Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams — page 6
CHAPTER FOUR
ENGINE
All Dyna Glide models covered in this manual
ENGINE PRINCIPLES
are equipped with the Twin Cam 88 engine, an
air-cooled 4-stroke, overhead-valve V-twin engine.
Figure 1 explains basic four-stroke engine opera-
The engine consists of three major assemblies: en-
tion.
gine, crankcase and gearcase. Viewed from the en-
gine’s right side, engine rotation is clockwise.
SERVICE PRECAUTIONS
Both cylinders fire once in 720 degrees of crank-
shaft rotation. The rear cylinder fires 315 degrees
Before servicing the engine, note the following:
after the front cylinder. The front cylinder fires
1. Review the information in Chapter One, espe-
again in another 405 degrees. Note that one cylinder
cially the Basic Service Methods and Precision
is always on its exhaust stroke when the other fires
Measuring Tools sections. Accurate measurements
on its compression stroke.
are critical to a successful engine rebuild.
This chapter provides complete service and over-
2. Throughout the text there are references to the
haul procedures, including information for disas-
left and right side of the engine. This refers to the
sembly, removal, inspection, service and engine
engine as it is mounted in the frame, not how it may
reassembly.
sit on the workbench.
Tables 1-6 at the end of the chapter provide
3. Always replace worn or damaged fasteners with
spacer, shim and specification information.
those of the same size, type and torque require-
ENGINE
101
1
FOUR-STROKE OPERATING PRINCIPLES
Carburetor
Intake
valve
4
Air
Air/fuel
Cylinder
INTAKE
COMPRESSION
Intake valve opens
Intake valve closes
as piston begins
and piston rises
downward, drawing
in cylinder,
air/fuel mixture into
compressing
the cylinder, through
air/fuel mixture.
the valve.
Exhaust
valve
Exhaust
EXHAUST
POWER
Exhaust valve
Spark plug
opens as piston
ignites
rises in cylinder,
compressed
pushing spent
mixture, driving
gases out through
piston downward.
the valve.
Force is applied
to crankshaft
causing it to
rotate.
102
CHAPTER FOUR
ments. Make sure to identify each bolt before re-
placing it. Lubricate bolt threads with engine oil,
2
unless otherwise specified, before tightening. If a
specific torque value is not listed in Table 4, refer to
the general torque specifications in Chapter One.
CAUTION
The engine is assembled with hard-
ened fasteners. Do not install fasten-
ers with a lower strength grade
classification.
4. Use special tools where noted.
5. Store parts in boxes, plastic bags and containers
3
(Figure 2). Use masking tape and a permanent, wa-
terproof marking pen to label parts.
6. Use a box of assorted size and color vacuum
hose identifiers, Lisle (part No. 74600) (Figure 3)
for identifying hoses and fittings during engine re-
moval and disassembly.
7. Use a vise with protective jaws to hold parts.
8. Use a press or special tools when force is re-
quired to remove and install parts. Do not try to pry,
hammer or otherwise force them on or off.
9. Replace all O-rings and oil seals during reassem-
bly. Apply a small amount of grease to the inner lips
4
of each new seal to prevent damage when the en-
gine is first started.
10. Record the location, position and thickness of
all shims as they are removed.
SPECIAL TOOLS
Engine service requires a number of special tools.
These tools and their part numbers are listed with
the individual procedures. For a complete list of the
special tools mentioned in this manual, refer to Ta-
5
ble 9 in Chapter One. The engine tools used in this
chapter are either Harley-Davidson or JIMS special
tools. JIMS special tools are available through some
Harley-Davidson dealerships or many aftermarket
motorcycle suppliers.
When purchasing special tools, make sure to
specify that the tools required are for the 1999-on
Dyna Glide Twin-Cam 88 models. Many of the
tools are specific to this engine. Tools for other en-
gine models may be slightly different.
ENGINE
103
9. Starter motor and gears.
6
10. Alternator and electrical systems.
ENGINE
Removal
1. Thoroughly clean the engine of all dirt and debris.
2. Remove the seat as described in Chapter Thirteen.
4
NOTE
Always disarm the optional TSSM se-
curity system prior to disconnecting
the battery or the siren will sound.
7
3. Disconnect the negative battery cable as de-
scribed in Chapter Eight.
4. Support the motorcycle on a stand or floor jack.
See motorcycle Stands in Chapter Nine.
5. Remove the fuel tank as described in Chapter
Seven.
6. Remove the air filter and backing plate as de-
scribed in Chapter Seven.
7. Remove the carburetor as described in Chapter
Seven.
8. Remove the exhaust system as described in
Chapter Seven.
8
9. Remove the rear brake pedal and right side foot
peg bracket as described in Chapter Twelve.
10. Drain the engine oil as described in Chapter
Three.
11. Remove the bolts securing the oil line cover
and remove the cover (Figure 4).
12. Disconnect the three oil lines from the crank-
case. Plug the oil lines to prevent dirt from entering
the hoses.
13. On 1999-2000 models, remove the camshaft
position sensor as described in Chapter Eight.
14. Disconnect the following electrical connectors:
SERVICING ENGINE IN FRAME
a. Crankshaft position sensor (Figure 5).
b. Alternator stator and voltage regulator (Fig-
The following components can be serviced while
ure 6).
the engine is mounted in the frame:
c. Oil pressure switch (Figure 7).
1. Rocker arm cover and rocker arms.
d. MAP sensor (A, Figure 8).
2. Cylinder heads.
15. Remove the ignition coil and spark plug assem-
3. Cylinders and pistons.
bly as described in Chapter Eight.
4. Camshafts.
16. Remove the primary chain case assembly, includ-
5. Gearshift mechanism.
ing the inner housing, as described in Chapter Five.
6. Clutch.
17. Remove the engine oil dipstick.
7. Transmission.
18. Remove the alternator rotor (A, Figure 9) as
8. Carburetor.
described in Chapter Eight.
104
CHAPTER FOUR
19. On the right side of the engine stabilizer, per-
form the following:
9
a. Remove the link nut and spacer from the
frame tab (B, Figure 8).
b. Remove the two bolts from the horn bracket
and cylinder heads.
c. Remove the stabilizer link and horn bracket
as an assembly (Figure 10).
20. Remove the clutch cable from the lower por-
tion of the crankcase as described under Clutch Ca-
ble Replacement in Chapter Five.
21. Wrap the frame front down tubes (A, Figure
11) with protective tape to prevent surface damage
in the following steps.
10
22. Support the transmission case with a jack or
wooden blocks. Apply enough jack pressure on the
transmission prior to removing the en-
gine-to-transmission mounting bolts.
23. Using a ratchet strap, secure the transmission to the
frame so it will not shift after the engine is removed.
24. Remove the four bolts and washers (B, Figure
9) securing the engine to the transmission.
25. Support the engine with a floor jack. Apply
enough jack pressure on the crankcase to support it
prior to removing the engine mounting bolts.
26. Remove the two bolts and washers securing the
engine to the front isolator.
11
27. Straighten the lockplate tabs and remove the three
bolts, oil filter and oil filter mount (B, Figure 11).
28. Check the engine to make sure all wires, hoses,
and other related components have been discon-
nected from the engine. Check that nothing will in-
terfere with the removal of the engine from the right
side of the frame.
NOTE
Due to the weight of the engine as-
sembly, a minimum of two people are
required to safely remove the engine
from the frame.
12
29. Slide the engine assembly forward to clear the
two locating dowels on the lower en-
gine-to-transmission mounting bolt locations. The
dowels stick out approximately 1/2 in. (12.7 mm).
The engine may have to be rotated slightly to clear
the dowels.
30. Remove the engine from the right side of the
frame.
31. If the transmission was removed along with the
engine, remove the four bolts securing the transmis-
ENGINE
105
Installation
13
NOTE
Due to the weight of the engine as-
sembly, a minimum of two people is
required to safely install the engine
into the frame.
1. If removed, install the two lower locating dowels
in the transmission case (Figure 13).
4
2. Re-check that all wiring, hoses and other related
components are out of the way and will not interfere
with engine installation.
3. Correctly position a floor jack and piece of wood
under the frame to support the engine when it is in-
stalled into the frame.
4. Install the engine from the right side of the frame
and place it on the floor jack. Apply enough jack
14
pressure on the crankcase to support it prior to in-
stalling the engine mounting bolts.
5. Slide the engine assembly toward the rear and onto
the two transmission locating dowels. The engine may
have to be rotated slightly to clear the dowels.
6. Install the four engine-to-transmission bolts and
washers hand-tight at this time.
7. Install the two bolts and washers securing the en-
gine to the front isolator. Tighten finger-tight at this
time.
8. Tighten the engine-to-transmission bolts in a
criss-cross pattern in the following sequence:
a. Tighten to 15 ft.-lb. (20 N•m).
15
b. Tighten to 30-35 ft.-lb. (41-47 N•m).
9. Tighten the front isolator bolts to the specifica-
tion in Table 4.
10. Remove the ratchet strap from the transmission
and frame.
11. Remove the floor jack.
NOTE
Step 12 is shown with the engine re-
moved from the frame to better illus-
trate the procedure.
12. Install the oil filter mount as follows:
sion to the engine. Remove the transmission from
a. Install new O-ring seals (Figure 14) onto the
the engine.
mount.
32. Mount the engine in an engine stand (Figure
b. Apply ThreeBond TB1342, or an equivalent,
12)
(JIMS part No. 1022 or an equivalent).
to the bolt threads prior to installing them
33. Service the front engine mount, if necessary.
onto the new lockplate.
34. Clean the front and rear engine mount bolts and
c. Install the oil filter mount onto the crankcase
washers in solvent and dry thoroughly.
and install the lockplate, three bolts and
35. Replace leaking or damaged oil hoses.
washers (Figure 15).
106
CHAPTER FOUR
16
ROCKER ARM ASSEMBLY
1. Bolt
2. Rocker arm cover
3. Gasket
4. Bolt
5. Breather cover
6. Gasket
7. Valve
8. Breather baffle
9. Filter element
10. Gasket
11. Bushing
12. Rocker arm
Intake-front cylinder
Exhaust-rear cylinder
13. Rocker arm shaft
14. Washer
15. Rocker arm support
16. Rocker arm
Intake-rear cylinder
Exhaust-front cylinder
17. O-ring seal
18. Rocker arm housing
19. Gasket
ENGINE
107
d. Install the two bolts securing the horn bracket
17
PUSHROD ASSEMBLY
to the cylinder heads and tighten to the speci-
fication in Table 4.
e. Install the link nut and spacer onto the frame
tab (B, Figure 8).
16. Install the alternator rotor (A, Figure 9) as de-
scribed in Chapter Eight.
17. Install the engine oil dipstick.
18. Install the primary chain case inner housing
4
and assembly as described in Chapter Five.
19. Adjust the clutch and primary chain as de-
scribed in Chapter Three.
20. Install the ignition coil and spark plug assem-
bly as described in Chapter Eight.
21. Connect the following electrical connectors:
a. Crankshaft position sensor (Figure 5).
b. Alternator stator and voltage regulator (Fig-
ure 6).
c. Oil pressure switch (Figure 7).
d. MAP sensor (A, Figure 8).
22. On 1999-2000 models, install the camshaft po-
sition sensor as described in Chapter Eight.
1.
O-ring
7.
Lower cover
23. Connect the three oil lines onto the crankcase
2.
Upper cover
8.
Allen bolt
and install new hose clamps.
3.
Spring cap
9.
Lifter cover
24. Install the oil line cover and bolts (Figure 4).
retainer
10.
Anti-rotation pin
Tighten the bolts to the specification in Table 4.
4.
Spring cap
11.
Gasket
5.
Spring
12.
Hydraulic lifter
25. Install the rear brake pedal and right side foot
6.
Washer
13.
Pushrod
peg bracket as described in Chapter Twelve.
26. Install the exhaust system as described in
Chapter Seven.
27. Install the carburetor as described in Chapter
d. Tighten the bolts to the specification in Table
Seven.
4.
28. Install the air filter and backing plate as de-
e. Bend down the locking tab against the top and
scribed in Chapter Seven.
bottom bolt heads.
29. Install the fuel tank as described in Chapter
f. Install the oil filter.
Seven.
13. Remove the protective tape from the frame
30. Remove the stand from under the motorcycle
front down tubes.
and place the motorcycle on the jiffy stand.
14. Install the clutch cable onto the lower portion
31. Connect the negative battery cable as described
of the crankcase as described under Clutch Cable
Chapter Eight.
Replacement in Chapter Five.
32. Install the seat.
15. On the right side of the engine stabilizer, per-
33. Refill the engine oil as described in Chapter
form the following:
Three.
a. Install the stabilizer link and horn bracket as
34. Check vehicle alignment as described in Chap-
an assembly (Figure 10).
ter Nine.
b. Place a spacer between the frame tab and the
stabilizer link.
ROCKER ARMS AND PUSHRODS
c. Position the horn ground wire beneath the
bracket and the front cylinder head.
Refer to Figure 16 and Figure 17.
108
CHAPTER FOUR
The rocker arm and pushrod procedures are
shown on the rear cylinder. The same procedures
18
also relate to the front cylinder. If differences occur
they are identified.
NOTE
The rocker arms and pushrod proce-
dures are shown with the engine re-
moved to better illustrate the steps.
Removal
1. If the engine is mounted in the frame, perform
the following:
19
a. Perform Steps 1-8 under Engine Removal in
this chapter.
b. Remove the upper cylinder head mounting
bracket.
2. Using a crisscross pattern, loosen and remove
the rocker arm cover bolts (Figure 18).
3. Remove the rocker arm cover and gasket.
4. Disassemble the breather as follows:
a. Remove the bolts (A, Figure 19) and remove
the cover (B) and gasket.
b. Remove the breather baffle (A, Figure 20),
valve (B), and gasket (Figure 21).
c. Install new gaskets during installation.
20
5. Remove both spark plugs as described in Chap-
ter Three, to make it easier to rotate the engine by
hand.
CAUTION
Do not rotate the engine using the
camshaft sprocket mounting bolt.
Doing so may break the bolt head and
damage the camshaft.
CAUTION
The piston must be at top dead center
(TDC) to avoid damage to the
pushrods and rocker arms in the fol-
21
lowing steps.
6A. With the primary chain cover in place, position
the piston for the cylinder being worked on at top
dead center (TDC) on the compression stroke as fol-
lows:
a. Support the motorcycle on a stand with the
rear wheel off the ground. See motorcycle
Stands in Chapter Nine.
b. Shift the transmission into fifth gear.
ENGINE
109
22
24
4
closed. This indicates that the piston is at top
23
dead center (TDC) on the compression stroke
and both valves are closed. Also, the push
rods are in the unloaded position.
f. Look into the spark plug hole with a flashlight
and verify that the piston is at TDC.
7. Using a crisscross pattern, loosen, then remove
the four bolts and washers (Figure 22) securing the
rocker arm support and remove the support.
8. Remove the O-ring seal (Figure 23) from the
rocker arm housing.
9. Mark each pushrod with its top and bottom posi-
tion and its operating position in the cylinder head.
c. Rotate the rear wheel in the direction of nor-
mal rotation.
NOTE
d. Stop rotating the rear wheel when both the in-
When removing the pushrods in the
take and exhaust valves are closed.
following steps, do not intermix the
e. Wiggle both rocker arms. There should be
parts from each set. When reinstalling
the original pushrods, install them so
free play indicating that both valves are
that each end faces its original oper-
closed. This indicates that the piston is at top
ating position. The pushrods develop
dead center (TDC) on the compression stroke
a set wear pattern and installing them
and both valves are closed. Also, the push
upside down may cause rapid wear to
rods are in the unloaded position.
the pushrod, lifter and rocker arm.
f. Look into the spark plug hole with a flashlight
and verify that the piston is at TDC.
10. Remove the intake (A, Figure 24) and exhaust
6B. With the primary chain cover removed, position
(B) pushrods up through the cylinder head.
the piston for the cylinder being worked on at top dead
11. Remove the pushrod covers as follows:
center (TDC) on the compression stroke as follows:
a. Using a screwdriver, pry the spring cap re-
a. Shift the transmission into NEUTRAL.
tainer (Figure 25) out from between the cyl-
b. Install the sprocket shaft nut onto the end of
inder head and spring cap.
the left side of the crankshaft.
b. Slide the upper cover down (A, Figure 26)
c. Place a socket or wrench on the compensating
and remove the pushrod cover assembly (B)
sprocket shaft nut.
from the cylinder head and the lifter cover.
d. Rotate the compensating sprocket shaft coun-
c. Repeat for the opposite pushrod cover.
terclockwise until both the intake and exhaust
valves are closed.
NOTE
e. Wiggle both rocker arms. There should be
In order to clear the cylinder’s lower
free play indicating that both valves are
cooling fins, the lifter cover’s two in-
110
CHAPTER FOUR
25
27
26
28
ner Allen bolts must be loosened with
a short 90-degree Allen wrench (A,
29
Figure 27).
12. Remove the lifter cover mounting bolts and re-
move the cover (B, Figure 27).
13. Remove the lifter cover gasket from the crank-
case.
NOTE
Do not intermix the lifters when re-
moving them in Step 13. Mark them so
they can be installed in their original
positions.
30
14. Remove the anti-rotation pin (A, Figure 28)
and both hydraulic lifters (B).
15. Cover the crankcase opening with duct tape
(Figure 29) to prevent the entry of debris.
16. Loosen the rocker housing six bolts (Figure
30) 1/8 turn at a time in the pattern shown in Figure
31.
17. Tap the rocker arm housing with a rubber mal-
let to free it, then lift it off the cylinder head.
18. Remove the rocker arm housing gasket.
ENGINE
111
31
ROCKER ARM HOUSING TORQUE SEQUENCE
4
112
CHAPTER FOUR
Installation
32
1. Position the new rocker arm housing gasket onto
the cylinder so that the breather channel (Figure 32)
is covered and install the gasket (Figure 33).
2. Install the rocker arm housing onto the cylinder
head.
3. Apply ThreeBond TB1342, or an equivalent,
threadlocking compound to the bolt threads. Install
the rocker housing six bolts (Figure 30) and tighten
1/8 turn at a time in the pattern shown in Figure 31.
Tighten to the specification in Table 4.
4. Install a new O-ring seal (Figure 23) onto the
rocker arm housing. Apply a light coat of clean en-
33
gine oil to the O-ring.
5. Install the hydraulic lifters (B, Figure 28) into
the crankcase receptacles with both flat surfaces
facing toward the front and rear of the engine. This
is necessary for installation of the anti-rotation pin
in the next step.
CAUTION
Failure to install the anti-rotational
pin will allow the lifter to rotate off the
camshaft lobe, resulting in severe in-
ternal engine damage.
6. Install the anti-rotation pin (A, Figure 28) and
34
make sure it is seated correctly within the crankcase
receptacle and against the flats on both hydraulic
lifters (C, Figure 28).
7. Rotate the engine until both lifters for the cylin-
der head being serviced seat onto the cam’s lowest
position (base circle). The lifter’s top surface will
be flush with the top surface of the crankcase sur-
face as shown in Figure 34.
8. Install a new lifter cover gasket (Figure 35) onto
the crankcase.
NOTE
In order to clear the cylinder’s lower
35
cooling fins, the lifter cover two inner
Allen bolts must be tightened with a
short 90-degree Allen wrench (A, Fig-
ure 27).
9. Install the lifter cover and the mounting bolts (B,
Figure 27). Tighten the bolts to the specification in
Table 4.
10. Install new O-ring seals (Figure 36) onto each
end of the pushrod covers. Apply a light coat of
clean engine oil to the O-rings.
ENGINE
113
11. If the pushrod cover assembly was disassem-
36
bled, reassemble it as described under Pushrods in
this chapter.
CAUTION
The pushrod covers and the pushrods
must be installed in the correct loca-
tion in the cylinder head and pushrod
cover as indicated in Table 3.
4
12. Compress the pushrod cover and install it into
the correct location in the lifter cover and cylinder
head (Figure 37). Do not install the spring cap re-
tainer at this time.
13. Repeat Steps 11 and 12 for the other pushrod
37
cover.
14. Install the pushrods as follows:
CAUTION
Two different length pushrods are
used in the Dyna Glide’s engine. The
black exhaust pushrod (A, Figure 38)
is longer than the silver intake
pushrod (B).
a. If installing the existing pushrods, install each
pushrod in its original position and in the cor-
rect orientation. Refer to (A, Figure 24) for
intake and (B) for exhaust. The pushrods are
38
symmetrical and can be installed with either
end facing up.
b. Make sure the pushrod is centered into its re-
spective lifter.
15. Install the rocker arm support assembly and
bolts (Figure 39).
CAUTION
To avoid damaging a pushrod,
rocker arms or valves, tighten the
rocker arm support mounting bolts
evenly and in a crisscross pattern.
When tightening the mounting bolts,
spin each pushrod by hand to ensure
39
that the rocker arm support is being
tightened evenly. If one or both
pushrods cannot be rotated, loosen
the mounting bolts and determine
the cause.
16. Tighten the rocker arm support assembly and
bolts evenly in a crisscross pattern to the torque
specification in Table 4.
17. Ensure that the pushrod cover O-rings are cor-
rectly seated in the cylinder head and lifter cover.
114
CHAPTER FOUR
40
42
41
43
Depress the spring cap (A, Figure 40) and install
the spring cap retainer (B). Make sure the spring cap
44
retainer is correctly seated. Repeat for the remain-
ing pushrod cover.
18. Assemble the breather as follows:
a. If removed, install the valve onto the breather
baffle and pull the tip through from the other
side (Figure 41) to seat it.
b. Install a new gasket (Figure 42).
c. Install a new filter element.
d. Hold the filter element in place and install the
breather baffle (Figure 43).
e. Install the cover and bolts (Figure 44), and
tighten them securely.
45
19. Install a new rocker arm cover gasket (Figure
45).
20. Install the rocker arm cover.
NOTE
There are two different length bolts
(Figure 46) securing the rocker arm
cover.
21. Apply ThreeBond TB1342, or an equivalent,
threadlocking compound to the bolt threads. Install
ENGINE
115
46
ROCKER ARM COVER TORQUE SEQUENCE
Short bolts
4
Long bolts
d. Replace the rocker arm and/or the rocker arm
47
support if the side clearance is greater than
the specification in Table 2.
2. Prior to disassembling the rocker arms, mark each
one with an IN (intake) or EX (exhaust) (Figure 50)
to ensure they are installed in their original positions.
3. Remove the rocker arm shafts (A, Figure 51)
and remove the rocker arms (B).
4. Clean all parts in solvent. Blow compressed air
through all oil passages.
5. Install the rocker arm shaft (A, Figure 52) part
way into the rocker arm support (B) in its original
position.
the rocker arm cover six bolts (Figure 47) and
6. Install a rocker arm (C, Figure 52) into its origi-
tighten 1/8 turn at a time in the sequence shown in
nal position and push the shaft part way through the
Figure 46. Tighten to the specification in Table
rocker arm.
4.
7. Align the notch in the rocker arm shaft (A, Fig-
ure 53) with the mating bolt hole (B) in the support
and install the shaft all the way. Check for correct
Rocker Arm Disassembly/Assembly
alignment (Figure 54).
8. Repeat Step 6 and Step 7 for the remaining
Refer to Figure 48.
rocker arm and shaft.
1. Before removing the rocker arms, measure the
rocker arm end clearance as follows:
Rocker Arm Component Inspection
a. Insert a feeler gauge between the rocker arm
and the inside rocker arm support boss as
When measuring the rocker arm components,
shown in Figure 49.
compare the actual measurements to the specifica-
b. Record the measurement.
tions in Table 2. Replace any part that is damaged or
c. Repeat for each rocker arm.
out of specification as described in this section.
116
CHAPTER FOUR
48
ROCKER ARM ASSEMBLY
1. Bolt
2. Rocker arm cover
3. Gasket
4. Bolt
5. Breather cover
6. Gasket
7. Valve
8. Breather baffle
9. Filter element
10. Gasket
11. Bushing
12. Rocker arm
Intake-front cylinder
Exhaust-rear cylinder
13. Rocker arm shaft
14. Washer
15. Rocker arm support
16. Rocker arm
Intake-rear cylinder
Exhaust-front cylinder
17. O-ring seal
18. Rocker arm housing
19. Gasket
49
51
50
52
ENGINE
117
53
57
4
54
58
1. Inspect the rocker arm pads and ball sockets
55
(Figure 55) for pitting and excessive wear.
2. Examine the rocker arm shaft (Figure 56) for scor-
ing, ridge wear or other damage. If these conditions are
present, replace the rocker arm shaft. If the shaft does
not show any wear or damage, continue with Step 8.
3. Check the rocker arm bushing (Figure 57) for
wear or scoring.
4. Measure the rocker arm shaft diameter (Figure
58) where it contacts the rocker arm bushing and
rocker arm support. Measure both ends of the shaft.
Record each measurement.
5. Measure the rocker arm bushing inside diameter
(Figure 59) and the rocker arm support bore diame-
56
ter. Record each measurement.
6. Subtract the measurements taken in Step 4 from
those taken in Step 5 to obtain the following rocker
arm shaft measurements:
a. Shaft-to-rocker arm support.
b. Shaft-to-rocker arm bushing.
7. Replace the rocker arm, the bushings or the
rocker arm support if the clearance exceeds the
specifications in Table 2. Rocker arm bushing re-
placement is described in this chapter.
118
CHAPTER FOUR
8. Inspect the rocker arm shaft contact surfaces in
the rocker arm support (Figure 60) for wear or elon-
59
gation.
9. Inspect the gasket surface of the rocker arm
cover for damage or warp.
10. Inspect the rocker arm support (Figure 61) for
damage or warp.
11. Inspect both gasket surfaces of the rocker arm
housing for damage or warp.
Rocker Arm Bushing Replacement
Each rocker arm is equipped with two bushings
(Figure 57). Replacement bushings must be reamed
60
after installation. Use the JIMS rocker arm bushing
line reamer (part No. 94804-57). If the correct size
reamer is unavailable, have the bushings replaced
by a Harley-Davidson dealership.
NOTE
Since the new bushings must be
reamed, remove one bushing at a time.
The opposite bushing is then used as a
guide when reaming the first bushing.
1. Press one bushing (Figure 57) out of the rocker
arm. Do not remove the second bushing. If the bush-
ing is difficult to remove, perform the following:
a. Thread a 9/16 × 18 tap into the bushing.
61
b. Support the rocker arm in a press so that the
tap is at the bottom.
c. Insert a mandrel through the top of the rocker
arm and seat it on top of the tap.
d. Press on the mandrel to force the bushing and
tap out of the rocker arm.
e. Remove the tap from the bushing and discard
the bushing.
2. Position the new bushing with the split portion
facing toward the top of the rocker arm.
3. Press the new bushing into the rocker arm until
the bushing’s outer surface is flush with the end of
62
rocker arm bore.
4. Ream the new bushing with the bushing line
reamer as follows:
a. Mount the rocker arm in a vise with soft jaws
so that the new bushing is at the bottom.
CAUTION
Turn the reamer clockwise only. Do
not rotate the reamer counterclock-
wise or the reamer and bushing will
be damaged.
ENGINE
119
63
CYLINDER HEAD
1. Valve keepers
2. Upper retainer
4
3. Inner valve spring
4. Outer valve spring
5. Oil seal
6. Lower retainer
7. Valve guide
8. Bolt-short
9. Bolt-long
10. Cylinder head
11. Valve seat
12. Valve
13. Gasket
b. Mount a tap handle on top of the reamer and
3. Replace any damaged pushrod.
insert the reamer into the bushing. Turn the
reamer clockwise until it passes through the
CYLINDER HEAD
new bushing and remove it from the bottom
side.
Refer to Figure 63.
5. Remove the rocker arm from the vise and repeat
Steps 1-3 to replace the opposite bushing. The first
The cylinder head procedures are shown on the
bushing will now serve as a guide while reaming the
rear cylinder. The same procedures also relate to the
second bushing.
front cylinder. If differences occur they are identi-
6. After installing and reaming both bushings,
fied.
clean the rocker arm assembly in solvent. Then
NOTE
clean with hot, soapy water and rinse with clear,
The following procedures are shown
cold water. Dry with compressed air.
with the engine removed to better il-
7. Measure the inside diameter of each bushing.
lustrate the steps.
When properly reamed, the bushings must provide
the shaft clearance listed in Table 2.
Removal
Pushrod Inspection
1. Remove the rocker arm assemblies and pushrods
1. Clean the pushrods in solvent and dry with com-
as described in this chapter.
pressed air.
2. Using a crisscross pattern, loosen the four cylin-
2. Check the pushrods for bending, cracks and
der head bolts (Figure 64) 1/8 turn at a time. Re-
worn or damaged ball heads (Figure 62).
move the four bolts and note the different lengths.
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