vgs-20 fixtures tooling and accessories - · pdf filevgs-20 fixtures tooling and accessories...

1-800-325-3670114

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

VGS-20 FixturesTooling and Accessories for Harley Davidson®

VGS-3100 Head Holder Kit for Harley-Davidson® HeadsSunnen’s exclusive VGS-3100 head fixture allows quick and easy mounting of all Harley® Pan, Shovel, Sportster®, XR, and Evolution® cylinder heads in Sunnen’s VGS-20 Valve Guide and Seat Machine. Design input from renowned Harley® head builders and extensive field test-ing means you get the features designed for your specific needs. Clearance holes are provided for fins, motor mount studs, and other obstructions for trouble free mount-ing. (Requires the use of an optional Sunnen VGS-330A Extension Drive Adapter).

Optional VGS-3100 shown mounted in VGS-2540C Fixture (Included with VGS-20 Machine).

VGS-3102 Spacers (4).

Kit Includes: Mounting plate, VGS-3102 Spacers (4), and mounting hardware.

APPLICATION: Harley® Pan Heads (1949-1965)

APPLICATION: Harley® Shovel Heads (1966-1984)

APPLICATION: Harley® Evolution® Heads (1983-Present)

APPLICATION: Harley® Sportster® XL Heads (1957-1985)

Applications with Harley-Davidson® XR750 and XR1000 Heads not pictured.

VGS-3110 Locating Blocks for Evolution® HeadsThe optional VGS-3110 Locating Blocks can be used with late style VGS-3100 Head Holder Kits. They allow Harley® Evolution® heads to be mounted and referenced from the original dowel pin holes used at the factory. Valve seat counterbores, finished seat angle depth, throat cutting, and other machining can be referenced and duplicated from head to head using this system for ultimate precision. Especially recommended for performance or racing work.

Also provides exceptionally fast setup time when machin-ing multiple sets of Evolution® cylinder heads.

VGS-330A Extension DriveAdapter required when using VGS-3100.

www.sunnen.com 115

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

VCS-505 Single Blade, 3-Angle Seat Cutting Kit for Harley® Cylinder HeadsFor SGM Style Tooling, see pages 12-19 in the Cylinder Head Section.

Valve seat machining kit designed for Harley® cylinder heads features three angle, single blade carbide cutters. Eliminates grinding and cuts all three finished seat angles simultaneously while maintaining exact seat width and angles from seat to seat. Drastically reduces the time required for machining valve seats and increases accuracy.

For use with Sunnen .389 inch (9,9 mm) precision valve guide pilots and Sunnen Valve Guide and Seat Machines, models VGS-19 and VGS-20.

Part No. Description VSC-205 Cutter Body 1.0 - 1.6 inch (25-41 mm) VSC-305 Cutter Body 1.5 - 2.0 inch (38-52 mm) VSC-400 Setting Fixture VSC-50 Tool Sharpening Fixture PSP-215A Spring, Short PSP-216A Spring, Long VSC-509A Spring Bushings (4) PWM-5A Hex T-Wrench VSC-06045 (2) Cutter 30-45-60

Kit Includes:

VSC-100 Tool Sharpener Fixture KitThe VSC-100, when used in conjunction with Sunnen’s TS-100 Precision Tool Sharpener, sharpens cutters in the body eliminating the need to reset the tool each time.

VCS-505S Single Blade, 3-Angle Seat Cutter Kit (Sioux Pilots)Same as VSC-505 except cutter bodies fit Sioux .385 inch (9,8 mm) pilots.

Optional VSC-350 Cutter Bodyfor large diameter valves 1.9-2.5 inch (47-64 mm) range

The VSC-350 is similar to VSC-205 and VSC-305 cutter bodies but increases range to 2.5 inch (64 mm). Uses the same VSC carbide tool bits as other VSC cutter bodies.NOTE: For a complete listing of VSC carbide cutters and other tooling, refer to pages 12-19 or call Customer Service toll free.

VSC-55 Tool Sharpening FixtureSimilar to VSC-50. Used to “off-hand” grind any angle desired on VSC single angle cutters or cutter blanks.

VS-1015 Rapid Valve Seat Checker for Harley-Davidson® HeadsThe VS-1015 provides a quick way of accurately checking valve seat concentricity. The Sunnen VS-1015 Rapid Valve Seat Checker checks the critical intersection line between top and seat angles for roundness and runout. It

works off the same pilot used for machining the seat to deliver optimum accuracy. Provided with a large dial indicator which stays upright for quick and easy reading. Dial is marked in .001 increments.

For metric applications, order VS-1015M.

VGS-20964 Valve Guide Installation Kit

Part No. Description VGS-216A Air Hammer

VGS-217A Air Hammer Hose

VGS-191A .3125 inch (7,92 mm) Guide Driver




B-200L Press Fit Lubricant

Kit Includes:

Set Includes:VS-1010 Indicator Assembly with indicating wheel for Sunnen Pilots .389 inch (9,9 mm), plus these Indicator Wheel Assemblies:

For additional Indicator Wheel Assemblies see page 40.

The VS-1015 Rapid Valve Seat Checker can be used on other manufacturers’ pilots by ordering these indicating adapter wheels:

Part No. Description VS-1116A .385 inch (9,8 mm) diameter Sioux pilots VS-1117A .437 inch (11,1 mm) diameter Kwik Way Pilots VS-1118A .375 inch (9,5 mm) diameter K.O. Lee, Neway, Black and Decker pilots

VS-1500-44VS-1625-44

VS-1750-44VS-1875-44

VS-2000-44

VGS-20 FixturesTooling and Accessories

for Harley Davidson®

1-800-325-3670116

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

VGS-300 Valve Seat Pocket Cutter Kit1.500 to 2.250 inches (38,5 to 57,1 mm)

VS-300E Valve Guide Pilot Kit for Harley-Davidson® Heads

A convenient valve guide pilot kit for the most popular Harley® guide sizes. For a complete range of pilot sizes available, see pages 33 & 34 or call Customer Service toll free.

The VGS-300 is used to machine cylinder heads for the installation of new valve seat rings. Replaceable carbide inserts are easily adjusted to size with the micrometer provided, so the proper press fit can be obtained for cast iron or aluminum heads.

Kit Includes:

Part No. Description ASPC-1500 Seat Pocket Cutter Head 1.500 -1.687 inch (38,1 - 42,9 mm) Range ASPC-1687 Seat Pocket Cutter Head 1.687-1.875 inch (42,9 - 47,6 mm) Range ASPC-1875 Seat Pocket Cutter Head 1.875 - 2.062 inch (47,6 - 52,4 mm) Range ASPC-2062 Seat Pocket Cutter Head 2.062 - 2.250 inch (52,4 -57,1 mm) Range VGS-325 Cutter Head Driver for Sunnen .389 inch (9,88 mm) Pilot VGS-410A Pocket Cutter Setting Fixture with Setting Standard PSP-215A Short Spring PSP-216A Long Spring VSC-509A Spring Bushing (4) PWM-5A Hex T-Wrench

VGS-300S Valve Seat Pocket Cutter Kit(Sioux Pilots)Same as VGS-300, except Cutter Head Driver fits Sioux .385 inch (9,8 mm) pilots.

Kit consists of one each of the following pilots:

Diameter Pilot No. Inches Millimeters VS-310E .310 7,87 VS-311E .311 7,90 VS-312E .312 7,92 VS-340E .340 8,64 VS-341E .341 8,66 VS-342E .342 8,69 VS-376E .376 9,55 VS-377E .377 9,57 VS-378E .378 9,60 VS-379E .379 9,63 VS-380E .380 9,65

VGS-130A Drill ChuckDrill chuck with 0.5 inch (0-12,7 mm) capacity for drilling, reaming, and other machining applications. Used with VGS-20 Valve Guide and Seat Machine and includes integral quick change adapter and chuck key.


www.sunnen.com 117

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

VSC-575 Bowl Hog CutterUsed with Sunnen’s VSC cutter bodies to enlarge the bowl area below the valve seat for increased air flow or installation of larger diameter valves. The single blade, 75 degree cutter features a .38 inch (9,65 mm) radius at the bottom to blend machined areas and provide a chatter free finish. Cutter easily

adjusts to a wide range of diameters eliminating the need for multiple fixed diameter cutters.

VSC-K68B Blank CutterThe VSC-K68B is a .3125 inch (7,92 mm) wide blank cutter for the VSC system. This cutter consists of a carbide tip silver-soldered on a cutter blank. The blank cutter can then be ground by the user to any desired angle or specification. Great for high performance shops that use non-standard valve seat configurations.

VSC-RB Radius Cutter BlankSimilar to the VSC-K68B but supplied with a .5 inch (12,7 mm) wide carbide tip. This allows the user to grind a radius suitable to individual requirements.

Special Profile VSC CuttersSpecial profile VSC cutters are available on a special order basis. These special profile cutters will be made from a blank cutter ground to your specifications. When ordering, send full description with all specifications.

Sunnen VSC Carbide CuttersSunnen offers a complete line of standard and special carbide cutters for use with VSC cutter bodies. Carbide cutters for 3-angle valve seat machining, chamber relief, throat alterations, and other machining requirements are available directly from stock. All VSC carbide bits can be easily re-sharpened on Sunnen’s TS-100 Tool Sharpener. See pages 11-19 & 28-31 for additional tooling and supplies.

VSC 3-Angle Carbide Valve Seat CuttersVSC 3-Angle bits save time and improve accuracy by machining all three valve seat angles simultaneously while producing identical seat widths on every seat. Eliminates grinding when used with Sunnen Valve Guide and Seat Machines and tooling. Available in a wide variety of fin-ished seat widths, angles, and radiused profiles for stock or performance work. See pages 28-31 for a complete list-ing of VSC carbide bits or call Customer Service toll free.

VSC Form ToolsThese carbide bits are used for combustion chamber relief, unshrouding of valves, throat alterations, blending, and other machining operations. Especially useful for R&D and performance work. Bits can be easily re-sharpened and modified to suit individual requirements on Sunnen’s TS-100 Tool Sharpener.

75°.38 R.

VSC-575

1.0

VSC-523 used for chamber relief, cuts with a .236 inch (5,99 mm) radius.


VSC-390 flat bottom, flush cutting tool. Especially useful for cutting out Harley® bronze valve seats to remove the press fit so they can be removed easily.

VSC-523 Chamber

Relief

VSC-527 Chamber

Relief

VSC-390


VSC-512 used for throat alterations, cuts with a .875 inch (22,22 mm) radius.


VSC-511 Chamber

Relief

VSC-512 ThroatRelief

VSC-518 Chamber Relief

VGS-20 FixturesTooling and Accessories


1-800-325-3670118

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®


Part No. Description

VGS-430A Seat Ring Driver Adapter, Manual

Seat Ring Driver Adapter Rings: VGS-453A 1.50 inch (38,10 mm) x 1.625 inch (41,27 mm) VGS-454A 1.75 inch (44,45 mm) x 1.875 inch (47,62 mm) VGS-455A 2.00 inch (50,80 mm) x 2.215 inch (53,97 mm)

Part No. Diameter Range VC-276 .276 - .315 inch (7,01 - 8,00 mm) VC-315 .315 - .354 inch (8,00 - 8,99 mm) VC-354 .354 - .394 inch (8,99 - 10,00 mm) VC-433 .433 - .472 inch (10,99 - 11,98 mm) VC-472 .472 - .512 inch (11,98 - 13,00 mm)

VGS-1750 and VGS-1750M Seat Depth Indicator KitsThe Sunnen VGS-1750 and VGS-1750M Seat Depth Indicators are designed for installation on Sunnen Valve Guide and Seat Machines, models VGS-19 and VGS-20. The VGS-1750 is calibrated in inches and the VGS-1750M for metric use.

Features:•Helpsoperatorcontrolvalvestem

installed height.•Aidsinmaintainingconsistent

combustion chamber volume.•Enablesthemachinisttocutseatsandseatpocketsto

an exact depth dimension.

VGS-20965 Seat Driver Kit for Harley-Davidson® HeadsDrivers slide over the valve guide pilot to provide a simple, efficient method of installing new valve seats. NOTE: Refer to page 35 for additional tooling.

Part No. Description VGS-1756A Dial Indicator (VGS-1756M for metric) VGS-1757A Indicator Clamp VGS-1758 Post Support VGS-1759A Post

Kit Includes:

Kit Includes:

Note: This kit is retro-fitable to Sunnen VGS-20 machines after serial number 1271, without modification to the machine. For serial numbers prior to 1271, a drill and tap operation on the face casting and trimming the belt shroud is required. In addition to the VGS-1750 indicator kit, a VGS-1265A Lift Cable Plate Assembly must be ordered. Call Sunnen Customer Service for details.

VGS-660 Electronic Level for Sunnen Guide and Seat Machines

The optional VGS-660 Electronic Level is a precision measurement sensor that provides wide angular range with excellent linearity. The readout unit contains a standard nine-volt battery (included) which provides power for the system electronics and liquid crystal display. Angular position is displayed digitally to within 0.1 of a degree.

VGS-2682 Stud Level PinUsed to align the VGS-20 spindle 90° to any flat surface. Insures proper cylinder head alignment to repair broken studs or other holes in areas where a guide pilot cannot be used.

VGS-1800A Collet ChuckFor drilling, tapping, reaming, and bronze liner installation. Insures positive gripping of tools with minimum runout for increased accuracy. Includes: collet chuck with adapter (1); .75 inch wrench (1); 30 mm

wrench (1); (collets must be ordered separately).

VC-200 Collet SetSet includes the most popular collet sizes for the VGS-1800A Collet Chuck. Collets may be ordered individually if desired.

Kit Includes:

Set Includes One Each of Collets Listed:

Part No. Description VGS-661 Level with Liquid Crystal Display VGS-667 Mounting Bracket with Hardware VGS-661-1A Replacement Cable

A complete line of collets not listed above are available on a special order basis from .019 inch (0,48 mm) to .433 inch (10,99 mm) diameter range. For information call Customer Service toll free.

www.sunnen.com 119

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

P-310 Valve Guide Gage Set P-195 Valve Guide Hone Set for Harley-Davidson® HeadsThe only way

to be sure clearance is correct is to GAGE IT! The Sunnen P-310 checks all types of guides for size and roundness. FAST!

Correct clearance between valve guides and valve stems is critical for top Harley® engine performance, so an accurate way to check clearances is critical. Sunnen’s exclusive P-310 Valve Guide Gage is designed for the professional Harley® shop and is equipped with a .0002 inch (,005 mm) graduated indicator for accurate guide sizing on every job — with no guessing. That’s why the Sunnen P-310 Valve Guide Gage Set has become a standard in the industry and should be an essential part of your shop.

The P-310 is extremely accurate, using the engine’s valve stems to set the gage. Simply zero the gage off the valve stems to be used and the indicator will read the exact clearance. It checks all types of guides... knurled, threaded, bronze or cast iron. It’s quick and versatile. The probes slide easily through the valve guide to explore the entire length of the guide for size, taper, and out-of-round.

The P-310 Valve Guide Gage Set is an ideal accessory for the VGS-20 Valve Guide and Seat Machine, HS-60 Power Bench, or the P-195 Valve Guide Honing Set. Everything you need for accurately checking Harley® valve guides in a single professional kit.

Part No. Description P-300 Gage Dial calibrated in .0002 inch (0,005 mm) increments P-312 Probe .3125 inch (8,0 mm) P-344 Probe .3437 inch (8,73 mm) P-350 Indicator only P-360 Wrench P-375 Probe .375 inch (9,5 mm) P-610A Metal Storage Case (stores items listed plus 5 more probes)

Set Includes:

Replacement and Additional Probes:

For metric applications, order P-310M. Gage may also be set with ring gage or micrometer.

Probe Size Diameter Range Part No. Inches Inches Millimeters P-236 .224 to .264 5,69 to 6,70 P-250 .25 .238 to .278 6,05 to 7,06 P-281 .5937 .269 to .309 6,83 to 7,85 P-312* .3125 .300 to .340 7,62 to 8,64 P-344* .3437 .332 to .372 8,43 to 9,45 P-375* .375 .363 to .403 9,22 to 10,24 P-406 .4062 394 to .434 10,01 to 11,02 P-438 .4375 .426 to .466 10,82 to 11,84 P-469 .1562 .457 to .497 11,61 to 12,62 P-500 .5 .488 to .528 12,40 to 13,41

*Included with P-310 Valve Guide Gage Set.

For portable valve guide sizing that produces straight, round holes and includes fast setup, look no further than the P-195. This hone set allows you to set your guide clearances accurately and produce a superior finish at the same time. The P-195 set includes all the tooling required for precision I.D. sizing of Harley-Davidson® valve guide bores for the popular .3125 inch (8,0 mm), .3437 inch (8,73 mm), and .375 inch (9,5 mm) sizes. Optional tooling can be added for honing Harley® heads for oversize O.D. valve guides or for a wide variety of other jobs. A slow speed drill (approximately 200 RPM) is recommended for driving power. See page 48 for additional tooling and supplies.

Part No. Description P-180 Hone Head and Driver BL10-308AS Mandrel .308 - .316 inch (7,82 - 8,02 mm) S-308 Truing Sleeve PK-10A Mandrel Adapter L10-J69 Stones, box of 6 BL10-339AS Mandrel .339 - .347 inch (8,61 - 8,81 mm) S-339 Truing Sleeve PK-10A Mandrel Adapter L12-370AS Mandrel .370 - .385 inch (9,4 - 9,8 mm) S-370 Truing Sleeve PK-12A Mandrel Adapter L12-J67 Stones, box of 6 AN-1105A Storage Box

TruingSleeve

Adapter

Stone

Head & Driver

Mandrel(Includes wedge)

P-195 Hone Set for Harley-Davidson® Heads Includes:

Valve Guide Gages and Hone Sets


1-800-325-3670120

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

Tooling for Honing Harley® Heads for Oversize O.D. Valve Guides for use with P-195 hone set

AN-1075 Speed Control Unit

Single Stroke Diamond Sizing Tools for Harley® Valve Guides

Valve Guide Sizing Tools

For all EVO®, Pan/Early Shovel, XR-750/1000, XL-Sportster®, 45 inch (1143 mm) Flat Head, and 74 - 80 inch (1879 - 2032 mm) Flat Head order:

For late Shovel and Knuckle order:

Part No. Description BL16-557AS Mandrel .557 - .588 inch (14,1 - 14,9 mm) S-557 Truing Sleeve L16-J67 Stones, box of 6 PK-16-A Adapter

Part No. Description BL20-619AS Mandrel .619 - .650 inch (15,7 - 16,5 mm) S-619 Truing Sleeve L20-J67 Stones, Box of 6 PAK-20-A Adapter

Finding electric drills which go down to the correct 200 rpm for driving the valve guide hone can sometimes be a problem. The AN-1075 reduces rpm when used with AC/DC drill motors and motors (brush-type only) where ampere rating is 15 amps or less. Unit furnished with on/off switch, fuse, AC cord and grounded AC outlet plug.

(Each tool includes arbor, sleeve and pilot.)

Tool No. Inches mm Inches mm

VG-315-D5 .3125 8 .310 - .320 7,87 - 8,13

VG-344-D5 .3437 8.73 .339 - .349 8,61 - 8,86 VG-374-D5 .375 9.5 .369 - .379 9,37 - 9,63

Size Finished Diameter Range

MB-30-5 Honing OilRecommended for valve guide reconditioning and general honing. Required when sizing bronze guides.

Available in 5-gallon (18,9 liter) pails. HS-60 requires 10 gallons (37,8 liters) minimum.

NOTE: For a complete listing of HS-60 tooling and accessories, refer to pages 44-47.

Valve Guide Gages and Hone Sets for Harley Davidson®

www.sunnen.com 121

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

Part No. Description

VR- 601 Butt VR- 602 General Purpose VR- 603 Titanium VR- 604 Stellite VR- 607 General Purpose (used with water soluble coolant only)

The VRC-500 provides a means of checking the runout of the valve face in relation to the valve stem. Accommodates stem diameters from .25-.75 inches (6-19 mm); head diameters from .625-4.5 inches (16-114 mm); and stem lengths up to 9.0 inches (76 mm) long.

The indicator reads in .0001 inch (,002 mm) increments and can be positioned for easy reading. Accuracy is ensured since the VRC-500 is set off of the valve stem.

Part No. Description VR-1701 Butt VR-1702 General Purpose (Water) VR-1703 General Purpose (Oil) VR-1704 Titanium (Water or Oil)

Grinding Wheels for VR-7000 & VR-8000

Grinding Wheels for VR-6500

Wheels made from specially for-mulated abrasives to provide good stock removal rates and surface fin-ishes for valve face and butt grind-ing. Available for oil or water base coolants.

VRC-500M Metric CheckerComponents of the VRC-500M are the same as the VRC-500 (as shown above), except the indicator is replaced with a metric indicator calibrated in 0,005 mm increments. Large capacity means you can check valves with stems from 6-19 mm diameter and head diameters from 16-114 mm.

VRC-500 Precision Valve Checker

MBC-200 Work LightThe MBC-200 is equipped with a 6-foot (1,83 meters) cord with a 3-wire molded-on grounding type plug. Fits all Sunnen pedestal machines (bulb not included).

Tooling and Accessories for Harley Davidson®

1-800-325-3670122

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

MAN-845-5 Oil5 Gallon (18,9 liters) Pail

For rod reconditioning, pin fitting and other such honing jobs.

Machine reservoir capacity: LBB-1660: 15 gallons (56,8 liters) LBC-1803 and LBB-1810: 25 gallons (94 liters)

AN-600 Honing HeadDiameter Range 2.500-6.500 inches (64mm-165mm)

Ideal for honing Harley-Davidson® or other small engine cylinders. Accuracy to .0005 inch (,01 mm). Uses same stone sets as

AN model Portable Cylinder Hone. Can be used with any pedestal model Sunnen Honing Machine. (Stone sets listed on 1.)

CRF-750 Universal Holding Fixturefor CRF-100 connecting rod and fixtures

Accommodates Harley-Davidson® and most other motorcycle cylinders and other parts within the CRF-750’s range, that can be placed on the honing machine. Fixture can be installed or

removed quickly and easily. Takes thrust on forward and back strokes. Includes two pairs of fingers with long-wearing, adjustable carbide pads. For cylinders order KKN-735A Torque Bracket Assembly.

KKN-735A Torque BracketThe KKN-735A is used in conjunction with the CRF-750 Universal Holding Fixture. It allows honing torque to be taken at the center of the bore length. It is especially useful for odd shaped cylinders typical of

motorcycle applications.

AG-300 GageThe AG-300 gage has become the standard in the industry for quickly checking rod bores for taper, out-of-round, and size within .0001 inch (,0025 mm). Its direct reading range is .375 - 3.375 inches (9,5 - 85,7 mm) with optional point sets and can be set with a micrometer, setting standard, or precision ring gage.

You can measure the exact amount of press fit or clearance with a single gage to .0001 inch (,0025 mm) accuracy. Whether you’re sizing Harley® rod races, piston pin bores, pin bushings, or other parts, the AG-300 Precision Gage makes it fast and accurate.NOTE: AG-400 Gage has fingers that are .600" longer than the AG-300. See page 102 in Gaging Section.

PL-100 Mandrel Kitfor Honing Harley-Davidson® Rod Races

Used to hone rod races for oversize rollers. Fits all 1.5 inch (38,1 mm) and 1.625 inch (41,27 mm) Harley® rods.

KL-770 Mandrel Kitfor honing I.D. of Harley-Davidson® piston pin bushings in connecting rods

Part No. Description 2GP28-1500WD Mandrel for 1.5 inch (38,1 mm) rods ST-1500 Truing Sleeve 2GP28-1625WD Mandrel for 1.625 inch (41,27 mm) rods ST-1625 Truing Sleeve P28-A53 Stones, roughing, box of 12 P28-J63 Stones, medium finishing, box of 12 P28-J93 Stones, fine finishing, box of 12

Kit Includes:

NOTE: One LN-0116A eccentric sleeve required for mandrels.

Part No. Description Approx. Surface Finish

Microinch Micrometer

P28-A53 Stones, roughing 18 Ra 0,46 Ra P28-J63 Stones, medium finishing 12 Ra 0,31 Ra P28-J93 Stones, fine finishing 3-5 Ra 0,08-0,13 Ra

Replacement Stones for above mandrels (12 stones per box):

Stones for Honing Rod Races Using Sunnen CR or Y44 Mandrels

Shops using Sunnen CR or Y44 mandrels for honing 1.5 inch (38,10 mm) and 1.625 inch (41,27 mm) Harley® rod races should use the stones listed below.

Part No. Description Y44-A53 Stone, roughing, 2 per box Y44-J63 Stone, medium finishing, 2 per box Y44-J95 Stone, fine finishing, 2 per box

Part No. Description AK20-775-UA Mandrel .775 - .805 inch (19,7 - 20,4 mm) range S-775 Truing Sleeve AK20-A Adapter K20-J25 Stones, roughing, box of 12 K20-J67 Stones, finishing, box of 12

Note: Use PD-B bronze shoes for power stroked machines and long life when honing rod races.


www.sunnen.com 123

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

Part No. Description 3GP20-781UA Mandrel .775 - .812 inch (19,7 - 20,6 mm) ST-780 Truing Sleeve P20-J47 Stones, roughing, box of 12 P20-J67 Stones, finishing, box of 12

Part No. Description AK20-775UA Mandrel, .775 inch-.805 inch (19,7-20,4 mm) range S-775 Truing Sleeve PAK-20A Adapter for mandrel K20-J25 Stones, roughing, box of 12 K20-J67 Stones, finishing, box of 12

ExpanderMandrel

Diameter Range

Inches mm

Expander(includes

facing cutter)

ALR-720 .720-.840 18,3-21,3 AL-12*

*ALR expander mandrels cannot be used without AL-12 expanders. Please order separately.

For a complete listing of expander mandrels and acces-sories see page 55. Part No. Description

3P16-526AS Mandrel .526-.557 inch (13,36-14,15 mm) P16-A Adapter with retainer S-526 Truing sleeve P16-J93 Stones, roughing, box of 12

NOTE: Order C-526 alignment bushing for Sunnen power stroke machines with adjustable spindle nose. Tooling listed is available under special order – call Sunnen Customer Service toll free for price and delivery before ordering.

Part No. Description Y20-713BS Mandrel, .713 inch-.744 inch (18,11-18,90 mm) range Y20-A Adapter for mandrel S-713 Truing Sleeve Y20-J55 Stones, roughing, 12 per box Y20-J95 Stones, finishing, 12 per box

Tooling for Honing Connecting RodsFor honing I.D. of Harley® connecting rods for oversize O.D. pin bushings

Tooling for Honing Connecting RodsFor honing Harley-Davidson® pin bores in pistons with standard pin diameter .791 inch (20,09 mm)

Tooling for Rocker Arm BushingsFor honing Evo®, Sportster® and Shovel Head with .554 inch (14,07 mm) standard shaft diameter

Part No. Description AK20-900UC Mandrel .900 - .930 inch (22,9 - 23,6 mm) S-900 Truing Sleeve AK20-A Adapter K20-J25 Stones, roughing, box of 12 K20-A69 Stones, finishing, box of 12

Bushing Expander for Harley®

Connecting RodsFor expanding new pin bushings in the connecting rod before honing to size. Use for all Harley-Davidson® connecting rods with .791 inch (20,09 mm) pin diameter. Can be used with any Sunnen horizontal honing machine.

•Assures100%contactforperfectheattransfer •Additionalprotectionforyourpinfit •Squeezesbushingintoeveryholeirregularity •Swedgesbushinginminutes •Trimsbushingedgessquareandclean

Caution: Do not use these mandrels for honing.

Pressed-in bushing touches on the high spots only.

Expanded bushing fills in val-leys and is locked in perfectly to rod eye.

Keeps bushings from working loose.

Portable Tooling for Pin BushingsFor honing pin bushings in Harley® connecting rods with .791 inch (20,09 mm) piston pin diameter

Allows pin bushings in connecting rods to be honed without removing rods from crankshaft. Can be used for honing new bushings to standard or honing bushings for oversized pins. Tooling listed adapts mandrel to fit optional Sunnen P-180 driver (required) and can be driven by .25 inch or larger air or electric drill. Note: P-180 driver included in Sunnen P-195 Valve Guide Hone Set listed on page 48.

Tappet Block ToolingFor honing Harley-Davidson® tappet blocks oversize with standard tappet diameter .731 inch (18,57 mm)


1-800-325-3670124

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

Portable Cylinder Hones• The fastest and most accurate portable hone for Harley-Davidson® cylinder reconditioning... to .0005 inch (,013 mm).

• Can also be used in trucks, tractors, stationary engines, automobiles, boats, etc.

• The only method that maintains alignment of the original bore.

• Reconditions cylinder bore with less stock removal than other methods – maintains uniform wall thickness – assures longer block life.

• Produces any finish specified by engine and ring manufacturers.

• Recommended for fast seating of any type rings.

• Correct stone length optimized for cylinder honing.

• Fast stock removal – up to .005 inch (0,13 mm) per minute.

• Can be set up in a few minutes.

• All cylinder hones include AN-1105A molded storage box.

Additional Portable Hones and AccessoriesSunnen manufactures a complete line of portable cylinder hones and abrasives for bore diameters from 1.250 to 15 inches (31,75 -381 mm). Refer to pages 89-91 or page 125 for additional information or call Customer Service toll free.

Drive Shanks

AN-112 Standard Portable Cylinder HoneRange 2.5 - 7 inches (63 - 178 mm)

The 2.5 - 7 inch (63 - 178 mm) diameter range of the AN-112 gives excellent coverage for Harley-Davidson® and most other common bore sizes. Stone sets available for honing a wide variety of materials throughout the range of 2.5 - 7 inches (63 - 178 mm) diameter. Includes a 2 inch (50,88 mm) drive shank and 12 inch (304,8 mm) extension.

NOTE: All stone sets must be ordered separately.

SNJ-8-749 Piloted Portable HoneIn-line honing for Harley Davidson® engine and transmission cases. Allows you to locate from tapered bearing side to ensure precise alignment on straight bearing side. Also eliminates the need of lapping bearing.

SNJ-75-887X Piloted Portable Hone Range 1.75 - 2.0 inches (44-51 mm)

Roughing Stones S18 - A45Finishing Stones S18 - J63

CK-NX8X Torque FixtureUsed for honing Harley® Cylinders in CV/CK Vertical Honing Machines. Can be used with Evolution®, Shovel® and Pan Head Cylinders.Allow 4-6 weeks for delivery.

CK PL3X 5.125 BoresU TwinU Twin Pro

*Supplied with hone.

For best results: Alter stones to 1.5" long, center mount.

Recommended Stone Sets:

Roughing Stonesfor New Bearings

Finishing Stones

SNJ1-A45

SNJ1-J63

SNJ2-A45

SNJ2-J63

SNJ3-A45

SNJ3-J63

Stone Sets*(Consists of 3 Stones)

For General Purpose Honing

1.250"-1.437"31,75mm-36,50mm

1.250"-1.437"31,75mm-36,50mm

1.250"-1.437"31,75mm-36,50mm

Part No. Description AN-26A* 3 inch (76 mm) Accessories: AN-70 Universal Joint AN-80 Quick Coupler

Part No. Description AN-241* 12 inch (305 mm) AN-242 24 inch (610 mm) AN-244 48 inch (1220 mm)

Shaft Extensions

Portable Honing Equipmentfor Harley Davidson®

www.sunnen.com 125

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

†Range on these sets as follows: MM —3.3 - 4.1 inch (83,8 - 104,1 mm), NN40—4.0 - 5.6 inch (101,6 - 142,2 mm), WW51—5.1"-9.2" (129,5-233,7 mm).Note: For special high performance finishes when honing outboard or two cycle engines, call Sunnen Customer Service for details.Shipping Weight of all Stone Sets approximately 1.25 lbs. (.5 kg) per Set.

Abrasive sets

Hone Body Inches mm (320 Grit)

2.98-3.78 75,7-96,0 GG-PHT-732 3.78-4.68 96,0-118,9 MM-PHT-731 4.48-6.08 113,8-154,4 NN-PHT-731 4.98-9.68 125,5-245,9 WW-PHT-731

Diameter Range

ANStandard

and Heavy Duty

For Use In Diameter Range Roughing Finishing Med. Finish Fine Finish Extra Fine Polishing Stone Cylinder Hone When Used In Stone Set Stone Set Stone Set Stone Set Finish Stone Stone Set Length Models inches mm (70 Grit) (150 Grit) (220 Grit) (280 Grit) Set (400 Grit) (600 Grit)† inches mm

2.5 - 2.7 63-70 Cast Iron G25-J17 G25-J45 G25-J55 G25-J65 G25-J87 G25-CO5 4 102

2.7 - 4.1 69-104 Cast Iron M27-J17 M27-J45 M27-J55 M27-J65 M27-J87 MM33-CO6† 4 102 Short C. Iron Cyls. M27-J17-71 M27-J45-71 M27-J55-71 M27-J65-71 — — 2.8125 71

Hardened Sleeves M27-J11 M27-J43 — M27-J63 M27-J85 MM33CO5 4 102 Steel — M27-A45 — M27-A65 M27-J87 MM33-CO5 4 102 3.5 - 5.5 89-139 Cast Iron N37-J17 N37-J45 N37-J55 N37-J65 N37-J87 NN40-CO5 4 102 Short C. Iron Cyls. N37-J17-71 N37-J45-71 N37-J55-71 N37-J65-71 — — 2.8125 71 Hardened Sleeves N37-J11 N37-J43 — N37-J63 N37-J85 NN40-CO5 4 102 Steel — N37-A45 — N37-A65 N37-J87 NN40-CO5 4 102

Deutch Diesel Cyls. VW Air Cooled Cyls M27-J45 — — — — — 4 102 Chilled Iron Liners

ANStandard

andHeavy Duty

Cast Iron 120 45 32 20 8 3 — — Hardened Steel 55 30 20 12 5 2 — — Steel — 32 20 15 7 3 — —

Approx. Surface Finish in Microinches (Ra)

Harley-Davidson® M27-J45 — — — — — 4 102

Stone Sets for Sunnen Portable Cylinder Hones and AN-600 Hone Head

PHT Plateau Honing Tools

Sunnen’s PHT tools are used as a final finishing step, after initial honing, to provide a plateau surface on cylinder walls. Made from special abrasive impregnated filament, these long lasting honing tools are available for portable and CV/CK hone heads. For additional information contact your local Sunnen Field Engineer or call Customer Service toll free.

For Portable and AN-600 Hone Heads:

Caution: Check diameter and range required before ordering. Range of PHT abrasives differs from standard honing stones.

AN-980 Chamfering ConeChamfers the sharp edges of cylinders for safe piston and ring installation. Handles all diameter cylinders or sleeves. Unit consists of tapered neoprene cone covered by long-lasting replaceable abrasive cone (includes a spare). Easy to use with .25 inch (6,3 mm) or larger drill. See page 76 for replacement cones.

Portable Honing Equipmentfor Harley Davidson®

1-800-325-3670126

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

Inches Metric inch mm inch mm lbs kg GR-6071 GRM-6071 3.5 88 9.8125 235 2 1 GR-6121 GRM-6121 6 150 11.6875 298 2 1 GR-6241 GRM-6241 12 300 17.6875 451 2 1

Model No.Max. Gaging

DepthOverall Length

Shipping Weight

Inches Metric inch mm inch mm lbs kg GA-4051 GAM-4051 2.5 62 7.3125 187 1.5 ,7 GA-4101 GAM-4101 5 125 9.8125 251 1.5 ,7 GA-4141 GAM-4141 7 175 11.9375 302 1.5 ,7


DepthOverall Length

Shipping Weight

Inches Metric inch mm inch mm lbs kg GR-9071 GRM-9071 3.5 88 9.25 237 4 1,8 GR-9121 GRM-9121 6 150 11.75 300 4 1,8 GR-9241 GRM-9241 12 300 17.75 452 4 1,8


DepthOverall Length

Shipping Weight

For Diameters From .495 - 8 Inches (112,6 - 203 mm)

Precision gaging is the only way to make sure your bore sizes are correct and insure quality on every job. Don’t rely on slow, antiquated methods or measuring instruments to insure the quality of your work. Whether it’s cylinders, bearing races, case bushings or other parts requiring close tolerances, your work will only be as accurate as your method of checking it. Sunnen’s complete line of self centralizing dial bore gages and precision setting fixtures make this an easy task with uncompromising accuracy. Now, you can check bores for size, taper, and out-of-round to .0001 inch (,002 mm) accuracy in seconds. Each gage comes packed in its own sturdy box with all tools and wrenches required for setup and adjustment. (For additional information consult Sunnen Catalog X-SP-5500 or call Customer Service toll free.)

GA/GAM-4000 Series GagesDiameter Range .495 - .750 Inches (12,6 - 19,0 mm)

Non-retractable gage with .0001 inch (,002 mm) reading indicator. Capable of measuring to within .200 inch (5,0 mm) of the bottom of a blind hole. Indicators reading in .0005 inch (,010 mm) are available on special order.

GR/GRM-6000 Series GagesDiameter Range .740 - 1.190 Inches (18,8 - 30,2 mm)

Retractable gage with .0001 inch (,002 mm) reading indicator. Capable of measuring to within .270 inch (6,8 mm) of the bottom of a blind hole. Indicators reading in .0005 inch (,010 mm) are available on special order.

GR/GRM-9000 Series GagesDiameter Range 1.18 - 2.0 Inches (30,0 - 50,8 mm)

Retractable gage with .0001 inch (,002 mm) reading indicator. Capable of measuring to within .335 inch (8,5 mm) of the bottom of a blind hole. Indicators reading in .0005 inch (,010 mm) are available on special order.

GA-2125 and GR-2125Diameter Range 2 - 8 Inches (50,8 - 203 mm)Gage Holes Up To 12 Inches (304 mm) Long

For cylinders, sleeves, large con rods... many other gaging jobs. The GA-2125 is self-aligning in the bore, requires no centering. Lets you explore the entire cylinder from top to bottom... in seconds.

The retractable self-centering mechanism in the gage head of the GR-2125 makes it easy to gage interrupted bores typical of 2-cycle motorcycle and marine engine applications

without “hanging up.” The retraction feature allows precise exploration of a high performance cylinder without leaving telltale gaging marks.

•Gagesareself-centering.•Adjustabledialforeasierreading.•Dialismarkedin.0005inch(,012mm)increments.•Carbidegagingpoints...forlonglife.•Insulatedgripeliminates“drift.”•Furnishedinmoldedcasewithextensionpointsand wrenches.

For metric models, order GAM-2125 or GRM-2125. Range: 50 to 203 mm. Dial marked in ,01 mm increments.

NOTE: .0001 inch (,002 mm) reading dial bore gages and special lengths also available. Consult Sunnen Catalog X-SP-5500 for a complete listing of gages and accessories or call Customer Service toll free.

Dial Bore Gages & Accessoriesfor Harley Davidson®

www.sunnen.com 127

Cylinder H

eadC

onnecting Rod

Block

Reconditioning

Resurfacing

Cleaning

Gaging

Harley

®

Dial Bore Gages & Accessoriesfor Harley Davidson®

Model No. Description CF-220A* Range 2 - 3 inch (51 - 76 mm) CF-230A* Range 3 - 4 inch (76 - 102 mm) CF-240A* Range 4 - 5 inch (102 - 127 mm) CF-250A* Range 5 - 6 inch (127 - 152 mm) CF-260A Range 6 - 7 inch (152 - 178 mm) CF-215A* Ring Gage 2.000 inch (50,8 mm)

GA/GAM- 4000 Series

GR/GRM-6000 Series

GR/GRM-9000 Series

CF-502Setting Fixture

(gage not included)CF-1126

Setting Fixture (gage not included)GR-2000 Series

Setting Fixtures For Dial Bore GagesFor Diameters from .054 - 8 inches (1,37 - 203 mm)

Sunnen’s precision setting fixtures make easy work of accurately setting Sunnen’s complete line of dial bore gages. These fixtures eliminate the errors and “feel” associated with other setting methods for accurate, dependable measurements. Setting master is made from stress-relieved cast iron and is multi-session cold room stabilized. The .0001 inch (,002 mm) reading micrometer head includes precision lapped carbide anvils and comes complete with a precision ring gage for calibration. Setting fixtures can be used without removing them from the protective storage case included with each fixture. For additional information consult Sunnen Catalog X-SP-5500 or call Customer Service toll free.

CF-502 Setting FixtureDiameter Range .054 - 2.000 Inches (1,4 - 50,8 mm)

For use with 4000, 6000, and 9000 Series Dial Bore Gages.

Model CF-502 is equipped with a large micrometer head with range of 0 - 2 inches (0,0 - 50,8 mm) marked in .0001 inch (,0025 mm) increments.

Setting Fixture comes with CF-576A .750 inch (19,05 mm) master calibrating ring.

CF-502M Metric Setting Fixture has a 0 to 51 mm micrometer head marked in ,002 mm increments. Supplied in a sturdy, nested box.

CF-1126 Setting FixtureDiameter Range 2 - 8 Inches (51 - 203 MM)

For use with 2000 Series Dial Bore Gages.

The CF-1126 incorporates a tenth-reading micrometer head with precision carbide anvil. Accurate within .0001 inch (0,0025 mm). Ring gage checking standard included. Precision setting standards in 1 inch (25,4 mm) increments.

Setting Master has rugged stress-relieved, cast iron base. May be used without removing from protective case.

The setting fixture itself covers the 7 to 8 inch (178 to 203 mm) range. In addition, the fixture is supplied with standards to cover the 2 to 6 inch (50 to 152,4 mm) range. Order additional setting standard to give complete 2 to 8 inch (50 to 203,2 mm) range as follows:

* Included with CF-1126.

Note: See pages 101-113 for dial bore gages for automotive use.

vgs-20 fixtures tooling and accessories - · pdf filevgs-20 fixtures tooling and accessories...

Documents