3 SPECIFICATIONS GENERAL ENGINE IGNITION SPECIFICATIONS Number of cylinders 2 4-cycle, 45°V Twin Type Horsepower 91 @ 5800 RPM Torque (foot-pounds) 87 @ 5200 RPM Compression ratio 10.0 to 1 5° BTDC Timing with engine at RPM listed below and V.O.E.S. connected 20° BTDC Regular idle Bore 3.500 in. 88.9 mm Stroke 3.812 in. 96.82 mm Piston displacement 73.4 in.3 1203 cc 2.1 quarts 1.
ITEM NEW COMPONENTS SERVICE WEAR LIMITS ROCKER ARM Shaft fit in bushing (loose) 0.0005-0.0020 in. 0.013-0.051 mm 0.0035 in. 0.089 mm End clearance 0.003-0.013 in. 0.08-0.33 mm 0.025 in 0.64 mm Bushing fit in rocker arm (tight) 0.004-0.002 in. 0.10-0.05 mm 0.0007-0.0022 in. 0.018-0.056 mm 0.0035 in. 0.089 mm 0.007-0.020 in. 0.18-0.51 mm 0.032 in. 0.81 mm ROCKER ARM SHAFT Shaft fit in rocker cover (loose) PISTON Compression ring gap (top and 2nd) Oil control ring rail gap 0.009-0.
ITEM NEW COMPONENTS SERVICE WEAR LIMITS GEARCASE Cam gear shaft in bushing (loose) 0.0007-0.0022 in. 0.018-0.056 mm 0.003 in. 0.08 mm Cam gear shaft end play (min) (except rear intake) 0.005-0.024 in. 0.13-0.61 mm 0.025 in. 0.64 mm Rear intake cam gear shaft end play (min) 0.006-0.024 in. 0.15-0.61 mm 0.040 in. 1.02 mm Flywheels at rim 0.000-0.010 in. 0.00-0.25 mm 0.010 in. 0.25 mm Shaft at flywheel end 0.000-0.002 in. 0.00-0.05 mm 0.002 in. 0.05 mm 0.001-0.005 in. 0.025-0.
ITEM TORQUE NOTES Crank pin nut 150-185 ft-lbs 203-251 Nm LOCTITE 620 RETAINING COMPOUND, page 3-59 Crankcase 1/4 in. screws 70-110 in-lbs 7.9-12.4 Nm page 3-63 Crankcase 5/16 in. screws 15-18 ft-lbs 20-24 Nm page 3-63 80-110 in-lbs 9.0-12.4 Nm Crankcase cover screws Cylinder head screws Cylinder studs See note special pattern to tighten, page 3-46 special pattern to tighten, page 3-20 10 ft-lbs 13.6 Nm Front isolator to cylinder head bolt 73-78 ft-lbs 98.9-105.
ENGINE GENERAL FUEL The V2 EvolutionTM engine is a two-cylinder, four-cycle, aircooled, overhead-valve V-twin. It has three major component assemblies. Gasoline/alcohol Blends Cylinder The cylinder assembly includes cylinder head, valves, rocker arm cover, rocker arms and piston. Cylinders mount on the crankcase in a 45 degree “V” with both connecting rods connected to a single crank pin. Crankcase The up-and-down motion of the piston in the cylinder is converted to circular motion in the crankcase.
ADJUSTMENT/TESTING Combustion chamber leakage can result in unsatisfactory engine performance. A compression test can help determine the source of cylinder leakage. Use CYLINDER COMPRESSION GAUGE (Part No. HD-33223-1). General When an engine needs repair, it is not always possible to determine definitely beforehand whether repair is possible with only cylinder heads, cylinders and pistons disassembled or whether complete engine disassembly is required for crankcase repair.
Cylinder Leakage Test The cylinder leakage test pinpoints engine problems including leaking valves, worn, broken or stuck piston rings and blown head gaskets. The cylinder leakage tester applies compressed air to the cylinder at a controlled pressure and volume, and measures the percent of leakage from the cylinder. Table 3-2. Air Leakage Test AIR LEAK LOCATION POSSIBLE CAUSES Carburetor intake. Intake valve leaking. Exhaust pipe. Exhaust valve leaking. Use a CYLINDER LEAKDOWN TESTER (Part No.
STRIPPING MOTORCYCLE FOR ENGINE REPAIR DISASSEMBLING ENGINE FOR CYLINDER HEAD REPAIR 1. 5673 Lift and secure the motorcycle. a. Place vehicle on a lift and anchor front wheel in place. Raise lift so the top of the cylinder head is easy to access. b. Raise rear wheel off lift using REAR WHEEL SUPPORT STAND (Part No. B-41174). Attach straps to frame Floor hoist 1WARNING To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before proceeding.
b0202x3x b0251x3x 2 1 1. 2. 3. 3 Crating strap 4. 4 6 5 7 5. 6. 7. Ground strap Rear isolator Swingarm mount block bolts (2, upper) Swingarm mount block bolts (2, lower) Rubber isolator (2) Lockwashers (2) Isolator bolts (2) Figure 3-3. Rear Tie Bar Assembly Figure 3-2. Supporting the Engine 20. See Figure 3-3. Remove isolator bolt (7) and lockwasher (6) on each side. 1. 2. 3. 4. 5. 6. 7. 8. 9. 9 8 21. Slowly raise floor hoist until rubber isolators (5) can be removed.
INSTALLING THE ENGINE ENGINE CRANKCASE INSTALLATION 1. See Figure 3-2. Place engine crankcase on supports so frame may be installed over the top of the engine. 2. See Figure 3-3. If removed, attach swingarm mount block to engine. Install upper bolts (3), washers and locknuts finger tight. Install lower bolts (4), washers and locknuts finger tight. Tighten upper bolts to 41-45 ft-lbs (55.6-61.0 Nm) and lower bolts to 68-75 ft-lbs (92.2-101.7 Nm). 3. 19. Attach disconnected wires. See Section 7.
CYLINDER HEAD Before removing the cylinder head assembly, see DISASSEMBLING ENGINE FOR CYLINDER HEAD REPAIR on page 3-8. The rocker arm covers and internal components must be removed before removing cylinder heads. 1CAUTION All washers and fasteners used in the V2TM engine are hardened. Do not mix or replace hardened washers and fasteners with unhardened parts. Do not reuse fiber cover seals. These actions may result in accelerated wear and increased noise. 1. 2. REMOVAL See Figure 3-5.
3. Rotate crankshaft until both valves are closed on head being repaired. 4. Remove two 5/16 in. rocker arm retaining bolts (12) at push rod end. 5. Remove remaining fasteners and washers (13, 14 and 15) holding lower rocker arm cover to cylinder head. 6. Remove lower rocker cover (18). 5698 Position of rocker arm retaining bolts NOTE Retaining notch Remove lower rocker boxes as an assembly; then disassemble as required. 1CAUTION Mark rocker arm shafts for reassembly in their original positions.
. xlhcylhead 7 8 5 6 11 9 1 7 8 16 5 6 5 11 9 16 2 17 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
b0134x3x 5694 8 7 12 10 6 1 11 Valve Spring Compressor (Part No. HD-34736B) 13 Figure 3-11. Compressing Valve Springs 9 4 2767a 15 14 5 2 3 1. Right crankcase half Pin (2) O-ring (2) Plate Screw Tappet lifter (2) Push rod cover (2) 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Seal (2) Retainer (2) O-ring (2) Screw (2) Push rod (2) Washer (2) Washer Locating pin (2) Figure 3-10. Middle Valve Train Components (Quantities per Engine Cylinder) CLEANING, INSPECTION AND REPAIR 1.
2768a 2770a Figure 3-13. Measuring Rocker Arm Shaft Diameter (Rocker Arm Bushing Position) Figure 3-15. Measuring Rocker Arm Bushing Inner Diameter 5699 diameter and valve guide inner diameter. Check measurements against SERVICE WEAR LIMITS. 15. Inspect spark plug threads for damage. If threads in head are damaged, a special plug type insert can be installed using a 12 mm spark plug repair kit. 16. Inspect valve springs for broken or discolored coils. 17. See Figure 3-16.
2771a 2411a 9/16 in. -18 tap Figure 3-16. Checking Spring Free Length 5700 Gasket surface flat within 0.006 in. (0.15 mm) Figure 3-18. Removing Rocker Arm Bushing 3. Measure outer diameter of a new standard valve guide. The guide diameter should be 0.0020-0.0033 in. (0.0510.084 mm). larger than bore in head. If it is not, select one of the following oversizes: +0.001 in., +0.002 in., or +0.003 in. (+0.025, +0.05 +0.08 mm) (intake and exhaust). 4. See Figure 3-19.
5692 5695 Driver Handle (Part No. HD-34740) Valve Guide Brush (Part No. HD-34751) Valve Guide Installation Tool (Part No. HD-34741) Cylinder Head Holding Fixture (Part No. HD-39786) Figure 3-20. Honing Valve Guides b0169x3x Cylinder Head Stand (Part No. HD-39782) Head Seat 60° Figure 3-19. Installing Shoulderless Valve Guide Grinding Valve Faces and Seats 0.040-0.062 in. (1.02-1.57 mm) Valve After installing valve guides, valve seats must be refaced to make them concentric with guides.
1CAUTION Do not grind valve to shorten. Grinding will remove the case hardening and expose the stem’s mild steel core resulting in rapid end wear. 8. See Figure 3-22. Wipe valve seats and valve faces clean. Measure valve stem protrusion. If valve stem protrudes more than 2.034 in. (51.66 mm), replace valve seat or cylinder head. If valve stem protrusion is within the acceptable range, valves and seats are ready for lapping. 5696 Valve stem must not protrude more than 2.034 in. (51.
ASSEMBLY b0172x3x 1CAUTION 2 Make sure all lapping compound is removed from cylinder head and valves after lapping is completed. If lapping compound contaminates any internal engine components or engine oil, excessive engine wear and damage may result. 1. Wash cylinder head and valves in warm, soapy water to remove all lapping compound. 2. Scrub valve guide bores with VALVE GUIDE BRUSH (Part No. HD-34751) and hot, soapy water. 3. Blow dry with compressed air. 4.
INSTALLATION If only cylinder head work was needed, reinstall cylinder head following these instructions. If further repair is required, see CYLINDER AND PISTON on page 3-22. 1. See Figure 3-9. Coat mating surfaces of cylinder studs (12) and head screws (1, 2) with parts cleaning solution. 2. Scrape old oil and any carbon deposits from threads by using a back-and-forth motion, threading each head screw onto its mating cylinder stud. 3. Remove head screws from studs. Wipe or blow dry thread surfaces.
1CAUTION Do not turn engine over until both push rods can be turned with fingers. Otherwise, damage to push rods or rocker arms may result. 20. See Figure 3-5. Install fasteners (12, 13, 14 and 15). Slowly snug all fasteners in small increments (one turn at a time). Use a cross pattern on the four large bolts (12, 13) that fasten the lower rocker box to head. This will bleed the lifters. Tighten screws (14) to 90-120 in-lbs (10.2-13.6 Nm). Tighten bolts (15) to 10-13 ft-lbs (13.618 Nm).
