So my oil pump went bad on my 2006 Road King. I removed the oil pump and while doing so noticed it had scratched up and potentially bent the crank arm. I figured I'd try another oil pump and see if I could get away with it if it was just scratches. No such luck. The second oil pump lasted about 10 minutes before the inner gears were torn to shreds.

So now I'm at a point where I think I need to split the case and replace the crank, assuming there's no way of repairing the crank arm with it still on the bike.

Has anyone done this job before? Since I'm at it I'll remove the heads and put on a big bore kit. Does it make sense to remove the heads first then remove the crankcase from the bike? Can the crankcase be removed without first removing the tranny? Trying to find how to videos out there but haven't found much. I'm not even sure where to begin.

Any advice is appreciated.

 

Engine comes out pretty easily. It can come out complete or you can pull the top end apart in the bike then remove the bottom end. same amount of work either way. Transmission will stay in the bike. Primary will have to come apart too.

 

I find it easier to pull whole engine and do it all on the bench. They aren't heavy and everything is easier to get to if frame isn't in the way.

 

First thing you need to do is get the OEM service manual for your bike. As has been stated, the trans remains in the frame and will have to be supported in some fashion. The primary should be removed as well as the top end and the lower unit is easily removed from the frame. I would suggest that you find a competent shop to split the cases, refurbish the lower unit and replace the crank. Or, pack the lower unit up and send it to Hoban Brothers (AKA Darkhorse) for a rebuild of the lower unit and crank repair or replacement. I would also suggest having the left side crank main bearing concerted to the Timken type or at least the HD "Lefty" bearing. The new crank should be trued, balanced and plugged or welded to insure against future failure. This won't be a cheap fix, so get your wallet out.

 

agree it won't be cheap! I took the top end off and pulled the bottom end out, was easy enough to get the top end off while still mounted in the chassis. I brought the bottom end to R&R and had them bore it out 4.125 and had them replace the crank, rods, wheels, bearings were upgraded. With that work plus, cylinders/pistons, head work, I could have purchased a short block 124 from them or an S&S 124.

 

There ya go! The HD Long Block program is another option for the OP; cheaper than an S&S motor, upgrade to a 95" or 103", a lot less work and decent warranty.

http://www.harley-davidson.com/conte...e_program.html

 

Last couple of R&R flywheels I dealt with had very light press on crank pin. S&S over size pin was my fix. Ate the cost with no help from a business that should of stood behind their work.

 

Who assembled the wheels?

 

Originally R&R and sent to DH for the fix.

 

Not much to taking out a Twin Cam engine. There's more time involved with removing the outer and inner primary than there is taking out the engine.