Harley Davidson Touring 2004 Service Manual sm03c
HOM
CAUTION
6906
E
PISTON
Removal
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-11 and 15-29.
Disassembly
Piston Rings, Removal
1WARNING1WARNING
Always wear proper eye protection when removing the
compression rings. Slippage may propel the ring with
enough force to cause eye injury.
1. Carefully remove first and second compression rings
using the proper piston ring expander (Snap-On PRS8).
2. Using your fingers, remove the top and bottom oil rails
from the third ring groove. Remove the expander spring.
3. Discard the piston rings.
Cleaning and Inspection
Cleaning
CAUTION
Do not sand blast or glass bead blast pistons. Bead
blasting rounds off ring lands and will result in oil contamination leading to accelerated wear.
1. To remove all carbon and combustion deposits, soak the
pistons in a special detergent that will not corrode aluminum. Maintain the temperature of the cleaning solution
well below 212
2. Thoroughly rinse the pistons and dry with moisture free
compressed air.
3. Clean the oil drain holes leading from the oil control ring
groove to the underside of the piston crown. Run a small
bristle brush through the passageways to ensure their
cleanliness, but be careful not to damage or enlarge the
holes. Do not use a wire brush.
4. Verify that all other oil holes are clean and open.
o
F. (100o C.).
6. Using Magnaflux Dye Penetrant, inspect the piston for
surface cracks. Pay special attention to the area around
the pin bores, ring lands and oil drain holes beneath the
piston crown. If no cracks are found, thoroughly wash
piston to remove traces of dye.
Inspection
1. Lightly oil a good piston pin and insert it into the piston
pin bore to feel for the proper interference fit. The pin
should slide in and out without binding, but also without
pivoting or rocking. Replace piston and/or pin if clearance exceeds 0.0008 in. (0.020 mm).
2. Carefully inspect the pistons for damage or excessive
wear. Discard pistons with cracked, broken or bent ring
lands. Check the piston skirt for cracks, gouges, deep
scratches or heavy scoring. Check the piston heads for
evidence of burning, etching or melting. Look for marks
or imprints caused by contact with valves. Pistons with
superficial wear marks, minor scratching or mild scoring
may continue to be used.
3. Run your index finger around the edge of the piston
crown to feel for dings, nicks or burrs. Lightly file the
edge of the crown to remove any defects.
Worn ring grooves result in high oil consumption and
blow-by of exhaust gases. Blow-by of exhaust gases
contaminates the engine oil supply with acids and
leaves sludge in the crankcase. It also reduces engine
efficiency by weakening the combustion seal necessary
for efficient transfer of energy to the piston.
4. Measure the piston ring side clearance as follows:
a. Insert the edge of a new ring into the piston ring
groove. Insert a feeler gauge between the upper
surface of the ring and the ring land. See Figure 3-
88.
CAUTION
Exercise care to avoid scratching the sides of the piston
ring grooves.
5. Thoroughly clean the three piston ring grooves of all carbon deposits. A broken compression ring properly
ground to a sharp chisel-like edge may be used for this
purpose.
Figure 3-88. Measure Piston Ring Side Clearance
2004 Touring: Engine 3-77
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EARLY STYLE
FULLY COATED
No Bare
Aluminum
f2114x3x
NOTE
On late style pistons, the measurement is taken on the bare
aluminum to avoid measuring errors. An oval-shaped opening is present on each side of the piston for proper placement
of the micrometer. See upper frame of Figure 3-90. Since the
oval openings are too small for a standard flat anvil micrometer, which would result in measuring errors, use a 3-4 inch
blade or ball anvil style micrometer, or a 4-5 inch micrometer
with spherical ball anvil adapters. See lower frame of Figure
3-90.
c. Using a grease pencil, mark the top, middle and
bottom of the piston ring travel zone in the cylinder
bore. Measure at markings in cylinder parallel and
perpendicular to crankshaft.
CAUTION
Do not check piston running clearance immediately after
honing or deglazing cylinder. Since heat will cause measurements to vary by as much as 0.0002 inch (0.005 mm),
both piston and cylinder must be at room temperatures.
d. Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).
f1685x3x
Figure 3-89. Measure Early Style Piston for
Running Clearance
b. Since the grooves wear unevenly, repeat this check
at several locations around the piston groove circumference.
c. Discard the piston if the side clearance of either
compression ring exceeds 0.0045 in. (0.11 mm).
Discard the piston if the oil control ring side clearance exceeds 0.010 in. (0.25 mm).
5. Measure the running clearance on fully coated early
style pistons as follows:
NOTE
Check the piston clearance in the cylinder in which the piston
will run. The torque plates must be installed on the cylinder
and it must be deglazed and suitable for continued service.
a. Holding outside micrometer, measure piston skirt
diameter across the thrust faces (perpendicular to
pin bore). Start below the bottom ring land and
move micrometer towards bottom of skirt. Micrometer will be loose, then tight (about 1/2 inch from bottom), and then loose again. See lower frame of
Figure 3-89.
b. Measure the piston skirt at the tightest spot and
then transfer that measurement to the dial bore
gauge.
LATE STYLE
Bare
Aluminum
f2113x3x
4-5 Inch
Micrometer
Spherical Ball
Anvil Adapters
f2109x3x
Figure 3-90. Measure Late Style Piston for
Running Clearance
3-78 2004 Touring: Engine
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REAR
2
4
1
3
FRONT
4
2
3
1
1. Expander spring
2. Bottom oil rail
3. Top oil rail
4. Second compression ring
5. Top compression ring
5
5
f2066x3x
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6905
Figure 3-91. Measure Ring End Gap
Assembly
Piston Rings, Installation
NOTE
Always use
and must not be reused if the engine has been operated.
Always deglaze (or hone) the cylinder before installing new
rings. Ring sets are available to fit oversize pistons.
new
piston rings. Piston rings take a definite set
NOTE
Ring end gap dimensions also apply to oversize rings.
Replace ring if end gap exceeds specification. If end gap is
under specification, filing is permissible.
3. Use compressed air to remove any dirt or dust that may
have settled in the oil drain holes and piston ring
grooves.
4. Install piston rings as follows:
a. Apply clean H-D 20W50 engine oil to three piston
ring grooves.
b. Install expander spring into third ring groove. Spiral
bottom oil rail into space below expander spring
positioning the gap 90 degrees from the gap in the
expander spring. Spiral top oil rail into space above
expander spring positioning gap 180 degrees from
the gap in the bottom oil rail.
1. Before placing each ring on the piston, perform the following check.
CAUTION
Insufficient ring end gap may cause the ends to abut at
engine operating temperatures, resulting in ring breakage, cylinder scuffing and/or piston seizure.
Excessive ring end gap results in high oil consumption
and blow-by of exhaust gases. While blow-by contaminates the oil supply and leaves sludge in the crankcase,
it also reduces engine efficiency by weakening the combustion seal necessary for efficient transfer of energy to
the piston.
2. Insert the new ring into the cylinder, square it in the bore
using the top of the piston and measure the ring end gap
with a feeler gauge. See Figure 3-91. Do not use the ring
if the end gap does not fall within the following specifications.
CAUTION
Table 3-8. Ring End Gap
Ring Type
Top compression ring 0.010 in. (0.25 mm) - 0.020 in. (0.51 mm)
2nd compression ring 0.014 in. (0.36 mm) - 0.024 in. (0.61 mm)
Oil control ring
rails
0.010 in. (0.25 mm) - 0.050 in. (1.27 mm)
Ring End Gap
Figure 3-92. Piston Ring Gap Alignment
2004 Touring: Engine 3-79
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CAUTION
Use the proper piston ring spreader to prevent excessive
ring twist and expansion. Over expansion may cause the
ring to crack opposite the ring gap. Damaged or distorted rings result in blow-by of exhaust gases,
increased oil consumption and lower service life on
valves and other components.
CAUTION
Installing the second compression ring upside down will
cause oil to be scraped up into the combustion chamber
resulting in excessive oil consumption and low service
life on valves and other components.
c. Using the proper piston ring expander (Snap-On
PRS8), carefully install the second compression
ring making sure that the dot (punch mark) near the
ring gap faces the piston crown. Rotate the ring so
the gap is 90 degrees from the gap in the top oil rail.
d. Carefully install the top compression ring using the
proper piston ring expander (Snap-On PRS8).
Rotate the ring so the gap is 180 degrees from the
gap in the second compression ring.
e. Rotate the three piston rings using the palms of
both hands. The rings must rotate freely without
sticking.
f. Verify that the ring gaps are still properly staggered.
See Figure 3-92.
Installation
1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
steps 1-23 and 28-37.
3-80 2004 Touring: Engine
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NOTES
2004 Touring: Engine 3-81
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UPPER CONNECTING ROD
Removal
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-11 and 15-29.
Disassembly/Assembly
NOTE
Service of connecting rods is limited to replacement of the
upper bushing. Damage to connecting rods or lower bushing
service requires replacement of the flywheel assembly.
Upper Connecting Rod Bushing
Removal
NOTE
Replace the upper rod bushing if the piston pin to rod bushing clearance exceeds 0.002 inch (0.051 mm).
CAUTION
Place clean shop towels in and around the crankcase
bore to prevent chips and shavings from falling into the
crankcase.
1. Obtain the CONNECTING ROD CLAMPING TOOL (HD95952-33B) and proceed as follows:
a. Slide clamp over connecting rod so that slots
engage cylinder head studs. See Figure 3-94. Exercise caution to avoid scratching or bending studs.
b. With the knurled side up, install threaded cylinders
(HD-95952-1) onto studs to secure position of
clamp.
c. Alternately turn each clamp thumbscrew a few turns
to gradually fix position of connecting rod. Turning
only one thumbscrew will move rod off-center, while
tightening second thumbscrew can cause rod to flex
or bend.
2. Obtain the CONNECTING ROD BUSHING REMOVER/
INSTALLER (HD-95970-32D) and proceed as follows:
a. Sparingly apply graphite lubricant to threads of rod
to prolong service life and ensure smooth operation.
b. Slide receiver cup (HD-95984-99) onto threaded rod
with the closed side facing hex nut.
c. Insert threaded rod through upper rod bushing.
d. Slide remover side of driver (HD-95986-99) down
threaded rod. The driver is stamped to ensure
proper orientation.
e. Slide Nice bearing and flat washer down threaded
rod until it contacts driver.
Threaded
Cylinders
Part No. HD-95952-1
Figure 3-93. Connecting Rod Clamping Tool
(Part No. HD-95952-33B)
f1597x3x
Threaded
Cylinder
ThumbscrewClamp
Figure 3-94. Install Connecting Rod Clamping Tool
f. Thread the hex cylinder onto rod until assembly is
snug. See upper frame of Figure 3-96.
g. Holding nut at end of threaded rod with a 5/8 inch
box wrench, turn hex cylinder with a 5/8 inch socket
until bushing is free.
h. Unthread hex cylinder from rod. Remove flat
washer, Nice bearing and driver. Remove threaded
rod from bushing bore.
i. Remove bushing from receiver cup and discard.
Installation
1. Obtain the CONNECTING ROD BUSHING REMOVER/
INSTALLER (HD-95970-32D) and proceed as follows:
3-82 2004 Touring: Engine
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f1601x3x
f1602x3x
f1598x3x
Driver
Installer Side
Slot
Oil Hole
Upper Rod
Bushing
Connecting
Rod
Threaded
Rod
Flat
Washer
Hex
Cylinder
Nice
Bearing
Receiver
Cup
Driver
Remover Side
Remover Stackup
Installer Stackup
Hold hex nut on threaded rod with 5/8 inch box.
Turn cylinder hex with 5/8 inch socket.
E
Driver
Part No. HD-95986-99
Figure 3-95. Connecting Rod Bushing Remover/Installer
a. Slide receiver cup (HD-95984-99) onto threaded rod
b. Insert threaded rod through upper rod bushing bore.
c. Slide
d. Slide installer side of driver (HD-95986-99) down
e. Slide Nice bearing and flat washer down threaded
f. Thread the hex cylinder onto rod until assembly is
g. Holding nut at end of threaded rod with a 5/8 inch
h. Unthread hex cylinder from rod and remove flat
Receiver Cup
Part No. HD-95984-99
(Part No. HD-95970-32D)
with the closed side facing hex nut.
new
bushing down threaded rod. Start bushing into bore. Verify that center of slot in bushing is
aligned with oil hole at top of rod. Also, be sure that
bushing is square in bore and not cocked. See center frame of Figure 3-96.
threaded rod until shoulder contacts bushing. The
driver is stamped to ensure proper orientation.
rod until it contacts driver.
snug.
box wrench, turn hex cylinder with a 5/8 inch socket
until collar on driver bottoms against connecting
rod. See lower frame of Figure 3-96.
washer, Nice bearing and driver. Remove threaded
rod from bushing bore, but exercise caution to avoid
scratching or gouging bushing.
Reaming Upper Rod Bushing
1. Obtain the CONNECTING ROD BUSHING REAMER
(HD-42318) and REAMER HANDLE/DRIVE SOCKET
(HD-43645). Proceed as follows:
a. Carefully insert bit of reamer into upper connecting
rod bushing. Do not apply lubricant to reamer or
bushing. Ream the bushing dry or cut will not be
accurate.
b. Install handle/drive socket on reamer lug. See Fig-
ure 3-98.
c. Placing thumb on dr
ive socket, apply slight pressure
on reamer while rotating handle/drive socket in a
clockwise direction.
Figure 3-96. Remove/Install Connecting Rod Bushing
2004 Touring: Engine 3-83
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Handle/Drive Socket
Reamer
Figure 3-97. Connecting Rod Bushing Reamer (Part No.
HD-42318) and Handle/Drive Socket (Part No. HD-43645)
f1642x3x
2. Using contact cleaner or cleaning solvent, thoroughly
wipe upper connecting rod and bushing of any metal
shavings or debris.
Honing Upper Rod Bushing
1. Obtain the CONNECTING ROD BUSHING HONE (HD-
42569) and REAMER LUBRICANT (HD-39964). Proceed as follows:
a. Install hone in a high speed electric drill.
b. Apply reamer lubricant to finishing stones of hone
and inside of upper connecting rod bushing.
c. Start finishing stones of hone into bushing.
d. Activating the drill, move the entire length of the fin-
ishing stone arrangement forward and backward
through the bushing bore for 10 to 12 complete
strokes. See Figure 3-100. Work for a crosshatch
pattern of approximately 60˚.
CAUTION
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine failure.
Figure 3-98. Ream Connecting Rod Bushing
CAUTION
For best results, do not push on reamer or apply pressure to the reamer handle. While excessive pressure
results in a rough cut, bushing bore will be tapered if
pressure is not centrally applied.
d. Continue rotating handle/drive socket until entire bit
has passed through bushing and shank of reamer
rotates freely in the bore.
CAUTION
Never back reamer out of connecting rod or bushing will
be damaged.
e. Remove handle/drive socket, and carefully pulling
on bit, draw shaft of reamer out of connecting rod
bushing.
CAUTION
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine failure.
Figure 3-99. Connecting Rod Bushing Hone
(Part No. HD-42569)
f1643x3x
Figure 3-100. Hone Connecting Rod Bushing
3-84 2004 Touring: Engine
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2. Using contact cleaner or cleaning solvent, thoroughly
wipe upper connecting rod and bushing of any metal
shavings or debris. Continue wiping until a clean cloth
shows no evidence of dirt or debris.
3. Lightly oil a good piston pin and insert it into the upper
connecting rod bushing bore to feel for the proper interference fit. The pin should slide in and out of the bushing
without binding, but also without pivoting or rocking.
4. Remove shop towels exercising caution that shavings,
chips and other debris do not fall into crankcase.
Installation
See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps
1-24 and 29-39.
2004 Touring: Engine 3-85
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Legend:
1. T20 TORX Screw
2. Cam Position Sensor Cover
3. Screw
4. Cam Cover
5. Cam Cover Gasket
6. Primary Cam Chain
7. Flange Bolt
8. Flat Washer
9. Primary Cam Sprocket
10. Spacer
11. Retaining Ring
12. Primary Cam Chain Tensioner
13. Flange Bolt
14. Flat Washer
15. Crank Sprocket
16. Crankshaft Bushing
33
30
32
28
17. Roll Pin
18. Oil Pressure Relief Valve Piston
19. Valve Spring
20. Chain Guide
21. Screw
22. Cam Support Plate
23. Secondary Cam Chain Tensioner
24. Retaining Ring
25. O-Ring
26. Cleaning Plug
27. Retaining Ring
35
36
41
34
40
38
39
47
46
45
43
44
42
39
29
20
31
10
18
11
12
26
17
25
23
22
21
37
28. Rear Cam (Roller) Bearing
29. Front Cam (Ball) Bearing
30. Bearing Retainer Plate
31. T20 TORX Screw
32. Secondary Cam Chain
33. Roller Bearing Inner Race
34. Thrust Washer
24
4
35. O-Ring
36. Rear Camshaft
37. Front Camshaft
38. Feed Gerotor Set
39. Separator Plate
40. Wave Washer
41. Scavenge Gerotor Set
42. O-Ring
43. Oil Pump Housing
44. O-Ring (Scavenge Port Stub)
45. O-Ring (Oil Feed Hole)
46. O-Ring (Blind Hole)
47. Right Crankcase Half
5
27
19
8
7
9
13
16
15
6
14
2
f2143x3x
Figure 3-101. Cam Support Plate/Oil Pump Assemblies (Exploded View)
3-86 2004 Touring: Engine
1
3
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