VGS-20 Fixtures Tooling and Accessories

VGS-20 Fixtures
Tooling and Accessories
for Harley Davidson®
Cylinder Head
VGS-3100 Head Holder Kit for
Harley-Davidson® Heads
Connecting Rod
Sunnen’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 VGS20 Valve Guide and Seat Machine. Design input from
renowned Harley® head builders and extensive field testing 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 mounting. (Requires the use of an optional Sunnen VGS-330A
Extension Drive Adapter).
APPLICATION: Harley® Shovel Heads (1966-1984)
Kit Includes: Mounting plate, VGS-3102 Spacers (4), and
mounting hardware.
Block
Reconditioning
Resurfacing
APPLICATION: Harley® Evolution® Heads (1983-Present)
Applications with Harley-Davidson® XR750 and XR1000 Heads not pictured.
Cleaning
Optional VGS-3100 shown
mounted in VGS-2540C Fixture
(Included with VGS-20 Machine).
VGS-3102 Spacers (4).
VGS-3110 Locating Blocks for Evolution®
Heads
Gaging
The 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.
APPLICATION: Harley® Sportster® XL Heads (1957-1985)
Also provides exceptionally fast setup time when machining multiple sets of Evolution® cylinder heads.
VGS-330A Extension Drive
Harley®
Adapter required when using VGS-3100.
APPLICATION: Harley® Pan Heads (1949-1965)
114
1-800-325-3670
VGS-20 Fixtures
Tooling and Accessories
for Harley Davidson®
Similar to VSC-50. Used to
“off-hand” grind any angle
desired on VSC single angle
cutters or cutter blanks.
Connecting Rod
For SGM
Style
Tooling,
see pages
12-19
in the
Cylinder
Head
Section.
VSC-55 Tool Sharpening Fixture
Cylinder Head
VCS-505 Single Blade, 3-Angle Seat
Cutting Kit for Harley® Cylinder Heads
VGS-20964 Valve
Guide Installation Kit
Kit Includes:
Kit Includes:
Part No. VSC-205
VSC-305
VSC-400
VSC-50
PSP-215A
PSP-216A
VSC-509A
PWM-5A
VSC-06045
Air Hammer Hose
VGS-191A
.3125 inch (7,92 mm) Guide Driver
VGS-192A
.3437 inch (8,73 mm) Guide Driver
VGS-193A
.375 inch (9,52 mm) Guide Driver
VGS-194A
.4375 inch (11,11 mm) Guide Driver
B-200L
Press Fit Lubricant
VS-1015 Rapid Valve Seat Checker for
Harley-Davidson® Heads
Description
Cutter Body 1.0 - 1.6 inch (25-41 mm)
Cutter Body 1.5 - 2.0 inch (38-52 mm)
Setting Fixture
Tool Sharpening Fixture
Spring, Short
Spring, Long
Spring Bushings (4)
Hex T-Wrench
(2) Cutter 30-45-60
VCS-505S Single Blade, 3-Angle Seat
Cutter Kit (Sioux Pilots)
Optional VSC-350 Cutter Body
for large diameter valves 1.9-2.5 inch (47-64 mm) range
VSC-100 Tool Sharpener Fixture Kit
The 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.
VS-1500-44
VS-1625-44
VS-1750-44
VS-1875-44
VS-2000-44
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
.437 inch (11,1 mm) diameter Kwik Way Pilots
.375 inch (9,5 mm) diameter K.O. Lee, Neway, Black and Decker pilots
VS-1117A
VS-1118A
For metric applications, order VS-1015M.
www.sunnen.com
115
Harley®
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.
Set Includes:
VS-1010 Indicator Assembly with indicating wheel for
Sunnen Pilots .389 inch (9,9 mm), plus these Indicator
Wheel Assemblies:
Gaging
Same as VSC-505 except cutter bodies fit Sioux .385 inch
(9,8 mm) pilots.
The 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.
Cleaning
Air Hammer
VGS-217A
Resurfacing
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.
Description
VGS-216A
Block
Reconditioning
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.
Part No.
VGS-20 Fixtures
Tooling and Accessories
for Harley Davidson®
Cylinder Head
VGS-300 Valve Seat Pocket Cutter Kit
1.500 to 2.250 inches (38,5 to 57,1 mm)
VS-300E Valve Guide Pilot Kit for
Harley-Davidson® Heads
Connecting Rod
Block
Reconditioning
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.
Resurfacing
Kit Includes:
Cleaning
Gaging
Part No. ASPC-1500
ASPC-1687
ASPC-1875
ASPC-2062
VGS-325
VGS-410A
PSP-215A
PSP-216A
VSC-509A
PWM-5A
Description
Seat Pocket Cutter Head 1.500 -1.687 inch
(38,1 - 42,9 mm) Range
Seat Pocket Cutter Head 1.687-1.875 inch
(42,9 - 47,6 mm) Range
Seat Pocket Cutter Head 1.875 - 2.062 inch
(47,6 - 52,4 mm) Range
Seat Pocket Cutter Head 2.062 - 2.250 inch
(52,4 -57,1 mm) Range
Cutter Head Driver for Sunnen .389 inch
(9,88 mm) Pilot
Pocket Cutter Setting Fixture with Setting Standard
Short Spring
Long Spring
Spring Bushing (4)
Hex T-Wrench
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.
Kit consists of one each of the following pilots:
Diameter
Pilot No.
Inches
VS-310E
.310
VS-311E
.311
VS-312E
.312
VS-340E
.340
VS-341E
.341
VS-342E
.342
VS-376E
.376
VS-377E
.377
VS-378E
.378
VS-379E
.379
VS-380E
.380
VGS-130A Drill Chuck
Drill 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.
VGS-300S Valve Seat Pocket Cutter Kit
(Sioux Pilots)
Harley®
Same as VGS-300, except Cutter Head Driver fits Sioux
.385 inch (9,8 mm) pilots.
116
Millimeters
7,87
7,90
7,92
8,64
8,66
8,69
9,55
9,57
9,60
9,63
9,65
1-800-325-3670
VGS-20 Fixtures
Tooling and Accessories
for Harley Davidson®
Used with Sunnen’s VSC cutter
bodies to enlarge the bowl area
1.0
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
VSC-575
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 3-Angle Carbide Valve Seat Cutters
VSC Form Tools
VSC-511 used for chamber
relief, cuts with a .25 inch
(6,35 mm) radius.
The 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 Blank
Similar 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 Cutters
VSC-523 used for chamber
relief, cuts with a .236 inch
(5,99 mm) radius.
Cleaning
Special 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.
VSC-523
Chamber
Relief
VSC-511
Chamber
Relief
VSC-K68B Blank Cutter
Resurfacing
These 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°
Block
Reconditioning
VSC 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 finished seat widths, angles, and radiused profiles for stock
or performance work. See pages 28-31 for a complete listing of VSC carbide bits or call Customer Service toll free.
.38 R.
Connecting Rod
VSC-575 Bowl Hog Cutter
Sunnen 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.
Cylinder Head
Sunnen VSC Carbide Cutters
VSC-512 used for throat
alterations, cuts with a .875
inch (22,22 mm) radius.
VSC-512
Throat
Relief
Gaging
VSC-527
Chamber
Relief
VSC-527 used for chamber
relief, cuts with a .344 inch
(8,73 mm) radius.
Harley®
VSC-518 used for chamber
relief, cuts with a .188 inch
(4,77 mm) radius.
VSC-390
VSC-518
Chamber Relief
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.
www.sunnen.com
117
VGS-20 Fixtures
Tooling and Accessories
for Harley Davidson®
Cylinder Head
VGS-1750 and VGS-1750M Seat Depth
Indicator Kits
VGS-660 Electronic Level for Sunnen
Guide and Seat Machines
Connecting Rod
The 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.
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.
Block
Reconditioning
Features:
•Helps operator control valve stem
installed height.
•Aids in maintaining consistent
combustion chamber volume.
•Enables the machinist to cut seats and seat pockets to
an exact depth dimension.
Kit Includes:
Kit Includes:
Part No.
Description
Dial Indicator (VGS-1756M for metric)
Indicator Clamp
Post Support
Post
VGS-1756A
VGS-1757A VGS-1758 VGS-1759A
Part No.
Description
VGS-661
VGS-667
VGS-661-1A
Level with Liquid Crystal Display
Mounting Bracket with Hardware
Replacement Cable
VGS-2682 Stud Level Pin
Resurfacing
Used 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.
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-1800A Collet Chuck
Cleaning
VGS-20965 Seat Driver
Kit for Harley-Davidson®
Heads
Drivers 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.
Kit Includes:
Gaging
Part No.
Description
VGS-430A
Seat Ring Driver Adapter, Manual
VGS-453A
VGS-454A
VGS-455A
Seat Ring Driver Adapter Rings:
1.50 inch (38,10 mm) x 1.625 inch (41,27 mm)
1.75 inch (44,45 mm) x 1.875 inch (47,62 mm)
2.00 inch (50,80 mm) x 2.215 inch (53,97 mm)
For 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 Set
Set includes the most popular collet sizes for the
VGS-1800A Collet Chuck. Collets may be ordered
individually if desired.
Set Includes One Each of Collets Listed:
Harley®
Part No.
Diameter Range
.276 - .315 inch (7,01 - 8,00 mm)
.315 - .354 inch (8,00 - 8,99 mm)
.354 - .394 inch (8,99 - 10,00 mm)
.433 - .472 inch (10,99 - 11,98 mm)
.472 - .512 inch (11,98 - 13,00 mm)
VC-276
VC-315
VC-354
VC-433
VC-472
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.
118
1-800-325-3670
Valve Guide Gages
and Hone Sets
for Harley Davidson®
Connecting Rod
The 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!
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.
Truing
Sleeve
Set Includes:
Head & Driver
Cleaning
Description
Dial calibrated in .0002 inch (0,005 mm) increments
.3125 inch (8,0 mm)
.3437 inch (8,73 mm)
Indicator only
Wrench
.375 inch (9,5 mm)
Metal Storage Case (stores items listed plus 5 more probes)
Adapter
Stone
P-195 Hone Set for Harley-Davidson® Heads Includes:
Replacement and Additional Probes:
Part No.
P-180
BL10-308AS
S-308
PK-10A
L10-J69
BL10-339AS
S-339
PK-10A
L12-370AS
S-370
PK-12A
L12-J67
AN-1105A
www.sunnen.com
Description
Hone Head and Driver
Mandrel .308 - .316 inch (7,82 - 8,02 mm)
Truing Sleeve
Mandrel Adapter
Stones, box of 6
Mandrel .339 - .347 inch (8,61 - 8,81 mm)
Truing Sleeve
Mandrel Adapter
Mandrel .370 - .385 inch (9,4 - 9,8 mm)
Truing Sleeve
Mandrel Adapter
Stones, box of 6
Storage Box
Harley®
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.
Gaging
Mandrel
(Includes wedge)
For metric applications, order P-310M.
Gage may also be set with ring gage or micrometer.
Resurfacing
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.
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.
Block
Reconditioning
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.
Part No.
P-300 Gage P-312 Probe
P-344 Probe
P-350
P-360
P-375 Probe
P-610A
Cylinder Head
P-195 Valve Guide Hone Set for
Harley-Davidson® Heads
P-310 Valve Guide Gage Set
119
Valve Guide Gages
and Hone Sets
for Harley Davidson®
Cylinder Head
Tooling for Honing Harley® Heads for
Oversize O.D. Valve Guides for use with
P-195 hone set
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:
Connecting Rod
Part No.
BL16-557AS
S-557
L16-J67
PK-16-A
Valve Guide Sizing Tools
Single Stroke Diamond Sizing Tools for
Harley® Valve Guides
Description
Mandrel .557 - .588 inch (14,1 - 14,9 mm)
Truing Sleeve
Stones, box of 6
Adapter
Block
Reconditioning
For late Shovel and Knuckle order:
(Each tool includes arbor, sleeve and pilot.)
Tool No.
Part No.
BL20-619AS
S-619
L20-J67
PAK-20-A
Description
Mandrel .619 - .650 inch (15,7 - 16,5 mm)
Truing Sleeve
Stones, Box of 6
Adapter
Resurfacing
AN-1075 Speed Control Unit
Finished Diameter Range
Size
Inches
mm Inches
mm
VG-315-D5
.3125
8
.310 - .320
7,87 - 8,13
VG-344-D5
VG-374-D5
.3437
.375
8.73
9.5
.339 - .349
.369 - .379
8,61 - 8,86
9,37 - 9,63
MB-30-5 Honing Oil
Recommended 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.
Cleaning
NOTE: For a complete
listing of HS-60 tooling and
accessories, refer to pages
44-47.
Gaging
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.
Harley®
120
1-800-325-3670
Tooling and Accessories
for Harley Davidson®
VRC-500 Precision Valve Checker
Cylinder Head
Wheels made from specially formulated abrasives to provide good
stock removal rates and surface finishes for valve face and butt grinding. Available for oil or water base
coolants.
Connecting Rod
Grinding Wheels for VR-7000 & VR-8000
Part No.
VR-1701
VR-1702
VR-1703
VR-1704
Description
Butt
General Purpose (Water)
General Purpose (Oil)
Titanium (Water or Oil)
Grinding Wheels for VR-6500
Description
Butt
General Purpose
Titanium
Stellite
General Purpose (used with water soluble coolant only)
VR- 601
VR- 602
VR- 603
VR- 604
VR- 607
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.
VRC-500M Metric Checker
MBC-200 Work Light
The 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).
Cleaning
Components 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.
Resurfacing
Part No.
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.
Block
Reconditioning
Gaging
Harley®
www.sunnen.com
121
Tooling and Accessories
for Harley Davidson®
Cylinder Head
PL-100 Mandrel Kit
AG-300 Gage
for Honing Harley-Davidson®
Rod Races
Connecting Rod
The AG-300 gage has become the
standard in the industry for quickly
checking rod bores for taper, outof-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.
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.
Kit Includes:
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.
Block
Reconditioning
NOTE: AG-400 Gage has fingers that are .600" longer than the
AG-300. See page 102 in Gaging Section.
Description
Mandrel for 1.5 inch (38,1 mm) rods
Truing Sleeve
Mandrel for 1.625 inch (41,27 mm) rods
Truing Sleeve
Stones, roughing, box of 12
Stones, medium finishing, box of 12
Stones, fine finishing, box of 12
NOTE: One LN-0116A eccentric sleeve required for mandrels.
MAN-845-5 Oil
5 Gallon (18,9 liters) Pail
Replacement Stones for above mandrels (12 stones per box):
For rod reconditioning, pin fitting and other
such honing jobs.
Part No.
Description
Resurfacing
Machine reservoir capacity:
LBB-1660: 15 gallons (56,8 liters)
LBC-1803 and LBB-1810: 25 gallons (94 liters)
P28-A53
P28-J63
P28-J93
Approx. Surface Finish
Microinch
Micrometer
Stones, roughing
Stones, medium finishing
Stones, fine finishing
18 Ra
12 Ra
3-5 Ra
0,46 Ra
0,31 Ra
0,08-0,13 Ra
Stones for Honing Rod Races Using
Sunnen CR or Y44 Mandrels
AN-600 Honing Head
Diameter Range 2.500-6.500 inches
(64mm-165mm)
Cleaning
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 Page 91.)
CRF-750 Universal Holding Fixture
Gaging
for CRF-100 connecting rod and fixtures
Harley®
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 longwearing, adjustable carbide pads. For cylinders order KKN735A Torque Bracket Assembly.
KKN-735A Torque Bracket
The 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.
122
Part No.
2GP28-1500WD
ST-1500
2GP28-1625WD
ST-1625
P28-A53
P28-J63
P28-J93
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.
Y44-A53
Y44-J63
Y44-J95
Description
Stone, roughing, 2 per box
Stone, medium finishing, 2 per box
Stone, fine finishing, 2 per box
Note: Use PD-B bronze shoes for power stroked machines and long
life when honing rod races.
KL-770 Mandrel Kit
for honing I.D. of
Harley-Davidson®
piston pin bushings in
connecting rods
Part No.
AK20-775-UA
S-775
AK20-A K20-J25
K20-J67
1-800-325-3670
Description
Mandrel .775 - .805 inch (19,7 - 20,4 mm) range
Truing Sleeve
Adapter
Stones, roughing, box of 12
Stones, finishing, box of 12
Tooling and Accessories
for Harley Davidson®
For honing I.D. of Harley connecting rods for
oversize O.D. pin bushings
®
Part No.
AK20-900UC
S-900
AK20-A
K20-J25
K20-A69
Description
Mandrel .900 - .930 inch (22,9 - 23,6 mm)
Truing Sleeve
Adapter
Stones, roughing, box of 12
Stones, finishing, box of 12
Tooling for Honing Connecting Rods
Part No.
3GP20-781UA
ST-780
P20-J47
P20-J67
Description
Mandrel .775 - .812 inch (19,7 - 20,6 mm)
Truing Sleeve
Stones, roughing, box of 12
Stones, finishing, box of 12
•
•
•
•
•
Part No.
3P16-526AS
P16-A
S-526
P16-J93
Description
Mandrel .526-.557 inch (13,36-14,15 mm)
Adapter with retainer
Truing sleeve
Stones, roughing, box of 12
Tappet Block Tooling
Expander
Mandrel
Part No.
Y20-713BS
Y20-A
S-713
Y20-J55
Y20-J95
Description
Mandrel, .713 inch-.744 inch (18,11-18,90 mm) range
Adapter for mandrel
Truing Sleeve
Stones, roughing, 12 per box
Stones, finishing, 12 per box
Inches
mm
.720-.840
18,3-21,3
Expander
(includes
facing cutter)
AL-12*
*ALR expander mandrels cannot be used without AL-12
expanders. Please order separately.
For a complete listing of expander mandrels and accessories see page 55.
Portable Tooling for Pin Bushings
For 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.
Part No.
AK20-775UA
S-775
PAK-20A
K20-J25
K20-J67
www.sunnen.com
Description
Mandrel, .775 inch-.805 inch (19,7-20,4 mm) range
Truing Sleeve
Adapter for mandrel
Stones, roughing, box of 12
Stones, finishing, box of 12
Harley®
Diameter Range
Gaging
For honing Harley-Davidson® tappet blocks
oversize with standard tappet diameter
.731 inch (18,57 mm)
Keeps bushings from working
loose.
Cleaning
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.
Expanded bushing fills in valleys and is locked in perfectly
to rod eye.
Resurfacing
For honing Evo®, Sportster® and Shovel Head with
.554 inch (14,07 mm) standard shaft diameter
Pressed-in bushing touches
on the high spots only.
Assures 100% contact for perfect heat transfer
Additional protection for your pin fit
Squeezes bushing into every hole irregularity
Swedges bushing in minutes
Trims bushing edges square and clean
ALR-720
Tooling for Rocker Arm Bushings
Caution: Do not use these
mandrels for honing.
Block
Reconditioning
For honing Harley-Davidson® pin bores in
pistons with standard pin diameter .791 inch
(20,09 mm)
For 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.
Connecting Rod
Bushing Expander for Harley®
Connecting Rods
Cylinder Head
Tooling for Honing Connecting Rods
123
Portable Honing Equipment
for Harley Davidson®
Cylinder Head
Portable Cylinder Hones
AN-112 Standard Portable Cylinder Hone
• The fastest and most accurate portable hone for
Harley-Davidson® cylinder reconditioning... to
.0005 inch (,013 mm).
Range 2.5 - 7 inches (63 - 178 mm)
•C
an also be used in trucks, tractors, stationary engines,
automobiles, boats, etc.
Connecting Rod
• The only method that maintains alignment of the
original bore.
•R
econditions cylinder bore with less stock removal than
other methods – maintains uniform wall thickness –
assures longer block life.
•P
roduces any finish specified by engine and ring
manufacturers.
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 Hone
In-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.
• Recommended for fast seating of any type rings.
Block
Reconditioning
• Correct stone length optimized for cylinder honing.
•F
ast stock removal – up to .005 inch (0,13 mm) per minute.
• Can be set up in a few minutes.
•A
ll cylinder hones include AN-1105A molded storage box.
Additional Portable Hones and
Accessories
Recommended Stone Sets:
Resurfacing
Stone Sets*
Sunnen 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
Cleaning
Part No.
AN-26A*
Accessories:
AN-70
AN-80
Description
3 inch (76 mm)
Universal Joint
Quick Coupler
Gaging
Shaft Extensions
Part No.
AN-241*
AN-242
AN-244
Description
12 inch (305 mm)
24 inch (610 mm)
48 inch (1220 mm)
(Consists of 3 Stones)
For General Purpose Honing
1.250"-1.437"
1.250"-1.437"
1.250"-1.437"
31,75mm-36,50mm 31,75mm-36,50mm 31,75mm-36,50mm
Roughing Stones
for New Bearings
SNJ1-A45
SNJ2-A45
SNJ3-A45
Finishing Stones
SNJ1-J63
SNJ2-J63
SNJ3-J63
For best results: Alter stones to 1.5" long, center mount.
SNJ-75-887X Piloted Portable Hone
Range 1.75 - 2.0 inches (44-51 mm)
Roughing Stones
S18 - A45
Finishing Stones
S18 - J63
CK-NX8X Torque Fixture
Harley®
Used 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.
*Supplied with hone.
CK PL3X 5.125 Bores
U Twin
U Twin Pro
124
1-800-325-3670
Portable Honing Equipment
for Harley Davidson®
For Use In
Diameter Range
Cylinder Hone
When Used In
Models
inches mm
Roughing
Stone Set
(70 Grit)
Finishing Med. Finish Fine Finish Extra Fine
Polishing
Stone
Stone Set Stone Set Stone Set Finish Stone Stone Set
Length
(150 Grit) (220 Grit) (280 Grit) Set (400 Grit) (600 Grit)† inches mm
G25-J17
G25-J45
2.5 - 2.7 63-70
Cast Iron
G25-J55
G25-J65
G25-J87
—
—
Hardened Sleeves M27-J11
Steel
—
Cast Iron
N37-J17
M27-J43
M27-A45
N37-J45
—
—
N37-J55
Short C. Iron Cyls. N37-J17-71 N37-J45-71 N37-J55-71 N37-J65-71
—
—
Hardened Sleeves N37-J11
N37-J43
—
N37-J63
N37-J85
NN40-CO5
Steel
—
N37-A45
—
N37-A65
N37-J87
NN40-CO5
Approx.
Surface Finish in
Microinches (Ra)
Cast Iron
Hardened Steel
Steel
120
55
—
45
30
32
32
20
20
—
M27-J63
M27-A65
N37-J65
20
12
15
—
M27-J85
M27-J87
N37-J87
102
—
MM33CO5
MM33-CO5
NN40-CO5
8
5
7
3
2
3
4
102
4
4
4
102
102
—
—
—
—
—
—
102
2.8125 71
4 102
4 102
Block
Reconditioning
Deutch Diesel Cyls.
VW Air Cooled Cyls M27-J45
Chilled Iron Liners
4
MM33-CO6†
4 102
—
2.8125 71
—
4 102
Connecting Rod
Cast Iron
M27-J17
M27-J45 M27-J55
M27-J65
M27-J87
Short C. Iron Cyls. M27-J17-71 M27-J45-71 M27-J55-71 M27-J65-71
—
Harley-Davidson® M27-J45
—
—
—
—
G25-CO5
2.7 - 4.1 69-104
AN
Standard
and
Heavy Duty
3.5 - 5.5 89-139
Cylinder Head
Stone Sets for Sunnen Portable Cylinder Hones and AN-600 Hone Head
Resurfacing
†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.
AN-980 Chamfering Cone
PHT Plateau Honing Tools
Cleaning
Gaging
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.
Chamfers 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.
For Portable and AN-600 Hone Heads:
Abrasive sets
(320 Grit)
AN
Standard
and
Heavy Duty
GG-PHT-732
MM-PHT-731
NN-PHT-731
WW-PHT-731
2.98-3.78
3.78-4.68
4.48-6.08
4.98-9.68
75,7-96,0
96,0-118,9
113,8-154,4
125,5-245,9
Harley®
Diameter Range
Hone Body
Inches
mm
Caution: Check diameter and range required before
ordering. Range of PHT abrasives differs from standard
honing stones.
www.sunnen.com
125
Dial Bore Gages &
Accessories
for Harley Davidson®
Cylinder Head
For Diameters From .495 - 8 Inches
(112,6 - 203 mm)
Connecting Rod
Block
Reconditioning
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 Gages
Diameter Range .495 - .750 Inches
(12,6 - 19,0 mm)
Resurfacing
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.
Model No.
Cleaning
Inches
GA-4051
GA-4101
GA-4141
Metric
GAM-4051
GAM-4101
GAM-4141
Max. Gaging
Depth
inch mm
2.5
62
5
125
7
175
Overall
Length
inch
mm
7.3125
187
9.8125
251
11.9375 302
Shipping
Weight
lbs
kg
1.5
,7
1.5
,7
1.5
,7
GR/GRM-6000 Series Gages
Gaging
Diameter 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.
Harley®
Model No.
Inches
GR-6071
GR-6121
GR-6241
126
Metric
GRM-6071
GRM-6121
GRM-6241
Max. Gaging
Depth
inch mm
3.5
88
6
150
12
300
Overall
Length
inch
mm
9.8125 235
11.6875 298
17.6875 451
Shipping
Weight
lbs
kg
2
1
2
1
2
1
GR/GRM-9000 Series Gages
Diameter 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.
Model No.
Inches
GR-9071
GR-9121
GR-9241
Metric
GRM-9071
GRM-9121
GRM-9241
Max. Gaging
Depth
inch mm
3.5
88
6
150
12
300
Overall
Length
inch
mm
9.25
237
11.75
300
17.75
452
Shipping
Weight
lbs
kg
4
1,8
4
1,8
4
1,8
GA-2125 and GR-2125
Diameter 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.
•Gages are self-centering.
•Adjustable dial for easier reading.
•Dial is marked in .0005 inch (,012 mm) increments.
•Carbide gaging points... for long life.
•Insulated grip eliminates “drift.”
•Furnished in molded case with extension points and 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.
1-800-325-3670
Dial Bore Gages &
Accessories
for Harley Davidson®
Setting Fixtures For Dial Bore Gages
For Diameters from .054 - 8 inches
(1,37 - 203 mm)
CF-1126 Setting Fixture
Diameter Range 2 - 8 Inches (51 - 203 MM)
CF-502 Setting Fixture
For use with 4000, 6000, and 9000 Series Dial Bore Gages.
Setting Fixture comes with CF-576A .750 inch (19,05 mm)
master calibrating ring.
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:
Model No.
CF-220A*
CF-230A*
CF-240A*
CF-250A*
CF-260A
CF-215A*
Description
Range 2 - 3 inch (51 - 76 mm)
Range 3 - 4 inch (76 - 102 mm)
Range 4 - 5 inch (102 - 127 mm)
Range 5 - 6 inch (127 - 152 mm)
Range 6 - 7 inch (152 - 178 mm)
Ring Gage 2.000 inch (50,8 mm)
Resurfacing
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.
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.
Block
Reconditioning
For use with 2000 Series Dial Bore Gages.
Connecting Rod
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.
Diameter Range .054 - 2.000 Inches
(1,4 - 50,8 mm)
Cylinder Head
Note: See pages 101-113 for dial bore gages for automotive use.
* Included with CF-1126.
CF-502M Metric Setting Fixture has a 0 to 51 mm
micrometer head marked in ,002 mm increments.
Supplied in a sturdy, nested box.
Cleaning
Gaging
Harley®
CF-502
Setting Fixture
(gage not included)
GA/GAM4000 Series
GR/GRM6000 Series
GR/GRM9000 Series
GR-2000 Series
www.sunnen.com
CF-1126
Setting Fixture
(gage not included)
127