VGS-20 Fixtures

Tooling and Accessories

for Harley Davidson®

VGS-3100 Head Holder Kit for

Cylinder Head

Harley-Davidson® Heads
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 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
Connecting Rod

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). APPLICATION: Harley® Shovel Heads (1966-1984)

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

mounting hardware.
Reconditioning
Block

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

Resurfacing

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

Optional VGS-3100 shown VGS-3110 Locating Blocks for Evolution®

mounted in VGS-2540C Fixture VGS-3102 Spacers (4).
(Included with VGS-20 Machine).
Heads
Cleaning

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
Gaging

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

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®

VCS-505 Single Blade, 3-Angle Seat VSC-55 Tool Sharpening Fixture

Cylinder Head
Cutting Kit for Harley® Cylinder Heads Similar to VSC-50. Used to
For SGM “off-hand” grind any angle
Style desired on VSC single angle
Tooling, cutters or cutter blanks.
see pages
12-19
in the

Connecting Rod
Cylinder
Head
VGS-20964 Valve
Section.
Guide Installation Kit

Kit Includes:

Reconditioning
Part No. Description
Valve seat machining kit designed for Harley® cylinder
VGS-216A Air Hammer

Block
heads features three angle, single blade carbide cutters.
Eliminates grinding and cuts all three finished seat angles VGS-217A Air Hammer Hose
simultaneously while maintaining exact seat width and VGS-191A .3125 inch (7,92 mm) Guide Driver
angles from seat to seat. Drastically reduces the time VGS-192A .3437 inch (8,73 mm) Guide Driver
required for machining valve seats and increases accuracy.
VGS-193A .375 inch (9,52 mm) Guide Driver
For use with Sunnen .389 inch (9,9 mm) precision valve VGS-194A .4375 inch (11,11 mm) Guide Driver
guide pilots and Sunnen Valve Guide and Seat Machines,
B-200L Press Fit Lubricant
models VGS-19 and VGS-20.

Resurfacing
Kit Includes: VS-1015 Rapid Valve Seat Checker for
Part No. Description Harley-Davidson® Heads
VSC-205 Cutter Body 1.0 - 1.6 inch (25-41 mm) The VS-1015 provides a quick way of accurately checking
VSC-305 Cutter Body 1.5 - 2.0 inch (38-52 mm) valve seat concentricity. The Sunnen VS-1015 Rapid
VSC-400 Setting Fixture Valve Seat Checker checks the critical intersection line
VSC-50 Tool Sharpening Fixture between top and seat angles for roundness and runout. It
PSP-215A Spring, Short works off the same pilot

Cleaning
PSP-216A Spring, Long used for machining the
VSC-509A Spring Bushings (4) seat to deliver optimum
PWM-5A Hex T-Wrench accuracy. Provided with
VSC-06045 (2) Cutter 30-45-60
a large dial indicator
which stays upright for
quick and easy reading.
VCS-505S Single Blade, 3-Angle Seat Dial is marked in .001
Cutter Kit (Sioux Pilots) increments.
Same as VSC-505 except cutter bodies fit Sioux .385 inch Set Includes:

Gaging
(9,8 mm) pilots. VS-1010 Indicator Assembly with indicating wheel for
Sunnen Pilots .389 inch (9,9 mm), plus these Indicator
Optional VSC-350 Cutter Body Wheel Assemblies:
for large diameter valves 1.9-2.5 inch (47-64 mm) range VS-1500-44 VS-1750-44 VS-2000-44
VS-1625-44 VS-1875-44
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. For additional Indicator Wheel Assemblies see page 40.
Harley®

NOTE: For a complete listing of VSC carbide cutters The VS-1015 Rapid Valve Seat Checker can be used on
and other tooling, refer to pages 12-19 or call Customer other manufacturers’ pilots by ordering these indicating
Service toll free. adapter wheels:

VSC-100 Tool Sharpener Fixture Kit Part No. Description

VS-1116A .385 inch (9,8 mm) diameter Sioux pilots
The VSC-100, when used in
conjunction with Sunnen’s TS-100 VS-1117A .437 inch (11,1 mm) diameter Kwik Way Pilots
Precision Tool Sharpener, sharpens VS-1118A .375 inch (9,5 mm) diameter K.O. Lee, Neway,
cutters in the body eliminating the Black and Decker pilots
need to reset the tool each time.
For metric applications, order VS-1015M.
[Link] 115
 VGS-20 Fixtures
Tooling and Accessories
for Harley Davidson®
Cylinder Head

VGS-300 Valve Seat Pocket Cutter Kit VS-300E Valve Guide Pilot Kit for
1.500 to 2.250 inches (38,5 to 57,1 mm) Harley-Davidson® Heads
Connecting Rod
Reconditioning

A convenient valve guide pilot kit for the most popular Harley®
Block

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 Kit consists of one each of the following pilots:
inserts are easily adjusted to size with the micrometer
provided, so the proper press fit can be obtained for cast Diameter
iron or aluminum heads. Pilot No. Inches Millimeters
VS-310E .310 7,87
Resurfacing

Kit Includes: VS-311E .311 7,90

Part No. Description VS-312E .312 7,92
ASPC-1500 Seat Pocket Cutter Head 1.500 -1.687 inch VS-340E .340 8,64
(38,1 - 42,9 mm) Range VS-341E .341 8,66
ASPC-1687 Seat Pocket Cutter Head 1.687-1.875 inch VS-342E .342 8,69
(42,9 - 47,6 mm) Range VS-376E .376 9,55
ASPC-1875 Seat Pocket Cutter Head 1.875 - 2.062 inch VS-377E .377 9,57
(47,6 - 52,4 mm) Range VS-378E .378 9,60
Cleaning

ASPC-2062 Seat Pocket Cutter Head 2.062 - 2.250 inch VS-379E .379 9,63
(52,4 -57,1 mm) Range VS-380E .380 9,65
VGS-325 Cutter Head Driver for Sunnen .389 inch
(9,88 mm) Pilot
VGS-410A Pocket Cutter Setting Fixture with Setting Standard VGS-130A Drill Chuck
PSP-215A Short Spring
Drill chuck with 0.5 inch (0-12,7 mm) capacity for drilling,
PSP-216A Long Spring reaming, and other machining applications. Used with
Gaging

VSC-509A Spring Bushing (4) VGS-20 Valve Guide and Seat Machine and includes
PWM-5A Hex T-Wrench integral quick change adapter and chuck key.

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.
Harley®

116 1-800-325-3670
 VGS-20 Fixtures
Tooling and Accessories
for Harley Davidson®

Sunnen VSC Carbide Cutters VSC-575 Bowl Hog Cutter

Cylinder Head
Sunnen offers a complete line of standard and special Used with Sunnen’s VSC cutter
carbide cutters for use with VSC cutter bodies. Carbide .38 R. 75° bodies to enlarge the bowl area
cutters for 3-angle valve seat machining, chamber relief, 1.0 below the valve seat for increased
throat alterations, and other machining requirements are air flow or installation of larger
available directly from stock. All VSC carbide bits can be diameter valves. The single blade,
easily re-sharpened on Sunnen’s TS-100 Tool Sharpener. 75 degree cutter features a .38 inch
See pages 11-19 & 28-31 for additional tooling and supplies. (9,65 mm) radius at the bottom to
VSC-575

Connecting Rod
blend machined areas and provide
VSC 3-Angle Carbide Valve Seat Cutters a chatter free finish. Cutter easily
adjusts to a wide range of diameters eliminating the need
VSC 3-Angle bits save time and improve accuracy by for multiple fixed diameter cutters.
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 VSC-K68B Blank Cutter
Machines and tooling. Available in a wide variety of fin-
The VSC-K68B is a .3125 inch (7,92 mm) wide blank cutter
ished seat widths, angles, and radiused profiles for stock
for the VSC system. This cutter consists of a carbide

Reconditioning
or performance work. See pages 28-31 for a complete list-
tip silver-soldered on a cutter blank. The blank cutter
ing of VSC carbide bits or call Customer Service toll free.

Block
can then be ground by the user to any desired angle or
specification. Great for high performance shops that use
VSC Form Tools non-standard valve seat configurations.
These carbide bits are used for combustion chamber
relief, unshrouding of valves, throat alterations, blending,
and other machining operations. Especially useful for R&D VSC-RB Radius Cutter Blank
and performance work. Bits can be easily re-sharpened Similar to the VSC-K68B but supplied with a .5 inch (12,7
and modified to suit individual requirements on Sunnen’s mm) wide carbide tip. This allows the user to grind a radius

Resurfacing
TS-100 Tool Sharpener. suitable to individual requirements.

VSC-511 used for chamber

relief, cuts with a .25 inch Special Profile VSC Cutters
(6,35 mm) radius. Special profile VSC cutters are available on a special order
VSC-523 basis. These special profile cutters will be made from a
Chamber blank cutter ground to your specifications. When ordering,
Relief
send full description with all specifications.

Cleaning
VSC-511 VSC-523 used for chamber
Chamber relief, cuts with a .236 inch
Relief (5,99 mm) radius.

VSC-512 used for throat

alterations, cuts with a .875
inch (22,22 mm) radius.
VSC-527

Gaging
Chamber
Relief

VSC-512 VSC-527 used for chamber

Throat relief, cuts with a .344 inch
Relief
(8,73 mm) radius.
Harley®

VSC-518 used for chamber

relief, cuts with a .188 inch
(4,77 mm) radius.
VSC-390

VSC-390 flat bottom, flush

cutting tool. Especially useful for
VSC-518
Chamber Relief cutting out Harley® bronze valve
seats to remove the press fit so
they can be removed easily.

[Link] 117
 VGS-20 Fixtures
Tooling and Accessories
for Harley Davidson®

VGS-1750 and VGS-1750M Seat Depth VGS-660 Electronic Level for Sunnen
Cylinder Head

Indicator Kits Guide and Seat Machines

The Sunnen VGS-1750 and The optional VGS-660 Electronic
VGS-1750M Seat Depth Indicators are Level is a precision measurement
designed for installation on Sunnen sensor that provides wide angular
Valve Guide and Seat Machines, range with excellent linearity. The
models VGS-19 and VGS-20. The readout unit contains a standard
VGS-1750 is calibrated in inches and nine-volt battery (included) which
Connecting Rod

the VGS-1750M for metric use. provides power for the system
Features: electronics and liquid crystal
display. Angular position is
• Helps operator control valve stem displayed digitally to within 0.1 of
installed height. a degree.
• Aids in maintaining consistent
combustion chamber volume.
• Enables the machinist to cut seats and seat pockets to Kit Includes:
an exact depth dimension.
Reconditioning

Part No. Description

Kit Includes: VGS-661 Level with Liquid Crystal Display

Block

VGS-667 Mounting Bracket with Hardware

Part No. Description VGS-661-1A Replacement Cable
VGS-1756A Dial Indicator (VGS-1756M for metric)
VGS-1757A Indicator Clamp VGS-2682 Stud Level Pin
VGS-1758 Post Support Used to align the VGS-20 spindle 90° to
VGS-1759A Post any flat surface. Insures proper cylinder
head alignment to repair broken studs or
Resurfacing

Note: This kit is retro-fitable to Sunnen VGS-20 machines after serial

number 1271, without modification to the machine. For serial numbers prior
other holes in areas where a guide pilot
to 1271, a drill and tap operation on the face casting and trimming the belt cannot be used.
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
VGS-20965 Seat Driver For drilling, tapping,
reaming, and bronze
Kit for Harley-Davidson® liner installation.
Cleaning

Heads Insures positive

Drivers slide over the valve guide gripping of tools with
pilot to provide a simple, efficient minimum runout for
method of installing new valve increased accuracy.
seats. NOTE: Refer to page 35 for Includes: collet chuck
additional tooling. with adapter (1); .75
Kit Includes: inch wrench (1); 30 mm
wrench (1); (collets must be ordered separately).
Part No. Description
Gaging

VGS-430A Seat Ring Driver Adapter, Manual

VC-200 Collet Set
Seat Ring Driver Adapter Rings:
VGS-453A 1.50 inch (38,10 mm) x 1.625 inch (41,27 mm) Set includes the most popular collet sizes for the
VGS-454A 1.75 inch (44,45 mm) x 1.875 inch (47,62 mm) VGS-1800A Collet Chuck. Collets may be ordered
VGS-455A 2.00 inch (50,80 mm) x 2.215 inch (53,97 mm) individually if desired.
Set Includes One Each of Collets Listed:
Part No. Diameter Range
Harley®

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)

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®

P-310 Valve Guide Gage Set P-195 Valve Guide Hone Set for

Cylinder Head
The only way Harley-Davidson® Heads
to be sure
clearance
is correct is
to GAGE IT!
The Sunnen
P-310 checks

Connecting Rod
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

Reconditioning
designed for the professional Harley® shop and is equipped with a
.0002 inch (,005 mm) graduated indicator for accurate guide sizing

Block
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 For portable valve guide sizing that produces straight, round holes
should be an essential part of your shop. and includes fast setup, look no further than the P-195. This hone
The P-310 is extremely accurate, using the engine’s valve stems to set allows you to set your guide clearances accurately and produce
set the gage. Simply zero the gage off the valve stems to be used a superior finish at the same time. The P-195 set includes all the
and the indicator will read the exact clearance. It checks all types tooling required for precision I.D. sizing of Harley-Davidson® valve
of guides... knurled, threaded, bronze or cast iron. It’s quick and guide bores for the popular .3125 inch (8,0 mm), .3437 inch (8,73

Resurfacing
versatile. The probes slide easily through the valve guide to explore mm), and .375 inch (9,5 mm) sizes. Optional tooling can be added
the entire length of the guide for size, taper, and out-of-round. 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
The P-310 Valve Guide Gage Set is an ideal accessory for the recommended for driving power. See page 48 for additional tooling
VGS-20 Valve Guide and Seat Machine, HS-60 Power Bench, or the and supplies.
P-195 Valve Guide Honing Set. Everything you need for accurately
checking Harley® valve guides in a single professional kit.
Truing Head & Driver
Set Includes: Sleeve
Part No. Description

Cleaning
P-300 Gage Dial calibrated in .0002 inch (0,005 mm) increments
P-312 Probe .3125 inch (8,0 mm) Adapter
P-344 Probe .3437 inch (8,73 mm)
P-350 Indicator only Stone
P-360 Wrench
P-375 Probe .375 inch (9,5 mm)
P-610A Metal Storage Case (stores items listed plus Mandrel
5 more probes) (Includes wedge)

Gaging
For metric applications, order P-310M.
Gage may also be set with ring gage or micrometer.
P-195 Hone Set for Harley-Davidson® Heads Includes:
Replacement and Additional Probes:
Part No. Description
Probe Size Diameter Range
Part No. Inches Inches Millimeters P-180 Hone Head and Driver
P-236 .224 to .264 5,69 to 6,70 BL10-308AS Mandrel .308 - .316 inch (7,82 - 8,02 mm)
P-250 .25 .238 to .278 6,05 to 7,06 S-308 Truing Sleeve
Harley®

P-281 .5937 .269 to .309 6,83 to 7,85 PK-10A Mandrel Adapter

P-312* .3125 .300 to .340 7,62 to 8,64 L10-J69 Stones, box of 6
P-344* .3437 .332 to .372 8,43 to 9,45 BL10-339AS Mandrel .339 - .347 inch (8,61 - 8,81 mm)
P-375* .375 .363 to .403 9,22 to 10,24 S-339 Truing Sleeve
P-406 .4062 394 to .434 10,01 to 11,02 PK-10A Mandrel Adapter
P-438 .4375 .426 to .466 10,82 to 11,84 L12-370AS Mandrel .370 - .385 inch (9,4 - 9,8 mm)
P-469 .1562 .457 to .497 11,61 to 12,62 S-370 Truing Sleeve
P-500 .5 .488 to .528 12,40 to 13,41 PK-12A Mandrel Adapter
L12-J67 Stones, box of 6
*Included with P-310 Valve Guide Gage Set. AN-1105A Storage Box

[Link] 119
 Valve Guide Gages
and Hone Sets
for Harley Davidson®

Tooling for Honing Harley® Heads for Valve Guide Sizing Tools
Cylinder Head

Oversize O.D. Valve Guides for use with

P-195 hone set Single Stroke Diamond Sizing Tools for
Harley® Valve Guides
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:
Part No. Description
Connecting Rod

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

For late Shovel and Knuckle order: (Each tool includes arbor, sleeve and pilot.)
Reconditioning

Part No. Description Tool No. Size Finished Diameter Range

Block

BL20-619AS Mandrel .619 - .650 inch (15,7 - 16,5 mm) Inches mm Inches mm
S-619 Truing Sleeve VG-315-D5 .3125 8 .310 - .320 7,87 - 8,13
L20-J67 Stones, Box of 6 VG-344-D5 .3437 8.73 .339 - .349 8,61 - 8,86
PAK-20-A Adapter
VG-374-D5 .375 9.5 .369 - .379 9,37 - 9,63

AN-1075 Speed Control Unit

MB-30-5 Honing Oil
Resurfacing

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.

Finding electric drills which go down to the correct 200

rpm for driving the valve guide hone can sometimes be
Gaging

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®

Wheels made from specially for- VRC-500 Precision Valve Checker

Cylinder Head
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.

Connecting Rod
Grinding Wheels for VR-7000 & VR-8000
Part No. Description
VR-1701 Butt
VR-1702 General Purpose (Water)
VR-1703 General Purpose (Oil)
VR-1704 Titanium (Water or Oil)

Reconditioning
Grinding Wheels for VR-6500 The VRC-500 provides a means of checking the runout of

Block
the valve face in relation to the valve stem. Accommodates
Part No. Description stem diameters from .25-.75 inches (6-19 mm); head
VR- 601 Butt diameters from .625-4.5 inches (16-114 mm); and stem
lengths up to 9.0 inches (76 mm) long.
VR- 602 General Purpose
VR- 603 Titanium The indicator reads in .0001 inch (,002 mm) increments
and can be positioned for easy reading. Accuracy is
VR- 604 Stellite
ensured since the VRC-500 is set off of the valve stem.
VR- 607 General Purpose (used with water soluble coolant only)

Resurfacing
VRC-500M Metric Checker
MBC-200 Work Light
Components of the VRC-500M are the same as the
The MBC-200 is equipped with a 6-foot VRC-500 (as shown above), except the indicator is
(1,83 meters) cord with a 3-wire molded-on replaced with a metric indicator calibrated in 0,005 mm
grounding type plug. Fits all Sunnen pedestal increments. Large capacity means you can check valves
machines (bulb not included). with stems from 6-19 mm diameter and head diameters
from 16-114 mm.

Cleaning
Gaging
Harley®

[Link] 121
 Tooling and Accessories
for Harley Davidson®

AG-300 Gage PL-100 Mandrel Kit

Cylinder Head

The AG-300 gage has become the for Honing Harley-Davidson®

standard in the industry for quickly Rod Races
checking rod bores for taper, out- Used to hone rod races for oversize
of-round, and size within .0001 inch rollers. Fits all 1.5 inch (38,1 mm) and
(,0025 mm). Its direct reading range 1.625 inch (41,27 mm) Harley® rods.
is .375 - 3.375 inches (9,5 - 85,7 mm)
with optional point sets and can be set Kit Includes:
Connecting Rod

with a micrometer, setting standard, or

Part No. Description
precision ring gage.
2GP28-1500WD Mandrel for 1.5 inch (38,1 mm) rods
You can measure the exact amount of press fit or
ST-1500 Truing Sleeve
clearance with a single gage to .0001 inch (,0025 mm)
accuracy. Whether you’re sizing Harley® rod races, piston 2GP28-1625WD Mandrel for 1.625 inch (41,27 mm) rods
pin bores, pin bushings, or other parts, the AG-300 ST-1625 Truing Sleeve
Precision Gage makes it fast and accurate. P28-A53 Stones, roughing, box of 12
NOTE: AG-400 Gage has fingers that are .600" longer than the P28-J63 Stones, medium finishing, box of 12
Reconditioning

AG-300. See page 102 in Gaging Section. P28-J93 Stones, fine finishing, box of 12
Block

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 Approx. Surface Finish
such honing jobs. Part No. Description
Microinch Micrometer
Machine reservoir capacity:
P28-A53 Stones, roughing 18 Ra 0,46 Ra
LBB-1660: 15 gallons (56,8 liters)
Resurfacing

LBC-1803 and LBB-1810: 25 gallons (94 liters) P28-J63 Stones, medium finishing 12 Ra 0,31 Ra
P28-J93 Stones, fine finishing 3-5 Ra 0,08-0,13 Ra

AN-600 Honing Head Stones for Honing Rod Races Using

Diameter Range 2.500-6.500 inches Sunnen CR or Y44 Mandrels
(64mm-165mm) Shops using Sunnen
Ideal for honing Harley-Davidson® CR or Y44 mandrels for
or other small engine cylinders. honing 1.5 inch
Cleaning

Accuracy to .0005 inch (,01 (38,10 mm) and 1.625

mm). Uses same stone sets as inch (41,27 mm) Harley®
AN model Portable Cylinder Hone. Can be used with any rod races should use the
pedestal model Sunnen Honing Machine. (Stone sets listed stones listed below.
on Page 91.) Part No. Description
Y44-A53 Stone, roughing, 2 per box
CRF-750 Universal Holding Fixture Y44-J63 Stone, medium finishing, 2 per box
for CRF-100 connecting rod and fixtures Y44-J95 Stone, fine finishing, 2 per box
Gaging

Accommodates Harley-Davidson® Note: Use PD-B bronze shoes for power stroked machines and long
and most other motorcycle life when honing rod races.
cylinders and other parts within
the CRF-750’s range, that can be
placed on the honing machine. KL-770 Mandrel Kit
Fixture can be installed or for honing I.D. of
removed quickly and easily. Takes thrust on forward and Harley-Davidson®
back strokes. Includes two pairs of fingers with long- piston pin bushings in
Harley®

wearing, adjustable carbide pads. For cylinders order KKN- connecting rods
735A Torque Bracket Assembly.

KKN-735A Torque Bracket Part No. Description

AK20-775-UA Mandrel .775 - .805 inch (19,7 - 20,4 mm) range
The KKN-735A is used in conjunction with
the CRF-750 Universal Holding Fixture. It S-775 Truing Sleeve
allows honing torque to be taken at the AK20-A Adapter
center of the bore length. It is especially K20-J25 Stones, roughing, box of 12
useful for odd shaped cylinders typical of K20-J67 Stones, finishing, box of 12
motorcycle applications.

122 1-800-325-3670
 Tooling and Accessories
for Harley Davidson®

Tooling for Honing Connecting Rods Bushing Expander for Harley®

Cylinder Head
For honing I.D. of Harley connecting rods for
®
Connecting Rods
oversize O.D. pin bushings For expanding new Caution: Do not use these
mandrels for honing.
Part No. Description
pin bushings in the
connecting rod before
AK20-900UC Mandrel .900 - .930 inch (22,9 - 23,6 mm) Pressed-in bushing touches
honing to size. Use for on the high spots only.
S-900 Truing Sleeve all Harley-Davidson®
AK20-A Adapter connecting rods with
Expanded bushing fills in val-
.791 inch (20,09 mm)

Connecting Rod
K20-J25 Stones, roughing, box of 12 leys and is locked in perfectly
to rod eye.
K20-A69 Stones, finishing, box of 12 pin diameter. Can be
Keeps bushings from working
used with any Sunnen loose.

horizontal honing
Tooling for Honing Connecting Rods machine.
For honing Harley-Davidson® pin bores in • Assures 100% contact for perfect heat transfer
pistons with standard pin diameter .791 inch • Additional protection for your pin fit
(20,09 mm) • Squeezes bushing into every hole irregularity

Reconditioning
Part No. Description • Swedges bushing in minutes
• Trims bushing edges square and clean

Block
3GP20-781UA Mandrel .775 - .812 inch (19,7 - 20,6 mm)
ST-780 Truing Sleeve
Expander Diameter Range Expander
P20-J47 Stones, roughing, box of 12 Mandrel (includes
Inches mm facing cutter)
P20-J67 Stones, finishing, box of 12
ALR-720 .720-.840 18,3-21,3 AL-12*

Tooling for Rocker Arm Bushings *ALR expander mandrels cannot be used without AL-12

Resurfacing
For honing Evo®, Sportster® and Shovel Head with expanders. Please order separately.
.554 inch (14,07 mm) standard shaft diameter For a complete listing of expander mandrels and acces-
Part No. Description sories see page 55.
3P16-526AS Mandrel .526-.557 inch (13,36-14,15 mm)
P16-A Adapter with retainer Portable Tooling for Pin Bushings
S-526 Truing sleeve For honing pin bushings in Harley® connecting
P16-J93 Stones, roughing, box of 12 rods with .791 inch (20,09 mm) piston pin diameter
Allows pin bushings in connecting rods to be honed

Cleaning
NOTE: Order C-526 alignment bushing for Sunnen power stroke
machines with adjustable spindle nose. Tooling listed is available without removing rods from crankshaft. Can be used for
under special order – call Sunnen Customer Service toll free for honing new bushings to standard or honing bushings
price and delivery before ordering. 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.
Tappet Block Tooling Note: P-180 driver included in Sunnen P-195 Valve Guide Hone
For honing Harley-Davidson® tappet blocks Set listed on page 48.
oversize with standard tappet diameter Part No. Description

Gaging
.731 inch (18,57 mm) AK20-775UA Mandrel, .775 inch-.805 inch (19,7-20,4 mm) range
Part No. Description S-775 Truing Sleeve
Y20-713BS Mandrel, .713 inch-.744 inch (18,11-18,90 mm) range PAK-20A Adapter for mandrel
Y20-A Adapter for mandrel K20-J25 Stones, roughing, box of 12
S-713 Truing Sleeve K20-J67 Stones, finishing, box of 12
Y20-J55 Stones, roughing, 12 per box
Y20-J95 Stones, finishing, 12 per box
Harley®

[Link] 123
 Portable Honing Equipment
for Harley Davidson®

Portable Cylinder Hones AN-112 Standard Portable Cylinder Hone

Cylinder Head

• The fastest and most accurate portable hone for Range 2.5 - 7 inches (63 - 178 mm)
Harley-Davidson® cylinder reconditioning... to The 2.5 - 7 inch (63 - 178 mm) diameter range of the
.0005 inch (,013 mm). AN-112 gives excellent coverage for Harley-Davidson® and
•C
 an also be used in trucks, tractors, stationary engines, most other common bore sizes. Stone sets available for
automobiles, boats, etc. honing a wide variety of materials throughout the range of
2.5 - 7 inches (63 - 178 mm) diameter. Includes a 2 inch
•T
 he only method that maintains alignment of the (50,88 mm) drive shank and 12 inch (304,8 mm) extension.
original bore.
Connecting Rod

NOTE: All stone sets must be ordered separately.

•R
 econditions cylinder bore with less stock removal than
other methods – maintains uniform wall thickness –
assures longer block life.
SNJ-8-749 Piloted Portable Hone
•P
 roduces any finish specified by engine and ring
manufacturers. In-line honing for Harley
Davidson® engine and
• Recommended for fast seating of any type rings.
transmission cases.
• Correct stone length optimized for cylinder honing. Allows you to locate from
Reconditioning

•F
 ast stock removal – up to .005 inch (0,13 mm) per minute. tapered bearing side to
Block

ensure precise alignment

• Can be set up in a few minutes. on straight bearing side.
•A
 ll cylinder hones include AN-1105A molded storage box. Also eliminates the need
of lapping bearing.

Additional Portable Hones and Recommended Stone Sets:

Accessories
Stone Sets*
Resurfacing

Sunnen manufactures a complete line of portable cylinder (Consists of 3 Stones)

hones and abrasives for bore diameters from 1.250 to 15 For General Purpose Honing
inches (31,75 -381 mm). Refer to pages 89-91 or page 125
1.250"-1.437" 1.250"-1.437" 1.250"-1.437"
for additional information or call Customer Service toll free. 31,75mm-36,50mm 31,75mm-36,50mm 31,75mm-36,50mm
Roughing Stones
for New Bearings SNJ1-A45 SNJ2-A45 SNJ3-A45
Drive Shanks
Finishing Stones SNJ1-J63 SNJ2-J63 SNJ3-J63
Cleaning

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

Part No. Description
AN-26A* 3 inch (76 mm)
Accessories:
AN-70 Universal Joint SNJ-75-887X Piloted Portable Hone
AN-80 Quick Coupler Range 1.75 - 2.0 inches (44-51 mm)
Roughing Stones
S18 - A45
Gaging

Finishing Stones
Shaft Extensions S18 - J63

Part No. Description

AN-241* 12 inch (305 mm) CK-NX8X Torque Fixture
AN-242 24 inch (610 mm)
Used for honing
AN-244 48 inch (1220 mm) Harley® Cylinders in
Harley®

CV/CK Vertical Honing

*Supplied with hone.
Machines. Can be used
with Evolution®, Shovel®
and Pan Head Cylinders.
Allow 4-6 weeks for
delivery.
CK PL3X 5.125 Bores
U Twin
U Twin Pro

124 1-800-325-3670
 Portable Honing Equipment
for Harley Davidson®

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

Cylinder Head
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

Connecting Rod
Harley-Davidson® M27-J45 — — — — — 4 102
AN
Deutch Diesel Cyls.
Standard
and VW Air Cooled Cyls M27-J45 — — — — — 4 102

Heavy Duty Chilled Iron Liners
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

Reconditioning
Short C. Iron Cyls. N37-J17-71 N37-J45-71 N37-J55-71 N37-J65-71 — — 2.8125 71

Block
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
Approx. Cast Iron 120 45 32 20 8 3 — —
Surface Finish in
Hardened Steel 55 30 20 12 5 2 — —
Microinches (Ra)
Steel — 32 20 15 7 3 — —
†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).

Resurfacing
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.

PHT Plateau Honing Tools AN-980 Chamfering Cone

Chamfers the sharp edges of
cylinders for safe piston and
ring installation. Handles all
diameter cylinders or sleeves.

Cleaning
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.
Sunnen’s PHT tools are used as a final finishing step, after
initial honing, to provide a plateau surface on cylinder

Gaging
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:

Diameter Range Abrasive sets
Harley®

Hone Body
Inches mm (320 Grit)
AN 2.98-3.78 75,7-96,0 GG-PHT-732
Standard
3.78-4.68 96,0-118,9 MM-PHT-731
and 4.48-6.08 113,8-154,4 NN-PHT-731
Heavy Duty
4.98-9.68 125,5-245,9 WW-PHT-731

Caution: Check diameter and range required before

ordering. Range of PHT abrasives differs from standard
honing stones.

[Link] 125
 Dial Bore Gages &
Accessories
for Harley Davidson®

For Diameters From .495 - 8 Inches GR/GRM-9000 Series Gages

Cylinder Head

(112,6 - 203 mm) Diameter Range 1.18 - 2.0 Inches

(30,0 - 50,8 mm)
Precision gaging is the only way to make sure your bore
sizes are correct and insure quality on every job. Don’t rely Retractable gage with
on slow, antiquated methods or measuring instruments .0001 inch (,002 mm)
to insure the quality of your work. Whether it’s cylinders, reading indicator. Capable
bearing races, case bushings or other parts requiring of measuring to within
close tolerances, your work will only be as accurate as .335 inch (8,5 mm) of the
Connecting Rod

your method of checking it. Sunnen’s complete line of self bottom of a blind hole.
centralizing dial bore gages and precision setting fixtures Indicators reading in
make this an easy task with uncompromising accuracy. .0005 inch (,010 mm) are
Now, you can check bores for size, taper, and out-of-round available on special order.
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. Max. Gaging Overall Shipping
(For additional information consult Sunnen Catalog Model No. Depth Length Weight
X-SP-5500 or call Customer Service toll free.)
Reconditioning

Inches Metric inch mm inch mm lbs kg

GR-9071 GRM-9071 3.5 88 9.25 237 4 1,8
Block

GA/GAM-4000 Series Gages GR-9121 GRM-9121 6 150 11.75 300 4 1,8

Diameter Range .495 - .750 Inches GR-9241 GRM-9241 12 300 17.75 452 4 1,8
(12,6 - 19,0 mm)
Non-retractable gage with .0001 inch
(,002 mm) reading indicator. Capable of
GA-2125 and GR-2125
measuring to within .200 inch (5,0 mm) Diameter Range 2 - 8 Inches (50,8 - 203 mm)
of the bottom of a blind hole. Indicators Gage Holes Up To 12 Inches (304 mm) Long
Resurfacing

reading in .0005 inch (,010 mm) are For cylinders, sleeves,

available on special order. large con rods... many
other gaging jobs. The
GA-2125 is self-aligning
in the bore, requires
no centering. Lets you
Max. Gaging Overall Shipping explore the entire cylinder
Model No. Depth Length Weight from top to bottom... in
Inches Metric inch mm inch mm lbs kg seconds.
Cleaning

GA-4051 GAM-4051 2.5 62 7.3125 187 1.5 ,7 The retractable

GA-4101 GAM-4101 5 125 9.8125 251 1.5 ,7 self-centering mechanism
GA-4141 GAM-4141 7 175 11.9375 302 1.5 ,7 in the gage head of the
GR-2125 makes it easy
to gage interrupted
GR/GRM-6000 Series Gages bores typical of 2-cycle
Diameter Range .740 - 1.190 Inches motorcycle and marine
(18,8 - 30,2 mm) engine applications
Gaging

Retractable gage with .0001 without “hanging up.” The retraction feature allows precise
inch (,002 mm) reading indicator. exploration of a high performance cylinder without leaving
Capable of measuring to within telltale gaging marks.
.270 inch (6,8 mm) of the bottom • Gages are self-centering.
of a blind hole. Indicators reading • Adjustable dial for easier reading.
in .0005 inch (,010 mm) are
• Dial is marked in .0005 inch (,012 mm) increments.
available on special order.
• Carbide gaging points... for long life.
• Insulated grip eliminates “drift.”
Harley®

• Furnished in molded case with extension points and

wrenches.
Max. Gaging Overall Shipping For metric models, order GAM-2125 or GRM-2125. Range:
Model No. Depth Length Weight 50 to 203 mm. Dial marked in ,01 mm increments.
Inches Metric inch mm inch mm lbs kg NOTE: .0001 inch (,002 mm) reading dial bore gages and
GR-6071 GRM-6071 3.5 88 9.8125 235 2 1 special lengths also available. Consult Sunnen Catalog
GR-6121 GRM-6121 6 150 11.6875 298 2 1 X-SP-5500 for a complete listing of gages and accessories
GR-6241 GRM-6241 12 300 17.6875 451 2 1 or call Customer Service toll free.

126 1-800-325-3670
 Dial Bore Gages &
Accessories
for Harley Davidson®

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

Cylinder Head
Setting Fixtures For Dial Bore Gages CF-1126 Setting Fixture
For Diameters from .054 - 8 inches Diameter Range 2 - 8 Inches (51 - 203 MM)
(1,37 - 203 mm)
Sunnen’s precision setting fixtures make easy work of For use with 2000 Series Dial Bore Gages.
accurately setting Sunnen’s complete line of dial bore The CF-1126 incorporates a tenth-reading micrometer
gages. These fixtures eliminate the errors and “feel” head with precision carbide anvil. Accurate within .0001

Connecting Rod
associated with other setting methods for accurate, inch (0,0025 mm). Ring gage checking standard included.
dependable measurements. Setting master is made from Precision setting standards in 1 inch (25,4 mm) increments.
stress-relieved cast iron and is multi-session cold room Setting Master has rugged stress-relieved, cast iron base.
stabilized. The .0001 inch (,002 mm) reading micrometer May be used without removing from protective case.
head includes precision lapped carbide anvils and comes
complete with a precision ring gage for calibration. Setting The setting fixture itself covers the 7 to 8 inch (178 to
fixtures can be used without removing them from the 203 mm) range. In addition, the fixture is supplied with
protective storage case included with each fixture. For standards to cover the 2 to 6 inch (50 to 152,4 mm) range.
additional information consult Sunnen Catalog X-SP-5500 Order additional setting standard to give complete 2 to 8

Reconditioning
or call Customer Service toll free. inch (50 to 203,2 mm) range as follows:

Block
CF-502 Setting Fixture Model No. Description
Diameter Range .054 - 2.000 Inches CF-220A* Range 2 - 3 inch (51 - 76 mm)
(1,4 - 50,8 mm) CF-230A* Range 3 - 4 inch (76 - 102 mm)
For use with 4000, 6000, and 9000 Series Dial Bore Gages. CF-240A* Range 4 - 5 inch (102 - 127 mm)
Model CF-502 is equipped with a large micrometer head CF-250A* Range 5 - 6 inch (127 - 152 mm)
with range of 0 - 2 inches (0,0 - 50,8 mm) marked in .0001

Resurfacing
CF-260A Range 6 - 7 inch (152 - 178 mm)
inch (,0025 mm) increments.
CF-215A* Ring Gage 2.000 inch (50,8 mm)
Setting Fixture comes with CF-576A .750 inch (19,05 mm)
master calibrating ring. * 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/GAM-
CF-1126
4000 Series
Setting Fixture
GR/GRM- GR-2000 Series (gage not included)
GR/GRM- 9000 Series
6000 Series

[Link] 127