Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams — page 26
500
CHAPTER THIRTEEN
3. Carefully slide the windshield forward and off
the fork brackets. Remove the windshield.
1
4. Install by reversing these removal steps. Do not
overtighten the two screws on each side to avoid
cracking the windshield.
Removal/Installation
(FXDXT)
1. Place the motorcycle on level ground on the jiffy
stand.
2. Remove the headlamp as described under Head-
light Bulb Replacement in Chapter Eight.
3. Loosen, but do not remove, the upper screw on
2
each side securing the windshield and front fairing
to the support brackets on the fork.
4. Remove the lower screw on each side securing
the windshield and front fairing to the support
brackets on the fork.
5. Carefully pull the windshield and front fairing
slightly away from the support bracket on each side.
6. Move the windshield and front fairing up and
away toward the front of the motorcycle.
7. Slide the front fairing support brackets off the
upper screws loosened in Step 3.
c.
Lift the saddlebag assembly slightly up and
8. Remove the windshield and front fairing.
forward and pull it off the mounting studs.
9. Install by reversing these removal steps. Tighten
d.
Remove the saddlebag assembly.
the screws securely.
3.
On FXDXT models, perform the following:
a. Hold onto the saddlebag handle.
SADDLEBAGS
b. Press the release pin at the rear of the
saddlebag frame.
1. Place the motorcycle on level ground on the jiffy
c. Pull the bottom of the saddlebag slightly
stand.
away from the frame.
2. On FXDS-CONV models, perform the follow-
d. Slide the saddlebag up and toward the front of
ing:
the motorcycle and pull it off the mounting
a. Hold onto the saddlebag handle.
bushings and acorn nuts.
b. Working under the saddlebag, unscrew the
e. Remove the saddlebag assembly.
two large knobs securing the saddlebag frame
4.
Install by reversing these removal steps. Make
to the mounting studs on the fender brace.
sure the saddlebag is locked into place.
SUPPLEMENT
2002-2005 MODEL SERVICE INFORMATION
This Supplement contains all procedures and spec-
ifications unique to the 2002-2005 models. If a spe-
cific procedure is not included, refer to procedure in
the prior chapter in the main body of this manual.
This Supplement is divided into sections that corre-
spond to the chapters in the main body of this manual
Tables 1-12 are located at the end of the appropriate
sections.
14
502
SUPPLEMENT
CHAPTER ONE
GENERAL INFORMATION
Table 1 MODEL DESIGNATION
2005
FXDC, FXDCI Dyna Super Glide Custom
Table 2 MOTORCYCLE DIMENSIONS
Wheel base
FXDWG, FXDWGI
66.10 in. (1678.95 mm)
FXDL, FXDLI
65.60 in. (1666.24 mm)
FXD (2003)
62.80 in. (1595.12 mm)
FXD, FXDI (2004-on)
62.50 in. (1587.50 mm)
FXDX, FXDXI
63.88 in. (1622.55 mm)
FXDX T-Sport
63.90 in. (1623.06 mm)
FXDC, FXDCI
62.50 in. (1587.50 mm)
Overall length
FXDWG (2003)
94.50 in. (2400.30 mm)
FXDWG, FXDWGI (2004-on)
93.60 in. (2377.40 mm)
FXDL, FXDLI
94.00 in. (2387.60 mm)
FXD, FXDI
91.00 in. (2311.40 mm)
FXDX (2003)
92.88 in. (2359.15 mm)
FXDX, FXDXI (2004-on)
91.40 in. (2321.56 mm)
FXDX T-Sport
92.60 in. (2352.04 mm)
FXDC, FXDCI
91.00 in. (2311.40 mm)
Overall width
FXDWG (2003)
33.50 in. (850.90 mm)
FXDWG, FXDWGI (2004-on)
35.00 in. (889.00 mm)
FXDL (2003)
28.50 in. (723.90 mm)
FXDL, FXDLI (2004-on)
36.80 in. (934.72 mm)
FXD (2003)
28.50 in. (723.90 mm)
FXD, FXDI (2004-on)
36.80 in. (934.72 mm)
FXDX (2003)
33.00 in. (838.20 mm)
FXDX, FXDXI (2004-on)
36.80 in. (934.72 mm)
FXDX T-Sport
33.00 in. (838.20 mm)
FXDC, FXDCI
36.80 in. (934.72 mm)
Road clearance
FXDWG, FXDWGI
5.40 in. (137.16 mm)
FXDL, FXDLI
4.60 in. (116.84 mm)
FXD, FXDI
5.40 in. (137.16 mm)
FXDX, FXDXI
5.40 in. (137.16 mm)
FXDX T-Sport
5.90 in. (149.86 mm)
FXDC, FXDCI
5.40 in. (137.16 mm)
Overall height
FXDWG (2003)
47.50 in. (1206.50 mm)
FXDWG, FXDWGI (2004-on)
47.80 in. (1214.12 mm)
FXDL (2003)
47.50 in. (1206.50 mm)
FXDL, FXDLI (2004-on)
44.80 in. (1137.92 mm)
FXD (2003)
47.50 in. (1206.50 mm)
(continued)
2002-2005 MODEL SERVICE INFORMATION
503
Table 2 MOTORCYCLE DIMENSIONS (continued)
Overall height (continued)
FXD, FXDI (2004-on)
47.80 in. (1214.12 mm)
FXDX (2003)
51.25 in. (1301.75 mm)
FXDX, FXDXI (2004-on)
47.40 in. (1204.00 mm)
FXDX T-Sport
51.25 in. (1301.75 mm)
FXDC, FXDCI
44.80 in. (1137.92 mm)
Saddle height
FXDWG (2003)
26.75 in. (679.45 mm)
FXDWG, FXDWGI (2004-on)
26.80 in. (680.72 mm)
FXDL, FXDLI
25.20 in. (640.08 mm)
FXD, FXDI
26.50 in. (673.10 mm)
FXDX (2003)
27.25 in. (692.15 mm)
FXDX, FXDXI (2004-on)
27.30 in. (693.42 mm)
FXDX T-Sport
27.88 in. (708.15 mm)
FXDC, FXDCI
26.50 in. (673.10 mm)
Table 3 MOTORCYCLE WEIGHT (DRY)
Model
lbs.
kg
FXDWG (2003)
612
277.6
FXDWG, FXDWGI (2004-on)
639
290
FXDL (2003)
614
278.5
FXDL, FXDLI (2004-on)
623
282.6
FXD (2003)
612
277.6
FXD, FXDI (2004-on)
622
282
FXDX (2003)
612
277.6
FXDX, FXDXI (2004-on)
622
282
FXDX T-Sport
642
291.2
FXDC, FXDCI
622
282
Table 4 SPECIAL TOOLS
Description
Manufacturer
Part No.
Cylinder head support stand
H-D
HD-39782-A
Intake valve seat adapter
H-D
HD-39782A-3
Exhaust valve seat adapter
H-D
HD-39782A-4
Valve guide driver
H-D
B-45524-1
Valve guide installer sleeve
H-D
B-45524-2A
Valve guide brush
H-D
HD-34751-A
Valve guide reamer
H-D
B-45523
14
T-handle
H-D
HD-39847
Valve guide reamer honing
lubricant
H-D
HD-39964
Valve guide hone
H-D
B-45525
Crankshaft bearing support tube
H-D
HD-42720-5
Pilot/driver
H-D
B-45655
Crankshaft support fixture
H-D
HD-44358
Sprocket shaft bearing cone
installer
H-D
HD-997225-55B
504
SUPPLEMENT
CHAPTER THREE
LUBRICATION, MAINTENANCE AND TUNE-UP
1
2
TIRES AND WHEELS
3
Tire Inspection
Tire inspection is the same as on previous models
with the addition of tread wear indicator bars on
original equipment Dunlop tires.
When the tire tread is worn to 1/32 in. (0.8 mm)
or less, the tread wear indicator bars will appear on
the tread surface as shown in Figure 1. The location
of the bars is noted with a raised triangle on the tire
sidewall. The tire must be replaced at this time.
4
PERIODIC LUBRICATION
Primary Chaincase Oil Level Check
(All 2005 Models)
The primary chaincase oil level check is identical
to prior to years with the exception of the seal on the
clutch inspection cover. The O-ring has been replaced
with a large gasket. Install the new large gasket as fol-
lows:
1. Position the new gasket with the rubber molding
CAUTION
and the words Toward Engine facing away from the
Do not push the screw through the tri-
clutch inspection cover.
angular shaped hole in the new gasket
2. Align the triangular shaped hole in the new gasket
as the sealing qualities of the gasket
with the top hole in the clutch inspection cover.
will be damaged.
2002-2005 MODEL SERVICE INFORMATION
505
6. Use a T27 Torx driver and tighten the screws in a
5
crisscross pattern to 84-108 in.-lb. (9.5-12.2 N•m).
Primary Chaincase Oil Change
(2004-On Models)
The primary chaincase oil change is the same as
on previous models with the exception of the addi-
tional O-ring seal on the drain plug (Figure 3). The
drain plug is now equipped with an O-ring seal that
must be replaced every time the drain plug is re-
moved. Install a new O-ring onto the drain plug, in-
stall it and tighten to 36-60 in.-lb (4.1-6.8 N•m).
6
Refer to the preceding procedure regarding the
installation of the new clutch cover gasket.
PERIODIC MAINTENANCE
Throttle Cable Adjustment
(Fuel Injected Models)
There are two different throttle cables. At the throt-
tle grip, the front cable is the throttle control cable (A,
Figure 4) and the rear cable is the idle control cable
(B). At the fuel induction module, the throttle control
7
cable is located at the bottom receptacle in the throttle
wheel and the idle control cable is located at the top.
1. Remove the air filter and backing plate as de-
scribed in Chapter Seven.
2. At the handlebar, perform the following:
a. Roll the rubber boots (Figure 5) off the adjust-
ers.
b. Loosen both control cable adjuster locknuts (A,
Figure 6), then turn the cable adjusters (B)
clockwise as far as possible to increase cable
14
slack.
3. Turn the handlebars so the front wheel points
straight ahead. Then turn the throttle grip to open the
throttle completely and hold it in this position.
4. At the handlebar, turn the throttle control cable ad-
3.
Insert the screw, with the captive washer, though
juster (B, Figure 6) counterclockwise until the throt-
the clutch inspection cover and carefully thread it it all
tle cam (A, Figure 7) stops just touches the cam stop
the way through the triangular shaped hole in the
(B) on the throttle body. Then tighten the throttle cable
new gasket.
adjuster and release the throttle grip.
4. Install the clutch inspection cover and new gasket
5. Turn the front wheel all the way to the full right
onto the chaincase cover and thread the top screw part
lock position and hold it there.
way in.
6. At the handlebar, turn the idle cable adjuster until
5. Make sure the clutch inspection cover (Figure 2) is
the lower end of the idle control cable housing just
correctly aligned with the chaincase cover and install
contacts the spring in the cable support sleeve (C, Fig-
the remaining four screws with captive washers.
ure 7). Tighten the idle control cable locknut.
506
SUPPLEMENT
7. Check the adjustment as follows:
WARNING
a. Operate the throttle grip to make sure the cables
Do not ride the motorcycle until the
return to the idle position when released.
throttle cables are properly adjusted.
Also, the cables must not catch or pull
b. If the cable does not return to idle, turn the idle
when the handlebar is turned from side
adjuster shortening the sleeve until correct ad-
to side. Improper cable routing and ad-
justment is reached. Tighten the locknut.
justment can cause the throttle to stick
8. Install the backing plate and the air filter as de-
open. This could cause loss of control
scribed in Chapter Seven.
and a possible crash. Recheck this ad-
9. Shift the transmission into neutral and start the en-
justment before riding the motorcycle.
gine.
10. Increase engine speed several times. Release the
throttle and make sure the engine speed returns to idle.
Air Filter Element Removal/Installation
If the engine speed does not return to idle, at the han-
(Fuel Injected Models)
dlebar, loosen the idle control cable adjuster locknut
Air filter service is identical to carbureted mod-
and turn the cable adjuster clockwise as required.
els.
Tighten the idle control cable adjuster locknut.
11. Allow the engine to idle. Then turn the handlebar
from side to side. Do not operate the throttle. If the en-
IDLE SPEED ADJUSTMENT
gine speed increases when the handlebar assembly is
turned, the throttle cables are routed incorrectly or
Fuel Injected Models
damaged. Turn off the engine. Recheck cable routing
and adjustment.
Idle speed adjustment on fuel injected models
12. Roll the rubber boots (Figure 5) back onto the ad-
can only be set by a Harley-Davidson dealership us-
justers.
ing the Digital Technician diagnostic unit.
Table 5 MAINTENANCE TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N•m
Clutch inspection cover screws
-
84-108
9.5-12
Primary chaincase drain plug
-
36-60
4.1-6.8
CHAPTER FOUR
ENGINE
Refer to Table 6 and Table 7 for revised engine
ROCKER ARMS AND PUSHRODS
specifications for 2003-2005 models.
Removal/Installation
ENGINE
The removal procedure is the same as on prior years.
The installation procedure is the same as on prior
Removal/Installation
years with the exception of the breather assembly
The removal procedure is the same as on prior
components. The 1999-2002 models were equipped
years. On fuel injected models, remove the fuel injec-
with a breather assembly consisting of four parts, the
tion module as described in the Chapter Seven section
cover, filter element, breather baffle and gaskets. On
of this Supplement.
the 2003 models the breather assembly was combined
2002-2005 MODEL SERVICE INFORMATION
507
8
11
ROCKER ARM
ASSEMBLY
12
1. Bolt
2. Breather assembly
3. Filter assembly
4. Rocker arm assembly
into a one-piece unit along with the filter element and
9
gasket (Figure 8). The 2004-on models use the com-
ponents equipped on the 1999-2002 models.
Front cylinder head
Rear cylinder head
CYLINDER HEAD
Removal/Installation
On 2004-on models, refer to Figure 9 for the front
and rear cylinder head bolt tightening sequence.
14
Tighten the cylinder head bolts as follows:
1. Starting with bolt No. 1, tighten each bolt in order
to 120-144 in.-lb. (13.6-16.3 N•m).
2. Starting with bolt No. 1, tighten each bolt in order
10
to 15-17 ft.-lb. (20.3-23.1 N•m).
3. Make a vertical mark with a permanent marker on
each bolt head (A, Figure 10). Make another mark on
the cylinder head (B, Figure 10) at a 90° angle, or 1/4
turn from the mark on the head bolt.
4. Use the marks as a guide and tighten each bolt head
90°, or 1/4 turn, clockwise until the marks are aligned
(Figure 11).
On 2004-on models, the two O-rings (Figure 12)
are no longer used in junction with the cylinder head
dowel pins.
508
SUPPLEMENT
VALVE AND VALVE COMPONENTS
13
(2005 MODELS)
CYLINDER HEAD
(2005 MODELS)
Complete valve service requires a number of spe-
cial tools, including a valve spring compressor, to re-
move and install the valves. The following procedures
describe how to check for valve component wear and
to determine what type of service is required.
Refer to Figure 13.
Valve Removal
1. Remove the cylinder head as described in Chap-
ter Four.
2. Install the valve spring compressor (Figure 14)
squarely over the valve spring upper retainer (Fig-
ure 15) and against the valve head.
CAUTION
To avoid loss of spring tension, com-
press the spring only enough to re-
move the valve keepers.
3. Tighten the valve spring compressor until the
valve keepers separate from the valve stem. Lift the
valve keepers out through the valve spring com-
pressor with a magnet or needlenose pliers.
4. Gradually loosen the valve spring compressor
and remove it from the cylinder head.
5. Remove the spring upper retainer and the
valve spring.
CAUTION
Remove any burrs from the valve stem
groove before removing the valve
(Figure
16); otherwise the valve
guide will be damaged as the valve
stem passes through it.
6. Remove the valve from the cylinder head while
1.
Valve keepers
rotating it slightly.
2.
Upper retainer
7. Using needlenose pliers, carefully twist and re-
3.
Spring
move the valve stem seal/spring seat assembly from
4.
Valve stem seal/spring
seat assembly
the valve guide. Discard the valve stem seal/spring
5.
Valve guide
seat assembly.
6.
Valve guide collar
(exhaust valve only)
CAUTION
7.
Bolt-short
Keep the components of each valve
8.
Bolt-long
assembly together by placing each set
9.
Cylinder head
in a divided carton, or into separate
10.
Valve seat
small boxes or small reclosable plas-
11.
Valve
tic bags. Identify the components as
12.
Gasket
either intake or exhaust. If both cylin-
2002-2005 MODEL SERVICE INFORMATION
509
14
18
ders are disassembled, also label the
15
components as front and rear. Do not
intermix components from the valves
or excessive wear may result.
8. Repeat Steps 3-7 to remove the remaining valve.
Valve Inspection
When measuring the valves and valve compo-
nents in this section, compare the actual measure-
ments to the new and wear limit specifications in
Table 6. Replace parts that are out of specification
or are damaged as described in this section.
16
1. Clean valves in solvent. Do not gouge or damage
the valve seating surface.
2. Inspect the valve face. Minor roughness and pit-
Deburr
ting (Figure 17) can be removed by lapping the
valve as described in this chapter. Excessive un-
evenness to the contact surface indicates the valve
is not serviceable.
3. Inspect the valve stem for wear and roughness.
Valve
Then measure the valve stem outside diameter with
stem
a micrometer (Figure 18).
14
4. Remove all carbon and varnish from the valve
guides with a stiff spiral wire brush before measur-
ing wear.
17
5. Measure the valve guide inside diameter with a
small hole gauge (Figure 19) at the top, center and
bottom locations. Then measure the small hole gauge.
6. Determine the valve stem-to-valve guide clear-
ance by subtracting the valve stem outside diameter
from the valve guide inner diameter.
7. If a small hole gauge is not available, insert each
valve into its guide. Attach a dial indicator to the
valve stem next to the head (Figure 20). Hold the
valve slightly off its seat and rock it sideways in
both directions 90° to each other. If the valve rocks
510
SUPPLEMENT
19
20
Dial gauge
Valve
more than slightly, the guide is probably worn. Take
the cylinder head to a Harley-Davidson dealership
21
or machine shop and have the valve guides
measured.
8. Check the valve spring as follows:
a. Inspect the valve spring for visual damage.
b. Use a square to visually check the spring for
distortion or tilt (Figure 21).
c. Measure the valve spring free length with a
vernier caliper (Figure 22) and compare it to
the specifications.
d. Repeat sub-steps a-c for each valve spring.
e. Replace the defective spring(s).
9. Check the valve spring upper retainer seats for
22
cracks or other damage.
10. Check the valve keepers fit on the valve stem
end (Figure 23). They should index tightly into the
valve stem groove.
11. Inspect the valve seats (Figure 24) in the cylin-
der head. If they are worn or burned, they can be re-
conditioned as described in Chapter Four. Seats and
valves in near-perfect condition can be recondi-
tioned by lapping with fine Carborundum paste.
a. Clean the valve seat and corresponding valve
mating areas with contact cleaner.
b. Coat the valve seat with layout fluid.
c. Install the valve into its guide and tap it
23
against its seat. Do not rotate the valve.
d. Lift the valve out of the guide and measure
the seat width at various points around the
seat with a vernier caliper.
e. Compare the seat width with the specifica-
tions. If the seat width is less than specified or
uneven, resurface the seats as described in
Chapter Four.
f. Remove all layout fluid residue from the seats
and valves.
2002-2005 MODEL SERVICE INFORMATION
511
Valve Installation
24
1. Clean the end of the valve guide.
2. Assemble the valve stem seal/spring seat assem-
bly as follows:
a. Apply engine oil to the oil seal (A, Figure 25)
and the spring seat (B).
b. Position the oil seal with the spring end going
in last (C, Figure 25) and insert it into the
spring seat.
c. Press the oil seal down until it seats com-
pletely within the spring seat (D, Figure 25).
3. Coat a valve stem with Torco MPZ, molybde-
num disulfide paste or equivalent. Install the valve
25
part way into the guide. Then slowly turn the valve
as it enters the oil seal and continue turning it until
the valve is installed all the way.
4. Work the valve back and forth in the valve guide
to ensure the lubricant is distributed evenly within
the valve guide.
5. Withdraw the valve and apply an additional coat
of the lubricant.
6. Reinstall the valve into the valve guide but do
not push the valve past the top of the valve guide.
7. Push the valve all the way into the cylinder head
until it bottoms (A, Figure 26).
CAUTION
The oil seal will be torn as it passes
the valve stem keeper groove if the
plastic capsule is not installed in Step
8. The capsule is included in the top
end gasket set.
8. Hold the valve in place and install the plastic
capsule (B, Figure 26) onto the end of the valve
stem. Apply a light coat of clean engine oil to the
14
outer surface of the capsule.
9. With the valve held in place, slowly slide the
valve stem seal/spring seat assembly onto the valve
26
stem. Push the assembly down until it bottoms on
the machined surface of the cylinder head.
10. Remove the plastic capsule from the valve
stem. Keep the capsule as it will be used on the re-
maining valves.
11. Position the valve spring with tapered end go-
ing on last and install the valve spring (A, Figure
27). Make sure it is properly seated on the spring
seat.
12. Install the upper spring retainer (B, Figure 27)
on top of the valve spring.
512
SUPPLEMENT
CAUTION
To avoid loss of spring tension, only
27
compress the springs enough to in-
stall the valve keepers.
13. Compress the valve spring with a valve spring
compressor (Figure 14) and install the valve keep-
ers (Figure 28).
14. Make sure both keepers are seated around the
valve stem prior to releasing the compressor.
15. Slowly release tension from the compressor
and remove it. After removing the compressor, in-
spect the valve keepers to make sure they are prop-
erly seated (Figure 29). Tap the end of the valve
stem with a soft-faced hammer to ensure the keepers
28
are properly seated.
16. Repeat Steps 1-15 for the remaining valve.
17. Install the cylinder head as described in this
Supplement.
Valve Guide Replacement
Tools
The following tools or their equivalents are re-
quired to replace the valve guides.
1. Cylinder head support stand (HD-39782-A).
2. Intake valve seat adapter (HD-39782A-3).
29
3. Exhaust valve seat adapter (HD-39782A-4).
4. Valve guide driver (B-45524-1).
5. Valve guide installer sleeve (B-45524-2A).
6. Valve guide brush (HD-34751-A).
7. Valve guide reamer (B-45523) and T-handle
(HD-39847).
8. Valve guide reamer honing lubricant (HD- 39964).
9. Valve guide hone (B-45525).
10. Hydraulic press.
Procedure
a.
Install the intake (A, Figure
30) or exhaust (B)
CAUTION
valve seat adapter into the tube at the top of the
The valve guides must be removed and
support stand (C).
installed using the following special
b.
Install the support stand on the hydraulic press
tools to avoid damage to the cylinder
table.
head. Use the correct size valve guide
removal tool to remove the valve guides
c.
Install the cylinder head (A, Figure 31) onto the
or the tool may expand the end of the
support stand (B) centering the cylinder head
guide. An expanded guide will widen
valve seat onto the seat adapter.
and damage the guide bore in the cylin-
d.
Insert the valve guide driver (C, Figure 31) into
der head as it passes through it.
the valve guide bore until it stops on the valve
1. Remove the old valve guide as follows:
guide shoulder.
2002-2005 MODEL SERVICE INFORMATION
513
30
32
new guides. Then purchase the new valve guides to
31
match their respective bore diameters. Determine the
bore diameter as follows:
a. Measure the valve guide bore diameter in the
cylinder head with a bore gauge or snap gauge.
Record the bore diameter.
b. The new valve guide outside diameter must be
0.0020-0.0033 in. (0.050-0.083 mm) larger
than the guide bore in the cylinder head. When
purchasing new valve guides, measure the
new guide’s outside diameter with a microme-
ter. If the new guide’s outside diameter is not
within this specification, install oversize valve
guide(s). See a Harley-Davidson dealership
for available sizes and part numbers.
NOTE
14
e.
Center the valve guide driver under the press
The intake valves are not equipped with
ram and make sure the driver is perpendicular to
the valve guide collar. On exhaust
the press table.
valves, the collar must be installed onto
f.
Support the cylinder head, slowly apply pres-
the valve guide, see Step 4.
sure and drive valve guide out through the com-
4. On exhaust valve guides, install the collar onto
bustion chamber side. Discard the valve guide.
the valve guide as follows:
g.
Remove the cylinder head and special tools
a. Insert the valve guide collar (A, Figure 32) onto
from the press bed.
the installer sleeve (B) and center it squarely onto
h.
Repeat sub-steps a-g for the remaining valve
the counter bore of the installer sleeve.
guide.
b. Install the new valve guide (C, Figure 32) into
2.
Clean the valve guide bores in the cylinder head.
the installer sleeve (B) until it contacts the valve
3.
Because the valve guide bores in the cylinder head
guide collar.
may have enlarged during removal of the old guides,
c. Install the installer sleeve and valve guide onto
measure each valve guide bore prior to purchasing the
the press table and center it.
514
SUPPLEMENT
d. Slowly apply pressure and drive valve guide
33
onto the collar until the valve guide bottoms in
the installer sleeve.
e. Remove the valve guide/collar assembly (D,
Figure 32) from the installer sleeve.
5. Apply a thin coat of Vaseline to the entire outer
surface of the valve guide before installing it in the
cylinder head.
CAUTION
When installing oversize valve guides,
make sure to match each guide to its re-
spective bore in the cylinder head.
6.
Install the new valve guide as follows:
a.
Install the intake (A, Figure 30) or exhaust (B)
valve seat adapter into the tube at the top of the
support stand (C).
b.
Install the support stand on the hydraulic press
table.
c.
Install the cylinder head (A, Figure 33) onto the
support stand (B) centering the cylinder head
valve seat onto the seat adapter.
d.
On exhaust valves, position the valve guide
ceptacle until the installer sleeve (C, Figure 33)
with the collar end going in last. The intake
contacts the machined surface of the cylinder
valve guides are non-directional, either end can
head.
go in first.
l.
Remove the cylinder head and special tools
e.
Install the valve guide onto the cylinder head re-
from the press bed.
ceptacle.
m. Repeat sub-steps a-l for the remaining valve
f.
Install the valve guide installer sleeve (C, Fig-
guides.
ure 33) over the valve guide, and insert the ta-
7.
Replacement valve guides are sold with a smaller
pered end of the valve guide driver (D) into the
inside diameter than the valve stem. Ream the guide to
installer sleeve.
fit the valve stem as follows:
g.
Center the valve guide driver under the press
ram and make sure the driver is perpendicular to
a. Apply a liberal amount of reamer lubricant to
the press table.
the ream bit and to the valve guide bore.
h.
Support the cylinder head, slowly apply pres-
b. Start the reamer straight into the valve guide
sure and slowly start to drive the valve guide
bore.
into the cylinder head receptacle. Stop and back
off the press ram to allow the valve guide to
CAUTION
center itself.
Only apply pressure to the end of the
i.
Verify that the support stand (A, Figure 33) and
drive socket. If pressure is applied to the
valve guide driver (D) are square with the press
T-handle, the bore will be uneven,
table.
rough cut and tapered.
j.
Once again apply press pressure and continue
to drive the valve guide part way into the cylin-
c. Apply thumb pressure to the end of the drive
der head receptacle. Once again, stop and back
socket portion of the T-handle while rotating the
off the press ram to allow the valve guide to
T-handle clockwise. Only light pressure is re-
center itself.
quired. Apply additional lubricant to the
k.
Again apply press pressure and continue to
reamer and into the valve guide while rotating
drive the valve guide into the cylinder head re-
the reamer.
2002-2005 MODEL SERVICE INFORMATION
515
d. Start the drill and move the hone back and
34
forth in the valve guide bore for 10 to 12 com-
plete strokes to obtain a 60° crosshatch pat-
tern.
9. Repeat Steps 7 and 8 for each valve guide.
10. Soak the cylinder head in a container filled with
hot, soapy water. Then clean the valve guides with a
valve guide brush or an equivalent bristle brush. Do
not use a steel brush. Do not use cleaning solvent,
kerosene or gasoline as these chemicals will not re-
move all of the abrasive particles produced during
the honing operation. Repeat this step until all of the
valve guides are thoroughly cleaned. Then rinse the
cylinder head and valve guides in clear, cold water
35
and dry them with compressed air.
11. After cleaning and drying the valve guides, apply
clean engine oil to the guides to prevent rust.
12. Resurface the valve seats as described in Valve
Seat Reconditioning in this chapter.
PISTONS AND PISTON RINGS
Piston Clearance
Later model 2003 and the 2004-on models have a
d.
Continue to rotate the reamer until the entire bit
small oval-shaped opening on the piston skirt coat-
has traveled through the valve guide and the
ing. This opening is used to locate the micrometer
shank of the reamer rotates freely.
for an accurate outer diameter measurement. This
small oval-shaped opening is too small for the stan-
CAUTION
dard flat anvil micrometer to obtain an accurate
Never back the reamer out through the
measurement. Use a 3-4 in. blade or ball anvil style
valve guide as the guide will be dam-
micrometer, or a 4-5 in. micrometer with spherical
aged.
ball adapters to achieve a correct measurement.
1. Make sure the piston skirt and cylinder bore is
e.
Remove the T-handle from the reamer. Remove
clean and dry.
the reamer from the combustion chamber side
14
2. Measure the cylinder bore with a bore gauge
of the cylinder head.
(Figure 34) as described under Cylinder Block In-
f.
Apply low-pressure compressed air to remove
spection in Chapter Four.
the small shavings from the valve guide bore.
Then clean the valve guide bore with the small
NOTE
spiral brush.
Some early 2003 models were not
8.
Hone the valve guide as follows:
equipped with the bare aluminum
spots on the piston skirt coating.
a. Install the valve guide hone into a high-speed
electric drill.
3A. On early 2003 models, measure the piston di-
b. Lubricate the valve guide bore and hone
ameter with a micrometer as follows:
stones with the reamer lubricant—do not use
a. Hold the micrometer at the bottom of the pis-
motor oil.
ton skirt at a right angle to the piston pin bore
c. Carefully insert the hone stones into the valve
(Figure 35). Adjust the micrometer so the
guide bore.
spindle and anvil just touch the skirt.
516
SUPPLEMENT
b. Start below the bottom ring and slowly move
36
the micrometer toward the bottom of the skirt.
c. The micrometer will be loose, then tight at
about 0.5 in. (12.7 mm) from the bottom and
then loose again.
d. Measure the piston skirt at the tightest point.
3B. On late 2003 and 2004-on models, measure the
piston diameter with a micrometer as follows:
a. Use the previously described special microm-
eter and correctly position it on the bare alu-
minum spot on each side of the piston as
shown in Figure 36.
1. Place the support tube with the A side facing up
b. Measure the piston at this location only.
on the press bed.
4. Subtract the piston diameter from the largest
2. Position the right side crankcase with the outer
bore diameter; the difference is piston-to-cylinder
surface facing up and position the bearing directly
clearance. If the clearance exceeds the specification
over the support tube on the press bed.
in Table 6, the pistons should be replaced and the
3. Install the pilot shaft through the bearing and
cylinders bored oversize and then honed. Purchase
into the support tube.
the new pistons first. Measure their diameter and
4. Center the press driver over the pilot shaft.
add the specified clearance to determine the proper
5. Hold the crankcase half parallel to the press bed
cylinder bore diameter.
and have an assistant slowly apply press pressure on
the pilot shaft until the bearing is free from the case
CAMSHAFT SUPPORT PLATE
half.
6. Remove the case half and special tools from the
Rear Camshaft Sprocket and
press bed.
Crankshaft Drive Sprocket Alignment
The procedure is identical to previous models.
Installation
Refer to Table 7 for sprocket spacer thickness and
1. Apply a light coat of clean engine oil to the outer
part numbers.
surface of the bearing and to the crankcase recepta-
cle.
CRANKCASE AND CRANKSHAFT
2. Place the support tube with the B side facing up
on the press bed.
Right Side Main Bearing Replacement
3. Position the right side crankcase with the outer
surface facing up on the press bed.
Refer to Figure 37.
4. Position the new bearing with the manufac-
The following tools or their equivalents are re-
turer’s marks facing up and place it over the crank-
quired to remove and install the right side main
case receptacle.
bearing:
5. Install the pilot/driver through the bearing and
1. Hydraulic press.
into the support tube.
2. Crankshaft bearing support tube: (HD-42720-5).
6. Center the press driver over the pilot driver.
3. Pilot/driver: (B-45655).
7. Slowly apply press pressure on the pilot driver,
pressing the bearing into the crankcase. Apply pres-
sure until resistance is felt and the bearing bottoms
Removal
in the support tube. This will correctly locate the
bearing within the crankcase. Remove the pilot
NOTE
driver.
The Harley-Davidson support tube is
marked with an A on one end and a B
8. Remove the crankcase and the support tube from
on the other.
the press bed.
2002-2005 MODEL SERVICE INFORMATION
517
37
CRANKCASE ASSEMBLY
1. Connecting rod bushing
11. Retaining ring
2. Crankshaft assembly
12. Locating dowel
3. Oil hose fitting
13. O-ring
4. Crankshaft main bearing
14. O-ring
5. Needle bearing-camshaft
15. Locating dowel
6. Dowel pin
16. Medallion plate
7. Plug
17. Thrust washer
8. O-ring
18. Oil seal
9. Piston cooling jet
19. Sprocket shaft spacer
14
10. Screw
20. Bolt
9. Check on each side of the crankcase to make
The following tools or their equivalents are re-
sure the bearing is centered within the receptacle. If
quired to remove and install the right side main
not, reposition the bearing until it is centered
bearing:
correctly.
1. Hydraulic press.
10. Spin the bearing to make sure it rotates
2. Crankshaft bearing support tube: (HD-42720-5).
smoothly with no binding.
3. Pilot/driver: (B-45655).
Left Side Main Bearing Assembly
Bearing removal
Replacement
1. Place the crankcase on the workbench with the
Refer to Figure 37.
inboard surface facing up.
518
SUPPLEMENT
2. If still in place, remove the crankshaft spacer
38
from the bearing bore.
3. Carefully pull the thrust washer from the outer
surface of the crankcase past the oil seal.
4. Place the support tube on the workbench with
the A side facing up.
5. Position the crankcase with the inner surface
facing up and place the bearing bore over the sup-
port tube.
6. Use a suitable size drift and tap the oil seal out of
the bearing bore. Discard the oil seal.
7. Turn the crankcase over with the inner surface
facing up.
39
CAUTION
Do not damage the crankcase retain-
ing ring groove with the screwdriver.
The groove must remain sharp to cor-
rectly seat the retaining ring.
8. The roller bearing (A, Figure 38) is secured in
the crankcase with a retaining ring (B) on the inner
surface of the bearing bore. Remove the retaining
ring (B, Figure 38) as follows:
a. Use a flat tip screwdriver and place it under
the retaining ring. Carefully lift the edge of
the retaining ring up and out of the crankcase
groove.
Bearing installation
b. Slide the tip of the screwdriver around the
edge of the bearing and continue to lift the re-
1. Apply clean engine oil, or press lube, to the bear-
taining ring out of the crankcase groove.
ing receptacle in the crankcase and to the outer race
c. Remove the retaining ring.
of the new bearing.
2. Position the support tube (A, Figure 40) on the
9. Position the support tube (A, Figure 39) on the
press bed with the A side facing up.
press bed with the A side facing up.
3. Position the crankcase half with the inner side
10. Position the crankcase half with the outer side
facing up and position the crankshaft’s bearing
facing up and position the crankshaft’s bearing bore
bore over the support tube. Correctly align the two
over the support tube. Correctly align the two parts.
parts.
11. Slide the pilot/driver (B, Figure 39) through
4. Correctly position the new bearing (B, Figure
the crankcase bearing and into the support.
40) over the crankcase bore with the manufacturer’s
12. Center the press ram (C, Figure 39) directly
marks facing down.
over the pilot/driver (B) and slowly press the bear-
5. Slide the pilot/driver (C, Figure 40) through the
ing out of the crankcase.
new bearing and the crankcase and into the support.
13. Remove the crankcase and special tools from
6. Center the press ram (D, Figure 40) directly
the press bed.
over the pilot/driver (C) and slowly press the bear-
14. Clean the crankcase half in solvent and dry it
ing into the crankcase until it lightly bottoms in the
with compressed air.
crankshaft bearing bore.
2002-2005 MODEL SERVICE INFORMATION
519
CAUTION
40
Do not damage the crankcase retain-
ing ring groove with the screwdriver.
The groove must remain sharp to cor-
rectly seat the retaining ring.
NOTE
If the retaining ring will not correctly
seat in the crankcase groove, the
bearing is not correctly seated in the
crankcase bore. Repeat Steps 2-6
10. Install the bearing’s new retainer ring as fol-
lows:
a. Work the retaining ring into the crankcase
groove being careful not to damage the crank-
case groove.
b. Use a flat tip screwdriver and push the retain-
41
ing ring. Continue to push the retaining ring
into the crankcase groove and make sure it is
correctly seated in the groove.
Crankshaft End Play Inspection
All 2003-on models are equipped with assembled
roller bearings and this procedure is no longer nec-
essary.
Crankshaft Left Side Main Bearing Assembly
Inner Race Replacement
Removal
1. Support the crankshaft in a support fixture
(HD-44358), or an equivalent, with the bearing side
14
facing up (A, Figure 41).
2. Place a hardened plug (B, Figure 41) between the
bearing puller and the end of the crankshaft.
3. Install the bearing splitter under the bearing inner
race (C, Figure 41).
4. Apply graphite lubricant to the bearing puller
7.
Remove the crankcase and special tools from the
center screw, and attach a bearing puller (D, Figure
press.
41) to the splitter.
8. Make sure the bearing has been pressed in past
the retaining ring groove. If the groove is not visible
WARNING
above the bearing, repeat Steps 2-6 until the groove
In Step 5, never use the heat gun in
is visible.
conjunction with the penetrating oil.
9. Position the crankcase on the workbench with
The heat from the gun may ignite the
the inner surface facing up.
oil resulting in a fire.
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