or other parts of the

hand, minor or moderate injury may occur.

If retracted, hold the cam chain tensioner with the CAM

CHAIN TENSIONER UNLOADER (HD-42313), pull the

retention pin and ease the assembly into the unloaded

position.

Pin Stamped

f2068b3x

Timing Lines

1WARNING

Figure 3-113. Verify Alignment of Timing Lines

Always wear proper eye protection when removing re-

on Ends of Camshafts

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

cause eye injury.

1WARNING

Remove retaining ring from groove in tensioner post.

Discard retaining ring.

Always wear proper eye protection when installing re-

taining rings. Use the correct retaining ring pliers. Verify

Slide cam chain tensioner assembly from post disengag-

that the tips of the pliers are not damaged or excessively

ing spring pin from hole in cam support plate.

worn. Slippage may propel the ring with enough force to

cause eye injury.

Installation

18. With the sharp edge out, install new retaining ring in

Slide cam chain tensioner assembly onto post inserting

groove at end of front camshaft.

spring pin into hole in cam support plate.

f1676x3x

Acceptable Wear

Unacceptable Wear

Continue use of the tensioner shoe

Replace the tensioner shoe assembly

assembly (and chain) if worn to a depth

(and chain) if worn to a depth that is

(and chain) if there is any evidence of

that is less than half the thickness of the

equal to or greater than half the thick-

melting, burning or cracking.

shoe material.

ness of the shoe material.

Figure 3-114. Cam Chain Tensioner Shoe Wear

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Slide spring into bypass port until seated in open side of

piston.

Start new roll pin into hole in cam support plate. Com-

press spring using the blade of a small screwdriver.

Holding spring compressed, tap roll pin into cam support

plate until it approaches pin hole on opposite side.

Remove screwdriver to release spring. Verify that spring

is straight and square in bore.

Using a 1/8 inch punch with a small hammer, carefully

tap roll pin until flush with casting.

Install primary cam chain tensioner assembly. See CAM

6908

CHAIN TENSIONERS, INSTALLATION, in this section.

Figure 3-115. Oil Pressure Relief Valve Assembly

Inspection

Inspect oil pressure relief valve as follows:

1WARNING

NOTE

If diagnosing low oil pressure, start with step 1(a). If diagnos-

Always wear proper eye protection when installing re-

taining rings. Use the correct retaining ring pliers. Verify

ing high oil pressure, then begin with step 1(b).

that the tips of the pliers are not damaged or excessively

a. Measure distance from edge of cam support plate

worn. Slippage may propel the ring with enough force to

to inboard side of piston. Insert straight stiff wire into

cause eye injury.

unplugged hole outboard of roll pin until it bottoms,

With the sharp edge out, install new retaining ring in

and then mark and measure wire. With piston fully

groove of post. Verify that the ring is fully seated in the

seated in the bore, depth should be approximately

groove.

2.25 inches (57.15 mm). If it is not, continue with

step 1(b).

If retracted prior to disassembly, place cup of CAM

CHAIN TENSIONER UNLOADER

(HD-42313) over

b. Remove oil pressure relief valve. See OIL PRES-

spring coil of cam chain tensioner assembly. Retract the

SURE RELIEF VALVE, REMOVAL, on this page.

tensioner inserting a retention pin through hole in boss

c. Inspect spring for stretching, kinking or distortion.

on the primary cam chain side of cam support plate.

d. Inspect piston and bore for burrs, scoring or other

damage. Look for steel particles or aluminum chips.

Replace cam support plate and piston if any of

Oil Pressure Relief Valve

these conditions are found.

Removal

e. Install piston in bore and measure running clear-

Before removal, see INSPECTION on this page.

ance. If running clearance exceeds

0.003 inch

(0.076 mm), install new piston and remeasure.

Remove primary cam chain tensioner assembly. See

Replace cam support plate if running clearance still

CAM CHAIN TENSIONERS, REMOVAL.

exceeds specification.

Secure the cam support plate in a vise with access to

the roll pin. Be sure to install a pair of brass jaw inserts in

the vise to avoid damage to the casting.

Cam Needle Bearings

Using a 1/8 inch punch with a small hammer, carefully

tap roll pin from pin hole in cam support plate. Discard

Removal

roll pin.

Obtain the CAMSHAFT NEEDLE BEARING RE-

Remove spring and piston from bypass port.

MOVER/INSTALLER (HD-42325A).

Installation

Remove four button fasteners from threaded holes in

support plate, if installed. See Figure 3-116.

Secure the cam support plate in a vise. Install a pair of

Sparingly apply graphite lubricant to threads of collet to

brass jaw inserts to avoid damage to the casting.

prolong service life and ensure smooth operation.

Lubricate piston with clean H-D 20W50 engine oil. Slide

piston into bypass port with the open side facing out-

Slide collet through support plate so that threaded end

ward.

exits stamped side of plate.

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Install support plate with collet.

f1303x2x

Graphite

Lubricant

Install Nice bearing, flat washer and hex nut.

Hex Nut

Button

Fastener (4)

Support

Button

Plate

Fastener

Nice

Bearing

Support

Plate

Nice

Ring Dowel

Pilot

Bearing

Hole

Flat

Washer

Collet

Installer

Threaded End

Collet

Shaft

Collet

Threaded End

Expandable End

Hex

Nut

f1586x3x

Figure 3-116. Camshaft Needle Bearing Remover/Installer

Holding flat, turn hex in a

f1587x3x

(HD-42325A)

clockwise direction to expand collet.

Aligning two large holes in support plate with needle

bearing bores, hang right side of plate on ring dowel in

crankcase flange.

Align four holes at corners of support plate with threaded

holes in crankcase flange. Install button fasteners in

these holes to secure support plate to crankcase. See

upper frame of Figure 3-117.

Center expandable end of collet in bearing bore and

Hex

slide Nice bearing and flat washer on threaded end.

Flat

Start hex nut on threaded end.

Push expandable end of collet through bearing bore into

flywheel compartment. Feel for inside edge of needle

bearing using end of collet and then back off slightly.

Holding collet to prevent lateral movement, finger tighten

Turn hex nut in a clockwise direction

hex nut until Nice bearing contacts support plate.

to remove bearing.

10.

Using a 7/16 inch open end wrench, hold flat on collet to

prevent rotation. Using a second 7/16 inch open end

wrench, expand collet by turning hex at end of shaft in a

clockwise direction. See center frame of Figure 3-117.

Expandable end of collet makes contact with needle

bearing ID.

11.

Using a 15/16 inch open end wrench, turn hex nut in a

clockwise direction until bearing is free. If necessary,

hold flat on collet to prevent rotation. See lower frame of

Figure 3-117.

12.

Remove four button fasteners and pull support plate

from crankcase.

13.

Holding flat on collet, turn hex at end of shaft in a coun-

terclockwise direction to close collet. Remove and dis-

card needle bearing.

f1588x3x

Figure 3-117. Remove Cam Needle Bearing

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14. Remove hex nut, flat washer and Nice bearing from

threaded end of collet. Pull collet from support plate.

Install support plate with installer shaft (and pilot).

15. Return to step 1 to remove second needle bearing.

Support

Button

Plate

Fastener

Installation

Obtain the CAMSHAFT NEEDLE BEARING RE-

MOVER/INSTALLER (HD-42325A).

Sparingly apply graphite lubricant to threads of installer

Ring Dowel

shaft to prolong service life and ensure smooth opera-

Hole

tion.

Thread installer shaft into stamped side of support plate

until threads begin to emerge from opposite side.

Install pilot at end of installer shaft.

Place new needle bearing on pilot with lettered side fac-

ing shoulder.

Installer

Aligning two large holes in support plate with needle

Shaft

bearing bores, hang right side of plate on ring dowel in

f1589x3x

crankcase flange.

Turn hex on installer shaft in a clockwise direction

Align four holes at corners of support plate with threaded

to install bearing.

holes in crankcase flange. Install button fasteners in

these holes to secure support plate to crankcase. See

upper frame of Figure 3-118.

Using 15/16 inch open end wrench, turn hex at end of

installer shaft in a clockwise direction until resistance is

felt. See lower frame of Figure 3-118.

Turn end of installer shaft in a counterclockwise direction

until pilot is free of needle bearing bore.

10.

Remove four button fasteners and pull support plate and

installer shaft from crankcase.

11.

Remove pilot from installer shaft. Unthread installer

shaft from support plate.

12.

Return to step 1 to install second needle bearing.

f1590x3x

13.

Thread four button fasteners into threaded holes in sup-

port plate to prevent loss.

Figure 3-118. Install Cam Needle Bearing

Installation

See Section 3.10 BOTTOM END OVERHAUL, ASSEM-

BLY, steps 12-29.

Remove wireforms to release hydraulic lifters.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

steps 29-39.

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OIL PUMP

Inner Gerotor

Outer Gerotor

Removal

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11.

NOTE

When removing the cam support plate, it is not necessary to

disturb the lifter assemblies if a method is devised to prevent

the hydraulic lifters from dropping into the cam compartment.

Wear

One such method is provided in the following step. Leaving

Limit

the lifter assemblies intact simplifies the procedure, since the

lifter cover, gasket, anti-rotation pin and hydraulic lifters can

be left in place.

f1563x3x

Fashion lifter holding tool as follows:

a. Obtain a large binder clip (available at any office

Figure 3-120. Measure Gerotor Sets for Wear

supply store). Squeeze wireforms to remove from

binder clip. See upper frame of Figure 3-100.

b. Compress wireform slightly and insert free ends into

Thoroughly dry all parts with low pressure compressed

outer and inner lifter cover bores so that legs

air. Verify that all oil passages are clean and open.

engage walls of both hydraulic lifter sockets. See

Look for scoring, gouging or cracking caused by foreign

lower frame of Figure 3-100.

material that may have passed through the oil pump.

See Section 3.10 BOTTOM END OVERHAUL, DISAS-

Look for grooves or scratches on the cam support plate,

SEMBLY, steps 1-15.

which serves as the outboard side of the oil pump.

Check for excessive wear or damage on lobes of outer

Cleaning and Inspection

gerotors and between lobes on inner gerotor.

Mesh pieces of one gerotor set together as shown in

Clean all parts in a non-volatile cleaning solution or sol-

Figure 3-120. Use a feeler gauge to determine clear-

vent.

ance between tips of lobes on inner and outer gerotors.

The maximum allowable clearance is

0.004 inch

(0.10 mm). Replace gerotor set if clearance exceeds

specification. Inspect second gerotor set in the same

Oil Pump

O-Ring

manner.

Housing

Measure thickness of inner gerotor of one set with a

micrometer. Measure the outer gerotor of the same set.

Wide

Replace the gerotor set if the difference exceeds 0.001

Gerotor Set

inch (0.025 mm). Inspect second gerotor set in the same

(Scavenge)

manner.

Wave

Assemble the oil pump. Verify that feed gerotors stand

Washer

Narrow

proud of the oil pump surface

0.0215-0.0305 inch

Gerotor Set

(0.546-0.775 mm). If measurement is less than 0.0215

(Feed)

inch (0.546 mm), remove feed gerotor set and reassem-

ble using new wave washer. Repeat measurement and

replace oil pump body if still not within specification.

O-Ring

Separator

Plate

Installation

See Section 3.10 BOTTOM END OVERHAUL, ASSEM-

Separator

BLY, steps 11-29.

Plate

f1530b3x

Remove wireforms to release hydraulic lifters.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

Figure 3-119. Oil Pump Assembly

steps 29-39.

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Legend:

f2070x3x

Crankshaft Bearing

Ring Dowel

Cam Needle Bearing

Oil Inlet Fitting

Oil Outlet Fitting

Crankcase Breather Fitting

Right Crankcase Half

O-Ring

Piston Jet

10.

T20 TORX Screw

11.

Lock Ring

12.

Sprocket Shaft Bearing

13.

O-Ring

14.

Ring Dowel

15.

Plug

16.

O-Ring

17.

Oil Filter Mount

18.

Oil Filter Adapter

19.

Flat Washer

20.

Bolt

21.

Lockplate

22.

Oil Filter

23.

Crankcase Bolt

24.

Ring Dowel

25.

O-Ring

26.

Left Crankcase Half

27.

Thrust Washer

28.

Oil Seal

29.

Sprocket Shaft Spacer

Figure 3-121. Crankcase Assembly (Exploded View)

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CRANKCASE

Ram

Pilot/Driver

Support Tube

Removal

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-29.

“A”

End Up

See Section 3.10 BOTTOM END OVERHAUL, DISAS-

SEMBLY, steps 1-18.

f2126x3x

Disassembly/Assembly

RIGHT CRANKCASE HALF

Crankshaft Bearing

Removal

1CAUTION

Never move or lift the crankcase by grasping the cylin-

der studs. The crankcase is too heavy to be carried in

this manner and may be dropped. Dropping the crank-

case may result in parts damage and minor or moderate

injury.

See Figure 3-122. Obtain CRANKSHAFT/SPROCKET

SHAFT BEARING REMOVER/INSTALLER PILOT/

DRIVER

(B-45655) and CRANKSHAFT/SPROCKET

SHAFT BEARING REMOVER/INSTALLER SUPPORT

Figure 3-123. Remove Crankshaft Bearing

TUBE (HD-42720-5).

Place support tube on hydraulic press table with the “A”

Slide pilot/driver through bearing into support tube.

end up. The ends of the support tube are stamped “A”

and “B” to ensure proper orientation.

Center pilot/driver under ram of press. Apply pressure to

With the outboard side of the right crankcase half facing

pilot/driver until bearing is free. See Figure 3-123.

upward, position crankshaft bearing bore over support

Remove right crankcase half, pilot/driver and bearing

tube.

from support tube. Discard bearing.

Support Tube

Installation

Part No. HD-42720-5

See Figure 3-122. Obtain CRANKSHAFT/SPROCKET

SHAFT BEARING REMOVER/INSTALLER PILOT/

DRIVER

(B-45655) and CRANKSHAFT/SPROCKET

SHAFT BEARING REMOVER/INSTALLER SUPPORT

TUBE (HD-42720-5).

Turn support tube over so that the “B” end is up. The

ends of the support tube are stamped “A” and “B” to

ensure proper orientation.

With the outboard side of the right crankcase half facing

Pilot/Driver

upward, position crankshaft bearing bore over support

Part No. B-45655

d0687x3x

tube.

Obtain new crankshaft bearing and apply a thin film of

Figure 3-122. Crankshaft/Sprocket Shaft Bearing

clean engine oil to O.D.

Pilot/Driver and Support Tube

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Installation

Ram

Pilot/Driver

CAUTION

Support Tube

Crankshaft Bearing

O-rings that are missing, distorted, pinched or otherwise

“B”

damaged will result in either oil leakage or low oil pres-

End Up

sure. Use of the wrong O-ring will have the same results.

Since many O-rings are similar in size and appearance,

always use new O-rings keeping them packaged until

use to avoid confusion.

f2127x3x

Install new O-ring in groove of jet mounting flange. Apply

a very thin film of clean H-D 20W50 engine oil to O-ring

before installation.

Apply Loctite Low Strength Threadlocker 222 (purple) to

threads of two T20 TORX screws.

With the jet pointed upward, install TORX screws to

secure piston jet to crankcase. Tighten screws to 25-35

in-lbs (2.8-4.0 Nm).

LEFT CRANKCASE HALF

Sprocket Shaft Bearing

Removal

Figure 3-124. Install Crankshaft Bearing

1CAUTION

Never move or lift the crankcase by grasping the cylin-

der studs. The crankcase is too heavy to be carried in

Start crankshaft bearing into bore with the lettered side

this manner and may be dropped. Dropping the crank-

up. Lubricate leading edge of bearing before placement.

case may result in parts damage and minor or moderate

Slide pilot/driver through bearing into support tube.

injury.

Center pilot/driver under ram of press. Apply pressure to

pilot/driver until resistance is felt and bearing bottoms in

1WARNING

support tube. See Figure 3-124.

Do NOT rotate left crankcase half in the engine stand so

Remove pilot/driver and right crankcase half from sup-

the stator mount flange (sprocket shaft side) is facing up

port tube.

or the flywheel assembly will drop to the floor. Dropping

the flywheel assembly may result in parts damage and

minor or moderate injury.

Holding flywheel assembly so that it does not drop out of

Piston Jets

left crankcase half, rotate cradle so that engine is upright

and crankshaft and sprocket shaft are horizontal.

Removal

Carefully slide flywheel assembly out of left crankcase

Remove two T20 TORX screws to free piston jet from

half.

crankcase.

Remove left crankcase half from engine stand and move

Remove O-ring from groove in mounting flange of jet.

to bench area. Remove thrust washer from outboard

Discard O-ring.

side of crankcase by pulling it past the oil seal. Set thrust

washer aside for inspection or reuse.

Using a suitable drift, tap oil seal from bearing bore. Dis-

card oil seal.

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f2136x3x

f2132x3x

f2129x3x

Ram

Pilot/Driver

Support Tube (“A” end up)

Sprocket Shaft Bearing

Figure 3-125. Remove Sprocket Shaft Bearing

Figure 3-126. Install Sprocket Shaft Bearing

See Figure 3-122. Obtain CRANKSHAFT/SPROCKET

Installation

SHAFT BEARING REMOVER/INSTALLER SUPPORT

TUBE (HD-42720-5) and CRANKSHAFT/SPROCKET

1CAUTION

SHAFT BEARING REMOVER/INSTALLER PILOT/

DRIVER (B-45655).

Never move or lift the crankcase by grasping the cylin-

der studs. The crankcase is too heavy to be carried in

Place left crankcase half on work bench with inboard

this manner and may be dropped. Dropping the crank-

side of facing upward.

case may result in parts damage and minor or moderate

Using the tip of a flat blade screwdriver, carefully lift end

injury.

of lock ring out of groove in bearing bore. Working the

See Figure 3-122. Obtain CRANKSHAFT/SPROCKET

screwdriver around the edge, lift the lock ring up and out

SHAFT BEARING REMOVER/INSTALLER SUPPORT

of the groove. Be careful not to damage the lip of the

TUBE (HD-42720-5) and CRANKSHAFT/SPROCKET

groove during removal.

SHAFT BEARING REMOVER/INSTALLER PILOT/

Place support tube on hydraulic press table with the “A”

DRIVER (B-45655).

end up. The ends of the support tube are stamped “A”

Place support tube on hydraulic press table with the “A”

and “B” to ensure proper orientation.

end up. The ends of the support tube are stamped “A”

With the outboard side of the left crankcase half facing

and “B” to ensure proper orientation.

upward, position sprocket shaft bearing bore over sup-

With inboard side of the left crankcase half facing

port tube. See Figure 3-125.

upward, position sprocket shaft bearing bore over sup-

port tube.

10.

Slide pilot/driver through bearing into support tube.

See Figure 3-126. Obtain new sprocket shaft bearing

11.

Center pilot/driver under ram of press. Apply pressure to

and apply a thin film of clean engine oil to O.D.

pilot/driver until bearing is free.

Start sprocket shaft bearing into bearing bore with the

12.

Remove left crankcase half, pilot/driver and bearing from

lettered side down. Lubricate leading edge of bearing

support tube. Discard bearing.

before placement.

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Slide pilot/driver through bearing into support tube.

Hold-Down

Center pilot/driver under ram of press. Apply pressure to

Clamp

pilot/driver until bearing lightly bottoms in the bore.

Remove left crankcase half and pilot/driver from support

tube.

Place left crankcase half on work bench with inboard

side of facing upward.

10. Obtain new lock ring and work into groove in bearing

bore. Be careful not to damage the lip of the groove dur-

ing installation. Verify that lock ring is fully seated in the

groove.

Locating Pin

NOTE

If lock ring will not fit into groove, bearing bore may not have

Figure 3-127. Flywheel Fixture (Part No. HD-44358)

been properly cleaned and/or bearing may not be fully

seated in the bore.

f2154x3x

Sprocket Shaft Bearing Inner Race

Removal

If reusing flywheel, remove bearing inner race and thrust

washer as follows:

a. Obtain FLYWHEEL SUPPORT FIXTURE

(HD-

44358). See Figure 3-127. Install brass jaws or

shop towels around teeth of vise to prevent damage

to tool. Clamp tool in vise with the round hole top-

side.

b. Insert crankshaft end through hole resting flywheel

assembly on fixture. Slide knurled locating pin down

slot in tool to engage crank pin hole. Hand tighten

locating pin.

c. Slide hold-down clamp down slot to engage inboard

side of right flywheel half, and then hand tighten

knurled nut at bottom to secure. Repeat step to

secure hold-down clamp on opposite side of fly-

wheel.

NOTE

For proper clamping force, hold-down clamp must not be

tilted. Rotate hex on outboard stud until clamp is level.

d. Position WEDGE ATTACHMENT (HD-95637-46B)

on inboard side of thrust washer and turn hex nuts

an equal number of turns to draw halves of wedge

together.

Forcing Screw

Hardened Plug

3/8-16 Inch Bolt

Wedge Attachment

CAUTION

with Flat Washer

Bearing Inner Race

Install wedge attachment only so far as necessary to

Bridge

Sprocket Shaft

ensure positive contact with thrust washer. Installing

tool with more contact than absolutely necessary will

Figure 3-128. Remove Inner Race From Sprocket Shaft

result in damage to flywheel.

e. Obtain two 3/8-16 inch bolts 6-1/2 inches long (with

flat washers). Install flat washers on bolts. Obtain

Slide one bolt into channel on each side of bridge

bridge, forcing screw and hardened plug from

so that flat washer is between bridge and bolt head.

MAINSHAFT BEARING INNER RACE PULLER/

Thread bolts into wedge attachment an equal num-

INSTALLER (HD-34902B).

ber of turns.

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1. Install Thrust Washer and Bearing Inner Race On

f2265x3x

Sprocket Shaft. Assemble Tool.

Figure 3-129. Sprocket Shaft Timken Bearing

Cone Installer (Part No. HD-97225-55B)

g. Sparingly apply graphite lubricant to threads of forc-

ing screw to prolong service life and ensure smooth

operation. Start forcing screw into center hole of

bridge.

CAUTION

f2152b3x

Failure to use hardened plug may result in damage to

forcing screw and/or sprocket shaft.

2. Press Bearing Inner Race Onto Sprocket Shaft.

h. Place cupped side of hardened plug against end of

sprocket shaft. Thread forcing screw into bridge until

f2153b3x

the steel ball at the end of the screw makes firm

contact with hardened plug.

Using the Robinair Heat Gun (HD-25070), uniformly

heat the bearing inner race for about 30 seconds

using a circular motion.

NOTE

To faciliate removal without heat, apply a light penetrating oil

to shaft and leading edge of bearing inner race.

1WARNING

Never use both heat and penetrating oil. Use only one or

the other. Excessive heat can cause the penetrating oil

Pilot Shaft

Sleeve

to ignite resulting in flames or fire. Inadequate safety

Handle

Inner Race

precautions can result in death or serious injury.

Flat Washer

Thrust Washer

Nice Bearing

Turn forcing screw until thrust washer and bearing

inner race move approximately 1/8 inch (3.2 mm).

Figure 3-130. Press Inner Race Onto Sprocket Shaft

k. Turn hex nuts an equal number of turns to separate

halves of WEDGE ATTACHMENT.

CAUTION

After bottoming thrust washer on shaft, reposition

WEDGE ATTACHMENT

(HD-95637-46B) on

Install wedge attachment only so far as necessary to

inboard side of bearing inner race. Turn hex nuts an

ensure positive contact with bearing inner race. Install-

equal number of turns to draw halves of wedge

ing tool with more contact than absolutely necessary

together.

will result in damage to flywheel.

2006 Touring: Engine

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f2266x3x

Bearing

Flywheel Assembly

Left Crankcase Half

Thrust Washer

Inner Race

Oil Seal

Lock Ring

Spacer

Figure 3-131. Sprocket Shaft Bearing Assembly

m. Verify that the tool assembly is square, so that the

NOTE

bearing inner race is not cocked during removal.

To faciliate installation without heat, apply a light penetrating

See Figure 3-128.

oil to shaft and leading edge of bearing inner race.

n. Using the Robinair Heat Gun (HD-25070), uniformly

heat the bearing inner race for about 30 seconds

using a circular motion.

1WARNING

Never use both heat and penetrating oil. Use only one or

NOTE

the other. Excessive heat can cause the penetrating oil

To faciliate removal without heat, apply a light penetrating oil

to ignite resulting in flames or fire. Inadequate safety

to shaft and leading edge of bearing inner race.

precautions can result in death or serious injury.

o. Turn forcing screw until bearing inner race is pulled

Obtain the SPROCKET SHAFT TIMKEN BEARING

free of sprocket shaft.

CONE INSTALLER (HD-97225-55B). See Figure 3-129.

p. Remove thrust washer from sprocket shaft.

Assemble tool as described below.

a. Thread pilot onto sprocket shaft until contact is

Discard thrust washer and bearing inner race.

made with shoulder.

b. Sparingly apply graphite lubricant to threads of pilot

Installation

shaft to prolong service life and ensure smooth

Place new thrust washer over sprocket shaft with the ink

operation.

stamp facing outside

(and the chamfer on the ID

c. Slide sleeve over pilot until it contacts bearing inner

inboard).

race.

Place new bearing inner race on bench top. Using the

Robinair Heat Gun (HD-25070), uniformly heat bearing

d. Slide Nice bearing and large flat washer over pilot

inner race for about 60 seconds using a circular motion.

until contact is made with sleeve.

Wearing suitable gloves to protect hands from burns,

e. Thread handle onto pilot shaft. See upper frame of

place heated bearing inner race over sprocket shaft.

Figure 3-130.

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2006 Touring: Engine

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Rotate handle of tool in a clockwise direction until bear-

Check ring dowels for looseness, wear or damage.

ing inner race bottoms against thrust washer. See lower

Replace as necessary.

frame of Figure 3-130.

Use a file to carefully remove any nicks or burrs from

Remove handle, flat washer, Nice bearing, sleeve and

machined surfaces.

pilot from sprocket shaft.

Clean out tapped holes and clean up damaged threads.

Check the top of the crankcase for flatness with a

Cylinder Studs

straightedge and feeler gauge. Replace if warped.

Removal

Thread a 3/8”-16 nut onto cylinder stud.

Installation

Thread a second nut onto stud until it contacts the first.

See Section 3.10 BOTTOM END OVERHAUL, ASSEM-

Placing wrench on first nut installed, remove stud from

BLY, steps 1-29.

cylinder deck.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

Installation

steps 1-39.

Hand start stud in cylinder deck with the collar side

down.

Install steel ball bearing into unused cylinder head bolt.

Position head bolt on end of stud.

Using an air gun, tighten stud until collar almost contacts

cylinder deck.

Leaving cylinder head bolt installed, hand tighten stud to

10-20 ft-lbs (14-27 Nm).

Pipe Plug and Oil Fittings

Removal

Turn hex on oil fittings in a counterclockwise direction

until free.

Turn pipe plug in a counterclockwise direction until free.

Installation

Apply Loctite Pipe Sealant with Teflon 565 to threads.

Turn hex on oil fittings in a clockwise direction until snug.

Tighten fittings to 120-168 in-lbs (13.6-18.9 Nm).

Install pipe plug. Tighten pipe plug to 120-168 in-lbs

(13.6-18.9 Nm).

Cleaning and Inspection

Scrape old gasket material from the crankcase flanges.

Old gasket material left on mating surfaces will cause

leaks.

Clean all parts in a non-volatile cleaning solution or sol-

vent.

Thoroughly dry all parts with low pressure compressed

air.

Verify that all oil holes and passageways are clean and

open.

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FLYWHEEL/CONNECTING ROD

ASSEMBLY

Removal

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-29.

See Section 3.10 BOTTOM END OVERHAUL, DISAS-

SEMBLY, steps 1-18.

See Section

3.11 SUBASSEMBLY SERVICE AND

REPAIR, CRANKCASE, LEFT CRANKCASE HALF,

SPROCKET SHAFT BEARING, REMOVAL.

f1690x3x

Inspection

Figure 3-133. Check Connecting Rod Side Play

Replace the flywheel/connecting rod assembly if any of

the following conditions are noted:

● The crankshaft/sprocket shaft bearing inner races

CAUTION

are brinelled, burnt, scored, blued or damaged.

Do not attempt to straighten connecting rods. Straight-

ening rods will damage both the upper bushing and

Orient the assembly as shown in Figure 3-132. Holding

lower bearing.

the shank of each rod just above the bearing bore, pull

up and down on the connecting rods. Any discernable

● Connecting rods are bent or twisted.

up and down movement indicates excessive lower

● Connecting rods do not fall under their own weight

bearing clearance. Replace the flywheel/connecting rod

or are in a bind.

assembly.

NOTE

Insert a feeler gauge between the thrust washer and the

Bluing on connecting rods is from induction hardening and is

outboard side of the connecting rod. See Figure 3-133.

considered a normal condition.

Replace the assembly if rod side play exceeds 0.020

inch (0.51 mm).

NOTE

If the flywheel, connecting rods or right side bearing inner

race need to be replaced, then replace the entire flywheel

assembly.

Installation

See Section

3.11 SUBASSEMBLY SERVICE AND

REPAIR, CRANKCASE, LEFT CRANKCASE HALF,

SPROCKET SHAFT BEARING, INSTALLATION.

See Section 3.10 BOTTOM END OVERHAUL, ASSEM-

BLY, steps 1-29.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

steps 1-39.

f1689x3x

Figure 3-132. Check Connecting Rod Bearing Clearance

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2006 Touring: Engine

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SPECIFICATIONS

4.1

CVH CARBURETOR JET SIZES

TORQUE VALUES

Main Fuel

Slow Fuel

Model

Item

ft/in-lbs

Jet No.

Enrichener cable

49 state

190

20-35 in-lbs

2.3-4.0 Nm

mounting bracket hex nut

HDI

195

Cylinder head breather

120-144 in-lbs

13.6-16.3 Nm

bolts

California

185

Air cleaner cover bracket

40-60 in-lbs

4.5-6.8 Nm

screws

Air cleaner cover screw

36-60 in-lbs

4.1-6.8 Nm

FUEL TANK CAPACITY

Fuel valve hex jam nut

15-20 ft-lbs

20-27 Nm

Fuel tank adapter

22-26 ft-lbs

30-35 Nm

Capacity

English

Metric

Fuel tank rear mounting

15-20 ft-lbs

20-27 Nm

bolt

Total

5.0 Gallons

18.9 liters

Fuel tank front mounting

15-20 ft-lbs

20-27 Nm

Reserve

0.9 Gallons

3.4 liters

bolts

Battery hold-down clamp

15-20 ft-lbs

20-27 Nm

screw

Console mounting bolt

50-90 in-lbs

5.7-10.2 Nm

acorn nut

2006 Touring: Fuel

4-1

HOME

FUEL SYSTEM TROUBLESHOOTING (CARBURETED)

4.2

CARBURETOR TROUBLESHOOTING

OVERFLOW

Check for:

Remedy:

Restricted fuel tank vent system.

Correct restricted hose. Replace vapor valve.

Loose float bowl screws.

Tighten screws.

Damaged float bowl O-ring.

Replace O-ring.

Improper fuel level in float bowl.

Adjust float tab for correct fuel level.

Damaged or leaking float assembly.

Replace float assembly.

Particle contamination in fuel inlet fitting cavity.

Clean and clear cavity and fuel supply tract.

Worn or dirty inlet valve or seat.

Clean or replace valve and clean seat.

POOR IDLING

Check for:

Remedy:

Idle speed improperly adjusted.

Adjust operating idle speed.

Inlet system air leak (faster idling).

Correct as required.

Loose low speed jet.

Tighten jet.

Contaminated or plugged low speed system.

Clean contaminants and clear passages.

Enrichener valve not seated or leaking.

Adjust, clean or replace.

Leaking accelerator pump.

Repair.

POOR FUEL ECONOMY

Check for:

Remedy:

High speed riding style.

Modify riding habits.

Excessive use of enrichener system.

Limit system use.

Fuel level too high.

Adjust float level.

Restricted fuel tank vent system.

Correct restricted hose. Replace vapor valve.

Dirty air cleaner element.

Clean or replace as required.

Excessive accelerator pump output.

Check and clean accelerator pump bypass orifice.

Plugged or restricted bowl vent.

Clean and clear passages.

Vacuum piston assembly malfunction.

See Vacuum Piston Troubleshooting.

Loose jets.

Tighten jets.

10. Worn or damaged needle or needle jet.

10. Replace needle or needle jet.

11. Plugged air jets or passages.

11. Clean and clear passages.

12. Enrichener valve not seated or leaking.

12. Adjust, clean or replace.

13. Idle speed improperly adjusted.

13. Adjust operating idle speed.

POOR ACCELERATION

Check for:

Remedy:

Throttle cables misadjusted.

Adjust throttle cables.

Inlet system air leak.

Correct as required.

Restricted fuel tank vent system.

Correct restricted hose. Replace vapor valve.

Restricted fuel supply passages.

Correct and clear restriction.

Plugged bowl vent or overflow.

Clean and clear passages.

Enrichener valve not seated or leaking.

Adjust, clean or replace.

Worn or damaged needle or needle jet.

Replace assembly.

Vacuum piston malfunction.

See Vacuum Piston Troubleshooting.

Plugged jets or passages.

Clean and clear as required.

10. Fuel level (float chamber) too low.

10. Adjust float level.

11. Accelerator pump leaking or no output.

11. Repair as necessary.

4-2

2006 Touring: Fuel

Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 16