Harley Davidson Touring 2004 Service Manual spb03a

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SPECIFICATIONS 3.1

Table 3-1. General
To rque
Bore 3.875 in. (98.425 mm) Stroke 4.375 in. (111.125 mm) Piston displacement (approx.) 103 cu. in. (1690 cc) Compression ratio 9.0:1 Combustion chamber Hemispherical
Cam system
Max. sustained engine speed 5800 RPM Idle speed 1000 RPM ± 50 Weight 165 lbs (74.8 kg)
100 ft-lbs (138 Nm)
@ 3500 RPM
Tw in cams, chain driven with
spring loaded tensioners
Table 3-2. Ignition System
Ty pe
Ignition timing:
1050 RPM (hot idle) Spark plug size 12 mm Spark plug type Harley-Davidson 6R12 Spark plug gap 0.038-0.043 in. (0.97-1.09 mm) Spark plug torque 12-18 ft-lbs (16.3-24.4 Nm)
Sequential, non waste spark,
MAP-N control
20˚-30˚
Table 3-3. Oiling System
Pump
Pressure
Filtration
Cooling Thermostat controlled oil cooler
Tw in gerotor, dual scavenge, crank mounted
and driven, internal oil pump, dry sump
30-38 psi (207-262 kN/m2) at
2000 RPM and normal operating temperature
of 230˚ F (110˚ C) 10 micron media,
filtered between pump and engine
2004 FLHTCSE: Engine 3-1
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MANUFACTURING TOLERANCES 3.2

Table 3-4. Rocker Arms
IN.
Shaft fit in bushing (loose)
End clearance 0.003-0.013 0.08-0.033
Bushing fit in rocker arm (tight)
0.0005-0.0020 0.013-0.051
0.002-0.004 0.051-0.102
MM
Table 3-5. Rocker Arm Shaft
MM
Shaft fit in rocker arm support plate (loose)
IN.
0.0007-0.0022 0.018-0.056
Table 3-6. Hydraulic Lifters
IN.
Fit in crankcase (loose) 0.0008-0.0020 0.02-0.05
MM
Table 3-7. Cylinder Heads
IN.
Valve guide in head (tight) 0.0020-0.0033 0.051-0.084
Valve seat in head (tight) 0.003-0.0045 0.076-0.114
Head gasket surface (flatness)
0.006 0.0152
MM
Table 3-8. Valves
IN.
Fit in guide (exhaust) 0.0015-0.0033 0.038-0.084
Fit in guide (intake) 0.0008-0.0026 0.020-0.066
Seat width 0.040-0.062 1.02-1.58
Stem protrusion from cylinder head boss
1.990-2.024 50.55-51.41
MM
Table 3-9. Valve Spring Assembly
PRESSURE
Closed 165 lbs (75 kg). 1.820 in (46.2 mm).
Open 416 lbs (189 kg) 1.290 in. (32.7 mm)
Free length n/a 2.210 in (56.1 mm)
DIMENSION
Table 3-10. Pistons
IN.
Fit in cylinder 0.0014-0.0025 0.036-0.064
Ring end gap:
To p compression ring
2nd compression ring
Oil control ring
Ring side clearance:
To p compression ring
2nd compression ring
Oil control ring
Piston pin fit (loose) 0.0002-0.0005 0.005- 0.013
0.010-0.020
0.014-0.024
0.010-0.050
0.0012-0.0037
0.0012-0.0037
0.0031-0.0091
MM
0.254-0.508
0.3556-0.6096
0.25-1.27
0.030-0.094
0.030-0.094
0.079-0.231
Table 3-11. Connecting Rods
IN.
Piston pin fit (loose) 0.0003-0.0007 0.008-0.018
Side play between flywheels
Connecting rod to crankpin (loose)
0.005-0.015 0.13-0.38
0.0004-0.0017 0.0102-0.0432
MM
Table 3-12. Flywheels
IN.
Runout (flywheels at rim)
Runout (shaft at flywheel)
End play 0.003-0.010 0.076-0.254
0.000-0.010 0.0-0.25
0.000-0.002 0.0-0.05
MM
Table 3-13. Crankshaft (Roller) Bearing
IN.
Roller bearing fit (loose) 0.0002-0.0015 0.005-0.038
Crankshaft runout 0.0-0.003 0.0-0.076
Bearing fit in crankcase (tight)
Bearing inner race on crankshaft (tight)
0.0038-0.0054 0.097-0.137
0.0001-0.0010 0.0025-0.0254
MM
3-2 2004 FLHTCSE: Engine
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SERVICE WEAR LIMITS 3.3

Table 3-14. Rocker Arm/Rocker Shaft
REPLACE IF WEAR EXCEEDS
IN. MM
Shaft fit in bushing (loose) 0.0035 0.089
End clearance 0.025 0.635
Shaft fit in rocker arm support plate (loose)
0.0035 0.089
Table 3-15. Hydraulic Lifters
REPLACE IF WEAR EXCEEDS
IN. MM
Fit in crankcase 0.003 0.08
Roller fit 0.0015 0.038
Roller end clearance 0.015 0.38
Table 3-16. Cam Support Plate
REPLACE IF WEAR EXCEEDS
IN. MM
Cam chain tensioner shoe
Warpage 0.010 0.25
Crankshaft bushing fit 0.0008-0.001 0.0203-0.0254
0.080-0.090 2.03-2.29
1/2 thickness of shoe
Table 3-17. Cylinder Heads
REPLACE IF WEAR EXCEEDS
IN. MM
Valve guide (tight) < 0.002 < 0.051
Valve seat (tight) < 0.002 < 0.051
Head warpage > 0.006 > 0.152
Table 3-18. Cylinders
REPLACE IF WEAR EXCEEDS
IN. MM
Ta per 0.002 0.051
Out of round 0.002 0.051
Warpage of gasket or O-ring surfaces: top
Warpage of gasket or O-ring surfaces: base
0.006 0.152
0.004 0.102
Table 3-19. Cylinder Bore
REPLACE IF WEAR EXCEEDS
IN. MM
Standard 3.877 98.48
0.005 in. oversize 3.882 98.60
0.010 in. oversize 3.887 98.73
Table 3-20. Pistons
REPLACE IF WEAR EXCEEDS
IN. MM
Fit in cylinder (loose) 0.003 0.076
Piston pin fit (loose) 0.0008 0.020
Ring end gap
Ring side clearance
To p compression 0.030 0.762
2nd compression 0.034 0.863
Oil control ring rails 0.050 1.27
To p compression 0.0045 0.11
2nd compression 0.0045 0.11
Oil control ring rails 0.010 0.25
2004 FLHTCSE: Engine 3-3
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Table 3-21. Connecting Rods
REPLACE IF WEAR EXCEEDS
IN. MM
Piston pin fit (loose) 0.001 0.025
Side play between flywheels
Fit on crankpin (loose) 0.002 0.05
0.020 0.51
Table 3-22. Flywheels
REPLACE IF WEAR EXCEEDS
IN. MM
Flywheel runout at rim 0.015 0.38
Shaft runout at flywheel 0.003 0.08
End play 0.010 0.254
Table 3-23. Crankshaft Sprocket
Shaft Bearing
IN.
Bearing fit (loose) 0.0015 0.038
Crankshaft runout 0.003 0.076
Bearing fit in crankcase (tight)
Bearing inner race on crankshaft (tight)
0.0038-0.0054 0.097-0.137
0.0001 0.0254
MM
3-4 2004 FLHTCSE: Engine
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TORQUE VALUES 3.4

ITEM TORQUE NOTES
Rocker housing bolts 120-168 Oil vent line crankcase fitting 130-150 Oil fittings 120-168 Chrome oil vent line nuts 60-80 Oil cooler to mounting backet 80-110 Tr ansfer passage cover 90-120 Oil filter mount 130-150 Thermostat plug 15-20 ft-lbs 20.4-27.1 Nm page 3-23 Oil filter adapter 12-16 ft-lbs 16.3-21.7 Nm page 3-23 Thermostat plug 15-20 ft-lbs 20.4-27.1 Nm page 3-24
in-lbs in-lbs in-lbs
in-lbs
in-lbs in-lbs
in-lbs
13.6-18.9 Nm page 3-9
14.7-16.9 Nm page 3-17
13.6-19.0 Nm page 3-17
6.8-9.0 Nm page 3-17
9.1-12.4 Nm page 3-21
10.2-13.5 Nm page 3-23
14.7-16.9 Nm page 3-23
2004 FLHTCSE: Engine 3-5
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BREATHER ASSEMBLY 3.5

REMOVAL

See TOP END OVERHAUL in the Touring Models Service Manual.
NOTE
If breather style is different from that illustrated, see BREATHER ASSEMBLY under TOP END under SUBAS­SEMBLY SERVICE AND REPAIR, in the Touring Models Ser­vice Manual.

DISASSEMBLY

1. See Figure 3-1. Remove two fasteners from breather assembly.
2. Remove breather cover and gasket. Discard cover gas­ket.
3. Remove the breather baffle and gasket. Discard gasket.
4. Pull filter element from bore on inboard side of breather baffle. Discard filter element.
5. Pull stem of umbrella valve from hole at top of breather baffle. Discard umbrella valve.

CLEANING AND INSPECTION

INSTALLATION

See TOP END OVERHAUL in the Touring Models Service Manual.
f1531x4x
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1WARNING1WARNING
Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to deter­mine air flow rates. (00061a)
1. Clean all parts in a non-volatile cleaning solution or sol­vent.
2. Thoroughly dry all parts with low pressure compressed air.

ASSEMBLY

1. See Figure 3-1. Insert stem of through center hole at top of breather baffle. Use dena­tured alcohol or glass cleaner to lubricate stem. Care­fully pull rubber bead on stem through hole in baffle. Verify that rubber bead is pulled completely through hole and resides on bottom side of baffle.
2. Press
3. Place breather baffle gasket on a clean flat surface.
new
filter element into bore at bottom of baffle Hole in filter element accommodates umbrella valve stem.
Aligning holes, place breather baffle, cover gasket and breather cover on top. Slide two screws through stackup to keep assembly together until time of installation.
new
umbrella valve
1. Fastener
2. Breather cover
3. Cover gasket
4. Umbrella valve
5. Breather baffle
6. Filter element
7. Breather baffle gasket
8. Rocker arm support plate
Figure 3-1. Breather Components
3-6 2004 FLHTCSE: Engine
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f157x3x
1. Breather channel exposed (wrong)
2. Breather channel concealed (right)
f1576x3x
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WRONG
RIGHT
2

ROCKER HOUSING 3.6

VALVE SPRING TO ROCKER HOUS­ING CLEARANCE
1. After torquing cylinder head bolts, continue top end over­haul by installing the rocker housings. See ASSEMBLY under TOP END OVERHAUL in the Touring Models Ser­vice Manual.
2. Install a flange.
Even though all bolt holes (rocker housing, rocker arm support plate and breather assembly) may appear to be in alignment, the rocker housing gasket may be installed upside down. An upside down gasket will result in an open breather channel causing an oil leak when the vehi­cle is started, possibly resulting in engine and/or prop­erty damage.
3. See Figure 3-2. Ver ify that the rocker housing gasket is installed correctly by noting that the breather channel is concealed.
4. With the indent facing forward, place the rocker housing into position aligning the holes in the housing with those in the gasket.
new
rocker housing gasket on the cylinder head
CAUTION
Figure 3-2. Rocker Housing Gasket
2004 FLHTCSE: Engine 3-7
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5. Apply a small dab of LOCTITE THREADLOCKER 243 (blue) (HD-99642-97) to threads of six rocker housing bolts.
6. See Figure 3-3. Start the rocker housing bolts, two long bolts on the left side of the engine, four intermediate bolts in the interior.
NOTE
Rocker housing and rocker cover bolts have both an internal and external hex, which allows the bolts to be installed with either a short 3/16 inch allen wrench (tight spaces), or a 7/16 inch socket or open end/box wrench (open spaces). If the engine is left in the chassis for service, the short 3/16 inch allen wrench is indispensable when installing the rocker housing and rocker cover bolts on the left side of the engine (particularly the rear) where there is close proximity to the frame.
7. From the cam cover side, press rocker cover diagonally toward the intake valve.
8. See Figure 3-5. Snug bolts in torque sequence to hold housing in position. Do not torque.
9. See Figure 3-4. Using a feeler gauge, check for clear- ance around both valve spring assemblies and the rocker housing.
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f1578x3x
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1. Long bolt 1-3/4 in.
2. Intermediate bolt 1-1/4 in.
3. Intermediate bolt 1-1/4 in.
4. O-ring
5. Intermediate bolt 1-1/4 in.
6. Intermediate bolt 1-1/4 in.
7. Long bolt 1-3/4 in.
3
4
6
5
10. If spring assembly contacts rocker housing at any point around springs, loosen rocker cover bolts and press on side of cover opposite contact point to produced notice­able clearance between housing and valve assembly.
Figure 3-3. Rocker Housing Bolt Lengths
9977
8877
3-8 2004 FLHTCSE: Engine
Figure 3-4. Valve Spring to Rocker Housing Clearance
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2
4
5
6
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11. Tighten rocker housing bolts to 120-168
18.9 Nm) in the pattern shown in Figure 3-5.
NOTE
If the engine was left in the chassis for service, final tighten the rear left rocker housing bolt (rear cylinder) using a torque wrench with a 1/4 inch drive. Since this tool may not be avail­able in foot-pounds, tighten the bolt to 120-168
12. Re-check clearance at both valve spring assemblies and repeat until there is sufficient clearance between spring assemblies and rocker housing with the bolts torqued.
CAUTION
O-rings that are missing, distorted, pinched or otherwise damaged will result in either oil leakage or low oil pres­sure. Use of the wrong o-ring will have the same results. Since many o-rings are similar in size and appearance, always use ne to avoid confusion.
13. Install in rocker housing. Apply a thin film of clean SYN3 engine oil to o-ring before installation.
w o-rings keeping them packaged until use
new
o-ring in groove around breather baffle hole
in-lbs
in-lbs
(13.6-
.
Figure 3-5. Rocker Housing Torque Sequence
14. Continue the top end overhaul by installing the hydraulic lifters in the crankcase bores. See ASSEMBLY under TOP END OVERHAUL in the Touring Models Service Manual.
2004 FLHTCSE: Engine 3-9
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CYLINDER HEADS 3.7

GENERAL

Major components of the FLHTCSE engine differ from other touring models in specification and appearance. However, service procedures for the following components are the same as those found in the Touring Models Service Manual. See CYLINDER HEAD under SUBASSEMBLY SERVICE AND REPAIR in the Touring Models Service Manual.
For service wear limits, refer to Ta bl e 3-17.
9975
2
1
1. Hemispherical combustion chamber
2. Machined relief
Figure 3-6. FLHTCSE
Front Cylinder Head
3-10 2004 FLHTCSE: Engine
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1. Oval opening
2. 4-5 inch micrometer
3. Spherical ball anvil adapters
f2109x3x
f2113x4x
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3
2

PISTONS 3.8

GENERAL

Major components of the FLHTCSE engine differ from other touring models in specification and appearance. However, service procedures for the following components are the same as those found in the Touring Models Service Manual. See PISTON on SUBASSEMBLY SERVICE AND REPAIR in the Touring Models Service Manual.
For service wear limits, refer to Ta bl e 3-20. and Table 3-19.
NOTE The piston is measured on the bare aluminum to avoid mea­suring errors. An oval-shaped spot is present on each side of the piston for proper placement of the micrometer. See upper frame of Figure 3-8. Since the oval openings are too small for a standard flat anvil micrometer, which would result in mea­suring errors, use a 4-5 inch micrometer with spherical ball anvil adapters. See lower frame of Figure 3-8.
9974
Figure 3-8. FLHTCSE Piston Measurement
Figure 3-7. FLHTCSE Piston Orientation Arrow
(arrow points to front of engine)
2004 FLHTCSE: Engine 3-11
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BORING AND HONING CYLINDERS 3.9

CYLINDER BORE FINISHED SIZE

1. For cylinder removal, cleaning, inspection, boring and honing and installation, see CYLINDER in the Touring Models Service Manual.
2. Refer to Ta bl e 3-24. Bore the cylinder to 0.003 in. (0.08 mm) under the desired finished size. See BORING and HONING CYLINDER in the Touring Models Service Manual. Refer to Ta bl e 3-24.
CAUTION
An improper crosshatch pattern or too fine a hone will result in insufficient oil retention and possible piston seizure and/or high oil consumption.
3. Hone the cylinder to its finished size using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Hon­ing must be done with the torque plates attached. All honing must be done from the bottom (crankcase end of the cylinder. Work for a 60˚ crosshatch pattern.
4. Stop frequently to examine the cylinder bore and/or take measurements. Remember, a precise 60˚ cross hatch pattern in the piston travel area is important.
Table 3-24. Oversize Pistons/Cylinder Bores
PISTON CYLINDER BORE FINISHED SIZE
5. Thoroughly wash the cylinder bore with liquid dish soap and warm water to remove all abrasive particles and residual girt. Continue cleaning until a clean cloth shows no evidence or dirt or debris.
6. Immediately apply a thin film of clean engine oil to a clean white paper towel and thoroughly wipe the inside of the cylinder. This prevents the cylinder bore from rust­ing.
NOTE
After wiping the cylinder with a clean, oiled paper towel, the towel will be dark with contamination. Repeat this process using a new lightly oiled paper towel each time until the towel remains white. The cylinder is now clean.
7. With the cylinder at room temperature, check the piston clearance in the cylinder in which the piston will run. See INSPECTION under PISTON in Touring Models Service Manual.
8. For cylinder installation, see CYLINDER in Touring Mod­els Service Manual.
TYPE SIZE MINIMUM MAXIMUM
Standard STD 3.8750 in. (98.4250 mm) 3.8755 in. (98.438 mm)
Oversize
0.005 in. (0.13 mm) 3.8800 in. (98.552 mm) 3.8805 in. (98.565 mm)
0.010 (0.25 mm) 3.8850 in. (98.679 mm) 3.8855 in. (98.692 mm)
3-12 2004 FLHTCSE: Engine
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CAMS AND TIMING MARKS 3.10

GENERAL

Major components of the FLHTCSE engine differ from other touring models in specification and appearance. However, service procedures for the following components are the same as those found in the Touring Models Service Manual. See Camshafts and Camshaft Bearings under CAM SUP­PORT PLATE under SUBASSEMBLY SERVICE AND REPAIR in the Touring Models Service Manual.
f1607a3x
1. Rear camshaft punch mark
2. Front camshaft punch mark
Figure 3-9. FLHTCSE
2
1
Cam Timing Marks
2004 FLHTCSE: Engine 3-13
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FLYWHEEL/CONNECTING ROD ASSEMBLY 3.11

GENERAL

For removal, inspection, and installation, see FLYWHEEL/ CONNECTING ROD ASSEMBLY under SUBASSEMBLY SERVICE AND REPAIR in the Touring Models Service Man­ual.
For service wear limits, refer to Ta bl e 3-21. and Tab l e 3-22.
NOTE If the flywheel or connecting rods need to be replaced, then they must be replaced together as one assembly.
9978

SPROCKET SHAFT BEARING INNER RACE REPLACEMENT

PA RT NO. SPECIALTY TOOL
HD-44358 Flywheel support fixture
HD-95637-46A Wedge attachment
HD-34902B
HD-25070 Robinair heat gun
1. If reusing flywheel, remove bearing inner race and thrust washer as follows:
a. Obtain FLYWHEEL SUPPORT FIXTURE (HD-
44358). See Figure 3-11. Install brass jaws or shop towels around teeth of vise to prevent damage to tool. Clamp tool in vise with the round hole topside.
b. Insert crankshaft end through hole resting flywheel
assembly on fixture. Slide knurled locating pin down slot in tool to engage crank pin hole. Hand tighten locating pin.
c. Slide hold-down clamp down slot to engage inboard
side of right flywheel half, and then hand tighten knurled nut at bottom to secure. Repeat step to secure hold-down clamp on opposite side of fly­wheel.
For proper clamping force, hold-down clamp must not be tilted. Rotate hex on outboard stud until clamp is level.
d. Position WEDGE ATTACHMENT (HD-95637-46A)
on inboard side of thrust washer and turn hex nuts an equal number of turns to draw halves of wedge together.
Mainshaft bearing inner race puller/installer
NOTE
Figure 3-10. FLHTCSE
Flywheel/Connecting Rod Assembly
3-14 2004 FLHTCSE: Engine
CAUTION
Install wedge attachment only so far as necessary to ensure positive contact with thrust washer. Installing tool with more contact than absolutely necessary will result in damage to flywheel.
e. Obtain two 3/8-16 inch bolts 6-1/2 inches long (with
flat washers). Install flat washers on bolts. Obtain bridge, forcing screw and hardened plug from MAINSHAFT BEARING INNER RACE PULLER/ INSTALLER (HD-34902B).
f. Slide one bolt into channel on each side of bridge
so that flat washer is between bridge and bolt head. Thread bolts into wedge attachment an equal num­ber of turns.
g. Sparingly apply graphite lubricant to threads of forc-
ing screw to prolong service life and ensure smooth operation. Start forcing screw into center hole of bridge.
Page 15
1. Hold-down clamp
2. Locating pin
1
2
f1869x3d
1. Forcing screw
2. 3/8-16 Inch bolt with flat washer
3. Bridge
4. Hardened plug
5. Wedge attachment
6. Bearing inner race
7. Sprocket shaft
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CAUTION
Failure to use hardened plug may result in damage to forcing screw and/or sprocket shaft.
h. Place cupped side of hardened plug against end of
sprocket shaft. Thread forcing screw into bridge until the steel ball at the end of the screw makes firm contact with hardened plug.
i. Using the ROBINAIR HEAT GUN (HD-25070), uni-
formly heat the bearing inner race for about 30 sec­onds using a circular motion.
NOTE
To facilitate removal without heat, apply a light penetrating oil to shaft and leading edge of bearing inner race.
1WARNING1WARNING
Never use both heat and penetrating oil. Use only one or the other. Excessive heat can cause the penetrating oil to ignite resulting in flames or fire. Inadequate safety precautions can result in death or serious injury.
j. Turn forcing screw until thrust washer and bearing
inner race move approximately 1/8 inch (3.2 mm).
k. Turn hex nuts an equal number of turns to separate
halves of WEDGE ATTACHMENT.
l. After bottoming thrust washer on shaft, reposition
WEDGE ATTACHMENT (HD-95637-46A) on inboard side of bearing inner race. Turn hex nuts an equal number of turns to draw halves of wedge together.
CAUTION
Figure 3-11. Flywheel Support Fixture (Part No. HD-
44358)
Install wedge attachment only so far as necessary to ensure positive contact with bearing inner race. Install­ing tool with more contact than absolutely necessary will result in damage to flywheel.
m. Verify that the tool assembly is square, so that the
bearing inner race is not cocked during removal. See Figure 3-12.
n. Using the ROBINAIR HEAT GUN (HD-25070), uni-
formly heat the bearing inner race for about 30 sec­onds using a circular motion.
To facilitate removal without heat, apply a light penetrating oil to shaft and leading edge of bearing inner race.
o. Tu rn forcing screw until bearing inner race is pulled
free of sprocket shaft.
p. Remove thrust washer from sprocket shaft. q. Discard thrust washer and bearing inner race.
NOTE
Figure 3-12. Remove Inner Race From Sprocket Shaft
2. Place new thrust washer over sprocket shaft with the ink
stamp facing outside (and the chamfer on the ID inboard).
2004 FLHTCSE: Engine 3-15
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3. Place new bearing inner race on bench top. Using the
ROBINAIR HEAT GUN (HD-25070), uniformly heat bearing inner race for about 60 seconds using a circular motion.
4. Wearing suitable gloves to protect hands from burns, place heated bearing inner race over sprocket shaft.
NOTE
To facilitate installation without heat, apply a light penetrating oil to shaft and leading edge of bearing inner race.
1WARNING1WARNING
h9772-55b
Figure 3-13. Sprocket Shaft Timken Bearing
Cone Installer (Part No. HD-97225-55B)
Never use both heat and penetrating oil. Use only one or the other. Excessive heat can cause the penetrating oil to ignite resulting in flames or fire. Inadequate safety precautions can result in death or serious injury.
5. See Figure 3-13. Obtain the SPROCKET SHAFT TIMKEN BEARING CONE INSTALLER (HD-97225­55B). Assemble tool as described below.
a. See Figure 3-14. Thread pilot shaft onto sprocket
shaft until contact is made with shoulder.
b. Sparingly apply graphite lubricant to threads of pilot
shaft to prolong service life and ensure smooth operation.
c. Slide sleeve over pilot until it contacts bearing inner
race.
d. Slide Nice bearing and large flat washer over pilot
until contact is made with sleeve.
e. Thread handle onto pilot shaft. See upper frame of
Figure 3-14.
6. Rotate handle of tool in a clockwise direction until bear­ing inner race bottoms against thrust washer. See lower frame of Figure 3-14.
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7. Remove handle, flat washer, Nice bearing, sleeve and pilot from sprocket shaft.
3-16 2004 FLHTCSE: Engine
1. Pilot shaft
2. Handle
3. Flat washer
4. Nice bearing
5. Sleeve
6. Inner race
7. Thrust washer
Figure 3-14. Press Inner Race Onto Sprocket Shaft
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1. Oil spout fitting
2. Hose
3. Oil vent line parallel to transmission cover
4. S-bend
5. Crankcase fitting nut
1
2
3
9968
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OIL VENT LINE 3.12

REPLACEMENT

PA RT NO. SPECIALTY TOOL
HD-41137 Hose clamp pliers
IMPORTANT NOTE
Dispose of oil in accordance with local regulations.
1. See Figure 3-15. Back the chrome nut off of the crank­case oil fitting.
2. Using side cutters, cut the clamps on the short length of hose at the oil spout end of the vent line.
3. Remove the oil vent line.
4. If necessary, remove both fittings and clean sealant from threads in crankcase and oil fill.
Figure 3-15. Oil Vent Line (clamps removed)
NOTE
The spout fitting is a nipple styled fitting.
5. If removed, identify the crankcase end fitting and using pipe sealant or TEFLON threaded end of fitting. Thread fitting into crankcase and tighten to 130-150 in-lbs (14.7-16.9 Nm).
6. If removed, identify oil spout fitting and using pipe seal­ant or TEFLON of fitting. Thread fitting into oil spout and tighten to 130­150 in-lbs (14.7-16.9 Nm).
7. Slide crankcase fitting nut and rubber ferrule on crank­case end of vent line.
8. Push new hose with new clamps on the oil spout end of chrome vent line.
9. Orient s-bend in vent line toward crankcase and slide chrome vent line into case fitting.
10. Push hose onto oil spout fitting.
11. Position line parallel with transmission cover and with clearance to other components.
12. Push rubber ferrule into crankcase fitting. Thread chrome nut over ferrule and hand tighten.
®
tape, prepare the tapered threaded end
®
tape, prepare the tapered
13. Tighten chrome nut to 60-80 in-lbs (6.8-9.0 Nm).
14. Using HOSE CLAMP PLIERS (HD-41137), crimp the clamps on the hose.
15. Operate motorcycle and inspect for leaks.
2004 FLHTCSE: Engine 3-17
Page 18
HOME

OIL COOLER OPERATION 3.13

GENERAL

For engine oil flow through the engine, See ENGINE OIL FLOW under GENERAL INFORMATION in Touring Models Service Manual.
See Figure 3-16. The FLHTCSE installed oil cooler controlled by a thermostat in the oil filter mount.
Engine oil flows from the crankcase through the oil filter mount to the oil cooler through a supply hose. The oil circu­lates through the finned tubes of the cooler to dissipate heat and returns to the oil filter mount through a return hose.
Under pressure from the crankcase, engine oil enters the lower port in the oil filter mount. A passage way directs oil to flow to the oil filter. The oil circulates through the oil filter ele­ment and out the oil filter threaded fitting.
From the oil filter, the filtered oil flows in two directions:
1. From the oil filter adapter Into the thermostat chamber.
2. Through a side passage and out the supply oil fitting to the oil cooler.
See Figure 3-18.The thermostat chamber is located in line with the return port to the engine crankcase. The thermostat assembly consists of a temperature sensitive plunger com­pressed between a spring-loaded piston, spring and an open cage spreader.
While the engine oil temperature is below 180˚ F (82˚ C), the thermostat is in its closed position. See Closed Thermostat under 3.13 OIL COOLER OPERATION.
The filtered oil is circulated through the transfer passage where it returns to the crankcase. At the same time, oil is supplied under pressure to the oil cooler even though the oil cooler return port is blocked.
is equipped with a factory
8871
2
1
3
3
4
5
6
7
1. Oil filter mount
2. Transfer passage cover
3. Thermostat plug
4. Oil return fitting
5. Oil supply fitting
6. Supply hose
7. Return hose
8. Oil cooler
Figure 3-16. Oil Cooler and Bracket
(chrome cover removed for photo clarity)
8
While the engine operates at average temperatures, approxi­mately 195˚ F (91˚ C), the thermostat partially opens allowing cooler oil from the cooler to mix with warmer oil from the oil transfer passage as the oil returns to the crankcase. See Par-
tially Open Thermostat under 3.13 OIL COOLER OPERA­TION.
When the engine oil exceeds 210˚ F (99˚ C), the thermostat is in its fully open position. See Fully Open Thermostat under under 3.13 OIL COOLER OPERATION.
In this position, all the oil flows through the oil cooler and back through the oil filter mount before returning to the crank­case.
NOTE
Regardless of whether the thermostat is closed, partially open or fully open, oil is always pressurized in the transfer passage, the oil cooler supply hose, the oil cooler and the oil return hose.
The oil cooler should always be checked for dirt and debris to maintain cooler efficiency at every service interval.
3-18 2004 FLHTCSE: Engine
Page 19
1. Oil filter adapter
2. Passage to oil filter element
3. Return to crankcase
4. Supply from crankcase
5. Return hose fitting
6. Supply hose fitting
7. Open passage from oil filter
8. Open passage to oil cooler supply
2
1
5
46
8
7
8872
8875
4
3
HOME
9980
1
2
4
3
1. Transfer passage cover
2. Thermostat plug
3. Return hose fitting
4. Supply hose fitting
Figure 3-17. Oil Filter Mount on Engine
9982
1
3
2
1. Open cage spreader
2. Thermostat plunger
3. Piston
4. Spring
5. O-ring
6. Thermostat plug
Figure 3-18. Thermostat Assembly
4
6
5
9931
1
1. Return port to crankcase (thermostat removed)
2. Supply port from crankcase
Figure 3-19. Oil Filter Mount Ports to Crankcase
2
Figure 3-20. Oil Filter Mount
2004 FLHTCSE: Engine 3-19
Page 20
HOME

Closed Thermostat

See Figure 3-21. While the engine oil is cool, the thermostat is in its closed position. The spring holds the piston over the return passage from the oil cooler. Even though oil pressure is supplied to the oil cooler, oil is blocked from returning from the oil cooler.
See Figure 3-22. When closed, the piston opens a port in the transfer passage along the side of the thermostat chamber. The filtered oil is circulated around the piston through the transfer passage and into a port in the thermostat chamber where it flows through the open cage spreader and returns to the crankcase.

Partially Open Thermostat

As the engine oil exceeds 180˚ F (82˚ C), the thermostat plunger begins to expand and compresses the spring push­ing against the piston. The piston partially opens the return passage from the oil cooler and partially closes the port from the chamber to the transfer passage.
While the engine operates at an average temperature, 195˚ F (91˚ C), the thermostat remains partially open allowing cooler oil from the cooler to mix with warmer oil from the oil filter.

Fully Open Thermostat

See Figure 3-23. The thermostat fully opens when the engine oil temperature exceeds 210˚ F (99˚ C). The piston fully closes the port to the transfer passage and opens the return passage from the oil cooler.
8876
1
1. Return passage from oil cooler
2. Open passage from oil filter
Figure 3-21. Thermostat Chamber
8874
1 2
2
3
In this position, all the oil flows from the oil filter through the oil cooler and back through the return passage before return­ing to the crankcase. The oil from the oil cooler return will back up under pressure in the transfer passage even though the port from the oil filter is closed.
1. Port open from oil filter
2. Oil under pressure
3. Port open to crankcase return
Figure 3-22. Closed Thermostat
8873
1
1. Port open to oil cooler return
2. Oil under pressure
3. Port closed from oil filter
32
3-20 2004 FLHTCSE: Engine
Figure 3-23. Fully Open Thermostat
Page 21
HOME
1. Return hose clamp
2. Supply hose clamp
3. Oil cooler and guard
4. Bracket
8871
3
4
2
1

OIL COOLER 3.14

REMOVAL

1. Cover the front fender to protect finish.
IMPORTANT NOTE
Dispose of oil in accordance with local regulations.
2. Place a container under the motorcycle to catch excess oil.
3. Remove the fasteners holding the oil cooler and cover to mounting bracket.
4. Pull the cooler and cover forward and, using side cutters, cut the clamps on the supply and return hoses.
5. Remove the oil cooler with cover.
NOTE
The oil cooler guard is held in place with adhesive tape.
6. If replacing the oil hoses, remove oil pressure switch to gain access to clamps. Cut clamps at oil filter mount. Remove oil hoses.
7. The oil cooler should be checked for dirt and debris.

INSTALLATION

PA RT NO. SPECIALTY TOOL
HD-41137 Hose clamp pliers
1. If replacing the hoses, install new hoses with clamps at
the oil filter mount. Using HOSE CLAMP PLIERS (HD-
41137), clamp the supply and return hoses at the oil fil­ter mount.
2. Apply LOCTITE Thread Sealant to threads of oil pres­sure switch and install oil pressure switch. Tighten to 96­144 in-lbs. (10.84-16.26 Nm).
3. Connect oil pressure switch wire lead.
4. Attach hoses to oil cooler. Using HOSE CLAMP PLIERS (HD-41137), clamp the supply and return hoses at the oil cooler.
5. Install oil cooler and cover to mounting bracket. Tighten fasteners to 80-110 in-lbs (9.1-12.4 Nm).
6. Operate motorcycle and inspect for leaks.
Figure 3-24. Oil Cooler and Mount
(chrome cover removed for photo clarity)
2004 FLHTCSE: Engine 3-21
Page 22
HOME

OIL FILTER MOUNT 3.15

REMOVAL

9980
PA RT NO. SPECIALTY TOOL
HD-42311 or HD-44067 Oil filter wrench
1. Place a container under motorcycle to catch excess oil.
2. Bend a cardboard funnel and fit to motorcycle to route fluid away from regulator and oil cooler to container.
3. Using OIL FILTER WRENCH (HD-42311 or HD-44067), remove oil filter. Discard oil filter
IMPORTANT NOTE
Dispose of oil in accordance with local regulations.
4. If necessary, remove the threaded oil filter adapter and oil pressure switch.
5. Using side cutters, cut the clamps and remove oil cooler hoses.
6. If necessary, loosen but do not remove thermostat plug.
7. Bend tabs of the lockplate away from bolt heads.
8. Remove oil filter mount lockplate fasteners and flat washers. Discard lockplate.
9. Remove middle bolt with flat washer and remove oil filter mount.
Figure 3-25. Oil Filter Mount (engine removed from frame)
9931

DISASSEMBLY

1. If necessary, remove the thermostat. See 3.16 THER-
MOSTAT.
2. See Figure 3-26. Remove the o-rings in the oil filter mount.
3. Remove the transfer passage cover.
4. Remove the transfer passage cover gasket.
5. Remove the two oil cooler line fittings.
6. Clean the oil passages in a cleaning solution or solvent.
7. Remove thread locking adhesive from the threads of the oil filter adapter.
8. Inspect the oil passages and the oil filter mount.
Figure 3-26. Oil Filter Mount O-rings
(thermostat removed)
3-22 2004 FLHTCSE: Engine
Page 23
HOME
CAUTION
9983

ASSEMBLY

1. See Figure 3-27. Install a new gasket on the transfer
passage cover.
2. Install the transfer passage cover. Tighten to 90-120 in- lbs (10.2-13.5 Nm).
3. Using pipe sealant or TEFLON tape, prepare the tapered threaded end of oil supply and return fittings and install fittings.
4. If removed, replace the thermostat components: a. Replace the spreader. b. Replace the thermostat plunger and piston. c. Replace the spring. d. Install a new o-ring and loosely install thermostat
plug.

INSTALLATION

PA RT NO. SPECIALTY TOOL
HD-41137 Hose clamp pliers
1. Install the oil cooler oil hoses to the filter mount with new clamps.
2. Using HOSE CLAMP PLIERS (HD-41137), crimp the clamps.
3. Place flat washers in recessed bolt holes at top and bot­tom of filter mount flange.
4. Align holes in lockplate with holes in flat washers.
5. Slide two fasteners through lockplate, flat washers and filter mount flange. Apply LOCTITE 243 (blue) (HD­99642-97) to threads of installed bolts.
6. See Figure 3-26. Install new o-rings into grooves in oil filter mount.
To avoid cross threading tapped holes, exercise care when starting hex head bolts in crankcase.
7. Align holes in filter mount flange with holes in crankcase and tighten bolts until snug.
8. Install flat washer on remaining fastener, apply LOCTITE to threads and install in middle hole of mount flange.
9. Starting at the top, alternately tighten the fasteners to 130-150 in-lbs (14.7-16.9) Nm.
10. Bend the ends of the lockplate to capture the top and bottom fasteners.
11. If disassembled, tighten the Thermostat plug to 15-20 ft­lbs (20.4-27.1 Nm).
12. Apply LOCTITE THREADLOCKER 243 (blue) to tapered threads of oil filter adapter. Install oil filter adapter and tighten to 12-16 ft-lbs (16.3-21.7 Nm).
13. Install a new oil filter. See SCHEDULED MAINTE- NANCE in Touring Models Service Manual.
NOTE
If removed, install oil pressure switch using LOCTITE Thread Sealant and tighten to 96-144 in-lbs (10.84-16.26 Nm).
Figure 3-27. Transfer Passage Cover and Gasket
2004 FLHTCSE: Engine 3-23
Page 24
HOME

THERMOSTAT 3.16

TEST PROCEDURE

1. Using an infrared thermometer, measure the tempera­ture at the oil pan and at the oil cooler while operating motorcycle.
2. Compare temperatures. a. If the temperature of the oil cooler follows the tem-
perature of the oil pan at temperatures below 180˚ F (82˚ C), then the thermostat may be stuck open. Allow the engine to cool, remove the thermostat. and proceed.
b. If the temperature of the oil cooler is less than that
of the oil pan below 180˚ F (82˚ C) but, above 180˚ F (82˚ C), follows the temperature of the oil pan, the thermostat is operating correctly.
c. If the oil pan exceeds 210˚ F (99˚ C) and the oil
cooler is cooler, then the thermostat may be stuck closed. Allow the engine to cool, remove the ther­mostat and proceed.
3. Verify that thermostat plunger is fully retracted.
4. Place thermostat plunger in a container of water with a thermometer.
5. Refer to Ta bl e 3-25. Heat water to START TO OPEN temperature. Verify that the plunger extends.
6. Heat water pass START TO OPEN temperature to FULL OPEN temperature and verify that plunger is fully extended.
7. If plunger does not extend per specifications, replace thermostat assembly.
Table 3-25. Thermostat Operating Range
ITEM FAHRENHEIT CELSIUS

REMOVAL

1. Allow the motorcycle to cool.
2. Place a catch pan under motorcycle.
3. Bend a cardboard funnel and fit to motorcycle to route fluid away from regulator and oil cooler to container.
IMPORTANT NOTE
Dispose of oil in accordance with local regulations.
4. See Figure 3-28. With a ball Allen wrench, loosen and remove the thermostat plug.
5. Remove the spring.
6. Remove the thermostat plunger and piston with a pair of needle nosed pliers.
7. Remove the open cage spreader with a pick.

INSTALLATION

1. See Figure 3-28. Insert the open cage spreader part way into thermostat chamber.
2. Install the thermostat plunger and piston together.
3. Locate the plunger in the spreader and push in to bottom of chamber.
4. Install the spring.
5. Fit a new o-ring and install thermostat plug. Tighten to 15-20 ft-lbs (20.4-27.1 Nm).
9982
1
3
4
2
6
5
START TO OPEN (closed)
AVERAGE (partially open)
FULL OPEN (fully open)
3-24 2004 FLHTCSE: Engine
180˚ 82˚
195˚ 91˚
210˚ 99˚
1. Open cage spreader
2. Thermostat plunger
3. Piston
4. Spring
5. O-ring
6. Thermostat plug
Figure 3-28. Thermostat Components
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