Harley Davidson Touring 2004 Service Manual spb03a
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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
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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
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
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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
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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
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