Harley Davidson Touring 2004 Service Manual sm03b

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CAUTION
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TOP END OVERHAUL 3.9

DISASSEMBLY

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
f1570x3x
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.
2004 Touring: Engine 3-33
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A
5
1
3
3
1
5
Loosen Six Rocker Cover Bolts.
4
6
3
1
2
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Breather
Assembly
FRONT
6
2
4
4
2
2
REAR
4
B
1
Remove Two Breather Assembly Bolts.
Alternately Loosen Four Rocker Arm Bolts
1/4 Turn in Pattern Shown.
3
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2
6
4
O-Ring
2
4
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FRONT
1
3
3
3
5
5
1
1
1
3
REAR
2
2
Loosen Six Rocker Housing Bolts.
CD
6
4
Alternately Loosen Four Cylinder Head
Bolts 1/4 Turn in Pattern Shown.
4
3-34 2004 Touring: Engine
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)
f1635x3x
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.
3-36 2004 Touring: Engine
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
CAUTION
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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
f1640x3x
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
f1612x3x
Figure 3-30. Install Piston Support Plate
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CAUTION
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Threaded
Cylinder
E
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)
f1613x3x
Ring Compressor Band
(3-5/8 - 3-7/8 Inches)
Part No. HD-96333-103
B
OT
TO
M
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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A
S
S= Short Bolt
FRONT
L= Long Bolt
L
S
4
2
1
S
REAR
3
L
L
3
1
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
2
S
4
L
B
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Figure 3-34. Cylinder Head Torque Sequence
and Bolt Size
f2166x3x
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.
2
4
3
1
6
5
3
1
2
4
5
6
f2165x3x
Install Six Rocker Housing Bolts.
Tor que: 120-168 in-lbs
L
I
L
L
L
I
I
I
I
I
I
I
FRONT
REAR
O-Ring
E
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
.
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
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
Pin
Do
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
f1606x3x
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
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 31(d) to find the base circle.
b. With pr
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 31(d) to find the base circle.
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 31(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
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f2163x3x
Rocker Arm Torque:
18-22 ft-lbs
1
4
4
3
Breather
Assembly
Tor que: 90-120 in-lbs
FRONT
2
2
REAR
f2164x3x
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.
5
S
1
S
3
S
3
S
1
S
4
L
2
L
6
L
6
L
2
L
1
AB
Alternately Tighten Four Rocker Arm Bolts
3
5
S
Install Six Rocker Cover Bolts.
4
L
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
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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
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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
1
5
7
4
8
2
3
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
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.
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
9
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).
6
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
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CAUTION
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Rear
Camshaft
Front
Camshaft
Pin Stamped
Timing Lines
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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
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
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
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
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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3
6
2
5
4
2
4
1
1
CAM SUPPORT PLATE OIL PUMP
AB
Figure 3-50. Cam Support Plate/Oil Pump Torque Sequence
f1581b3x
3
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
in-lbs
(10.2-
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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)
t
-
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
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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.
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CAUTION
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Tor que: 125-155 in-lbs
1
9
26. Hold the retracted primary cam chain tensioner with the
7
6
4
10
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.
5
3
Figure 3-55. Cam Cover Torque Sequence
2
f1616b3x
28. Align holes in crankcase flange.
8
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
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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
23
14
15
24. Upper Push Rod Cover
25. Spring Cap Retainer
2
1
3
5
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
4
7
6
14
12
9
8
11
10
13
12
19
37
25
32
27
29
24
35
26
28
16
30
17
18
20
16
21
22
31
33
34
36
Figure 3-56. Rocker Arm/Breather/Lifter Assemblies (Exploded View)
3-54 2004 Touring: Engine
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1. Bolt
2. Breather Cover
3. Cover Gasket
4. Umbrella Valve
5. Breather Baffle
6. Filter Element
7. Breather Baffle Gasket
1
2
3
4 5
6
7
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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
3-56 2004 Touring: Engine
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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.
E
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
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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
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.
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
10
1
2
3
8
4
5
9
6
7
11
20
22
24
19
21
23
23
13
12
15
14
20
18
16
17
Figure 3-62. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)
3-62 2004 Touring: Engine
f21332x3x
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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.
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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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Valve Guide
Driver
Cylinder Head
Support Stand
Ram
E
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
CAUTION
CAUTION
CAUTION
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Valve Guide
Reamer
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
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
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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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
E
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
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
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.
A
B
Figure 3-85. Cylinder Torque Plates
(Part No. HD-42324A)
Lower Plate
3
4
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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1
Figure 3-86. Install Cylinder to Torque Plates
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CAUTION
f1686x3x
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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.
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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