Harley Davidson Touring 2004 Service Manual sm03b

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CAUTION

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TOP END OVERHAUL 3.9

DISASSEMBLY

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

NOTE

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

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

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

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

NOTE

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

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

5. Collapse upper and lower push rod covers.

6. To remove the rocker arm support plate,

Figure 3-21. Remove Spring Cap Retainer

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

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

both

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

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

Internal Hex

3/16 Inch Allen Wrench

External Hex

7/16 Inch Open End Wrench

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

Captive Washer

Lock Patch

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

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

a. With pr

b. With pr

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

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

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Loosen Six Rocker Cover Bolts.

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Breather

Assembly

FRONT

REAR

Remove Two Breather Assembly Bolts.

Alternately Loosen Four Rocker Arm Bolts

1/4 Turn in Pattern Shown.

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O-Ring

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FRONT

REAR

Loosen Six Rocker Housing Bolts.

Alternately Loosen Four Cylinder Head

Bolts 1/4 Turn in Pattern Shown.

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)

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Slot

Figure 3-25. Remove Piston Pin Circlip

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

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

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

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

b. Squeeze the handles of the tool together and pull

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

NOTE

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

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

3-26. Proceed as follows:

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

acorn nut to end of rod.

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

of pin bore.

d. Turn handle in a clockwise direction until piston pin

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

piston pin circlips during

CAUTION

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

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

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

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

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

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

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

Spacer and

Acorn Nut

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Rubber Coated Tip

Figure 3-27. Remove Piston Pin

Handle

ASSEMBLY

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

7. Install

new

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

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

Lightly squeeze handles of tool to capture circlip in claw.

b. Releasing pressure on handles, rotate circlip so that

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

c. Tilt the circlip forward until the end gap contacts

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

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

aligned with slot in piston.

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

bottoms. Release handles and remove tool.

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

the groove.

NOTE

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

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

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

3. Remove water pipe insulation from rod shank.

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

O-rings that are missing, distorted, pinched or otherwise damaged will result in either oil leakage or low oil pressure. Use of the wrong O-ring will have the same results. Since many O-rings are similar in size and appearance, always use ne use to avoid confusion.

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

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

w O-rings keeping them packaged until

new

O-ring over “downside” cylinder deck ring

new

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

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Circlip

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

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

c. Rotate engine until piston skirt is centered and

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

30.

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

96333-51C).

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

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

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

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

Figure 3-28. Install Piston Pin Circlip

NOTE

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

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

SERVICE AND REPAIR, PISTON.

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

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

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

a. Slide both adjustable knobs on tool down slots away

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

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

Piston

Support Plate

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Figure 3-30. Install Piston Support Plate

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CAUTION

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Threaded

Cylinder

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

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

NOTE

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

Figure 3-31. Piston Ring Compressor

(Part No. HD-96333-51C)

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Ring Compressor Band

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

Part No. HD-96333-103

Pliers

Figure 3-32. Install Cylinder

d. Note that the cylinders should have been marked

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

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

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

32.

f. Rotate the engine slightly to raise piston off support

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

g. Remove shop towels from around the crankcase

bore exercising caution to keep out any dirt or debris.

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

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

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

Figure 3-33. Install Threaded Cylinders to Studs

(Part No. HD-95952-1)

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S= Short Bolt

FRONT

L= Long Bolt

REAR

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

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

19. Tighten the four cylinder head bolts as follows:

CAUTION

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

a. Alternately turn each cylinder head bolt until ﬁnger

tight.

b. Tighten the cylinder head bolts to 120-144

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

ure 3-34.

c. Following the same sequence, tighten each bolt to

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

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

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

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

sequence shown in A of Figure 3-34.

in-lbs

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Figure 3-34. Cylinder Head Torque Sequence

and Bolt Size

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NOTE

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

20. Install a ﬂange.

Even though all bolt holes (rocker housing, rocker arm support plate and breather assembly) may appear to be in alignment, the rocker housing gasket may be installed upside down. An upside down gasket will result in an open breather channel causing an oil leak when the vehicle is started, possibly resulting in engine and/or property damage.

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

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

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

new

rocker housing gasket on the cylinder head

CAUTION

in-lbs

(13.6-18.9

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

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Install Six Rocker Housing Bolts.

Tor que: 120-168 in-lbs

FRONT

REAR

O-Ring

Breather Channel Concealed Breather Channel Exposed

CORRECT WRONG

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

NOTE Rocker housing and rocker cover bolts have both an internal and external hex, which allows the bolts to be installed with either a short 3/16 inch allen wrench (tight spaces), or a 7/16 inch socket or open end/box wrench (open spaces). If the engine is left in the chassis for service, the short 3/16 inch allen wrench is indispensable when installing the rocker housing and rocker cover bolts on the left side of the engine (particularly the rear) where there is close proximity to the frame.

NOTE If the engine was left in the chassis for service, ﬁnal tighten the rear left rocker housing bolt (rear cylinder) using a torque wrench with a 1/4 inch drive. Since this tool may not be available in foot-pounds, tighten the bolt to 120-168

f1577x3x f1576x3x

in-lbs

w O-rings keeping them packaged until

use to avoid confusion.

24. Install

new

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

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

CAUTION

Figure 3-36. Rocker Housing Torque Sequence

and Bolt Size

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Lifter Cover

Anti-Rotation

not

install the spring cap retainers at this time. To

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

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

Ribs

Gasket

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Figure 3-37. Install Lifters and Lock Position

With Anti-Rotation Pin

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

27. Install a

new

lifter cover gasket aligning the holes in the

gasket with those in the cover.

CAUTION

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

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

in-lbs

(10.2-13.6 Nm) in

a crosswise pattern.

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

Table 3-3. Push Rod/Cover Locations

Cylinder

Front

Rear

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

Cover and

Push Rod*

Intake Inside Rear

Exhaust Outside Front

Intake Inside Front

Exhaust Outside Rear

Lifter Cover

Bore

Cylinder Head/

Rocker Housing

Bore

31. To install the rocker arm support plate,

both

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

CAUTION

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

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

a. With pr

b. With pr

CAUTION

c. With engine mounted in engine stand

d. Finding the base circle

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

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Rocker Arm Torque:

18-22 ft-lbs

Breather

Assembly

Tor que: 90-120 in-lbs

FRONT

REAR

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Tor que: 15-18 ft-lbs

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

Alternately Tighten Four Rocker Arm Bolts

Install Six Rocker Cover Bolts.

1/4 Turn in Pattern Shown.

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

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

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

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

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

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

in-lbs

(10.2-13.6 Nm).

NOTE

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

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Figure 3-39. Install Spring Cap Retainer

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

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

NOTE

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

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

3.6 ASSEMBLING MOTORCYCLE AFTER STRIPPING.

If engine was removed for service, see Section 3.8

INSTALLING ENGINE IN CHASSIS.

NOTE

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

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

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

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

cylinder head bore leaving the bottom edge free.

c. Insert blade of small screwdriver between bottom

edge of spring cap retainer and top of spring cap.

d. While simultaneously depressing spring cap with tip

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

NOTE

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

e. Verify that spring cap retainer is seated tightly

against upper push rod cover.

38. Install a

new

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

3-44 2004 Touring: Engine

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BOTTOM END OVERHAUL 3.10

DISASSEMBLY

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY. If only servicing cam compartment components,

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

NOTE

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

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

Flange Bolt and

Right

Crankcase Half

Flat Washer

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

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

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

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

Cleaning

Plug

Camshaft

Front

Primary Cam

Sprocket

Primary

Cam Chain

Primary Cam Chain

Tensioner

Oil Pressure

Relief Valve

Flange Bolt and

Flat Washer

Figure 3-40. Cam Support Plate Assembly

Michalski

Chain Guide

Crank

Sprocket

f2141x3x

2004 Touring: Engine 3-45

HOM

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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