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SPECIFICATIONS 3.1
Table 3-1. General
Number of cylinders 2
Ty pe 4-cycle, 45˚, air-cooled
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
Page 2
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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
Page 3
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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
Page 4
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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
Page 5
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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
Page 6
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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
1
2
3
4
5
6
7
8
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
Page 7
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f157x3x
1. Breather channel exposed (wrong)
2. Breather channel concealed (right)
f1576x3x
1
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
Page 8
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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.
f1578x3x
2
1
f1578x3x
7
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
Page 9
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3
1
2
4
5
6
f1578x3x
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
Page 10
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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
Page 11
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1. Oval opening
2. 4-5 inch micrometer
3. Spherical ball anvil adapters
f2109x3x
f2113x4x
11
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
Page 13
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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
Page 14
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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
f2154x3x
1
2
3
4
5
6
7
HOME
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
Page 16
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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.
f2152x3x
f2153x3x
1
4
3
2
5
7
6
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
Page 17
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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
4
5
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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