2007 Harley-Davidson V-Rod (VRSC) OEM Service & Repair Manual

2007 VRSC: Engine 3-1 HOME 35 SPECIFICATIONS (ALL EXCEPT VRSCX) 3.1 Table 3-1. Engine General ITEM DATA Number of cylinders 2 Type 4-cycle, 60°, liquid cooled V-twin Torque (VRSCAW) (domestic model at crank) 100 Nm (74 ft-lbs) @ 7000 rpm Torque (VRSCD/VRSCDX/ VRSCR) (domestic model at crank) 109 Nm (80 ft-lbs) @ 7000 rpm Bore 100 mm (3.94 in.) Stroke (all) 72 mm (2.835 in.) Piston displacement (approx.) 1130 cc (69 cubic in.) Max. engine speed 9000 RPM Idle speed 1150-1250 RPM Engine & transmission weight 89.4 kg (197 lbs) Table 3-2. Oil Pump ITEM DATA Type Gerotor, internal oil pump, wet sump Pressure 3-6.5 bar (43-94 psi) at 3000 RPM and nor- mal operating temperature of 70° C (158° F) Filtration 10 micron media between pump & engine Table 3-3. Water Pump ITEM DATA Type Impeller type, thermostat controlled bypass Table 3-4. Valve Diameter ITEM MM IN Intake 40.0 1.575 Exhaust 34.5 1.358 Table 3-5. Valve Lash ITEM MM IN Intake Max 0.245 0.0096 Min 0.195 0.0078 Exhaust Max 0.345 0.0135 Min 0.295 0.0117

3-2 2007 VRSC: Engine HOME Table 3-6. Cylinder Heads ITEM MM IN Valve guide in head (interference fit) Max 0.051 0.002 Min 0.022 0.0009 Valve seat in head (interference fit) Max 0.100 0.0039 Min 0.059 0.002 Head gasket surface (flatness) 0.020 0.0008 Valve-to-guide running clearance - intake Max 0.0585 0.0023 Min 0.0285 0.0011 Valve-to-guide running clearance - exhaust Max 0.0685 0.0026 Min 0.0385 0.0015 Valve guide I.D. Max 6.015 0.2368 Min 6.000 0.2362 Valve stem diameter Intake Max 5.9715 0.2351 Min 5.9565 0.2345 Exhaust Max 5.9615 0.2347 Min 5.9465 0.2341 Valve to guide running clearance Intake Max 0.0585 0.0023 Min 0.0285 0.0011 Exhaust Max 0.0685 0.0027 Min 0.0385 0.0015 Valve seat to cylinder head press Max 0.0100 0.0004 Min 0.0590 0.0023 Valve seat run-out Max 0.0050 0.0002 Valve seat to guide run-out Max 0.0200 0.0008 Valve spring free length Outer Max 45.630 1.797 Inner Max 43.770 1.723 Valve spring installed height Outer Max 39.000 1.535 Inner Max 37.000 1.457 Cylinder head flatness Max 0.0200 0.0008 Intake valve stem protrusion Max 44.771 1.762 Min 44.171 1.739 Exhaust valve stem protrusion Max 43.893 1.728 Min 43.293 1.704

2007 VRSC: Engine 3-3 HOME Table 3-7. Cylinder Heads (continued) ITEM KG LB Spring force installed Outer @ 39 mm (1.535 in.) max Max 20.80 45.86 Min 18.97 41.88 Inner @37 mm (1.457 in.) max Max 11.31 24.95 Min 10.10 22.26 Maximally compressed (intake and exhaust) Outer Max 66.58 146.80 Min 60.87 134.22 Inner Max 34.15 75.31 Min 31.10 68.57 Table 3-8. Cam Drive Chain guide wear Pittings to be smaller than 16 mm (0.62 inches) in length, Maximum depth of tensioner show wear 0.8 mm. (0.03 inches) Sprocket wear Visual check. No pittings allowed. Lateral wear caused by chain is allowed Table 3-9. Cam Timing Intake (1130 cc) 103° ATDC Exhaust (1130 cc) 108° BTDC Total intake lift 10.9 mm (0.4291 in.) Duration intake @1 mm 248° Total exhaust Lift 9.98 mm (0.3929 in.) Duration exhaust @ 1 mm 206° Table 3-10. Piston Ring Gap ITEM MM IN Top ring gap Max 0.550 0.022 Min 0.350 0.014 2nd ring gap Max 0.600 0.024 Min 0.400 0.016 Oil control ring gap Max 0.890 0.035 Min 0.380 0.015 Top ring side clearance Max 0.075 0.003 Min 0.020 0.001 2nd ring side clearance Max 0.055 0.002 Min 0.010 0.000

3-4 2007 VRSC: Engine HOME Table 3-11. Connecting Rod/Piston ITEM MM IN Rod small end bore dia. Max 22.028 0.8672 Min 22.018 0.8669 Piston pin diameter Max 22.000 0.8661 Min 21.995 0.8659 Running clearance Max 0.033 0.0013 Min 0.018 0.0007 Table 3-12. Balance Shaft/Crankcase ITEM MM IN Balance shaft journal Max 17.012 0.6698 Min 17.001 0.6693 Press ﬁt inner race to journal Max -0.020 - 0.0008 Min -0.001 - 0.0000 Crankcase balance shaft bearing bore Max 39.971 1.5737 Min 39.955 1.5730 Bearing outer race to bearing bore press ﬁt Max -0.045 - 0.0018 Min -0.018 - 0.0007 Table 3-13. Connecting Rod Journals ITEM MM IN Rod bearing journal Red Max 47.991 1.8894 Min 47.983 1.8891 Blue Max 47.983 1.8891 Min 47.975 1.8888 Rod bearing bore with- out bearing Max 51.616 2.0321 Min 51.600 2.0315 Rod bearing bore with bearing Red Max 48.052 1.8918 Min 48.020 1.8906 Blue Max 48.044 1.8915 Min 48.012 1.890 Running clearance Max 0.069 0.0027 Min 0.029 0.0011 Axial ground play Max 0.290 0.0114 Min 0.140 0.0055

2007 VRSC: Engine 3-5 HOME Table 3-14. Crankshaft/Crankcase ITEM ALTERNATOR SIDE CLUTCH SIDE MM IN MM IN Main bearing journal Blue Max 55.977 2.20382 Max 55.952 2.20283 Min 55.971 2.20358 Min 55.946 2.20260 Green Max 55.984 2.20409 Max 55.959 2.20311 Min 55.977 2.20382 Min 55.952 2.20283 Red Max 55.990 2.20433 Max 55.965 2.20334 Min 55.984 2.20410 Min 55.959 2.20312 Main bearing bore Max 61.019 2.40232 Min 61.000 2.40158 Running clearance Blue Max 0.059 0.00232 Max 0.059 0.00232 Min 0.026 0.00103 Min 0.026 0.00103 Green Max 0.061 0.00240 Max 0.061 0.00240 Min 0.027 0.00107 Min 0.027 0.00107 Red Max 0.062 0.00244 Max 0.062 0.00244 Min 0.029 0.00115 Min 0.029 0.00115 Axial end play Max 0.060 0.00236 Min 0.050 0.00197

3-6 2007 VRSC: Engine HOME SPECIFICATIONS (VRSCX ONLY) 3.2 NOTE The following specifications are specific to the VRSCX Screamin’ Eagle 1250 engine. All other procedures and infor- mation can be references in the appropriate Service Manual for your model motorcycle. Table 3-15. Engine General ITEM DATA Number of cylinders 2 Type 4-cycle, 60°, liquid cooled V-twin Torque (domestic model at crank) 111.2 Nm (82 ft-lbs) @ 7000 rpm Bore 105 mm (4.13 in.) Stroke 72 mm (2.84 in.) Piston displacement (approx.) 1250 cc (76 cubic in.) Max. engine speed 9000 RPM Idle speed 1300 rpm ± 50 Engine & transmission weight 89.4 kg (197 lbs) Table 3-16. Cam Drive ITEM DATA Intake 112 ± 1° Exhaust 106 ± 1° Total intake lift 10.9 mm (0.4291 in.) Duration, intake @ 1 mm 248° Total exhaust lift 9.98 mm (0.3929 in.) Duration, exhaust @ 1 mm 206° Table 3-17. Cam Timing Intake (1250 cc) 108° ATDC Exhaust (1250 cc) 108° BTDC Total intake lift 10.9 mm (0.4291 in.) Duration intake @1 mm 248° Total exhaust Lift 9.98 mm (0.3929 in.) Duration exhaust @ 1 mm 206° Table 3-18. Piston Ring Gap ITEM DATA Top ring gap (maximum) 0.550 mm (0.022 in.) Top ring gap (minimum) 0.350 mm (0.014 in.) 2nd ring gap (maximum) 0.650 mm (0.026 in.) 2nd ring gap (minimum) 0.400 mm (0.016 in.) Oil control ring (maximum) 0.890 mm (0.035 in) Oil control ring (minimum) 0.380 mm (0.015 in.) Top ring side clearance (maximum) 0.077 mm (0.003 in.) Top ring side clearance (minimum) 0.032 mm (0.001 in.) 2nd ring side clearance (maximum) 0.075 mm (0.003 in.) 2nd ring side clearance (minimum) 0.030 mm (0.001 in.) Table 3-19. Crankcase/Cylinder Liner ITEM DATA Cylinder liner cover over stand (maximum) 0.090 mm (0.0035 in.) Cylinder liner cover over stand (minimum) 0.050 mm (0.0020 in.) Cylinder head deck flatness (maximum) 0.020 mm (0.0008 in.) Cylinder head deck flatness (minimum) 0.000 mm (0.0000 in.)

2007 VRSC: Engine 3-7 HOME Table 3-20. Cylinder Liner Out of Round ITEM DATA Cylinder liner out of round, installed (maximum) 0.020 mm (0.0008 in.) Piston major diameter, Class I (maximum) 104.981 mm (4.1331 in.) Piston major diameter, Class I (minimum) 104.977 mm (4.1330 in.) Piston major diameter, Class X (maximum) 104.989 mm (4.1334 in.) Piston major diameter, Class X (minimum) 104.981 mm (4.1331 in.) Piston major diameter, Class II (maximum) 104.993 mm (4.1336 in.) Piston major diameter, Class II (minimum) 104.989 (4.1334 in.) Table 3-21. Piston Major Diameter ITEM DATA Piston major diameter, Class I (maximum) 104.981 mm (4.1331 in.) Piston major diameter, Class I (minimum) 104.977 mm (4.1330 in.) Piston major diameter, Class X (maximum) 104.989 mm (4.1334 in.) Piston major diameter, Class X (minimum) 104.981 mm (4.1331 in.) Piston major diameter, Class II (maximum) 104.993 mm (4.1336 in.) Piston major diameter, Class II (minimum) 104.989 (4.1334 in.) Table 3-22. Running Clearance ITEM DATA Class I liner with class X piston (maximum) 0.019 mm (0.0007 in.) Class I liner with class X piston (minimum) 0.000 mm (0.0000 in.) Class II liner with class X piston (maximum) 0.032 mm (0.0013 in.) Class II liner with class X piston (minimum) 0.011 mm (0.0004 in.) Class I liner with class I piston (maximum) 0.023 mm (0.0009 in.) Class I liner with class I piston (minimum) 0.006 mm (0.0002 in.) Class II liner with class II piston (maximum) 0.024 mm (0.0009 in.) Class II liner with class II piston (minimum) 0.007 mm (0.0003 in.) Table 3-23. Piston to Cylinder Liner Wear ITEM REPLACE IF WEAR EXCEEDS Cylinder liner I.D. bore (freestate) 105.085 mm (4.1372 in.) Cylinder liner out of round (installed) 0.800 mm (0.0031 in.) Piston major diameter Class X 104.925 mm (4.1309 in.) Running clearance 0.080 mm (0.0031 in.) Table 3-24. Piston Rings ITEM REPLACE IF WEAR EXCEEDS Top ring gap 0.700 mm (0.0276 in.) 2nd ring gap 0.080 mm (0.0315 in.) Oil control ring gap 1.050 mm (0.0413 in.) Top ring side clearance 0.102 mm (0.0040 in.) 2nd ring side clearance 0.090 mm (0.0035 in.)

3-8 2007 VRSC: Engine HOME SERVICE WEAR LIMITS (ALL EXCEPT VRSCX) 3.3 Table 3-25. Crankshaft/Crankcase ITEM ALTERNATOR SIDE CLUTCH SIDE MM IN MM IN Main bearing journal Blue Max 55.977 2.20382 Max 55.952 2.20283 Min 55.971 2.20358 Min 55.946 2.20260 Green Max 55.984 2.20409 Max 55.959 2.20311 Min 55.977 2.20382 Min 55.952 2.20283 Red Max 55.990 2.20433 Max 55.965 2.20334 Min 55.984 2.20410 Min 55.959 2.20312 Main bearing bore Max 61.019 2.40232 Min 61.000 2.40158 Running clearance Blue Max 0.059 0.00232 Max 0.059 0.00232 Min 0.026 0.00103 Min 0.026 0.00103 Green Max 0.061 0.00240 Max 0.061 0.00240 Min 0.027 0.00107 Min 0.027 0.00107 Red Max 0.062 0.00244 Max 0.062 0.00244 Min 0.029 0.00115 Min 0.029 0.00115 Axial end play Max 0.060 0.00236 Min 0.050 0.00197

2007 VRSC: Engine 3-9 HOME GENERAL Wear limits are given here as a guideline for measuring used engine components. Replace components when they exceed values listed here. Table 3-26. Crankshaft/Crankcase ITEM REPLACE IF WEAR EXCEEDS MM IN Main bearing journal 55.940 2.202 Axial end play 0.300 0.011 Main bearing bore 61.019 2.4023 Table 3-27. Connecting Rod/Piston ITEM REPLACE IF WEAR EXCEEDS MM IN Small end bore diameter 22.050 0.868 Piston pin diameter 21.996 0.866 Table 3-28. Connecting Rod/Crankshaft ITEM REPLACE IF WEAR EXCEEDS MM IN Rod bearing journal 47.970 1.888 Rod bearing bore 51.616 2.0321 Table 3-29. Piston/Cylinder Liner ITEM REPLACE IF WEAR EXCEEDS MM IN Cylinder liner i. d. bore (freestate) 100.085 3.9403 Cylinder liner out-of- round (installed) 0.080 0.0031 Piston major diameter Class X 99.925 3.9341 Running clearance 0.080 0.0031 Table 3-30. Piston Rings ITEM REPLACE IF WEAR EXCEEDS MM IN Top ring gap 0.700 0.0276 2nd ring gap 0.750 0.0295 Oil control ring gap 1.050 0.0413 Top ring side clearance 0.100 0.0039 2nd ring side clearance 0.070 0.0028 Table 3-31. Cylinder Heads ITEM REPLACE IF WEAR EXCEEDS MM IN Cylinder head ﬂatness 0.100 0.0039 Cylinder head cam bore diameter 26.035 1.0250 Tappet bucket o.d. diameter 30.962 1.2190 Cylinder head bucket bore diameter 31.040 1.2220 Valve guide i.d. diameter 6.040 0.2378 Valve stem deﬂection 0.08 0.00315 Valve seat width - intake 1.700 0.0669 Valve seat width - exhaust 2.00 0.0787 Valve seat-to-guide runout 0.080 0.0031

3-10 2007 VRSC: Engine HOME SERVICE WEAR LIMITS (VRSCX ONLY) 3.4 GENERAL Wear limits are given here as a guideline for measuring used engine components. Replace components when they exceed values listed here. Table 3-32. Crankshaft/Crankcase ITEM REPLACE IF WEAR EXCEEDS MM IN Main bearing journal 55.940 2.202 Axial end play 0.300 0.011 Main bearing bore 61.019 2.4023 Table 3-33. Connecting Rod/Piston ITEM REPLACE IF WEAR EXCEEDS MM IN Small end bore diameter 22.050 0.868 Piston pin diameter 21.996 0.866 Table 3-34. Connecting Rod/Crankshaft ITEM REPLACE IF WEAR EXCEEDS MM IN Rod bearing journal 47.970 1.888 Rod bearing bore 51.616 2.0321 Table 3-35. Piston/Cylinder Liner ITEM REPLACE IF WEAR EXCEEDS MM IN Cylinder liner i. d. bore (freestate) 105.085 4.1372 Cylinder liner out-of- round (installed) 0.080 0.0031 Piston major diameter 104.925 4.1309 Running clearance 0.080 0.0031 Table 3-36. Piston Rings ITEM REPLACE IF WEAR EXCEEDS MM IN Top ring gap 0.700 0.0276 2nd ring gap 0.800 0.03419 Oil control ring gap 1.050 0.0413 Top ring side clearance 0.100 0.0039 2nd ring side clearance 0.070 0.0028 Table 3-37. Cylinder Heads ITEM REPLACE IF WEAR EXCEEDS MM IN Cylinder head ﬂatness 0.100 0.0039 Cylinder head cam bore diameter 26.035 1.0250 Tappet bucket o.d. diameter 30.962 1.2190 Cylinder head bucket bore diameter 31.040 1.2220 Valve guide i.d. diameter 6.040 0.2378 Valve stem deﬂection 0.08 0.00315 Valve seat width - intake 1.700 0.0669 Valve seat width - exhaust 2.00 0.0787 Valve seat-to-guide runout 0.080 0.0031

2007 Harley-Davidson V-Rod (VRSC) OEM Service & Repair Manual

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