Harley Davidson Touring 2004 Service Manual sm03b

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CAUTION

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TOP END OVERHAUL 3.9

DISASSEMBLY

1. Use low pressure spray to thoroughly clean exterior surfaces of engine prior to disassembly. Dirt caked on cooling ﬁns and other areas can fall into crankcase bore or stick to subassemblies as parts are removed. Abrasive particles can damage machined surfaces or plug oil passageways.

NOTE

Rocker cover and rocker housing bolts have both an internal and external hex, which allows the bolts to be removed with either a short 3/16 inch allen wrench (tight spaces), or a 7/16 inch socket or open end/box wrench (open spaces). See Fig-

ure 3-20. The internal hex is necessary if the engine is left in

the chassis for service. In these cases, the short 3/16 inch allen wrench is indispensable when removing the rocker cover and rocker housing bolts on the left side of the engine (particularly the rear) where there is close proximity to the frame. A dimple or cavity cast into the left side of the upper frame crossmember also aides in removing the rocker arm support plate assembly.

2. Alternately loosen the six rocker cover bolts following the pattern shown in A of Figure 3-22. Remove the rocker cover bolts.

NOTE

It is assumed that each step performed on one cylinder is automatically repeated on the other.

4. Insert the blade of a small screwdriver into cast loop of

5. Collapse upper and lower push rod covers.

6. To remove the rocker arm support plate,

Figure 3-21. Remove Spring Cap Retainer

spring cap retainer (at top of upper push rod cover), and while pushing down on spring cap, rotate bottom of screwdriver toward outboard side to remove. See Figure

3-21. Repeat step on second push rod cover.

both

lifters of the cylinder being serviced must be on the base circle (or lowest position) of the cam.

3. Remove the rocker cover and gasket. Discard the gasket.

Internal Hex

3/16 Inch Allen Wrench

External Hex

7/16 Inch Open End Wrench

Figure 3-20. Rocker Cover Bolt (1-1/4 Inch)

Captive Washer

Lock Patch

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Removing the rocker arms with the valve train loaded can result in bent push rods, damaged bushings or warped support plate.

To ﬁnd the base circle, it is ﬁrst necessary to rotate the engine. Based on the level of disassembly required, three methods of engine rotation are presented below.

a. With pr

b. With pr

imary cover installed - With vehicle on center stand, place the transmission in 5th gear and rotate rear wheel in a clockwise direction (as viewed from right side) until the base circle is found. See step 6(d) to ﬁnd the base circle.

imary cover removed - Remove primary cover. Place the transmission in neutral. Fit a 1-1/2 inch socket on the compensating sprocket shaft nut. Rotate nut in a counterclockwise direction until the base circle is found. See step 6(d) to ﬁnd the base circle.

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Loosen Six Rocker Cover Bolts.

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Breather

Assembly

FRONT

REAR

Remove Two Breather Assembly Bolts.

Alternately Loosen Four Rocker Arm Bolts

1/4 Turn in Pattern Shown.

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O-Ring

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FRONT

REAR

Loosen Six Rocker Housing Bolts.

Alternately Loosen Four Cylinder Head

Bolts 1/4 Turn in Pattern Shown.

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Figure 3-22. Top End Disassembly

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CAUTION

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Figure 3-23. Sprocket Shaft Engine Rotation Tool

CAUTION

Do not attempt to rotate engine by removing cam cover and placing socket on crank or primary cam sprocket ﬂange bolt. Head of ﬂange bolt can break off possibly resulting in damage to ﬂywheel or camshaft.

c. With engine mounted in engine stand

- Fashion tool as follows: Obtain used or discarded compensating sprocket shaft extension (HD-40266-85). Weld a 13/ 16 inch socket with a 1/2 inch drive to outboard side of extension. See Figure 3-23. Install tool on sprocket shaft and rotate in a counterclockwise direction until the base circle is found. See step 6(d) to ﬁnd the base circle.

d. Finding the base circle

: Using one of the methods above, rotate engine until piston is at Top Dead Center (TDC) of compression stroke. To accomplish this, ﬁrst raise lower push rod cover to access intake lifter (inside hole of lifter cover). Place index ﬁnger on top of the intake lifter. While rotating engine, feel lifter rise (valve open) and fall (valve closed). Now place ﬁnger tightly over spark plug hole and rotate engine again. In the compression stroke, air will be forced out against your ﬁnger until the piston reaches the TDC position. Stop engine rotation when the ﬂow of air through the spark plug hole stops. Direct the beam of a small ﬂashlight into spark plug hole to verify piston is at TDC. Both intake and exhaust valves are now closed and the push rods are in the unloaded position (and should turn freely).

7. Remove two bolts to release breather assembly from the rocker arm support plate. See B of Figure 3-22. See Section 3.11 SUBASSEMBLY SERVICE AND REPAIR,

BREATHER ASSEMBLY.

8. Alternately loosen each of the four rocker arm support plate bolts just 1/4 turn following the pattern shown in B of Figure 3-22. Continue turning the bolts in these increments until loose.

9. When the rocker arm support plate bolts are free of the cylinder head, lift the support plate assembly from the rocker housing. See Section 3.11 SUBASSEMBLY SER-

VICE AND REPAIR, ROCKER ARM ASSEMBLY.

NOTE Always service each cylinder separately. After the ﬁrst cylinder is serviced the engine must be rotated to ﬁnd the base circle on the second cam. Service on the remaining cylinder can then proceed.

10. Remove the intake and exhaust push rods. Tag the push

rods as they are removed, so that they can be installed in their original locations. Also take note of their orientation to be able to discern top from bottom at time of installation.

11. Remove push rod covers from cylinder head and lifter

cover bores. Remove three O-rings from push rod covers and discard. If O-ring is missing from upper push rod cover, be sure to dislodge it from the cylinder head bore.

12. Using a crosswise pattern, remove the four allen head

socket screws to release the lifter cover. Remove the lifter cover and gasket. Discard the gasket.

13. Remove the anti-rotation pin. Remove the hydraulic lift-

ers. Tag lifters as they are removed, so that they can be installed in their original locations. Also take note of their orientation (by observing location of the oil hole) to be able to discern front from rear at time of installation.

14. Place the lifters in clean plastic bags to keep out dust,

dirt and debris. See Section 3.11 SUBASSEMBLY SER-

VICE AND REPAIR, PUSH RODS/LIFTERS/COVERS.

15. Remove O-ring from groove around breather bafﬂe hole

in rocker housing. Discard the O-ring.

16. Alternately loosen the six rocker housing bolts following

the pattern shown in C of Figure 3-22. Remove the rocker housing bolts.

17. Remove the rocker housing and gasket. Discard the

gasket.

To prevent distortion of the cylinder head, cylinder and cylinder studs, gradually loosen the cylinder head bolts in the speciﬁed pattern.

18. Alternately loosen each of the four cylinder head bolts

just 1/4 turn following the pattern shown in D of Figure 3-

22. Continue turning the bolts in these increments until

loose. Remove the cylinder head bolts.

NOTE Save the cylinder head gasket if not damaged. The gasket is

needed to install the CYLINDER TORQUE PLATES (HD42324A) when measuring, boring or honing of the cylinder is required.

19. Remove cylinder head and head gasket. See Section

3.11 SUBASSEMBLY SERVICE AND REPAIR, CYLIN- DER HEAD.

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23. Remove O-ring seal from the bottom of the cylinder liner. Discard O-ring seal. See Section 3.11 SUBASSEMBLY

SERVICE AND REPAIR, CYLINDER.

24. Remove O-ring from ring dowel on “downside” of cylinder deck. Discard the O-ring.

1CAUTION

Always wear proper eye protection when removing cir-

Claw

clips. Slippage may propel the ring with enough force to cause eye injury.

Figure 3-24. Piston Pin Circlip

Remover/Installer (Part No. HD-42317A)

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Slot

Figure 3-25. Remove Piston Pin Circlip

20. Raise the cylinder just enough to place clean shop towels under the piston. This will prevent any dirt or debris, such as broken ring pieces, from falling into the crankcase bore.

25. Verify that clean shop towels are properly positioned over the crankcase bore to prevent the piston pin circlip from falling into the crankcase.

26. Remove the piston pin circlip as follows: a. Insert the PISTON PIN CIRCLIP REMOVER/

INSTALLER (HD-42317A) into the piston pin bore until claw on tool is positioned in slot of piston (directly under circlip). See Figure 3-25.

b. Squeeze the handles of the tool together and pull

from bore. In the event that the circlip should ﬂy out, hold a shop towel over the bore during removal. Remove circlip from claw and discard.

NOTE

It is not necessary to remove both piston removal. Leave the second circlip in the pin bore.

27. Remove the piston pin. If piston pin is difﬁcult to remove, use PISTON PIN REMOVER (HD-42320A). See Figure

3-26. Proceed as follows:

a. Remove acorn nut and spacer from rod end of tool. b. Slide rod end through piston pin. Install spacer and

acorn nut to end of rod.

c. Position rubber-coated tips of tool on ﬂat each side

of pin bore.

d. Turn handle in a clockwise direction until piston pin

is pulled free of bore. See Figure 3-27.

piston pin circlips during

CAUTION

Exercise caution to avoid bending the cylinder studs. Even a slight bend or nick can cause a stress riser leading to stud failure.

21. Carefully remove the cylinder to avoid bending the cylinder studs. As the piston becomes free of the cylinder, hold it upright to prevent it from striking the studs or dragging across the stud thread area. Mark the cylinder “F(ront)” or “R(ear)” to identify location.

22. Slide plastic tubing, rubber hose or conduit over each cylinder stud. Material approximately 6 inches (152 mm) long with an I.D. of 1/2 inch (12.70 mm) will protect cylinder studs and piston from damage.

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28. Remove the piston. Be sure to hold the rod shank upright to prevent it from striking the crankcase. Place a piece of foam-type water pipe insulation around each rod (about 3 inches long with a 2-1/4 inch O.D. and a 1 inch I.D.) to prevent damage if contact should occur.

29. Turn the piston over and mark the pin boss with the letters “F(ront)” or “R(ear)” to identify location. See Section 3.11 SUBASSEMBLY SERVICE AND REPAIR,

PISTON and UPPER CONNECTING ROD.

30. If performing a top end overhaul only, see Section 3.11

SUBASSEMBLY SERVICE AND REPAIR, TOP END,

before proceeding to Section 3.9 TOP END OVERHAUL,

ASSEMBLY, which follows. If performing a complete

engine overhaul, see Section 3.10 BOTTOM END

OVERHAUL, DISASSEMBLY.

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CAUTION

5. Insert piston pin through pin bore and upper connecting rod bushing. Push pin until it contacts circlip installed in opposite pin boss.

Do not reuse piston pin circlips. The circlips may weaken during removal causing them to break or dislodge during engine operation, a condition that will result in engine damage.

Figure 3-26. Piston Pin Remover (Part No. HD-42320A)

Spacer and

Acorn Nut

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Rubber Coated Tip

Figure 3-27. Remove Piston Pin

Handle

ASSEMBLY

6. Place clean shop towels over the cylinder and lifter bores to prevent the piston pin circlip from falling into the crankcase. Verify that the circlip groove is clean and free of dirt and grime.

7. Install

new

piston pin circlip with the PISTON PIN CIRCLIP REMOVER/INSTALLER (HD-42317A). Proceed as follows:

a. Slide circlip down nose of tool until it contacts claw.

Lightly squeeze handles of tool to capture circlip in claw.

b. Releasing pressure on handles, rotate circlip so that

the end gap is centered at top of tool and then recapture in claw.

c. Tilt the circlip forward until the end gap contacts

nose of tool. See upper frame of Figure 3-28.

d. Insert the tool into the piston pin bore until claw is

aligned with slot in piston.

e. Firmly push the tool into the piston pin bore until it

bottoms. Release handles and remove tool.

f. Inspect the circlip to verify that it is fully seated in

the groove.

NOTE

It is assumed that each step performed on one cylinder is automatically repeated on the other.

1. Slide plastic tubing, rubber hose or conduit over each cylinder stud, if removed. Material approximately 6 inches (152 mm) long with an I.D. of 1/2 inch (12.70 mm) will protect cylinder studs and piston from damage.

2. Apply clean H-D 20W50 engine oil to piston pin, piston bosses and upper connecting rod bushing.

3. Remove water pipe insulation from rod shank.

4. Place piston over rod end so that the arrow stamped at the top of the piston points toward the front of the engine.

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 use to avoid confusion.

8. Install dowel (that is, rear dowel on rear cylinder, front dowel on front cylinder). Apply a very thin ﬁlm of clean H-D 20W50 engine oil to O-ring before installation. Verify that O-ring is properly seated in groove.

9. Install Apply a very thin ﬁlm of clean H-D 20W50 engine oil to O-ring before installation.

w O-rings keeping them packaged until

new

O-ring over “downside” cylinder deck ring

new

O-ring seal at the bottom of the cylinder liner.

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Circlip

b. With the forked end of the tool pointing towards the

center of the engine and the adjustable knobs facing downward, capture shank of connecting rod in fork. Lay tool on cylinder deck so that adjustable knobs contact wall of cylinder bore.

c. Rotate engine until piston skirt is centered and

ﬁrmly seated on top of support plate. See Figure 3-

30.

14. Install cylinder as follows: a. Obtain the PISTON RING COMPRESSOR (HD-

96333-51C).

b. Fit tabs on pliers into slots of ring compressor band

(HD-96333-103). The arrow stamped on the band indicates the side that faces up, so disregard the word “bottom.” Place band around piston. Press the lever on the right side of the pliers to open the jaws for band expansion.

c. Orient tool so that the top of the band is positioned

between the top compression ring and the piston crown. Tightly squeeze handles of tool to compress piston rings. The racheting action of the tool allows release of the handles after the rings are compressed.

Figure 3-28. Install Piston Pin Circlip

NOTE

Excessive lubrication of cylinder sleeve O-ring seal will result in oil weepage between cylinder and crankcase as engine is run, a condition that may be incorrectly diagnosed as an oil leak.

10. Verify that the piston ring end gaps are properly staggered. If necessary, see Section 3.11 SUBASSEMBLY

SERVICE AND REPAIR, PISTON.

11. Apply clean H-D 20W50 engine oil to piston, piston rings and cylinder bore.

12. Remove plastic tubing or rubber hose from cylinder studs. Rotate engine until piston is at top dead center. If necessary, see step 31 for methods of engine rotation.

13. Install the PISTON SUPPORT PLATE (HD-42322). Proceed as follows:

a. Slide both adjustable knobs on tool down slots away

from forked end. Tighten knobs when contact is made with ﬂats at end of slots.

Figure 3-29. Piston Support Plate (Part No. HD-42322)

Piston

Support Plate

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Figure 3-30. Install Piston Support Plate

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CAUTION

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Threaded

Cylinder

h. Carefully set the cylinder over the two ring dowels in

the cylinder deck. Push down on the cylinder until it is fully seated in the crankcase bore.

NOTE

To hold the first cylinder in position while installing the second, install threaded cylinders (HD-95952-1) from CONNECTING ROD CLAMPING TOOL (HD-95952-33B) onto cylinder studs with the knurled side down. This will prevent the piston rings from raising the cylinder as the engine is rotated to bring the other piston into position for installation of the second cylinder. See Figure 3-33.

Figure 3-31. Piston Ring Compressor

(Part No. HD-96333-51C)

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Ring Compressor Band

(3-5/8 - 3-7/8 Inches)

Part No. HD-96333-103

Pliers

Figure 3-32. Install Cylinder

d. Note that the cylinders should have been marked

with the letters “F(ront)” or “R(ear)” to identify location. With the indent in the cooling ﬁns facing the right side of the engine, gently slide cylinder over the cylinder studs and the piston crown resting it on the top of the ring compressor band.

e. Place the palms of both hands at the top of the cyl-

inder. Push down on the cylinder with a sharp, quick motion to pass the piston ring area. See Figure 3-

32.

f. Rotate the engine slightly to raise piston off support

plate. Remove pliers from band and then remove band from around shank of connecting rod. Remove piston support plate.

g. Remove shop towels from around the crankcase

bore exercising caution to keep out any dirt or debris.

15. With the part number topside, place the head gasket over the two ring dowels in the upper ﬂange of the cylinder.

16. Note that the word “Front” or “Rear” is cast into the top of the cylinder head to ensure proper installation. With the indent in the cooling ﬁns facing the right side of the engine (for accommodation of the push rods and covers), carefully set the cylinder head over the two cylinder ring dowels. To avoid damage to machined surfaces or ring dowels, lower the cylinder head at an angle that closely approximates the angle of the crankcase.

Thoroughly clean and lubricate the threads of the cylinder head bolts before installation. Friction caused by dirt and grime will result in a false torque indication.

Figure 3-33. Install Threaded Cylinders to Studs

(Part No. HD-95952-1)

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S= Short Bolt

FRONT

L= Long Bolt

REAR

17. Lightly oil threads and shoulders of cylinder head bolts with clean H-D 20W50 engine oil.

18. Start the cylinder head bolts onto the cylinder studs, two short bolts on the left side of the engine, two long bolts on the right.

19. Tighten the four cylinder head bolts as follows:

CAUTION

Improperly tightened cylinder head bolts may result in gasket leaks, stud failure and distortion of the cylinder and/or cylinder head.

a. Alternately turn each cylinder head bolt until ﬁnger

tight.

b. Tighten the cylinder head bolts to 120-144

(13.6-16.3 Nm) in the sequence shown in A of Fig-

ure 3-34.

c. Following the same sequence, tighten each bolt to

15-17 ft-lbs (20.3-23.1 Nm).

d. Using a grease pencil, mark a straight line on the

cylinder head bolt continuing the line over onto the cylinder head. Using the marks as a guide, turn each bolt 1/4 turn or 90 degrees. See B of Figure 3-

34. Be sure to tighten the cylinder head bolts in the

sequence shown in A of Figure 3-34.

in-lbs

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Figure 3-34. Cylinder Head Torque Sequence

and Bolt Size

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NOTE

For best results, obtain Snap-on® Torque Angle Gauge TA360.

20. 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.

21. Verify that the rocker housing gasket is installed correctly by noting that the breather channel is concealed. See Figure 3-35.

22. With the indent facing forward, place the rocker housing into position aligning the holes in the housing with those in the gasket.

23. Apply a small dab of Loctite Medium Strength Threadlocker 243 (blue) to threads of six rocker housing bolts. Start the rocker housing bolts, two long bolts on the left side of the engine, four intermediate bolts in the interior. Alternately tighten the bolts to 120-168 Nm) in the pattern shown in Figure 3-36.

new

rocker housing gasket on the cylinder head

CAUTION

in-lbs

(13.6-18.9

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S= Short Bolt, 1 In. I = Intermediate Bolt, 1-1/4 In. L = Long Bolt, 1-3/4 In.

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Install Six Rocker Housing Bolts.

Tor que: 120-168 in-lbs

FRONT

REAR

O-Ring

Breather Channel Concealed Breather Channel Exposed

CORRECT WRONG

Figure 3-35. Install Rocker Housing Gasket (Rear Cylinder Shown)

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.

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

f1577x3x f1576x3x

in-lbs

w O-rings keeping them packaged until

use to avoid confusion.

24. Install

new

O-ring in groove around breather bafﬂe hole in rocker housing. Apply a thin ﬁlm of clean H-D 20W50 engine oil to O-ring before installation. See Figure 3-36.

25. Install the hydraulic lifters in the crankcase bores with the ﬂats facing forward and rearward. To preserve existing wear patterns, orientation of the oil hole (inboard or outboard) should have been noted during disassembly. To avoid damage, do not drop lifters onto cam lobes.

CAUTION

Figure 3-36. Rocker Housing Torque Sequence

and Bolt Size

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Lifter Cover

Anti-Rotation

not

install the spring cap retainers at this time. To

ensure proper installation, take note of Ta bl e 3-3.

30. Install the push rods in their original positions. Be sure to remove any tags that may have been used for marking location and orientation. To ensure proper installation, take note of Ta bl e 3-3. For example, if reassembling the rear cylinder, slide the intake push rod (silver) through the front hole in the rocker housing engaging the lifter socket in the inside hole of the lifter cover. Slide the exhaust push rod (black) through the rear hole in the rocker housing engaging the lifter socket in the outside hole of the lifter cover.

Ribs

Gasket

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Figure 3-37. Install Lifters and Lock Position

With Anti-Rotation Pin

26. Place anti-rotation pin on the machined ﬂat between the blocks cast into the crankcase. See Figure 3-37.

27. Install a

new

lifter cover gasket aligning the holes in the

gasket with those in the cover.

CAUTION

Movement or loss of the anti-rotation pin can result in lifter rotation causing catastrophic engine damage.

28. Install the lifter cover and start the four allen head socket screws (1/4 x 1 inch). During installation, verify that the anti-rotation pin is held in place by the ribs cast into the inboard side of the lifter cover. See Figure 3-37. Tighten the lifter cover screws to 90-120

in-lbs

(10.2-13.6 Nm) in

a crosswise pattern.

29. Hand compress the push rod cover assembly and ﬁt the O-ring end of the lower push rod cover into the lifter cover bore. Expanding the assembly, ﬁt the O-ring end of the upper push rod cover into the cylinder head bore.

Table 3-3. Push Rod/Cover Locations

Cylinder

Front

Rear

Push Rods Are Color Coded - Intake (Silver), Exhaust (Black)

Cover and

Push Rod*

Intake Inside Rear

Exhaust Outside Front

Intake Inside Front

Exhaust Outside Rear

Lifter Cover

Bore

Cylinder Head/

Rocker Housing

Bore

31. To install the rocker arm support plate,

both

lifters of the cylinder being serviced must be on the base circle (or lowest position) of the cam.

CAUTION

Installing the rocker arms and rotating the engine with the valve train loaded can result in bent push rods and/ or valve damage.

To ﬁnd the base circle, it is ﬁrst necessary to rotate the engine. Based on the level of disassembly, three methods of engine rotation are presented below.

a. With pr

b. With pr

CAUTION

c. With engine mounted in engine stand

d. Finding the base circle

: Using one of the methods above, rotate engine until piston is at Top Dead Center (TDC) of compression stroke. To accomplish

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Rocker Arm Torque:

18-22 ft-lbs

Breather

Assembly

Tor que: 90-120 in-lbs

FRONT

REAR

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Tor que: 15-18 ft-lbs

S= Short Bolt, 1 In. I = Intermediate Bolt, 1-1/4 In. L = Long Bolt, 1-3/4 In.

Alternately Tighten Four Rocker Arm Bolts

Install Six Rocker Cover Bolts.

1/4 Turn in Pattern Shown.

Figure 3-38. Rocker Arm/Rocker Cover Torque Sequence and Bolt Size

this, ﬁrst raise lower push rod cover to access intake lifter (inside hole of lifter cover). Place index ﬁnger on top of the intake lifter. While rotating engine, feel lifter rise (valve open) and fall (valve closed). Now place ﬁnger tightly over spark plug hole and rotate engine again. In the compression stroke, air will be forced out against your ﬁnger until the piston reaches the TDC position. Stop engine rotation when the ﬂow of air through the spark plug hole stops. Direct the beam of a small ﬂashlight into spark plug hole to verify piston is at TDC. Both intake and exhaust valves are now closed and the push rods are in the unloaded position.

32. Place the rocker arm support plate assembly into the rocker housing. Start the four rocker arm support plate bolts into the cylinder head.

33. Place breather assembly at top of rocker arm support plate. Apply a small dab of Loctite Medium Strength Threadlocker 243 (blue) to threads of two breather assembly bolts. Start bolts into cylinder head.

34. Alternately tighten each of the four rocker arm support plate bolts just 1/4 turn following the pattern shown in A of Figure 3-38. Continue turning the bolts in these increments until snug. Following the same numerical sequence, tighten the bolts to 18-22 ft-lbs (24.4-29.8 Nm).

35. Alternately tighten the two breather assembly bolts to 90-120

in-lbs

(10.2-13.6 Nm).

NOTE

If the engine was left in the chassis for service, ﬁnal tighten the rocker arm support plate bolt on the rear left side of the rear cylinder using a 3/8 inch drive torque wrench with a 1/2 inch ﬂank drive “dog bone” torque adapter (Snap-On FRDH161). Since any extension can act as a torque multiplier, the torque wrench must be perpendicular to the torque adapter when the bolt is tightened. The 90 degree orientation between the tools cancels the multiplier effect and prevents the bolt from being over-tightened. If the adapter is kept inline with the torque wrench, the multiplier effect is in force and distortion of the rocker housing will occur.

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Figure 3-39. Install Spring Cap Retainer

36. Lift up lower push rod covers and verify that both push rods spin freely.

39. Apply a small dab of Loctite Medium Strength Threadlocker 243 (blue) to threads of six rocker cover bolts. Start the rocker cover bolts, three short bolts on the left side of the engine, three long bolts on the right. Tighten the bolts to 15-18 ft-lbs (20.3-24.4 Nm) in the pattern shown in B of Figure 3-38.

NOTE

If the engine was left in the chassis for service, ﬁnal tighten the three rocker cover bolts on the left side of the rear cylinder using a 3/8 inch drive torque wrench with a 7/16 inch ﬂank drive “dog bone” torque adapter (Snap-On FRDH141). Since any extension can act as a torque multiplier, the torque wrench must be perpendicular to the torque adapter when the bolts are tightened. The 90 degree orientation between the tools cancels the multiplier effect and prevents the bolts from being over-tightened. If the adapter is kept inline with the torque wrench, the multiplier effect is in force and distortion of the rocker cover will occur.

40. If engine was left in the chassis for service, see Section

3.6 ASSEMBLING MOTORCYCLE AFTER STRIPPING.

If engine was removed for service, see Section 3.8

INSTALLING ENGINE IN CHASSIS.

NOTE

Always service each cylinder separately. After the ﬁrst cylinder is serviced the engine must be rotated to ﬁnd the base circle on the second cam. Service on the remaining cylinder can then proceed.

37. Complete installation of the push rod covers as follows: a. Verify that the O-ring ends of the upper and lower

push rod covers ﬁt snugly into the cylinder head and lifter cover bores.

b. Lodge the upper edge of spring cap retainer into the

cylinder head bore leaving the bottom edge free.

c. Insert blade of small screwdriver between bottom

edge of spring cap retainer and top of spring cap.

d. While simultaneously depressing spring cap with tip

of screwdriver, use foreﬁnger to slide bottom edge of spring cap retainer down shaft towards tip of screwdriver blade. As spring cap reaches its full length of travel, spring cap retainer should be in approximate position against upper push rod cover. See Figure 3-39.

NOTE

For best results, be sure that screwdriver, spring cap and spring cap retainer are free of grease and oil.

e. Verify that spring cap retainer is seated tightly

against upper push rod cover.

38. Install a

new

rocker cover gasket on the rocker housing ﬂange. Place the rocker cover into position aligning the holes in the cover with those in the gasket.

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BOTTOM END OVERHAUL 3.10

DISASSEMBLY

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY. If only servicing cam compartment components,

see steps 1-11. If performing a complete engine overhaul, reference steps 1-29.

NOTE

The cam support plate, lifter cover and crankshaft position sensor mount all use the same short allen head socket screw (1/4 x 1 inch). Only the cam cover uses the longer screw (1/4 x 1-1/4 inches). For ease of assembly, do not mix short and long screws. Store long screws inside cam cover to avoid confusion. The short screws are interchangeable.

2. Remove the ten allen head socket screws to release the cam cover. Remove and discard the cam cover gasket.

Flange Bolt and

Right

Crankcase Half

Flat Washer

3. Using a colored marker, mark the crank sprocket and one of the links of the primary cam chain. Maintaining the original direction of rotation during assembly may prolong service life.

4. Remove the ﬂange bolt and ﬂat washer from the crank sprocket. See Figure 3-40.

5. Remove the ﬂange bolt and ﬂat washer from the primary cam sprocket.

NOTE If too much loctite, or perhaps the wrong loctite, was used to install the primary cam sprocket ﬂange bolt, it may be very difﬁcult to remove. In these cases, break down loctite using heat from a small propane torch. Apply ﬂame evenly around bolt head in a circular motion, but not for so long as to turn bolt blue. Do not direct heat at chain tensioner assembly and other components or damage will result. Other methods of removal, such as use of a large breaker bar, also may result in damage to chain drive and other components.

Cleaning

Plug

Camshaft

Front

Primary Cam

Sprocket

Primary

Cam Chain

Primary Cam Chain

Tensioner

Oil Pressure

Relief Valve

Flange Bolt and

Flat Washer

Figure 3-40. Cam Support Plate Assembly

Michalski

Chain Guide

Crank

Sprocket

f2141x3x

2004 Touring: Engine 3-45

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Tensioner

Unloader

Slot

Figure 3-41. Cam Chain Tensioner Unloader

with Retention Pins (Part No. HD-42313)

Retention Pins

7. Insert small pry bar (seal remover) between inboard side of primary cam sprocket and cam support plate. Working around its circumference, carefully ease primary cam sprocket off splines of rear camshaft until loose.

8. Ease off crank sprocket with a slightly smaller pry bar (seal remover). Remove the primary cam sprocket, primary cam chain and crank sprocket.

9. Remove the primary cam sprocket spacer from the rear camshaft.

10. Squeeze tabs to remove chain guide from between blocks cast into cam support plate.

11. Release the cam support plate from the oil pump ﬂange. Alternately loosen and then remove the four allen head socket screws following the pattern shown in B of Figure

3-50.

12. Release the cam support plate from the crankcase ﬂange. Alternately loosen and then remove the six allen head socket screws following the pattern shown in A of

Figure 3-50.

13. Two ring dowels in crankcase ﬂange locate cam support plate (lower rear, upper front). See Figure 3-43. Insert small pry bar (seal remover) between inboard side of cam support plate and crankcase ﬂange in area adjacent to ring dowels. Alternately work each side free and then carefully ease cam support plate from end of crankshaft. See Section 3.11 SUBASSEMBLY SERVICE AND

REPAIR, CAM SUPPORT PLATE.

f2140x3x

Figure 3-42. Retract Primary Cam Chain Tensioner

1WARNING1WARNING

Use extreme caution when operating propane torch. Read the manufacturers instructions carefully before use. Do not direct open ﬂame or heat toward any fuel system component. Extreme heat can cause fuel ignition and explosion. Inadequate safety precautions could result in death or serious injury.

6. Using the CAM CHAIN TENSIONER UNLOADER (HD-

42313), retract the primary cam chain tensioner as follows:

a. With the handle pointing toward the front of the cam

support plate, place cup of tool over spring coil. Correctly positioned, the slot in the tool should be adjacent to the hole in the tensioner. See Figure 3-42.

b. Rotate the handle of the tool in a counterclockwise

direction until the hole in the tensioner is aligned with the hole in the boss of the cam support plate.

c. Insert a retention pin through the hole in the ten-

sioner and into the hole in the cam support plate.

f1573b3x

Ring

Dowel

O-Ring

Blind Hole

O-Ring

Oil Feed Hole

Right

Crankcase Half

Oil Pump

Figure 3-43. Oil Pump Assembly

Ring

Dowel

O-Ring

3-46 2004 Touring: Engine

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f1644x3x

f1645a3x

Crankshaft

Guide

Water Pipe

Insulation

Crankshaft

Guide

Left

Crankcase Half

Right

Crankcase Half

Crankshaft

Bearing

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1CAUTION

Do not pull the retention pin from the primary cam chain tensioner after removal of the cam support plate. With 35-40 pounds of spring pressure behind the tensioner, allowing it to accelerate through its full length of travel will result in spring stretching and/or cracking of the tensioner shoe. Furthermore, if the tensioner should contact ﬁngers or other parts of the hand, minor or moderate injury may occur.

14. Remove O-ring from groove around oil feed hole in crankcase ﬂange (directly below rear ring dowel). Remove O-ring from groove around blind hole in boss (directly above oil return hole in crankcase ﬂange). Discard O-rings. See Figure 3-43.

15. Pull oil pump from crankshaft. Remove O-ring from outboard side of oil pump housing. Remove O-ring from scavenge port stub. Discard O-rings. See Section 3.11

SUBASSEMBLY SERVICE AND REPAIR, OIL PUMP.

1WARNING1WARNING

Be sure that stator mount ﬂange (sprocket shaft side) is NOT facing up when the case halves are separated or the ﬂywheel assembly will drop to the ﬂoor. Dropping the ﬂywheel assembly may result in parts damage and minor or moderate injury.

16. Rotate crankcase in the engine stand so that the cam cover ﬂange is facing upward. Remove the nine crankcase bolts in the left case half. Follow the sequence shown in Figure 3-46.

Figure 3-44. Crankshaft Guide (Part No. HD-42326A)

1CAUTION

Never move or lift the crankcase by grasping the cylinder studs. The crankcase is too heavy to be carried in this manner and may be dropped. Dropping the crankcase may result in parts damage and minor or moderate injury.

17. Using pry points, loosen case halves. Lift right crankcase half off end of crankshaft.

18. Remove O-rings from two ring dowels in split line face of right case half. Discard the O-rings.

19. See Section 3.11 SUBASSEMBLY SERVICE AND

REPAIR, CRANKCASE.

ASSEMBLY

1. If removed, install left crankcase half in engine stand so that the split line face is vertical.

2. To prevent damage to the sprocket shaft bearing, slide CRANKSHAFT GUIDE (HD-42326A) over end of sprocket shaft. Install ﬂywheel assembly into left case half. Remove tool.

Figure 3-45. Install Crankshaft Guide to Protect

Crankshaft Bearing

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7. Rotate crankcase in the engine stand so that the stator

mount ﬂange (sprocket shaft side) is facing upward. Install service thrust washer on sprocket shaft with the ink stamp facing outside (and the chamfer inboard). If using OE part without markings, orient as required to preserve existing wear pattern.

8. To install Nice bearing, large ﬂat washer and handle from SPROCKET SHAFT TIMKEN BEARING CONE INSTALLER (HD-97225-55B) and proceed as follows:

a. Verify that seal lip garter spring is in place on both

b. Thread pilot onto sprocket shaft until contact is

c. With the lettering facing outside, slide oil seal over

d. Slide SPROCKET SHAFT OIL SEAL INSTALLER

new

oil seal into bearing bore, obtain pilot,

sides of seal.

made with shoulder.

pilot until it contacts bearing bore.

(HD-39361A) over pilot until it contacts oil seal. See

Figure 3-47.

f1585x3x

3. Install of right case half.

4. Apply a small (1.4 mm) wide to the split line face. For best results, use High-Performance Sealant (gray), Part No. HD-99650-

02.

5. To prevent damage to the crankshaft bearing, place CRANKSHAFT GUIDE (HD-42326A) over end of crankshaft. Mate case halves sliding bearing in right crankcase half over end of crankshaft. Remove tool. See

Figure 3-45.

6. Start the nine crankcase bolts and tighten as follows: a. Alternately turn each crankcase bolt until ﬁnger

b. Tighten the crankcase bolts to 10 ft-lbs (13.6 Nm) in

c. Following the same sequence, tighten each bolt to

Figure 3-46. Crankcase Torque Sequence

(Left Side View)

CAUTION

w O-rings keeping them packaged until

new

O-rings over two ring dowels in split line face

bead of sealant approximately 0.056 inch

tight.

the sequence shown in Figure 3-46.

15-19 ft-lbs (20.3-25.8 Nm).

Figure 3-47. Sprocket Shaft Oil Seal Installer

(Part No. HD-39361A)

f1882x3x

Sprocket Shaft

Oil Seal Installer

Figure 3-48. Install Oil Seal In Bore

3-48 2004 Touring: Engine

Page 17

CAUTION

f2068x3x

Rear

Camshaft

Front

Camshaft

Pin Stamped

Timing Lines

HOM

e. Slide Nice bearing and large ﬂat washer over pilot

until contact is made with seal installer.

f. Thread handle onto pilot shaft.

g. Rotate handle in a clockwise direction until oil seal

installer makes ﬁrm contact with crankcase stator mount. See Figure 3-48.

h. Remove handle, ﬂat washer, Nice bearing, seal

installer and pilot from sprocket shaft.

9. Slide sprocket shaft spacer over end of sprocket shaft. Push spacer into oil seal until seated against bearing race.

10. Rotate crankcase in the engine stand so that the cam cover ﬂange is facing upward.

11. Install oil pump as follows:

CAUTION

w O-rings keeping them packaged until

use to avoid confusion.

a. Install

new

O-ring on scavenge port stub of oil pump housing. Apply a very thin ﬁlm of clean H-D 20W50 engine oil to O-ring before installation.

b. Slide oil pump housing onto crankshaft ﬁtting O-ring

on scavenge port stub into crankcase bore at back of cam compartment. Firmly push on scavenge port stub with thumb to be sure that it is snug in bore. Inspect O-ring on stub to verify that it is not pinched or distorted.

c. Separate the gerotor gears into two sets, one wide

(scavenge) and the other narrow (feed).

NOTE

Lubricate parts with clean H-D 20W50 engine oil during assembly.

d. Fit the smaller of the

larger. Slide the wide gerotor set down the crank-

wide

gerotor gears into the

shaft until it bottoms in the oil pump housing.

e. Slide the ﬁrst of two separator plates down the

crankshaft until it contacts the wide gerotor set. Install wave washer and second separator plate.

f. Fit the smaller of the

narrow

gerotor gears into the larger. Slide the narrow gerotor set down the crankshaft until it contacts the separator plate.

Figure 3-49. Verify Alignment of Timing Lines

on Front and Rear Camshafts

w O-rings keeping them packaged until

use to avoid confusion.

g. Install

new

O-ring in groove on outboard side of oil pump housing. See Figure 3-43. Apply a very thin ﬁlm of clean H-D 20W50 engine oil to O-ring before installation.

12. Install

new

O-ring in groove around oil feed hole in

crankcase ﬂange (directly below rear ring dowel). Install

new

O-ring around blind hole in boss (directly above oil

return hole in crankcase ﬂange). Apply a thin ﬁlm of H-D 20W50 engine oil to O-rings before installation.

13. If not retracted, place cup of CAM CHAIN TENSIONER UNLOADER (HD-42313) over spring coil of secondary cam chain tensioner positioning ﬁnger on tool between tensioner and shoe. Rotate tool in a counterclockwise direction inserting retention pin through hole in boss on

primar

y cam chain side

of cam support plate. Pin engages hooks on tensioner to hold it in the retracted position. For best results, place cam support plate in a vise using brass jaw inserts to prevent casting damage.

14. Lubricate cam needle bearings with clean H-D 20W50 engine oil.

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CAM SUPPORT PLATE OIL PUMP

Figure 3-50. Cam Support Plate/Oil Pump Torque Sequence

f1581b3x

15. Using a straightedge, verify that the pin stamped timing lines on the ends of the front and rear camshafts are in alignment (although they may be somewhat difﬁcult to see). See Figure 3-49. If necessary, rotate camshafts in order to make this observation.

16. Aligning bushing in cam support plate with end of crankshaft, slide cam support plate over crankshaft onto two ring dowels in crankcase ﬂange. Use a rubber mallet to fully seat cam support plate on ring dowels.

17. Install the six allen head socket screws (1/4 x 1 inch) to secure the cam support plate to the crankcase ﬂange. Tighten screws to 90-120 pattern shown in A of Figure 3-50.

18. Secure the cam support plate to the oil pump ﬂange as follows:

a. Start two allen head socket screws (1/4 x 1 inch)

into holes 3 and 4. See B of Figure 3-50.

b. Obtain two ALIGNMENT TOOLS used to install lifter

guides on Evolution engines (HD-33443). Loosely install alignment tools in holes 1 and 2.

c. While rotating the engine, alternately snug and then

tighten the alignment tools to 40-45 Nm).

For methods of engine rotation, see Section 3.9 TOP END

OVERHAUL, DISASSEMBLY, step 7.

NOTE

in-lbs

(10.2-13.6 Nm) in the

in-lbs

(4.5-5.1

d. Alternately snug and then tighten the screws in

holes 3 and 4 to 40-45

e. Remove the alignment tool from hole 1. Install the

allen head socket screw and tighten to 40-45 (4.5-5.1 Nm).

f. Repeat step 18(e) to replace alignment tool in hole

2 with allen head socket screw.

g. Final tighten all four screws to 90-120

13.6 Nm). Use the pattern shown in B of Figure 3-

50. Numbers cast adjacent to the bolt holes also

indicate the oil pump torque sequence.

If only realigning the oil pump, ﬁrst loosen all screws following the pattern shown in B of Figure 3-50. Remove screws from holes 1 and 2 and then follow the alignment procedure starting at step 18(b).

19. Pull retention pin from hole in cam support plate to release secondary cam chain tensioner.

20. Squeeze tabs and install chain guide between blocks cast into cam support plate.

21. Install primary cam sprocket spacer onto rear camshaft.

22. If using the original cam support plate, camshafts, primary cam sprocket, crank sprocket and ﬂywheel assembly, then move to step 23. However, if any of these parts have been replaced, then proceed as follows:

NOTE

in-lbs

(4.5-5.1 Nm).

in-lbs

(10.2-

3-50 2004 Touring: Engine

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f2142x3x

a. Install primary cam sprocket onto splines of rear

camshaft. Install long

ﬂange bolt with thicker ﬂat

washer to secure sprocket to end of camshaft.

b. Install crank sprocket onto crankshaft. Install shor

ﬂange bolt with smaller diameter ﬂat washer (that is, washer from bulk inventory) to secure sprocket to end of crankshaft.

NOTE

Use of smaller diameter ﬂat washer with crank sprocket ﬂange bolt allows room on sprocket face for placement of straightedge under step 22(e).

c. To prevent rotation, position the CRANKSHAFT/

CAMSHAFT SPROCKET LOCKING TOOL (HD-

42314) between the crank and primary cam sprock ets. See Figure 3-52. The handle of the tool is stamped “Crank” and “Cam” to ensure proper orientation. Tighten the crank and primary cam sprocket ﬂange bolts to 15 ft-lbs (20.3 Nm). Remove the sprocket locking tool.

d. Push on rear camshaft to remove end play.

Figure 3-51. Crankshaft/Camshaft Sprocket Locking Tool

(Part No. HD-42314)

Figure 3-53. Check Alignment of Crank and

Primary Cam Sprocket Faces

e. Place a straightedge across the crank and primary

cam sprocket faces. Try to insert a 0.010 inch feeler gauge between the straightedge and each sprocket face. See Figure 3-53. If the feeler gauge does not ﬁt at either location, then proceed to step 22(f).

On the other hand, if the crank sprocket is “proud” (that is, rises above the face of the primary cam sprocket) more than 0.010 inch, remove the ﬂange bolt and primary cam sprocket, and noting the part number stamped on the existing spacer, replace it with the next larger size. See spacer sizes listed in

Ta bl e 3-4. Replace the spacer with the next smaller

size only if the primary cam sprocket is “proud” (rises above the face of the crank sprocket) more than 0.010 inch. Return to step 21 to repeat the check with the new spacer installed.

Sprocket

Locking Tool

f2139x3x

Figure 3-52. Lock Crank and Primary Cam Sprockets

Before Tightening Flange Bolts

Table 3-4. Primary Cam Sprocket Spacers

Spacer Size

0.287 25722-00

0.297 25723-00

0.307 25721-00

0.317 25719-00

0.327 25717-00

0.337 25725-00

f. Remove both crank and primary cam sprockets.

Discard smaller diameter ﬂat washer obtained from bulk inventory.

23. Install the primary cam chain and sprocket assembly as follows:

H-D Part Number

2004 Touring: Engine 3-51

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Crank

Primary Cam

Sprocket

Punch Marks

Figure 3-54. Verify Alignment of Crank and

Primary Cam Sprocket Punch Marks

a. Place the primary cam sprocket in the cam chain.

Hold the sprocket allowing the chain to hang loose. Rotate the sprocket so that the punch mark on the sprocket root faces straight downward.

NOTE

To maintain the original direction of rotation, verify that the colored mark placed on the chain link and crank sprocket is facing away from the cam support plate during installation.

b. Place the crank sprocket in the opposite end of the

chain with the punch mark on the sprocket tooth facing straight upward.

c. Maintaining the position of the sprockets on the

chain with the punch marks in alignment, start the primary cam sprocket onto the splines of the rear camshaft. Apply a thin ﬁlm of clean H-D 20W50 engine oil to the splines before installation.

d. Maintaining the position of the crank sprocket on the

chain, rotate the primary cam sprocket in a clockwise direction until the ﬂat on the crank sprocket is aligned with the ﬂat on the crankshaft. Install the crank sprocket.

24. Rotate the primary cam sprocket in a clockwise direction

until the punch mark on the root is aligned with the punch mark on the crank sprocket tooth. Lay a straightedge across the centerline of the crank and primary cam sprocket ﬂange bolt holes to verify that the punch marks are in alignment. See Figure 3-54.

Sprocket

f2138x3x

NOTE

If the punch marks are not in alignment, then the sprockets must be removed and reinstalled. The vehicle will not run properly if the sprockets are misaligned by even one tooth.

NOTE

Both crank and primary cam sprocket ﬂange bolts are specially hardened, while the ﬂat washers are of a special diameter and thickness. Therefore, use only genuine HarleyDavidson parts when replacement is necessary. The crank and primary cam sprocket ﬂange bolts and ﬂat washers are

NOT

interchangeable.

25. Install crank sprocket and primary cam sprocket ﬂange bolts and ﬂat washers as follows:

NOTE

Exercise caution to avoid mixing oil on washer with threadlocker on bolt or sealing integrity may be compromised.

a. Apply a thin ﬁlm of clean H-D 20W50 engine oil to

both sides of ﬂat washers. b. Install thinner c. Install thic d. Apply Loctite Primer 7649 (P/N 98968-99) to

threads of ﬂange bolts. e. Apply one drop

locker 262 (red) to threads of ﬂange bolts. f. Install shor

secure crank sprocket to end of crankshaft. g. Install long

secure primary cam sprocket to end of camshaft. h. Position CRANKSHAFT/CAMSHAFT SPROCKET

LOCKING TOOL (HD-42314) between the crank

and primary cam sprockets to prevent rotation. See

Figure 3-52. The handle of the tool is stamped

“Crank” and “Cam” to ensure proper orientation. i. Alternately tighten the crank and primary cam

sprocket ﬂange bolts to 15 ft-lbs (20.3 Nm). j. Loosen each ﬂange bolt one full turn. k. Tighten the crank sprocket ﬂange bolt to 24 ft-lbs

(32.5 Nm). l. Tighten the primary cam sprocket ﬂange bolt to 34

ft-lbs (46.1 Nm). m. Remove the sprocket locking tool.

ﬂat washer on short ﬂange bolt.

ker ﬂat washer on long ﬂange bolt.

of Loctite High Strength Thread-

t ﬂange bolt with thinner ﬂat washer to

ﬂange bolt with thicker ﬂat washer to

1CAUTION

Ease the primary cam chain tensioner into the unloaded position using the proper tool. Do not pull the retention pin to unload the tensioner or the pin may be damaged. Furthermore, if the tensioner should contact ﬁngers or other parts of the hand, minor or moderate injury may occur.

3-52 2004 Touring: Engine

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CAUTION

Tor que: 125-155 in-lbs

26. Hold the retracted primary cam chain tensioner with the

CAM CHAIN TENSIONER UNLOADER (HD-42313), pull retention pin from hole in cam support plate and ease the assembly into the unloaded position.

27. Apply clean H-D 20W50 engine oil to crank and primary cam sprockets.

Before cam cover installation, verify cleanliness of blind holes in the crankcase ﬂange. Tightening screws with dirt, water or oil in the holes can cause the casting to crack or break. Damage to the casting requires replacement of the right crankcase half.

Figure 3-55. Cam Cover Torque Sequence

f1616b3x

28. Align holes in crankcase ﬂange.

29. Install the cam cover using ten allen head socket screws (1/4 x 1-1/4 inches). Alternately tighten screws to 125155

in-lbs

Figure 3-55.

30. If performing a complete engine overhaul, see Section

3.9 TOP END OVERHAUL, ASSEMBLY, steps 1-39. If

only cam compartment components were serviced, just see steps 28-37.

new

cam cover gasket with those in the

(14.1-17.5 Nm) following the pattern shown in

2004 Touring: Engine 3-53

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Legend:

1. Bolt

2. Bolt

3. Rocker Cover

4. Rocker Cover Gasket

5. Breather Bolt

6. Breather Cover

7. Breather Cover Gasket

8. Umbrella Valve

9. Breather Bafﬂe

10. Filter Element

11. Breather Bafﬂe Gasket

12. Rocker Arm Bolt

13. Rocker Arm Support Plate

14. Rocker Arm Bushing

15. Rocker Arm

16. Rocker Arm Shaft

17. Rocker Arm

18. Breather Bafﬂe O-Ring

19. Rocker Housing Bolt

20. Rocker Housing Bolt

21. Rocker Housing

22. Rocker Housing Gasket

23. O-Ring

24. Upper Push Rod Cover

25. Spring Cap Retainer

26. Spring Cap

27. Spring

28. Flat Washer

29. O-Ring

30. Lower Push Rod Cover

31. O-Ring

32. Lifter Cover Screw

33. Lifter Cover

34. Anti-Rotation Pin

35. Lifter Cover Gasket

36. Hydraulic Lifter

37. Push Rod

Figure 3-56. Rocker Arm/Breather/Lifter Assemblies (Exploded View)

3-54 2004 Touring: Engine

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Page 23

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f2176x3x

1. Bolt

2. Breather Cover

3. Cover Gasket

4. Umbrella Valve

5. Breather Bafﬂe

6. Filter Element

7. Breather Bafﬂe Gasket

4 5

SUBASSEMBLY SERVICE AND REPAIR 3.11

TOP END

BREATHER ASSEMBLY

Removal

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-8.

Disassembly

1. Remove two bolts and lift breather assembly from rocker arm support plate. See Figure 3-57.

2. Remove the breather cover and gasket. Remove the breather bafﬂe and gasket. Discard gaskets.

3. Pull ﬁlter element from bore on inboard side of breather bafﬂe. Pull stem of umbrella valve from hole at top of breather bafﬂe. Discard both ﬁlter element and umbrella valve.

Cleaning and Inspection

1. Clean all parts in a non-volatile cleaning solution or solvent.

2. Thoroughly dry all parts with low pressure compressed air.

3. Set a straightedge diagonally across the length of the breather cover intersecting the opposite corners of the gasket surface. Slide a feeler gauge beneath the straightedge to check the breather cover for warpage. Repeat the step checking the opposite diagonal. Discard the breather cover if any low spot exceeds 0.005 inch (0.13 mm).

4. Repeat step 3 to inspect the gasket surface of the breather bafﬂe for ﬂatness. Discard the breather bafﬂe if any low spot exceeds 0.005 inch (0.13 mm).

Assembly

1. Insert stem of top of breather bafﬂe. Carefully pull rubber bead on stem through hole in bafﬂe. Use denatured alcohol or glass cleaner to lubricate stem, if necessary. Verify that rubber bead is pulled completely through hole and resides on bottom side of bafﬂe.

2. Press Hole in ﬁlter element accommodates umbrella valve stem.

new

umbrella valve through center hole at

new

ﬁlter element into bore at bottom of bafﬂe.

Figure 3-57. Breather Assembly

3. Place breather bafﬂe gasket on a clean ﬂat surface. 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.

Installation

1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps 31-39.

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ROCKER ARM ASSEMBLY

3. Remove the rocker arms from the rocker arm support plate. Mark the rocker arms to indicate location.

Removal

Cleaning and Inspection

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-9.

Disassembly

1. Remove the four bolts from the rocker arm support plate. If necessary, slightly wiggle the two bolts on the push rod side (right) to disengage them from the notches in the rocker arm shafts.

2. Using a hammer and brass drift, tap left side of rocker arm shafts so that the notched ends exit the rocker arm support plate ﬁrst. Mark the shafts so that they are installed in their original locations at time of assembly.

1. Clean all parts in a non-volatile cleaning solution or solvent. Thoroughly dry with low pressure compressed air.

2. Check rocker arms for uneven wear or pitting where contact is made with the valve stem tips. Check for concave wear where rocker arms contact the push rod ends. Replace rocker arm if excessive wear is found at either location.

3. Verify that oil holes in rocker arms and rocker arm support plate are clean and open.

4. Inspect rocker arm shafts for scratches, burrs, scoring or excessive wear. Replace as necessary.

A B

C D

Figure 3-58. Measure Rocker Arm Assembly for Wear

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6916

Remove Bushings.

9/16”-18 Tap

Driver

Discarded Shaft

6923

Ream Bushings.

Bushing Reamer

Part No. HD-94804-57

6922

Driver

Install Bushings.

5. Measure the inside diameter of the rocker arm support plate bore. See A of Figure 3-58. Measure the outside diameter of the rocker arm shaft where it ﬁts in the bore. See B of Figure 3-58. Repeat the measurement on opposite side of support plate and shaft. Replace the shaft or support plate if any measurement equals or exceeds 0.0035 inch (0.089 mm).

6. Measure the inside diameter of the rocker arm bushing. See C of Figure 3-58. Measure the outside diameter of the rocker arm shaft where it rides in the bushing. See D of Figure 3-58. Repeat the measurement on opposite side of rocker arm and shaft. Replace the shaft or bushings if any measurement equals or exceeds 0.0035 inch (0.089 mm).

7. To replace rocker arm bushings, proceed as follows:

NOTE

Remove, install and ream one bushing at a time.

a. Obtain a 9/16”-18 (14.29 mm) tap. Turn tap into

bushing until tight. Place rocker arm under ram of arbor press with tap at bottom. Slide a discarded rocker arm shaft through open end of rocker arm until contact is made with tap. Using shaft as driver (and untapped bushing as pilot), press against shaft until both tap and bushing are free. See upper frame of Figure 3-59.

b. Using a suitable driver, press

new

bushing into side of rocker arm until ﬂush with casting. See center frame of Figure 3-59. Be sure to orient bushing so that split line faces top of rocker arm.

Never back reamer out of rocker arm or new bushing will be damaged.

Assembly

1. Place the rocker arms into position on the rocker arm

2. Push the un-notched ends of the rocker arm shafts into

CAUTION

c. Lock rocker arm in a vise using brass jaw inserts or

shop towels to prevent casting damage. Insert tapered end of ROCKER ARM BUSHING REAMER (HD-94804-57) into old bushing in rocker arm. Note that old bushing on drive side of reamer serves as pilot. See lower frame of Figure 3-59. Rotate reamer until new bushing on far side is reamed, and then continuing in the same direction, draw drive side of reamer from new bushing.

d. Repeat steps 7(a) thru 7(c) to remove, install and

ream second bushing.

support plate.

the right side of the support plate and then into the rocker arms. As they approach their fully installed positions, rotate the shafts so that the notches are aligned with the bolt holes in the support plate.

Figure 3-59. Replace Rocker Arm Bushings

2004 Touring: Engine 3-57

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3. To check for proper end play, insert a feeler gauge between the rocker arm and support plate. See Figure 3-

60. Repeat measurement on other rocker arm. Replace

the rocker arm, rocker arm support plate, or both if end play exceeds 0.025 inch (0.635 mm).

4. Install the four bolts in the rocker arm support plate. For proper assembly, remember that the two bolts on the push rod side (right) must engage the notches in the rocker arm shafts.

Installation

1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps 31-39.

6917

Figure 3-60. Check End Play

3-58 2004 Touring: Engine

Page 27

CAUTION

f1584x3x

Flat

Washer

Spring Cap

Spring

Spring Cap

Retainer

Upper

Push Rod

Cover

O-Ring

Small

O-Ring

Intermediate

O-Ring

Large

Lower

Push Rod

Cover

Flared End

HOM

PUSH RODS/LIFTERS/COVERS

Removal

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-14.

Disassembly

1. With the exception of the lifter covers, all parts should have been disassembled and marked during the removal procedure. Disassemble the lifter covers as follows:

a. Separate upper and lower push rod covers.

b. Remove O-ring from seat at bottom of lower push

rod cover. Discard O-ring.

c. Remove O-ring from seat at top of upper push rod

cover. Slide O-ring, ﬂat washer, spring and spring cap from body of upper push rod cover. Discard Orings.

Cleaning and Inspection

1. Scrape old gasket material from the lifter cover ﬂange. Old gasket material left on mating surfaces will cause leaks.

2. With the exception of the hydraulic lifters, clean all parts in a non-volatile cleaning solution or solvent. Verify that the O-ring seats and contact surfaces of the push rod covers are completely clean.

3. Thoroughly dry all parts with low pressure compressed air. Verify that all oil holes are clean and open.

4. Verify that the hydraulic lifter rollers turn freely and are free of ﬂat spots, scuff marks and pitting. If ﬂat spots exist, examine the cam lobe on which the lifter operates.

5. Inspect the lifter socket for signs of wear. Verify that the plunger of the hydraulic lifter is fully extended up against the C-clip. Use index ﬁnger to pump plunger to verify lifter operation.

6. Examine the push rods. Replace any push rods that are bent, dented, broken or discolored. Replace the rod if the ball ends show signs of excessive wear or damage.

7. Cover all parts with a clean plastic sheet to protect them from dust and dirt.

Assembly

1. With the exception of the lifter covers, all parts will be assembled during the installation procedure. Assemble the lifter covers as follows:

Figure 3-61. Push Rod Cover Assembly

w O-rings keeping them packaged until

2004 Touring: Engine 3-59

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a. Obtain three new o-rings- small, intermediate and

large.

b. Install small O-ring on seat at the top of the upper

push rod cover.

NOTE

Apply a very thin ﬁlm of clean H-D 20W50 engine oil to Orings before installation.

c. Slide the spring cap, spring, ﬂat washer and inter-

mediate size O-ring onto the body of the upper push rod cover. Move parts up body until spring cap contacts upper O-ring seat.

d. Fit the straight end of the upper push rod cover into

the ﬂared end of the lower push rod cover.

e. Install large O-ring on seat at bottom of lower push

rod cover.

Installation

1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps 25-39.

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NOTES

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Legend:

1. Tapered Keepers

2. Spring Retainer

3. Inner Spring

4. Outer Spring

5. Valve Stem Seal

6. Spring Seat

7. Valve Guide

8. Cylinder Head Bolt

9. Cylinder Head Bolt

10. Cylinder Head

11. Valve Seat

12. Valve

13. Cylinder Head Gasket

14. Cylinder

15. Ring Dowel

16. O-Ring Seal

17. Cylinder Stud

18. Piston

19. Piston Pin

20. Circlip

21. Top Compression Ring

22. Second Compression Ring

23. Oil Rail

24. Oil Rail Spacer

Figure 3-62. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)

3-62 2004 Touring: Engine

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f1648x3x

CYLINDER HEAD

Removal

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11 and 15-19.

Disassembly

1. Before proceeding with the disassembly procedure, determine if cylinder head reconditioning is necessary. Proceed as follows:

a. Raise valve ports of cylinder head to strong light

source. If light is visible around edges of seats, then move to step 2 to recondition cylinder head.

b. Fill ports at top of cylinder head with solvent. Wait

ten full seconds and then check for leakage into combustion chamber. If solvent leakage into combustion chamber is evident, then move to step 2 to recondition cylinder head.

14mm End

Figure 3-65. Valve Spring Compressor

(Part No. HD-34736B)

12mm End

Figure 3-63. Cylinder Head Holding Fixture

(Part No. HD-39786)

f1658x3x

Cylinder Head

Holding Fixture

Figure 3-64. Install Cylinder Head Holding Fixture in Vise

Figure 3-66. Compress Valve Springs

2. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

39786) and proceed as follows: a. Note that both ends of the ﬁxture are threaded, one

end at 14mm and the other at 12mm. Thread the 12mm end of the tool into the spark plug hole of the cylinder head.

b. Clamp tool in vise at a 45 degree angle (or one that

offers a comfortable working position). See Figure

3-64.

3. Obtain the VALVE SPRING COMPRESSOR (HD34736B) and proceed as follows:

a. Place tool over cylinder head so that the blunt end is

centered on the valve head and adapter at end of forcing screw is seated on the valve spring retainer.

See Figure 3-66. b. Rotate forcing screw to compress valve springs. c. If spring retainer has not broken free of tapered

keepers, give head of tool a sharp tap with a soft

mallet. Using magnetic rod or small screwdriver,

remove the keepers from the valve stem groove.

2004 Touring: Engine 3-63

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d. Rotate forcing screw to release the valve spring

compression.

4. Remove the spring retainer and inner and outer valve springs.

5. Slide the valve from the valve guide.

6. Using pliers, twist and remove the valve stem seal from the top of the valve guide. Discard the valve stem seal.

7. Remove the spring seat from the cylinder head.

8. Mark the bottom of the valve “F(ront)” or “R(ear)” to indicate the cylinder head from which it was removed. Also, separate and tag tapered keepers, valve springs, spring retainers and spring seats so that they are installed on the same valve at time of assembly.

9. Repeat steps 3-8 to remove the other valve components.

10. Release the cylinder head holding ﬁxture from the vise and then remove the tool from the spark plug hole.

Cleaning and Inspection

Cleaning

1. Remove old gasket material from cylinder head. Gasket material left on sealing surfaces will cause leaks.

2. Remove all carbon deposits from combustion chamber and machined surfaces of cylinder head. Exercise caution to avoid removing any metal material. For best results, use an air tool with a w may result in scratches or nicks.

3. To soften stubborn deposits, soak the cylinder head in a chemical solution, such as GUNK HYDRO-SEAL or other carbon and gum dissolving agent. Repeat step 2 as necessary.

CAUTION

Do not use glass or sand to bead blast surfaces exposed to the engine oil. Bead blasting materials become lodged in the pores of the casting where they cannot be removed through ordinary cleaning methods. Only after the engine is put into use will heat expansion cause this material to be released, and the resulting oil contamination will accelerate wear and lead to engine failure. If bead blasting must be employed, use wallnut shells or other soft non-damaging abrasive that can be digested in the engine oil.

orn wire brush. Scraping

4. Thoroughly clean the cylinder head, spring retainers, tapered keepers, valves, inner and outer valve springs and spring seats in a non-volatile cleaning solution or solvent. Follow up with a thorough wash in hot soapy water. Blow dry with compressed air.

Inspection

Cylinder Head

1. Check for scratches and nicks on all gasket sealing surfaces.

2. With the combustion chamber side facing upward, set a straightedge diagonally across the length of the cylinder head intersecting the upper and lower corners of the gasket surface. Slide a feeler gauge beneath the straightedge to check the head for warpage. Checking the opposite diagonal, repeat the procedure to verify that the gasket surface is ﬂat (especially if a head gasket was blown). Discard the head if any low spot is 0.005 inch (0.13 mm) or greater.

NOTE

For good results, use one of the CYLINDER TORQUE PLATES (HD-42324A) in lieu of the straightedge. Lay the upper plate ﬂat on the machined surface of the head. As a preliminary check, see if the plate rocks from side to side. A head on which the plate rocks is immediately suspect. Insert a feeler gauge between the plate and head at various locations to see if warpage exceeds above speciﬁcation.

3. Verify that oil passageways are open and clean.

Valve Guides

1. Inspect external surfaces for cracks (particularly the combustion chamber side). Replace the guide if any cracks are found.

2. To verify cleanliness of valve guides, lightly hone bore using the VALVE GUIDE HONE (HD-34723) and then scrub with the VALVE GUIDE CLEANING BRUSH (HD-

34751) to remove any dust or debris. Polish the valve stem with ﬁne emery cloth or steel wool to remove carbon buildup, and then check valve stem to guide clearance as follows:

Carefully measure the inside diameter of the valve guide using an inside ball micrometer. Measure the outside diameter of the valve stem with an outside micrometer. The valve stem and/or guide are excessively worn if the clearance exceeds the limits shown in Tab l e 3-5. Repeat measurements with a new valve to determine if the guide must be replaced.

CAUTION

Be aware that bead blasting materials may also enter threaded holes adversely affecting fastener engagement and torque indication. Carefully cover all threaded holes if bead blasting is employed.

3-64 2004 Touring: Engine

Table 3-5. Service Wear Limits

Valve Valve Stem to Guide Clearance

Intake 0.0035 inch (0.089 mm)

Exhaust 0.0040 inch (0.102 mm)

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f1681x3x

Valve Guide

Driver

Cylinder Head

Support Stand

Ram

Cylinder Head

Support Stand

Intake Seat

Adapter

Part No. HD-39782A-3

Exhaust Seat

Adapter

Part No. HD-39782A-4

Tapered Keepers

1. Inspect parts for damage or rust pits. Replace as necessary.

2. Inspect inboard side of tapered keepers for excessive wear. Upraised center must be pronounced and ﬁt snugly in valve stem groove. Place keepers into groove and verify that they grip tightly without sliding.

Valve Seats

1. Inspect seats for cracking, chipping or burning. Replace seats if any evidence of these conditions are found.

2. Check seats for recession by measuring valve stem protrusion. See VALVE AND SEAT REFACING in this sec- tion, steps 5-6.

Figure 3-67. Cylinder Head Support Stand

(Part No. HD-39782A)

Figure 3-68. Valve Guide Driver (Part No. HD-34740)

Valves

1. Replace the valve if there is evidence of burning or cracking.

2. Inspect the end of the valve stem for pitting or uneven wear. Replace the valve if either of these conditions are found.

3. Inspect for burrs around the valve stem keeper groove. Remove burrs with a ﬁne tooth ﬁle if found.

4. To determine if the valve stem is excessively worn, see INSPECTION, VALVE GUIDES, step 2.

VALVE GUIDE REPLACEMENT

Removal

NOTE If valve guide replacement is necessary, always install new guide before refacing valve seat.

1. Obtain the CYLINDER HEAD SUPPORT STAND (HD-

39782A) and proceed as follows: a. Insert sleeve of intake or exhaust seat adapter into

tube at top of support stand. See Figure 3-67.

b. Position cylinder head so that valve seat is centered

on seat adapter. Support stand ensures that valve guide and seat are perpendicular. If perpendicularity is not achieved, the cylinder head valve guide bore will be damaged during the press procedure.

Valve Springs

1. Inspect springs for broken or discolored coils. Replace springs if either of these conditions are found.

2. Set the intake and exhaust valve springs on a level surface and use a straightedge to check for proper squareness and height.

3. Check free length of inner and outer springs using a dial vernier caliper or load test with the VALVE SPRING TESTER (HD-96796-47). Replace springs if free length or compression force do not meet speciﬁcations. See Section 3.1 SPECIFICATIONS.

Figure 3-69. Remove Valve Guide

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Valve Guide

Driver

Valve Guide

Installer Sleeve

Figure 3-70. Valve Guide Driver (Part No. HD-34740) and

Valve Guide Installer Sleeve (Part No. HD-34731)

f1680x3x

Valve Guide

Driver

Valve Guide

Installer Sleeve

Cylinder Head

Support Stand

Figure 3-71. Install Valve Guide

Installation

1. Measure the outside diameter of a new standard valve

guide, and then measure the cylinder head valve guide bore. The valve guide should be 0.0020-0.0033 inch (0.051-0.084 mm) larger than the bore.

If clearance is not within speciﬁcation, then select one of the following oversize guides - 0.001 inch (0.025 mm),

0.002 inch (0.05 mm) or 0.003 inch (0.08 mm).

NOTE

Since some material is typically removed when the guide is pressed out, it is normal to go to the next larger size for the proper interference ﬁt.

2. Measure cylinder head bore and outside diameter of selected oversize guide to verify correct interference ﬁt.

3. Obtain the CYLINDER HEAD SUPPORT STAND (HD39782A), VALVE GUIDE DRIVER (HD-34740) and VALVE GUIDE INSTALLER SLEEVE (HD-34731). Proceed as follows:

a. Insert sleeve of intake or exhaust seat adapter into

tube at top of support stand. Position cylinder head so that valve seat is centered on seat adapter. Support stand ensures that valve guide and seat are perpendicular. If perpendicularity is not achieved, cylinder head valve guide bore will be damaged during the press procedure.

b. Apply Vaseline to lightly lubricate external surfaces

of valve guide. Spread lubricant so that thin ﬁlm cov-

ers entire surface area. c. At top of cylinder head, start valve guide into bore. d. Place installer sleeve over valve guide, and then

insert tapered end of valve guide driver into installer

sleeve. e. Center valve guide driver under ram of arbor press

and apply pressure only until valve guide is started

in bore and then back off ram slightly to allow guide

to center itself. See Figure 3-71.

CAUTION

Do not press out the valve guide from the bottom of the cylinder head. Carbon buildup on the combustion chamber side of the guide can deeply gouge the cylinder head bore diminishing the likelihood of achieving the proper interference ﬁt and possibly requiring replacement of the cylinder head casting.

2. At the top of the cylinder head, insert VALVE GUIDE DRIVER (HD-34740) into valve guide bore until stopped by shoulder.

3. Center valve guide driver under ram of arbor press. Apply pressure until valve guide drops free of cylinder head. Discard the valve guide. See Figure 3-69.

3-66 2004 Touring: Engine

CAUTION

Always back off ram to allow the valve guide to ﬁnd center. Pressing guide into cylinder head in one stroke can bend driver, break guide, distort cylinder head casting and/or damage cylinder head valve guide bore.

f. Verify that support stand and driver are square.

Center driver under ram and press valve guide further into bore, but then back off ram again to allow valve guide to ﬁnd center.

g. Repeat step 3f and then apply pressure to driver

until installer sleeve contacts machined area of cylinder head.

4. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

39786) and proceed as follows:

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CAUTION

Valve Guide

Reamer

T- Handle

Figure 3-72. Valve Guide Reamer (Part No. HD-39932) and

Reamer T-Handle (Part No. HD-39847)

f1659x3x

Valve Guide

Reamer

T- Handle

Figure 3-73. Ream Valve Guide Bore

a. Thread the 12mm end of the tool into the spark plug

hole of the cylinder head.

b. Clamp tool in vise at a 45 degree angle (or one that

offers a comfortable working position).

NOTE

Valve guides must be reamed to within 0.0005 - 0.0001 inch (0.013 - 0.0025 mm) of ﬁnished size.

c. Placing thumb on dr

ive socket of reamer T-handle, apply slight pressure on reamer while rotating in a clockwise direction. See Figure 3-73. Squirt additional lubricant onto reamer and into guide as necessary.

For best results, do not push on reamer or apply pressure to the reamer handle. While excessive pressure results in a rough cut, bore will be tapered if pressure is not centrally applied.

d. Continue rotating reamer T-handle until entire bit

has passed through valve guide bore and shank of reamer rotates freely.

Never back reamer out of valve guide or bore will be damaged.

e. Remove T-handle from reamer, and carefully pulling

on bit, draw shaft of reamer out combustion chamber side of valve guide.

Abrasive particles can damage machined surfaces and plug oil passageways possibly resulting in engine failure.

6. Direct compressed air into the valve guide bore to remove any metal shavings or debris.

7. Clean valve guide bore with the VALVE GUIDE CLEANING BRUSH (HD-34751).

8. Obtain the VALVE GUIDE HONE (HD-34723) 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 valve guide bore. c. Start ﬁnishing stones of hone into bore. d. Activating the drill, move the entire length of the ﬁn-

ishing stone arrangement forward and backward

through the bore for 10 to 12 complete strokes. See

Figure 3-75. Work for a crosshatch pattern of

approximately 60˚.

5. Obtain the VALVE GUIDE REAMER (HD-39932), REAMER T-HANDLE (HD-39847) and REAMER LUBRICANT (HD-39964). Proceed as follows:

a. Install T-handle on reamer.

b. Apply a liberal amount of reamer lubricant to valve

guide bore and bit of reamer. Start bit of reamer into bore at top of cylinder head.

Abrasive particles can damage machined surfaces and plug oil passageways possibly resulting in engine failure.

9. Direct compressed air into the valve guide bore to remove any debris and then clean with the VALVE GUIDE CLEANING BRUSH (HD-34751). See Figure 3-

77.

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Figure 3-74. Valve Guide Hone (Part No. HD-34723)

bore with the type of swabs or patches found in gun cleaning kits. Continue to wipe bore until clean cloth shows no evidence of dirt or debris. Follow up with a thorough wash in hot soapy water. Blow dry with compressed air.

VALVE AND SEAT REFACING

NOTE

Verify correct valve stem to valve guide clearance before refacing. See Ta bl e 3-6. If new guides must be installed, complete that task before refacing valves and seats.

f1661x3x

Figure 3-75. Hone Valve Guide Bore

NOTE

Always verify valve stem to valve guide clearance after honing, since a worn reamer may cut the bore undersize.

10. Measure the inside diameter of the valve guide with an inside ball micrometer. Measure the outside diameter of the valve stem with an outside micrometer. The valve stem may be excessively worn or the valve guide bore undercut if the clearance is not within the limits (low end preferable) shown in Tab l e 3-6.

1. Hold the valve ﬁrmly against a wire wheel in a bench grinder. Remove all carbon deposits from the valve head, face and stem, but exercise caution to avoid removing any metal. Carbon left on the stem may affect alignment in the valve refacer. Polish the valve stem with steel wool or crocus cloth to remove any marks that might be left by the wire wheel.

Figure 3-76. Valve Guide Brush (Part No. HD-34751)

f1660x3x

Table 3-6. New Parts Limits

Valve Valve Stem to Guide Clearance

Intake 0.0008 - 0.0026 inch (0.020-0.066 mm)

Exhaust 0.0015 - 0.0033 inch (0.038-0.084 mm)

11. Using cleaning solvent, thoroughly clean cylinder head and valve guide bore. Scrub valve guide bore with the VALVE GUIDE CLEANING BRUSH (HD-34751). For best results, use a thin engine oil and clean valve guide

3-68 2004 Touring: Engine

Figure 3-77. Scrub Valve Guide Bore

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CAUTION

a. Thread the 12mm end of the tool into the spark plug

f1662x3x

hole of the cylinder head.

b. Clamp tool in vise at a 45 degree angle (or one that

offers a comfortable working position).

Dial Vernier

Caliper

4. Obtain the NEWAY VALVE SEAT CUTTER SET (HD-

35758A) and cut valve seat angle to 46°.

NOTE

Do not remove any more metal than is necessary to clean up the seat (that is, to provide a uniform ﬁnish and remove pitting).

5. From the bottom of the cylinder head, insert the valve stem into the valve guide. Push on bottom of valve until it contacts the valve seat.

6. Placing ﬁnger at bottom of valve to keep valve seated, use a dial vernier caliper to check the distance from the top of the valve stem to the machined area on the cylinder head. See Figure 3-78.

Seat wear and valve refacing causes the valve stem protrusion to change. If valve stem protrusion exceeds

2.034 inches (51.66 mm), but is less than 2.064 inches (52.43 mm), obtain the short service replacement valve. Service replacement valves are 0.030 inch (0.76 mm) shorter than the standard valve.

If protrusion exceeds 2.064 inches (52.43 mm), then use the existing valve, but replace the valve seat.

f1663x3x

Figure 3-78. Measure Valve Stem Protrusion

2. Install valve (both intake and exhaust) in a valve refacer set to a 45 degree angle. The valve refacer is required equipment, since accuracy in matching the angle of the valve face with the angle of the valve seat is critical.

Do not remove any more metal than is necessary to clean up and true the valve face. Removing metal reduces the service life of the valve. The amount of grinding needed to retrue the valve is a clear indication of its condition. Discard the valve if it cannot be quickly refaced while maintaining a good margin. Valves that do not clean up quickly are either warped, excessively worn or too deeply pitted to be used.

Obtain a new valve if grinding leaves the margin less than 0.0313 inch (0.795 mm). A valve in this condition does not seat normally, burns easily and may crack or cause pre-ignition.

3. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

39786) and proceed as follows:

Do not shorten the valve by grinding on the end of the stem. Grinding replaces the hardened case with mild steel which results in accelerated wear.

7. Remove valve from cylinder head. Apply magic marker or similar product to valve seat and allow to thoroughly dry.

8. Insert the valve stem into the valve guide. Push on bottom of valve until it contacts the valve seat.

9. Obtain the VALVE LAPPING TOOL (HD-96550-36A) and proceed as follows:

a. Attach suction cup at end of tool to valve head. b. Holding shank of tool between the palms of both

hands, oscillate the tool back and forth a few times. See Figure 3-80.

10. Remove the valve from the cylinder head and carefully inspect the mating surfaces under a good light.

Inspection of the valve seat should show an unbroken contact area of uniform width. If the seat is not concentric with the valve guide, then the cutter will remove more material in one spot than another. Carbon deposits may have caused the guide to be pressed in crooked, the guide may be cracked, or the cutter blade or cutter pilot have not have been properly cleaned.

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f1655x3x

Head

Figure 3-79. Valve Lapping Tool (Part No. HD-96550-36A)

6873

Valve Lapping

Tool

Figure 3-80. Oscillate Tool to Create Contact Area

NOTE If the results are not acceptable, then recut the valve seat or replace the valve guide.

11. Inspect the contact pattern on the valve seat to be sure

area is 0.040-0.062 inch (1.02-1.57 mm) wide and contacts the valve two-thirds of the way towards the outer edge of the valve face. See Figure 3-81. If necessary, modify the seat pattern as follows:

a. Use the 31° angle cutter to lower the valve seat sur-

face and reduce its width.

b. Use the 60° angle cutter to raise the valve seat sur-

face and reduce its width.

c. Use the 46° angle cutter to widen the valve seat sur-

face.

12. Using a magic marker, mark three equally spaced verti-

cal lines across the valve face and then insert the valve back into the cylinder head.

13. Attach suction cup of VALVE LAPPING TOOL (HD-

96550-36A) to valve head, and holding shank of tool between the palms of both hands, oscillate the tool back and forth a few times.

0.040-0.062 in.

(1.02-1.57 mm)

Seat

60˚

Valve

31˚

46˚ Cutting 45˚ Grinding

Margin

0.0313 in.

(0.795 mm)

Figure 3-81. Valve Seat Angles

14. Remove the valve and perform a ﬁnal inspection of the contact pattern. If necessary, return to step 11.

15. Remove the valve from the cylinder head. Use contact cleaner to thoroughly clean magic marker and/or dye from valve face and seat, if present.

16. Release the cylinder head holding ﬁxture from the vise and then remove the tool from the spark plug hole.

17. To conﬁrm quality of valve and seat refacing work, proceed as follows:

a. Insert valve in guide, and holding valve to seat,

raise port to strong light source. If light is visible around edge of seat, then valves and seats must be reconditioned.

b. Holding valve to seat, ﬁll port at top of cylinder head

with solvent. Wait ten full seconds and then check for leakage into combustion chamber. If solvent leakage into combustion chamber is evident, then valves and seats must be reconditioned.

18. Clean valves, cylinder head and valve seats in solvent. Follow up with a thorough wash in hot soapy water. Blow dry with compressed air.

Assembly

1. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

39786) and proceed as follows:

a. Thread the 12mm end of the tool into the spark plug

hole of the cylinder head.

b. Clamp tool in vise at a 45 degree angle (or one that

offers a comfortable working position).

2. Slide spring seat over valve guide until it contacts the machined area on the cylinder head casting. Use a little grease to hold the spring seat in position, if necessary.

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f1665x3x

f1664x3x

f1666x3x

Plastic

Capsule

Spring

Seat

Plastic

Capsule

Valve Stem Seal

Install plastic capsule.

Install valve stem seal.

Tap installer to seat valve stem seal.

Valve Stem

Seal Installer

At the time of disassembly, all parts should have been marked or tagged so that they are installed on the same valve (and in the same head).

3. Run the VALVE GUIDE CLEANING BRUSH (HD-34751) through the valve guide bore to verify cleanliness.

4. Using TORCO MPZ or another suitable product, apply a liberal amount of engine assembly lube to valve stem.

5. From the bottom of the cylinder head, insert the valve stem into the valve guide.

6. To distribute the assembly lube evenly around the valve stem and guide, hand spin the valve as it is installed. Work the valve back and forth in the bore to verify that it slides smoothly and seats properly.

7. Remove the valve and apply a second coat of assembly lube to the valve stem. Install the valve in the valve guide.

8. Retract the valve so that the stem is not visible above the top of the valve guide.

9. Using isopropyl alcohol or other suitable degreaser, thoroughly clean external surface of valve guide until completely free of grease and oil.

Figure 3-82. Valve Stem Seal Installer

(Part No. HD-34643A)

NOTE

Do not apply Loctite to inside of valve stem seal or top of valve guide or valve may stick to seal resulting in loss of compression and valve sticking.

10. Obtain tube of Loctite RC/620 (green) High Temperature Retaining Compound. Carefully apply Loctite to valve stem seal seating surface on outside diameter of valve guide. Exercise caution to keep compound out of valve guide bore.

Failure to install plastic capsule will cause the valve stem seal to catch the edge of the valve stem keeper groove. The resulting damage will lead to leakage around the valve stem, excessive oil consumption and valve sticking.

CAUTION

Figure 3-83. Install Valve Stem Seal

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11. Push on bottom of valve until it contacts the valve seat. Placing ﬁnger at bottom of valve to keep valve seated, slide plastic capsule over valve stem tip and keeper groove. See upper frame of Figure 3-83.

12. Apply a very thin ﬁlm of clean H-D 20W50 engine oil to capsule. Slide new valve stem seal over capsule and down valve stem until contact is made with top of valve guide. See center frame of Figure 3-83. Remove capsule from valve stem tip.

CAUTION

To avoid damaging the valve stem seal and/or cracking the valve guide, always use the proper valve stem seal installer tool. Use of an ordinary socket will damage the seal or guide, resulting in leakage around the valve stem, excessive oil consumption and valve sticking.

13. Obtain the VALVE STEM SEAL INSTALLER (HD34643A) and proceed as follows:

a. Slide the installer tool over the valve stem seal

using valve stem as pilot. The tool bore allows insertion of the valve stem, while the counterbore ﬁts over the valve stem seal.

CAUTION

f1654x3x

Valve Guide

Driver

Valve Stem

Seal Installer

Valve Stem

Seal

Valve

Repeated blows on installer after seal is in place will cause seal distortion resulting in leakage around the valve stem, excessive oil consumption and valve sticking.

b. Using a small hammer, gently tap the end of the tool

until it lightly bottoms on the installed spring seat. See lower frame of Figure 3-83. For best results, brace the cylinder head with chest area to prevent movement during seal installation.

NOTE If an arbor press is the preferred method of valve stem seal installation, use the VALVE STEM SEAL INSTALLER (HD34643A) with the VALVE GUIDE DRIVER (HD-34740). See

Figure 3-84.

CAUTION

Removing the valve after seal installation will cause the valve stem seal to catch the edge of the valve stem keeper groove. The resulting damage will lead to leakage around the valve stem, excessive oil consumption and valve sticking.

14. Apply a liberal amount of assembly lube to valve stem tip

and keeper groove.

15. Install the inner and outer valve springs over the valve

guide. Fit the spring retainer on top of the inner and outer valves springs. Like the spring seat, the smaller diameter ﬂange ﬁts inside the inner valve spring. The larger diameter ﬂange separates the inner and outer springs.

Valve

Seat

Figure 3-84. Using Arbor Press to Install Valve Stem Seal

16. Obtain the VALVE SPRING COMPRESSOR (HD34736B) and proceed as follows:

a. Place tool over cylinder head so that the blunt end is

centered on the valve head and adapter at end of forcing screw is seated on the valve spring retainer.

CAUTION

Over-compressing the valve spring can damage the valve stem seal resulting in leakage around the valve stem, excessive oil consumption and valve sticking.

b. Rotate forcing screw to compress valve springs.

c. With the tapered side down, ﬁt the keepers into the

valve stem groove. For best results, apply a dab of grease to the inboard side of the keepers before installation and use a magnetic rod for easy placement.

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d. Arranging tapered keepers so that the gaps are

evenly spaced, turn forcing screw to release valve spring compression.

17. Tap the end of the valve stem once or twice with a soft mallet to ensure that tapered keepers are tightly seated in the valve stem groove.

18. Repeat steps 1-17 to install the other valve components.

19. Release the cylinder head holding ﬁxture from the vise and then remove the tool from the spark plug hole.

20. Cover the cylinder head to protect it from dust and dirt until time of installation.

Installation

See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps 14-24 and 29-39.

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CYLINDER

Removal

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11 and 15-24.

Cleaning and Inspection

CLEANING

1. Scrape old gasket material from the machined surface at the top of the cylinder. Old gasket material left on the mating surface will cause leaks.

2. Clean cylinder in a non-volatile cleaning solution or solvent. Thoroughly dry with low pressure compressed air. Verify that oil passageways are clean and open.

3. Inspect the cylinder bore for defects or damage in the ring travel area. Replace cylinders that are severely scored, scuffed, scratched, burnt or gouged.

4. Using Magnaﬂux Dye Penetrant, inspect the cylinder for cracks. If no cracks are found, thoroughly wash cylinder to remove traces of dye.

5. Use a ﬁle to carefully remove any nicks or burrs from the machined surfaces of the cylinder.

6. Using a feeler gauge and the CYLINDER TORQUE PLATES (HD-42324A), check the machined surfaces for ﬂatness. Proceed as follows:

a. Lay gasket side of the upper plate (without vise grip)

ﬂat against the head gasket surface.

b. As a preliminary check, see if the plate rocks from

side to side. A cylinder on which the plate rocks is immediately suspect.

c. Insert a feeler gauge between the plate and cylinder

at various locations.

d. The head gasket surface must be ﬂat within 0.006

inch (0.15 mm).

e. Now turn the cylinder upside down and lay the seal

side of the lower plate (with vise grip) ﬂat against the O-ring seal surface. Repeat steps 6(b) and 6(c).

f. The O-ring seal surface must be ﬂat within 0.004

inch (0.102 mm).

g. Replace the cylinder (and piston) if either surface is

not within speciﬁcation.

Figure 3-85. Cylinder Torque Plates

(Part No. HD-42324A)

Lower Plate

Bolts

(with Flat Washers)

Vise

f2075x3x

Upper Plate

INSPECTION

CAUTION

Failure to use the cylinder torque plates can produce measurements that vary by as much as 0.001 inch (0.025 mm), possibly resulting in the use of parts that are not suitable for service.

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Figure 3-86. Install Cylinder to Torque Plates

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CAUTION

f1686x3x

1. To simulate an assembled cylinder for accurately measuring cylinder taper and out-of-round conditions, as well as for boring, honing or deglazing, obtain the CYLINDER TORQUE PLATES (HD-42324A). Install the torque plates as follows:

a. Remove O-ring seal from cylinder sleeve, if

installed.

b. Place used head gasket over two ring dowels at top

of cylinder.

c. Install brass jaws or shop towels around teeth of

vise to prevent damage to tool. Clamp stepped side of lower plate in vise with the simulated split line (machined strip) facing away.

d. Slide four bolts (with ﬂat washers) all the way

through holes of lower plate until washers contact outboard side. See A of Figure 3-86.

e. Slide cylinder down bolts with the indent in the cool-

ing ﬁns facing upward.

f. With the head gasket in place, align holes in upper

plate with ends of bolts. Blind holes in upper plate accommodate ring dowels in cylinder. Alternately tighten four bolts into upper plate in a crosswise pattern until snug.

Figure 3-87. Measure for Out-of-Round and Taper

g. Tighten the bolts to 84-108 in-lbs (9.5-12.2 Nm) in

the sequence shown in B of Figure 3-86.

h. Following the same sequence, tighten each bolt to

12-14 ft-lbs (16.3-18.9 Nm).

i. Using a grease pencil, mark a straight line on one of

the bolts continuing the line over onto the lower plate. Repeat step for remaining three bolts. Using the marks as a guide, turn each bolt 1/4 turn or 90 degrees. Be sure to tighten the bolts in the sequence shown in B of Figure 3-86.

NOTE

For best results, obtain Snap-on® Torque Angle Gauge TA360.

j. For purposes of inspection, remove the assembly

from the vise and place on bench top.

2. See Figure 3-87. Using an inside micrometer or dial bore gauge, check cylinder bore for out-of round and taper. Proceed as follows:

a. At the top of the piston ring travel zone (starting

about 0.50 inch or 12.70 mm from the top of the cylinder), measure the cylinder diameter at two locations- parallel and perpendicular to the crankshaft. Write the readings down.

b. Repeat the two measurements at the center of the

piston ring travel zone.

c. Repeat the measurements again at the bottom of

the bore at a point below the piston ring travel zone.

d. Rebore the cylinder if the parallel and perpen-

dicular measurements at either the top, middle or bottom of the bore vary by more than 0.002 inch (0.051 mm), which indicates an out-of-round condition.

Rebore the cylinder if the top, middle and bottom bore diameters either parallel or perpendicular to the crankshaft vary by more than 0.002 inch (0.051 mm), which indicates excessive taper.

Maximum cylinder wear occurs at the very top of top ring travel. Minimum wear occurs below ring travel. Failure to measure the cylinder at these points may result in a faulty decision regarding the suitability of the cylinder for continued use.

3. If cylinders are not scuffed or scored, and are not worn beyond the service limits described under step 2(d), see

DEGLAZING CYLINDER on the next page.

On the other hand, if cylinders are worn beyond the service limits, then they must be rebored and/or honed to accept the next standard oversize piston. See BORING

AND HONING CYLINDER on the next page.

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DEGLAZING CYLINDER

NOTE

Deglazing removes wear patterns, minor scuff marks and scratches without enlarging the bore diameter.

1. Lightly swab the cylinder bore with a cloth dipped in clean engine oil.

2. Obtain a 240 grit ﬂexible ball-type deglazing tool with a bristle tip or ﬁnishing stone arrangement able to produce a 60˚ cross hatch pattern.

3. Install the deglazing tool in a slow-speed drill. The speed at which the tool rotates determines the speed at which it must be stroked up and down the bore to produce the desired cross hatch pattern.

4. Starting at the bottom of the cylinder, move the deglazing tool up and down the entire length of the cylinder bore for 10 to 12 complete strokes.

5. Stop to examine the cylinder bore and/or take measurements. A precise 60˚ cross hatch pattern in the piston travel area is the most important.

CAUTION

The angular cross hatch pattern ensures an even ﬂow of oil onto the cylinder walls and promotes longer cylinder, piston and ring life. An Improper crosshatch pattern will result in insufﬁcient oil retention and possible piston seizure and/or high oil consumption.

CAUTION

Failure to remove all abrasive particles may result in premature cylinder, piston and ring wear and possible engine failure.

6. Thoroughly wash the cylinder bore with liquid dishwashing soap and warm water to remove all abrasive particles and residual grit. Continue cleaning until a clean cloth shows no evidence or dirt or debris.

7. Hot rinse the cylinder and dry with moisture free compressed air. Immediately apply a thin ﬁlm of clean engine oil to prevent rusting.

8. With the cylinder at room temperature, check the piston clearance in the cylinder in which the piston will run. See

PISTON, INSPECTION, step 5.

2. Hone the cylinder to its ﬁnished size using a 280 grit rigid hone.

3. 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.

4. Thoroughly wash the cylinder bore with liquid dishwashing soap and warm water to remove all abrasive particles and residual grit. Continue cleaning until a clean cloth shows no evidence or dirt or debris.

Table 3-7. Oversize Pistons

Piston

Standard

0.005 In. (0.13 mm)

Oversize

0.010 In. (0.25 mm)

Oversize

Example: A 0.005 in. (0.13 mm) oversize piston will have the proper running clearance with a cylinder bore size of

3.7550 - 3.7555 in. (95.377 - 95.390 mm).

5. Hot rinse the cylinder and dry with moisture free compressed air. Immediately apply a thin ﬁlm of clean engine oil to prevent rusting.

6. With the cylinder at room temperature, check the piston clearance in the cylinder in which the piston will run. See

PISTON, INSPECTION, step 5.

Cylinder Bore Finished Size

3.7500 - 3.7505 in.

(95.250 - 95.263 mm)

3.7550 - 3.7555 in.

(95.377 - 95.390 mm)

3.7600 - 3.7605 in.

(95.504 - 95.517 mm)

Installation

1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps 8-24 and 29-39.

BORING AND HONING CYLINDER

1. Bore the cylinder to 0.003 inch (0.08 mm) under the desired ﬁnished size. See Ta bl e 3-7.

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.

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