Harley Davidson 2008 Touring Models. Service Manual — page 21
3.16
TOP END OVERHAUL: ASSEMBLY
GENERAL
NOTES
•
It is assumed that each step performed on one cylinder is
automatically repeated on the other.
•
Do not mix 2007 and later pistons with earlier style pistons.
New style pistons have tapered wrist pin boss. The wrist
pin portion of the connecting rod is also tapered.
This section provides a sequential process for engine reas-
sembly after a complete
. If you reached this section after an inspection or
repair procedure, start where necessary and continue to the
end of the section.
•
Piston installation-see
•
•
Cylinder head installation-see
•
Push rods, lifters and covers installation-see
END OVERHAUL: ASSEMBLY, Push Rods, Lifters and
Covers
•
Rocker arm support plate installation-see
OVERHAUL: DISASSEMBLY, Rocker Arm Support Plate
.
•
Breather assembly installation-see
OVERHAUL: ASSEMBLY, Breather Assembly
PISTON
TOOL NAME
PART NUMBER
PISTON PIN CIRCLIP
REMOVER/INSTALLER
HD-42317-A
1.
Slide approximately 6.0 in. (152 mm) of plastic tubing,
rubber hose or conduit over each cylinder stud, if removed.
Use material with I.D. of 0.5 in. (12.7 mm) to protect cyl-
inder 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 connecting rod shank.
4.
See
. Place piston over rod end so that the
arrow stamped at the top of the piston points toward the
front of the engine.
5.
. Insert piston pin (1) through pin bore and
upper connecting rod bushing. Push pin until it contacts
circlip installed in opposite pin boss. Verify that end gap
(3) for circlip is 180 degrees from opening (2).
6.
Place clean shop towels over the cylinder and lifter bores
to prevent the piston pin circlip from falling into the crank-
case. Verify that the circlip groove is clean and free of dirt
and grime.
sm02379
Figure 3-25. Piston Installation Arrow
2
3
1
sm02380
1.
Piston pin
2.
Circlip opening
3.
End gap location
Figure 3-26. Preinstalled Circlip
NOTE
Do not reuse piston pin circlips. The circlips could weaken
during removal causing them to break or dislodge during engine
operation, a condition that will result in engine damage.
2008 Touring Service: Engine 3-33
7.
Install new piston pin circlip with the PISTON PIN CIRCLIP
REMOVER/INSTALLER (Part No. HD-42317-A).
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.
d.
See
. Insert the tool (1) into the piston pin
bore until claw is aligned with slot (2) 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.
sm02339
Figure 3-27. Aligning Circlip
1
2
3
sm02341
1.
Piston pin circlip remover/installer
2.
Slot
3.
Cylinder deck dowel (O-ring not shown)
Figure 3-28. Pin Circlip Remover/Installer (Part No.
HD-42317)
CYLINDER
TOOL NAME
PART NUMBER
PISTON SUPPORT PLATE
HD-42322
THREADED CYLINDERS
HD-95952-1
CONNECTING ROD CLAMPING TOOL
HD-95952-33C
PISTON RING COMPRESSOR
HD-96333-51E
NOTE
O-rings that are missing, distorted, pinched or otherwise dam-
aged 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 new o-rings,
keeping them packaged until use to avoid confusion.
1.
. Apply a very thin film of clean H-D 20W50
engine oil to new o-rings for both lower cylinder deck
dowels. Install and verify that o-ring is properly seated in
groove.
2.
. Apply a very thin film of clean H-D 20W50
engine oil to new o-ring seal for the bottom of the cylinder
liner. Install new o-ring seal.
NOTE
Excessive lubrication of cylinder sleeve o-ring seal will result
in oil weepage between cylinder and crankcase as engine is
run. This condition may be incorrectly diagnosed as an oil leak.
3.
See
. Verify that the piston ring end gaps are
staggered. Rotate each ring to position the gap 90 to 180
degrees from the gap in the ring above it. Locate the top
piston ring (5) gap towards the intake port.
4.
Apply clean H-D 20W50 engine oil to piston, piston rings
and cylinder bore.
5.
Remove protective covers from cylinder studs. Rotate
engine until piston is at top dead center. If necessary, see
3.15 TOP END OVERHAUL: DISASSEMBLY, Rocker Arm
Support Plate
for three methods of engine rotation.
6.
See
. Install the PISTON SUPPORT
PLATE (Part No. HD-42322).
a.
Slide both adjustable knobs (2) on support plate (1)
down away from forked end. Tighten knobs when
contact is made with flats at end of slots.
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.
3-34 2008 Touring Service: Engine
7.
. Install cylinder using PISTON RING
COMPRESSOR (Part No. HD-96333-51E).
a.
Fit tabs on pliers (1) into slots of ring compressor band
(2). 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.
b.
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 ratcheting action of the tool allows
release of the handles after the rings are compressed.
c.
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.
d.
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.
e.
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
8.
Remove shop towels from around the crankcase bore
exercising caution to keep out any dirt or debris.
9.
Carefully set the cylinder over the two dowel pins 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 (Part
No. HD-95952-1) from CONNECTING ROD CLAMPING
TOOL (Part No. HD-95952-33C) 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.
sm02342
Figure 3-29. O-ring Seal For Cylinder
3
4
2
1
1
2
4
3
5
5
6
7
sm02182
1.
Expander spring
2.
Bottom oil rail
3.
Top oil rail
4.
Second compression ring
5.
Top compression ring
6.
Front
7.
Rear
Figure 3-30. Piston Ring Alignment
2008 Touring Service: Engine 3-35
1
2
3
sm02343
1.
Support plate
2.
Knobs
3.
Screw
Figure 3-31. Piston Support Plate
BOT
TO
M
1
2
2
1
sm02344
1.
Pliers
2.
Compressor band
Figure 3-32. Piston Ring Compressor
sm02345
Figure 3-33. Install Threaded Cylinders to Studs
CYLINDER HEAD
1.
. With the part number topside, place the
head gasket over the two dowel pins in the upper flange
of the cylinder.
2.
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,
gently slide cylinder head over the two cylinder flange
dowel pins. Lower the cylinder head at an angle that
closely approximates the angle of the crankcase to avoid
damage to machined surfaces or the dowel pins.
NOTE
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.
3.
Lightly coat the threads and bottom face of the cylinder
head bolts in clean H-D 20W50 engine oil. Wipe off any
excess oil.
4.
See
. Loosely install the cylinder head bolts
onto the cylinder studs. Place two short bolts on the left
side of the engine and two long bolts on the right.
2
1
sm02295
1.
Cylinder
2.
Dowel pin
Figure 3-34. Cylinder Dowel Pins
3-36 2008 Touring Service: Engine
3
4
2
1
4
3
1
2
sm02349
1.
Short bolt
2.
Short bolt
3.
Long bolt
4.
Long bolt
Figure 3-35. Cylinder Head Bolt Torque Sequence (Top:
Front Cylinder Head, Bottom: Rear Cylinder Head)
NOTE
Improperly tightened cylinder head bolts may result in gasket
leaks, stud failure and distortion of the cylinder and/or cylinder
head.
5.
Tighten the four cylinder head bolts.
a.
Following sequence shown, alternately turn each
cylinder head bolt until finger tight.
b.
Following the same sequence, tighten the cylinder
head bolts to 120-144 in-lbs (13.5-16.2 Nm).
c.
Continuing the same sequence, tighten each bolt to
15-17 ft-lbs (20.3-23.0 Nm).
d.
. Using a grease pencil, mark a
straight line on the cylinder head bolt continuing the
line over onto the cylinder head.
e.
Using the marks as a guide, turn each bolt 1/4 turn
or 90 degrees. Be sure to tighten the cylinder head
bolts in the sequence shown in
sm02395
Figure 3-36. Final Tightening for Cylinder Head Bolts
NOTES
•
For best results, use SNAP-ON TORQUE ANGLE GAUGE
TA360.
•
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 a major oil leak when the vehicle
is started, possibly resulting in engine and/or property
damage.
•
On front cylinder head, install side of gasket marked "front"
facing up. On rear cylinder head, install side of gasket
marked "rear" facing up.
6.
. Install a new rocker housing gasket on
the cylinder head. Verify that the rocker housing gasket
covers the breather channel.
2008 Touring Service: Engine 3-37
2
1
sm02350
1.
CORRECT: Breather channel covered
2.
INCORRECT: Breather channel exposed
Figure 3-37. Install Rocker Housing Gasket (Rear Cylinder Shown)
7.
See
. With the indent (1) facing forward, place
the rocker housing into position aligning the holes in the
housing with those in the gasket.
8.
See
. Apply a small dab of LOCTITE
THREADLOCKER 243 (blue) to threads of six rocker
housing bolts. Loosely install the rocker housing bolts.
Place two long bolts on the left side of the engine and four
intermediate bolts in the interior. Alternately tighten the
bolts to 120-168 in-lbs (13.6-19.0 Nm) in the sequence
shown.
NOTES
•
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 in. drive.
•
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 new o-rings, keeping them packaged until use to avoid
confusion.
9.
. Apply a very thin film of clean H-D 20W50
engine oil to new baffle hole o-ring (2). Install new o-ring
in groove around breather baffle hole in rocker housing.
NOTE
Do not confuse breather baffle hole o-ring (Part No. 11270,
large inner diameter) with the top push rod o-ring (Part No.
11293, small inner diameter).
3-38 2008 Touring Service: Engine
4
6
2
1
5
3
1
5
3
4
6
2
sm02389
1.
Short bolt, 1.25 in. (31.8 mm)
2.
Long bolt, 1.75 in. (44.5 mm)
3.
Long bolt, 1.75 in. (44.5 mm)
4.
Short bolt, 1.25 in. (31.8 mm)
5.
Short bolt, 1.25 in. (31.8 mm)
6.
Short bolt, 1.25 in. (31.8 mm)
Figure 3-38. Rocker Housing Torque Sequence and Bolt
Size
2
1
sm02394
1.
Indent
2.
Breather baffle hole O-ring
Figure 3-39. Rocker Housing Alignment
PUSH RODS, LIFTERS AND COVERS
1.
Remove any labels used on the hydraulic lifters. Install
lifters in the crankcase bores with the oil hole on the
inboard side and the flats on the lifters facing forward and
rearward. To avoid damage, do not drop lifters onto cam
lobes.
2.
See
. Place the anti-rotational pin (4) on the
machined flat between the blocks cast into the crankcase.
3.
Install a new lifter cover gasket (2) aligning the holes in
the gasket with those in the cover (1).
NOTE
Movement or loss of the pin can result in lifter rotation causing
engine damage.
4.
Install the lifter cover and start the four allen head socket
screws (1/4 x 1.0 in). During installation, verify that the
anti-rotational pin (4) is held in place by the ribs (3) cast
into the inboard side of the lifter cover. Tighten the lifter
cover screws to 90-120 in-lbs (10.2-13.6 Nm) in a cross-
wise pattern.
5.
Install push rod covers.
a.
Hand compress the push rod cover assembly and fit
the o-ring end of the lower push rod cover into the
lifter cover bore.
b.
Extending the assembly, fit the o-ring end of the upper
push rod cover into the cylinder head bore.
c.
Do not install the spring cap retainers at this time.
NOTE
To install spring cap retainers, see
ASSEMBLY, Rocker Arm Support Plate
.
2008 Touring Service: Engine 3-39
6.
Refer to
. Install the push rods in their original
positions. Be sure to remove any tags that may have been
used for identification.
a.
. 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.
b.
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.
Table 3-32. Push Rod/Lifter Locations
CYLINDER
HEAD/ROCKER
HOUSING
BORE
LIFTER BORE
COVER
COVER &
PUSH ROD
CYL-
INDER
Rear
Inside
Intake
Front
Front
Outside
Exhaust
Front
Inside
Intake
Rear
Rear
Outside
Exhaust
4
2
1
3
sm02346
1.
Cover
2.
Gasket
3.
Ribs on cover
4.
Anti-rotational pin
Figure 3-40. Installing Lifters
2
4
1
3
sm02181
1.
Front cylinder exhaust push rod
2.
Front cylinder intake push rod
3.
Rear cylinder intake push rod
4.
Rear cylinder exhaust push rod
Figure 3-41. Push Rod Locations
ROCKER ARM SUPPORT PLATE
Installing the rocker arms and rotating the engine with the valve
train loaded can result in bent push rods, damaged bushings
or a warped support plate.
1.
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. To rotate engine, see
3.16 TOP END OVERHAUL: ASSEMBLY, Rocker Arm
Support Plate
.
2.
See
. Place the rocker arm support plate
assembly into the rocker housing. Loosely install the four
rocker arm support plate bolts with flat washers.
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 in. drive torque wrench with a 1/2 in.
flank drive "dog bone" torque adapter (Snap-on FRDH161).
Failure to properly use this combination will overtighten the
bolts causing distortion of the rocker housing.
3.
Tighten rocker arm support plate bolts.
a.
Following the sequence shown, alternately tighten
each of the four rocker arm support plate bolts just
1/4 turn. Continue turning the bolts in these incre-
ments until snug.
b.
Following the same sequence, tighten the bolts to 18-
22 ft-lbs (24.4-29.8 Nm).
4.
Lift up lower push rod covers and verify that both push
rods spin freely.
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.
3-40 2008 Touring Service: Engine
3
2
1
4
2
3
4
1
sm02386
Figure 3-42. Rocker Arm Torque Sequence
5.
Complete installation of the push rod covers.
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.
Insert 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.
NOTE
For best results, be sure that screwdriver, spring cap and
spring cap retainer are free of grease and oil.
d.
See
. 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.
e.
Verify that spring cap retainer is seated tightly against
upper push rod cover.
sm02347
Figure 3-43. Install Spring Cap Retainers
BREATHER ASSEMBLY
NOTE
For breather assembly service procedures, see
.
1.
. Alternately tighten the two bolts to secure
breather assembly to 90-120 in-lbs (10.2-13.6 Nm).
2.
See
. Install a new rocker cover gasket with
indent facing forward on the rocker housing flange. Place
the rocker cover into position aligning the holes in the
cover with those in the gasket.
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 in. drive torque wrench with a 7/16 in. flank drive
"dog bone" torque adapter (Snap-on FRDH141). Failure to
properly use this combination will overtighten the bolts causing
distortion of the rocker cover.
2008 Touring Service: Engine 3-41
3.
. Install rocker cover bolts.
a.
Apply a small dab of LOCTITE THREADLOCKER
243 (blue) to threads of six rocker cover bolts.
b.
Loosely install bolts in the rocker cover.
c.
Following the sequence shown, tighten bolts to 15-18
ft-lbs (20.3-24.4 Nm).
4.
Complete motorcycle assembly.
a.
If engine was left in the chassis for service, see
3.12 ASSEMBLING MOTORCYCLE AFTER SER-
VICE
.
b.
If engine was removed for service, see
3.14 INSTALLING ENGINE IN CHASSIS
sm02398
Figure 3-44. Rocker Cover Gasket Indent (Front Cylinder
Shown)
6
2
4
3
1
5
4
2
6
5
1
3
sm02326
1.
Short bolt, 1.0 in. (25.4 mm)
2.
Long bolt, 1.75 in. (44.5 mm)
3.
Short bolt, 1.0 in. (25.4 mm)
4.
Long bolt, 1.75 in. (44.5 mm)
5.
Short bolt, 1.0 in. (25.4 mm)
6.
Long bolt, 1.75 in. (44.5 mm)
Figure 3-45. Rocker Cover Bolts Torque Sequence
3-42 2008 Touring Service: Engine
3.17
BOTTOM END OVERHAUL: DISASSEMBLY
GENERAL
To perform a complete bottom end overhaul, follow all steps
listed in this section including inspection and repair procedures.
COVER AND CAM SUPPORT PLATE
TOOL NAME
PART NUMBER
CRANKSHAFT/CAMSHAFT
SPROCKET LOCKING TOOL
HD-47941
Prepare Engine
1.
If performing a complete engine overhaul, perform all steps
under
3.15 TOP END OVERHAUL: DISASSEMBLY
2.
If only servicing cam compartment components, partial
top end disassembly is required. Remove breather
assembly, rocker arm support plate, push rods and push
rod covers. Do not remove lifters. See appropriate topics
under
3.15 TOP END OVERHAUL: DISASSEMBLY
3.
Support lifters using improvised tool as described under
3.25 COVER AND CAM SUPPORT PLATE
.
4.
. Remove the ten allen head socket screws
with captive washers to release the cam cover. Remove
and discard the cam cover gasket.
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 in.). Only the cam cover uses the longer screw (1/4 x
1-1/4 in.). For ease of assembly, do not mix the short and long
screws. Store the long screws inside the cam cover to avoid
confusion. The short screws are interchangeable.
6
1
5
8
7
4
9
10
2
3
sm02183
Figure 3-46. Cam Cover Screws
Cam Chain and Sprockets
1.
See
. Using a colored marker, mark one of the
links (1) of the primary cam chain. Maintaining the original
direction of rotation during assembly may prolong service
life.
Be sure to follow manufacturer's instructions when using
propane torches. Failure to follow manufacturer's
instructions can cause a fire, which could result in death
or serious injury. (00465c)
•
Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.
•
Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.
•
Always keep hands away from tool tip area and heat shrink
attachment.
NOTE
A piece of wire can be inserted into retention hole (6) to keep
cam chain tensioner components assembled.
2.
Remove primary cam chain tensioner fasteners (4) and
primary cam chain tensioner (3).
NOTE
In next step, be sure side of tool labeled "crank side" faces
crank sprocket.
3.
See
. Install CRANKSHAFT/CAMSHAFT
SPROCKET LOCKING TOOL (Part No. HD-47941)
between cam sprocket (2) and crank sprocket (5).
NOTES
•
Only use approved methods for removing rear cam bolt.
Other methods of removal, such as the use of a large
breaker bar, may result in damage to chain drive and other
components.
•
If too much LOCTITE or perhaps the wrong LOCTITE was
used to install the rear cam bolt, it may be very difficult to
remove. In these cases, break down LOCTITE by using
heat from a small propane torch. Apply flame evenly
around bolt in a circular motion, but not for so long as to
turn bolt blue.
4.
Remove the rear cam sprocket bolt and flat washer (1)
from the rear cam sprocket (2).
5.
Remove the crank sprocket bolt and flat washer (4) from
the crank sprocket (5).
6.
Remove CAMSHAFT LOCKING TOOL.
7.
Insert small pry bar (seal remover) between inboard side
of rear cam sprocket and cam support plate. Working
around its circumference, carefully ease off rear cam
sprocket until loose on camshaft.
8.
Ease off crank sprocket with a slightly smaller pry bar (seal
remover). Remove the rear cam sprocket, primary cam
chain and crank sprocket.
2008 Touring Service: Engine 3-43
5
3
6
1
2
4
sm02399
1.
Link
2.
Rear cam sprocket
3.
Primary cam chain tensioner
4.
Primary cam chain tensioner fasteners
5.
Crank sprocket
6.
Retention hole
Figure 3-47. Cam Support Plate Assembly
4
5
3
2
1
sm02401
1.
Rear cam sprocket bolt (large) and flat washer
2.
Rear cam sprocket
3.
Camshaft locking tool (HD-47941)
4.
Crank sprocket bolt (small) and flat washer
5.
Crank sprocket
Figure 3-48. Cam Support Plate Assembly
Cam Support Plate
1.
. Following the sequence shown, altern-
ately loosen and then remove the four allen head socket
screws with captive washers to release the cam support
plate from the oil pump flange.
2.
. Following the sequence shown, altern-
ately loosen and then remove the six allen head socket
screws with captive washers to release the cam support
plate from the crankcase flange.
3-44 2008 Touring Service: Engine
4
2
1
3
sm02185
Figure 3-49. Oil Pump Torque Sequence
4
2
6
3
5
1
sm02404
Figure 3-50. Cam Support Plate Torque Sequence
3.
. Two ring dowels (2, 3) in crankcase
flange locate cam support plate.
a.
Insert small pry bar (seal remover) between inboard
side of cam support plate and crankcase flange in
area adjacent to ring dowels.
b.
Alternately work each side free and then carefully
ease cam support plate and camshafts from end of
crankshaft.
4.
3.25 COVER AND CAM SUPPORT PLATE
for
inspection and repair information.
2
1
3
sm02407
1.
Right crankcase half
2.
Forward ring dowel
3.
Rear ring dowel
Figure 3-51. Ring Dowels
CRANKCASE
1.
Carefully pull oil pump from crankshaft.
2.
See
. Remove o-rings (1, 2) from crankcase
housing. Discard o-rings. See
for inspec-
tion and repair information.
NOTE
Do NOT rotate left crankcase half in the engine stand so the
flywheel sprocket shaft is facing up. The flywheel assembly
will fall out of the case.
3.
Rotate crankcase in the engine stand so that the cam
cover flange is facing straight upward.
4.
. Remove the nine crankcase bolts in the
sequence shown.
NOTE
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.
5.
Using pry points, loosen case halves. Lift right crankcase
half off end of crankshaft.
6.
. Remove two dowel pins in split line face
of right case half.
7.
For inspection and repair information, see
2008 Touring Service: Engine 3-45
1
2
sm02408
1.
Oil feed hole O-ring
2.
O-ring on crankcase post
Figure 3-52. Oil Pump O-rings
1
5
4
2
8
6
7
3
9
sm02186
Figure 3-53. Crankcase Bolt Sequence
sm02296
Figure 3-54. Right Crankcase Forward Dowel Pin (Rear
Dowel Pin Not Shown)
3-46 2008 Touring Service: Engine
3.18
BOTTOM END OVERHAUL: ASSEMBLY
GENERAL
This section lists a sequential process for engine reassembly
after a complete bottom end disassembly and overhaul. If you
reached this section after an inspection or repair procedure,
start where necessary and continue to the end of the section.
•
Crankcase installation: see
•
Cover and cam support plate installation: see
3.18 BOTTOM END OVERHAUL: ASSEMBLY, Cover and
Cam Support Plate
.
CRANKCASE
TOOL NAME
PART NUMBER
HIGH-PERFORMANCE SEALANT,
GRAY
99650-02
SPROCKET SHAFT OIL SEAL
INSTALLER
HD-39361-B
CRANKSHAFT GUIDE
HD-42326-B
SPROCKET SHAFT BEARING
INSTALLER
HD-97225-55C
NOTE
O-rings that are missing, distorted, pinched or otherwise dam-
aged 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 new o-rings
keeping them packaged until use to avoid confusion.
1.
Bolt left crankcase half upright in engine stand.
2.
To facilitate assembly and prevent damage to the crank-
shaft (roller) bearing in the left crankcase half, slide
CRANKSHAFT GUIDE (Part No. HD-42326-B) onto fly-
wheel sprocket shaft.
3.
Slide flywheel assembly into left crankcase half. Remove
CRANKSHAFT GUIDE tool.
4.
Tip crankcase assembly in engine stand so that flywheel
sprocket shaft is pointing straight up.
5.
Ensure both dowel pins are installed in split line face of
right case half.
6.
With the right crankcase half resting on the cam cover
flange, apply a bead of sealant approximately 0.056
in. (1.42 mm) wide to the split line face and around the
two dowel pins. For best results, use HIGH-PERFORM-
ANCE SEALANT, GRAY (Part No. 99650-02).
7.
See
. To facilitate assembly and prevent
damage to the crankshaft (roller) bearing in the right
crankcase half, place CRANKSHAFT GUIDE (1) (Part No.
HD-42326-B) over end of crankshaft until it contacts
shoulder on shaft.
8.
Mate case halves sliding bearing roller in right crankcase
half over end of crankshaft. Remove CRANKSHAFT
GUIDE.
1
2
2
sm02297
1.
Crankshaft guide
2.
Water pipe insulation
Figure 3-55. Crankshaft Guide (Part No. HD-42326-A)
1
5
4
2
8
6
7
3
9
sm02186
Figure 3-56. Tightening Crankcase Bolts
9.
. Start the nine crankcase bolts and tighten
in the following sequence.
a.
Alternately turn each crankcase bolt until finger tight.
b.
Tighten the crankcase bolts to 10 ft-lbs (13.6 Nm) in
the order shown.
c.
Following the same sequence, tighten each bolt to to
15-19 ft-lbs (20.3-25.8 Nm).
10. Tip crankcase assembly so that sprocket shaft is pointing
straight up.
2008 Touring Service: Engine 3-47
11. Install thrust washer on sprocket shaft with "THIS SIDE
OUT" facing out (and the chamfer inboard). If using OE
part without markings, orient as required to preserve
existing wear pattern.
12. See
. Install new oil seal into bearing bore.
Obtain pilot adapter, pilot shaft, short collar, Nice bearing,
large flat washer and handle from SPROCKET SHAFT
BEARING INSTALLER (Part No. HD-97225-55C).
a.
Thread pilot adapter into sprocket shaft.
b.
Thread pilot shaft onto pilot adapter.
c.
Verify that lip garter spring is in place on both sides
of oil seal.
d.
Install sprocket shaft spacer in oil seal bore.
e.
With the lettering on the oil seal facing outside, slide
sprocket shaft spacer and oil seal over pilot shaft until
it contacts bearing bore.
f.
Slide SPROCKET SHAFT OIL SEAL
INSTALLER (Part No. HD-39361-B) over pilot shaft
until it contacts oil seal.
g.
Slide short collar over pilot shaft until it contacts seal
installer.
h.
Slide Nice bearing and large flat washer over pilot
shaft.
i.
Sparingly apply graphite lubricant to threads of pilot
shaft to prolong service life and ensure smooth oper-
ation.
j.
Thread handle onto pilot shaft to complete assembly
of tool.
13. Rotate handle in a clockwise direction until oil seal installer
makes firm contact with crankcase stator mount.
14. Remove handle, flat washer, Nice bearing, short collar,
seal installer, pilot shaft and pilot adapter from sprocket
shaft.
15. Rotate crankcase in engine stand so that cam cover flange
is facing upward.
1
1
sm02348
1.
Seal Installer
Figure 3-57. Sprocket Shaft Oil Seal Installer
NOTE
O-rings that are missing, distorted, pinched or otherwise dam-
aged 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 new o-rings
keeping them packaged until use to avoid confusion.
16. See
. Assemble and install oil pump. Lubricate
parts with clean H-D 20W50 engine oil during assembly.
a.
Apply a very thin film of clean H-D 20W50 engine oil
to new scavenge port stub o-ring (6). Install new o-
ring on scavenge port stub of oil pump housing.
b.
Slide oil pump housing (5) 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
(4) (scavenge) and the other narrow (1) (feed).
3-48 2008 Touring Service: Engine
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