Harley Davidson 2005 touring models. Service repair manual — page 70
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ROCKER HOUSING
3.5
VALVE SPRING TO ROCKER
f1576x3x
1
HOUSING CLEARANCE
1.
After torquing cylinder head bolts, continue top end over-
haul by installing the rocker housings. See ASSEMBLY
under TOP END OVERHAUL in the Touring Models Ser-
vice Manual.
2.
Install a new rocker housing gasket on the cylinder head
flange.
CAUTION
Even though all bolt holes (rocker housing, rocker arm
support plate and breather assembly) may appear to be
in alignment, the rocker housing gasket may be installed
upside down. An upside down gasket will result in an
open breather channel causing an oil leak when the vehi-
cle is started, possibly resulting in engine and/or prop-
erty damage.
3.
See Figure 3-2. Verify that the rocker housing gasket is
WRONG
installed correctly by noting that the breather channel is
concealed.
4.
With the indent facing forward, place the rocker housing
f1577x3x
2
into position aligning the holes in the housing with those
in the gasket.
RIGHT
1.
Breather channel exposed (wrong)
2.
Breather channel concealed (right)
Figure 3-2. Rocker Housing Gasket
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5.
Apply a small dab of LOCTITE THREADLOCKER 243
f1578x3x
(blue) (HD-99642-97) to threads of six rocker housing
2
3
bolts.
6.
See Figure 3-3. Start the rocker housing bolts, two long
bolts on the left side of the engine, four intermediate
bolts in the interior.
1
NOTE
Rocker housing and rocker cover bolts have both an internal
4
and external hex, which allows the bolts to be installed with
either a short 3/16 inch allen wrench (tight spaces), or a 7/16
inch socket or open end/box wrench (open spaces). If the
engine is left in the chassis for service, the short 3/16 inch
allen wrench is indispensable when installing the rocker
housing and rocker cover bolts on the left side of the engine
(particularly the rear) where there is close proximity to the
frame.
f1578x3x
7.
From the cam cover side, press rocker cover diagonally
toward the intake valve.
5
8.
See Figure 3-5. Snug bolts in torque sequence to hold
7
6
housing in position. Do not torque.
1.
Long bolt 1-3/4 in.
9.
See Figure 3-4. Using a feeler gauge, check for clear-
2.
Intermediate bolt 1-1/4 in.
ance around both valve spring assemblies and the
3.
Intermediate bolt 1-1/4 in.
rocker housing.
4.
O-ring
10. If spring assembly contacts rocker housing at any point
5.
Intermediate bolt 1-1/4 in.
around springs, loosen rocker cover bolts and press on
6.
Intermediate bolt 1-1/4 in.
side of cover opposite contact point to produced notice-
7.
Long bolt 1-3/4 in.
able clearance between housing and valve assembly.
Figure 3-3. Rocker Housing Bolt Lengths
9977
8877
Figure 3-4. Valve Spring to Rocker Housing Clearance
3-8
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11. Tighten rocker housing bolts to 120-168 in-lbs (13.6-
f1578x3x
19.0 Nm) in the pattern shown in Figure 3-5.
3
5
1
NOTE
If the engine was left in the chassis for service, final tighten
the rear left rocker housing bolt (rear cylinder) using a torque
wrench with a 1/4 inch drive. Since this tool may not be avail-
able in foot-pounds, tighten the bolt to 120-168 in-lbs (13.6-
19.0 Nm).
12. Re-check clearance at both valve spring assemblies and
repeat until there is sufficient clearance between spring
assemblies and rocker housing with the bolts torqued.
CAUTION
O-rings that are missing, distorted, pinched or otherwise
damaged will result in either oil leakage or low oil pres-
sure. 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.
13. Install new o-ring in groove around breather baffle hole
in rocker housing. Apply a thin film of clean SYN3 engine
6
4
oil to o-ring before installation.
2
14. Continue the top end overhaul by installing the hydraulic
lifters in the crankcase bores. See ASSEMBLY under
Figure 3-5. Rocker Housing Torque Sequence
TOP END OVERHAUL in the Touring Models Service
Manual.
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CYLINDER HEADS
3.6
2.
See Figure 3-7. Obtain the CYLINDER HEAD HOLDING
GENERAL
FIXTURE (HD-39786) and proceed as follows:
For service wear limits, refer to Table 3-17.
a. Note that both ends of the fixture are threaded, one
end at 14mm and the other at 12mm. Thread the
12mm end of the tool into the spark plug hole of the
cylinder head.
9975
b. See Figure 3-8. Clamp tool in vise at a 45 degree
2
angle (or one that offers a comfortable working posi-
tion).
1
h39786a
14mm End
12mm End
Figure 3-7. Cylinder Head Holding Fixture
(Part No. HD-39786)
1.
Hemispherical combustion chamber
2.
Machined relief
f1658x3x
Figure 3-6. FLHTCSE2 Front Cylinder Head
REMOVAL
See Touring Models Service Manual for removal of cylinder
heads.
DISASSEMBLY
1.
Before proceeding with the disassembly procedure,
determine if cylinder head reconditioning is necessary.
Proceed as follows:
a. Raise valve ports of cylinder head to strong light
Cylinder Head
source. If light is visible around edges of seats, then
Holding Fixture
move to step 2 to recondition cylinder head.
b. Fill ports at top of cylinder head with solvent. Wait
ten full seconds and then check for leakage into
combustion chamber. If solvent leakage into com-
Figure 3-8. Install Cylinder Head Holding Fixture in Vise
bustion chamber is evident, then move to step 2 to
recondition cylinder head.
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1.
Tapered keepers
2.
Spring retainer
3.
Inner spring
1
2
4.
Outer spring
5.
Valve stem seal
3
6.
Spring seat
7.
Valve guide
8
8.
Cylinder head bolt, short (2)
4
9.
Cylinder head bolt, long (2)
10. Cylinder head
11. Valve seat
5
12. Valve
13. Cylinder head gasket
14. Cylinder
9
15. Ring dowel
6
16. O-ring seal
17. Cylinder stud
7
18. Piston
19. Piston pin
10
20. Circlip (2)
21. Top compression ring
22. Second compression ring
23. Oil rail
24. Oil rail spacer
11
13
12
21
14
15
23
22
24
19
20
18
20
16
17
f21332x3x
Figure 3-9. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)
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3.
See Figure 3-10. Obtain the VALVE SPRING COM-
f1649x3x
PRESSOR (HD-34736B) and proceed as follows:
a. See Figure 3-11. Place tool over cylinder head so
that the blunt end is centered on the valve head and
adapter at end of forcing screw is seated on the
valve spring retainer.
b. Rotate forcing screw to compress valve springs.
c. If spring retainer has not broken free of tapered
keepers, give head of tool a sharp tap with a soft
mallet. Using magnetic rod or small screwdriver,
remove the keepers from the valve stem groove.
d. Rotate forcing screw to release the valve spring
Figure 3-10. Valve Spring Compressor
compression.
(Part No. HD-34736B)
4.
Remove the spring retainer and inner and outer valve
springs.
5.
Slide the valve from the valve guide.
f1648x3x
6.
Using pliers, twist and remove the valve stem seal from
the top of the valve guide. Discard the valve stem seal.
7.
Remove the spring seat from the cylinder head.
8.
Mark the bottom of the valve “F(ront)” or “R(ear)” to indi-
cate the cylinder head from which it was removed. Also,
separate and tag tapered keepers, valve springs, spring
retainers and spring seats so that they are installed on
the same valve at time of assembly.
9.
Repeat steps 3-8 to remove the other valve components.
10.
Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
CLEANING
1.
Remove old gasket material from cylinder head. Gasket
material left on sealing surfaces will cause leaks.
Figure 3-11. Compress Valve Springs
2.
Remove all carbon deposits from combustion chamber
and machined surfaces of cylinder head. Exercise cau-
tion to avoid removing any metal material. For best
results, use an air tool with a worn wire brush. Scraping
CAUTION
may result in scratches or nicks.
3.
To soften stubborn deposits, soak the cylinder head in a
Be aware that bead blasting materials may also enter
chemical solution, such as GUNK HYDRO-SEAL or
threaded holes adversely affecting fastener engagement
other carbon and gum dissolving agent. Repeat step 2
and torque indication. Carefully cover all threaded holes
as necessary.
if bead blasting is employed.
4.
Thoroughly clean the cylinder head, spring retainers,
CAUTION
tapered keepers, valves, inner and outer valve springs
and spring seats in a non-volatile cleaning solution or
Do not use glass or sand to bead blast surfaces exposed
solvent. Follow up with a thorough wash in hot soapy
to the engine oil. Bead blasting materials become lodged
water. Blow dry with compressed air.
in the pores of the casting where they cannot be
removed through ordinary cleaning methods. Only after
the engine is put into use will heat expansion cause this
material to be released, and the resulting oil contamina-
tion will accelerate wear and lead to engine failure. If
bead blasting must be employed, use walnut shells or
other soft non-damaging abrasive that can be digested
in the engine oil.
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INSPECTION
Table 3-26. Service Wear Limits
Valve
Valve Stem to Guide Clearance
Cylinder Head
Intake
0.0035 in. (0.089 mm)
1.
Check for scratches and nicks on all gasket sealing sur-
Exhaust
0.0040 in. (0.102 mm)
faces.
2.
With the combustion chamber side facing upward, set a
Valves
straightedge diagonally across the length of the cylinder
head intersecting the upper and lower corners of the
1.
Replace the valve if there is evidence of burning or
gasket surface. Slide a feeler gauge beneath the
cracking.
straightedge to check the head for warpage. Checking
2.
Inspect the end of the valve stem for pitting or uneven
the opposite diagonal, repeat the procedure to verify that
wear. Replace the valve if either of these conditions are
the gasket surface is flat (especially if a head gasket was
found.
blown). Discard the head if any low spot is 0.006 inch
3.
Inspect for burrs around the valve stem keeper groove.
(0.15 mm) or greater.
Remove burrs with a fine tooth file if found.
NOTE
4.
To determine if the valve stem is excessively worn, see
For good results, use one of the CYLINDER TORQUE
INSPECTION, VALVE GUIDES, step 2.
PLATES (HD-42324A) in lieu of the straightedge. Lay the
upper plate flat on the machined surface of the head. As a
Valve Springs
preliminary check, see if the plate rocks from side to side. A
head on which the plate rocks is immediately suspect. Insert
1.
Inspect springs for broken or discolored coils. Replace
a feeler gauge between the plate and head at various loca-
springs if either of these conditions are found.
tions to see if warpage exceeds above specification.
2.
Set the intake and exhaust valve springs on a level sur-
face and use a straightedge to check for proper square-
3.
Verify that oil passageways are open and clean.
ness and height.
Valve Guides
3.
Check free length of inner and outer springs using a dial
vernier caliper or load test with the VALVE SPRING
1.
Inspect external surfaces for cracks
(particularly the
TESTER (HD-96796-47). Replace springs if free length
combustion chamber side). Replace the guide if any
or compression force do not meet specifications. See
cracks are found.
Section 3.1 SPECIFICATIONS.
2.
To verify cleanliness of valve guides, lightly hone bore
using the VALVE GUIDE HONE (HD-34723) and then
Tapered Keepers
scrub with the VALVE GUIDE CLEANING BRUSH (HD-
1.
Inspect parts for damage or rust pits. Replace as neces-
34751) to remove any dust or debris. Polish the valve
sary.
stem with fine emery cloth or steel wool to remove car-
bon buildup, and then check valve stem to guide clear-
2.
Inspect inboard side of tapered keepers for excessive
ance as follows:
wear. Upraised center must be pronounced and fit
snugly in valve stem groove. Place keepers into groove
Carefully measure the inside diameter of the valve guide
and verify that they grip tightly without sliding.
using an inside ball micrometer. Measure the outside
diameter of the valve stem with an outside micrometer.
Valve Seats
The valve stem and/or guide are excessively worn if the
clearance exceeds the limits shown in Table
3-26.
1.
Inspect seats for cracking, chipping or burning. Replace
Repeat measurements with a new valve to determine if
seats if any evidence of these conditions are found.
the guide must be replaced.
2.
Check seats for recession by measuring valve stem pro-
trusion. See VALVE AND SEAT REFACING in this sec-
tion, steps 5-6.
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VALVE GUIDE REPLACEMENT
h34740a
Removal
NOTE
If valve guide replacement is necessary, always install new
guide before refacing valve seat.
1.
See Figure 3-12. Obtain the CYLINDER HEAD SUP-
PORT STAND (HD-39782A) and proceed as follows:
Figure 3-13. Valve Guide Driver (Part No. HD-34740)
a. Insert sleeve of intake or exhaust seat adapter into
tube at top of support stand.
b. Position cylinder head so that valve seat is centered
on seat adapter. Support stand ensures that valve
guide and seat are perpendicular. If perpendicular-
ity is not achieved, the cylinder head valve guide
f1681x3x
bore will be damaged during the press procedure.
1
CAUTION
2
Do not press out the valve guide from the bottom of the
cylinder head. Carbon buildup on the combustion cham-
ber side of the guide can deeply gouge the cylinder head
bore diminishing the likelihood of achieving the proper
interference fit and possibly requiring replacement of
the cylinder head casting.
2.
See Figure 3-13. At the top of the cylinder head, insert
VALVE GUIDE DRIVER (HD-34740) into valve guide
bore until stopped by shoulder.
3.
See Figure 3-14. Center valve guide driver under ram of
arbor press. Apply pressure until valve guide drops free
of cylinder head. Discard the valve guide.
3
1
1.
Valve guide driver
2.
Ram
3.
Cylinder head support stand
Figure 3-14. Remove Valve Guide
3
2
1.
Intake seat adapter (P/N HD-39782A-3)
2.
Exhaust seat adapter (P/N HD-39782A-4)
3.
Cylinder head support stand
Figure 3-12. Cylinder Head Support Stand
(Part No. HD-39782A)
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Installation
h34731b
1.
Measure the outside diameter of a new standard valve
guide, and then measure the cylinder head valve guide
bore. The valve guide should be 0.0020-0.0033 inch
(0.051-0.084 mm) larger than the bore.
If clearance is not within specification, then select one of
the following oversize guides - 0.001 inch (0.025 mm),
1
0.002 inch (0.05 mm) or 0.003 inch (0.08 mm).
NOTE
2
Since some material is typically removed when the guide is
1.
Valve guide driver (P/N HD-34740)
pressed out, it is normal to go to the next larger size for the
2.
Valve guide installer sleeve (P/N HD-34731)
proper interference fit.
2.
Measure cylinder head bore and outside diameter of
Figure 3-15. Valve Guide Driver and Installer Sleeve
selected oversize guide to verify correct interference fit.
3.
See Figure 3-12. See Figure 3-15. Obtain the CYLIN-
DER HEAD SUPPORT STAND (HD-39782A), VALVE
f1680x3x
GUIDE DRIVER
(HD-34740) and VALVE GUIDE
1
INSTALLER SLEEVE (HD-34731). Proceed as follows:
a. See Figure 3-16. Insert sleeve of intake or exhaust
2
seat adapter into tube at top of support stand. Posi-
tion cylinder head so that valve seat is centered on
seat adapter. Support stand ensures that valve
guide and seat are perpendicular. If perpendicular-
ity is not achieved, cylinder head valve guide bore
will be damaged during the press procedure.
b. Apply Vaseline to lightly lubricate external surfaces
of valve guide. Spread lubricant so that thin film cov-
ers entire surface area.
c. At top of cylinder head, start valve guide into bore.
d. Place installer sleeve over valve guide, and then
insert tapered end of valve guide driver into installer
sleeve.
3
e. Center valve guide driver under ram of arbor press
and apply pressure only until valve guide is started
in bore and then back off ram slightly to allow guide
to center itself.
CAUTION
1.
Valve guide driver
2.
Valve guide installer sleeve
Always back off ram to allow the valve guide to find cen-
3.
Cylinder head support stand
ter. Pressing guide into cylinder head in one stroke can
bend driver, break guide, distort cylinder head casting
Figure 3-16. Install Valve Guide
and/or damage cylinder head valve guide bore.
f.
Verify that support stand and driver are square.
Center driver under ram and press valve guide fur-
ther into bore, but then back off ram again to allow
valve guide to find center.
g. Repeat previous step and then apply pressure to
driver until installer sleeve contacts machined area
of cylinder head.
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4.
See Figure 3-7. Obtain the CYLINDER HEAD HOLDING
h39932
FIXTURE (HD-39786) and proceed as follows:
a. Thread the 12mm end of the tool into the spark plug
hole of the cylinder head.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
h39847
1
NOTE
Valve guides must be reamed to within 0.0005 - 0.0001 inch
(0.013 - 0.0025 mm) of finished size.
5.
See Figure 3-17. Obtain the VALVE GUIDE REAMER
(HD-39932), REAMER T-HANDLE
(HD-39847) and
REAMER LUBRICANT (HD-39964). Proceed as follows:
a. Install T-handle on reamer.
b. Apply a liberal amount of reamer lubricant to valve
2
guide bore and bit of reamer. Start bit of reamer into
1.
Valve guide reamer (P/N HD-39932)
bore at top of cylinder head.
2.
Reamer t-handle (P/N HD-39847)
c. See Figure 3-18. Placing thumb on drive socket of
reamer T-handle, apply slight pressure on reamer
Figure 3-17. Valve Guide Reamer and T-Handle
while rotating in a clockwise direction. Squirt addi-
tional lubricant onto reamer and into guide as nec-
essary.
f1659x3x
CAUTION
For best results, do not push on reamer or apply pres-
sure to the reamer handle. While excessive pressure
results in a rough cut, bore will be tapered if pressure is
not centrally applied.
1
d. Continue rotating reamer T-handle until entire bit
has passed through valve guide bore and shank of
reamer rotates freely.
2
CAUTION
Never back reamer out of valve guide or bore will be
damaged.
e. Remove T-handle from reamer, and carefully pulling
on bit, draw shaft of reamer out combustion cham-
ber side of valve guide.
1.
Valve guide reamer
2.
Reamer t-handle
Figure 3-18. Ream Valve Guide Bore
CAUTION
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine fail-
ure.
6.
Direct compressed air into the valve guide bore to
remove any metal shavings or debris.
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7.
See Figure 3-19. Clean valve guide bore with the VALVE
GUIDE CLEANING BRUSH (HD-34751).
f1661x3x
8.
See Figure 3-20. Obtain the VALVE GUIDE HONE (HD-
34723) and REAMER LUBRICANT (HD-39964). Pro-
ceed as follows:
a. Install hone in a high speed electric drill.
b. Apply reamer lubricant to finishing stones of hone
and valve guide bore.
c. Start finishing stones of hone into bore.
d. See Figure 3-21. Activating the drill, move the entire
length of the finishing stone arrangement forward
and backward through the bore for 10 to 12 com-
plete strokes. Work for a crosshatch pattern of
approximately 60˚.
CAUTION
Figure 3-21. Hone Valve Guide Bore
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine fail-
ure.
9.
Direct compressed air into the valve guide bore to
remove any debris and then clean with the VALVE
f1660x3x
GUIDE CLEANING BRUSH (HD-34751). See Figure 3-
22.
h34751a
Figure 3-19. Valve Guide Brush (Part No. HD-34751)
h34723a
Figure 3-22. Scrub Valve Guide Bore
Figure 3-20. Valve Guide Hone (Part No. HD-34723)
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NOTE
VALVE AND SEAT REFACING
Always verify valve stem to valve guide clearance after hon-
ing, since a worn reamer may cut the bore undersize.
NOTE
10. Measure the inside diameter of the valve guide with an
Verify correct valve stem to valve guide clearance before
inside ball micrometer. Measure the outside diameter of
refacing. Refer to Table 3-27. If new guides must be installed,
the valve stem with an outside micrometer. The valve
complete that task before refacing valves and seats.
stem may be excessively worn or the valve guide bore
undercut if the clearance is not within the limits (low end
1.
Hold the valve firmly against a wire wheel in a bench
preferable) shown in Table 3-27.
grinder. Remove all carbon deposits from the valve
head, face and stem, but exercise caution to avoid
removing any metal. Carbon left on the stem may affect
Table 3-27. New Parts Limits
alignment in the valve refacer. Polish the valve stem with
steel wool or crocus cloth to remove any marks that
Valve
Valve Stem to Guide Clearance
might be left by the wire wheel.
Intake
0.0008-0.0026 in. (0.020-0.066 mm)
2.
Install valve (both intake and exhaust) in a valve refacer
set to a 45 degree angle. The valve refacer is required
Exhaust
0.0015-0.0033 in. (0.038-0.084 mm)
equipment, since accuracy in matching the angle of the
valve face with the angle of the valve seat is critical.
11.
Using cleaning solvent, thoroughly clean cylinder head
Do not remove any more metal than is necessary to
and valve guide bore. Scrub valve guide bore with the
clean up and true the valve face. Removing metal
VALVE GUIDE CLEANING BRUSH (HD-34751). For
reduces the service life of the valve. The amount of
best results, use a thin engine oil and clean valve guide
grinding needed to retrue the valve is a clear indication
bore with the type of swabs or patches found in gun
of its condition. Discard the valve if it cannot be quickly
cleaning kits. Continue to wipe bore until clean cloth
refaced while maintaining a good margin. Valves that do
shows no evidence of dirt or debris. Follow up with a
not clean up quickly are either warped, excessively worn
thorough wash in hot soapy water. Blow dry with com-
or too deeply pitted to be used.
pressed air.
Obtain a new valve if grinding leaves the margin less
than 0.0313 inch (0.795 mm). A valve in this condition
does not seat normally, burns easily and may crack or
cause pre-ignition.
3.
Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
39786) and proceed as follows:
a. Thread the 12mm end of the tool into the spark plug
hole of the cylinder head.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
4.
Obtain the NEWAY VALVE SEAT CUTTER SET (HD-
35758A) and cut valve seat angle to 46°.
NOTE
Do not remove any more metal than is necessary to clean up
the seat (that is, to provide a uniform finish and remove pit-
ting).
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5.
From the bottom of the cylinder head, insert the valve
7.
Remove valve from cylinder head. Apply magic marker
stem into the valve guide. Push on bottom of valve until it
or similar product to valve seat and allow to thoroughly
contacts the valve seat.
dry.
8.
Insert the valve stem into the valve guide. Push on bot-
6.
Placing finger at bottom of valve to keep valve seated,
tom of valve until it contacts the valve seat.
use a dial vernier caliper to check the distance from the
9.
See Figure 3-24. Obtain the VALVE LAPPING TOOL
top of the valve stem to the machined area on the cylin-
(HD-96550-36A) and proceed as follows:
der head. See Figure 3-23.
a. Attach suction cup at end of tool to valve head.
a. Seat wear and valve refacing causes the valve stem
b. See Figure 3-25. Holding shank of tool between the
protrusion to change. If valve stem protrusion
palms of both hands, oscillate the tool back and
exceeds 2.034 inches (51.66 mm), but is less than
forth a few times.
2.064 inches (52.43 mm), obtain the short service
replacement valve. Service replacement valves are
0.030 inch (0.76 mm) shorter than the standard
valve.
h96550-36b
b. If protrusion exceeds
2.064 inches (52.43 mm),
then use the existing valve, but replace the valve
seat.
Figure 3-24. Valve Lapping Tool (Part No. HD-96550-36A)
CAUTION
Do not shorten the valve by grinding on the end of the
stem. Grinding replaces the hardened case with mild
6873
steel which results in accelerated wear.
f1662x3x
Dial Vernier
Valve Lapping
Caliper
Tool
Figure 3-25. Oscillate Tool to Create Contact Area
f1663x3x
Figure 3-23. Measure Valve Stem Protrusion
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10. Remove the valve from the cylinder head and carefully
12.
Using a magic marker, mark three equally spaced verti-
inspect the mating surfaces under a good light.
cal lines across the valve face and then insert the valve
back into the cylinder head.
NOTES
13.
Attach suction cup of VALVE LAPPING TOOL (HD-
● Inspection of the valve seat should show an unbroken
96550-36A) to valve head, and holding shank of tool
contact area of uniform width. If the seat is not concen-
between the palms of both hands, oscillate the tool back
tric with the valve guide, the cutter will remove more
and forth a few times.
material in one spot than another. Carbon deposits may
have caused the guide to be pressed in crooked, the
14.
Remove the valve and perform a final inspection of the
guide may be cracked, or the cutter blade or cutter pilot
contact pattern. If necessary, return to step 11.
may not have been properly cleaned.
15.
Remove the valve from the cylinder head. Use contact
cleaner to thoroughly clean magic marker and/or dye
● If the results are not acceptable, recut the valve seat or
replace the valve guide.
from valve face and seat, if present.
16.
Release the cylinder head holding fixture from the vise
11. See Figure 3-26. Inspect the contact pattern on the
and then remove the tool from the spark plug hole.
valve seat to be sure area is 0.040-0.062 inch (1.02-1.57
mm) wide and contacts the valve two-thirds of the way
17.
To confirm quality of valve and seat refacing work, pro-
towards the outer edge of the valve face. If necessary,
ceed as follows:
modify the seat pattern as follows:
a. Insert valve in guide, and holding valve to seat,
a. Use the 31° angle cutter to lower the valve seat sur-
raise port to strong light source. If light is visible
face and reduce its width.
around edge of seat, then valves and seats must be
reconditioned.
b. Use the 60° angle cutter to raise the valve seat sur-
face and reduce its width.
b. Holding valve to seat, fill port at top of cylinder head
with solvent. Wait ten full seconds and then check
c. Use the 46° angle cutter to widen the valve seat sur-
for leakage into combustion chamber. If solvent
face.
leakage into combustion chamber is evident, then
valves and seats must be reconditioned.
f1655x3x
1WARNING
Head
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye injury.
Seat
Wear safety glasses when working with compressed air.
60˚
Never use your hand to check for air leaks or to deter-
mine air flow rates. (00061a)
0.040-0.062 in.
(1.02-1.57 mm)
18. Clean valves, cylinder head and valve seats in solvent.
Follow up with a thorough wash in hot soapy water. Blow
Valve
dry with low pressure compressed air.
31˚
46˚ Cutting
Margin
45˚ Grinding
0.0313 in.
(0.795 mm)
Figure 3-26. Valve Seat Angles
3-20
2005 FLHTCSE2: Engine
HOME
11. See Figure 3-27. Push on bottom of valve until it con-
ASSEMBLY
tacts the valve seat. Placing finger at bottom of valve to
keep valve seated, slide plastic capsule over valve stem
1.
Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
tip and keeper groove.
39786) and proceed as follows:
a. Thread the 12mm end of the tool into the spark plug
hole of the cylinder head.
f1664x3x
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
1
2.
Slide spring seat over valve guide until it contacts the
machined area on the cylinder head casting. Use a little
grease to hold the spring seat in position, if necessary.
NOTE
At the time of disassembly, all parts should have been
marked or tagged so that they are installed on the same
valve (and in the same head).
3.
Run the VALVE GUIDE CLEANING BRUSH (HD-34751)
through the valve guide bore to verify cleanliness.
2
4.
Using TORCO MPZ or another suitable product, apply a
liberal amount of engine assembly lube to valve stem.
5.
From the bottom of the cylinder head, insert the valve
stem into the valve guide.
1.
Plastic capsule
6.
To distribute the assembly lube evenly around the valve
2.
Spring seat
stem and guide, hand spin the valve as it is installed.
Work the valve back and forth in the bore to verify that it
Figure 3-27. Install Plastic Capsule on Valve Stem
slides smoothly and seats properly.
7.
Remove the valve and apply a second coat of assembly
12.
See Figure 3-28. Apply a very thin film of clean H-D
lube to the valve stem. Install the valve in the valve
20W50 engine oil to capsule. Slide new valve stem seal
guide.
over capsule and down valve stem until contact is made
8.
Retract the valve so that the stem is not visible above the
with top of valve guide. Remove capsule from valve stem
top of the valve guide.
tip.
9.
Using isopropyl alcohol or other suitable degreaser, thor-
oughly clean external surface of valve guide until com-
pletely free of grease and oil.
f1665x3x
CAUTION
1
Do not apply Loctite to inside of valve stem seal or top of
valve guide or valve may stick to seal resulting in loss of
compression and valve sticking.
10. Obtain tube of Loctite RC/620 (green) High Temperature
Retaining Compound. Carefully apply Loctite to valve
stem seal seating surface on outside diameter of valve
guide. Exercise caution to keep compound out of valve
guide bore.
2
CAUTION
Failure to install plastic capsule will cause the valve
stem seal to catch the edge of the valve stem keeper
groove. The resulting damage will lead to leakage around
1.
Plastic capsule
the valve stem, excessive oil consumption and valve
2.
Valve stem seal
sticking.
Figure 3-28. Install Valve Stem Seal
2005 FLHTCSE2: Engine
3-21
HOME
f1666x3x
CAUTION
Valve Stem
To avoid damaging the valve stem seal and/or cracking
Seal Installer
the valve guide, always use the proper valve stem seal
installer tool. Use of an ordinary socket will damage the
seal or guide, resulting in leakage around the valve
stem, excessive oil consumption and valve sticking.
13. See Figure
3-29. Obtain the VALVE STEM SEAL
INSTALLER (HD-34643A) and proceed as follows:
a. Slide the installer tool over the valve stem seal
using valve stem as pilot. The tool bore allows inser-
tion of the valve stem, while the counterbore fits
over the valve stem seal.
CAUTION
Figure 3-30. Tap Installer to Seat Valve Stem Seal
Repeated blows on installer after seal is in place will
cause seal distortion resulting in leakage around the
valve stem, excessive oil consumption and valve stick-
ing.
b. See Figure 3-30. Using a small hammer, gently tap
f1654x3x
1
the end of the tool until it lightly bottoms on the
installed spring seat. For best results, brace the cyl-
inder head with chest area to prevent movement
during seal installation.
NOTE
See Figure 3-31. If an arbor press is the preferred method of
valve stem seal installation, use the VALVE STEM SEAL
2
INSTALLER (HD-34643A) with the VALVE GUIDE DRIVER
(HD-34740).
CAUTION
3
Removing the valve after seal installation will cause the
valve stem seal to catch the edge of the valve stem
5
keeper groove. The resulting damage will lead to leakage
around the valve stem, excessive oil consumption and
4
valve sticking.
h34643b
6
Figure 3-29. Valve Stem Seal Installer
(Part No. HD-34643A)
1.
Valve guide driver
2.
Valve stem seal installer
3.
Valve stem seal
4.
Valve
5.
Valve guide
6.
Valve seat
Figure 3-31. Using Arbor Press to Install Valve Stem Seal
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2005 FLHTCSE2: Engine
HOME
14. Apply a liberal amount of assembly lube to valve stem tip
INSTALLATION
and keeper groove.
15. Install the inner and outer valve springs over the valve
See Touring Models Service Manual for cylinder head instal-
guide. Fit the spring retainer on top of the inner and
lation procedure.
outer valves springs. Like the spring seat, the smaller
diameter flange fits inside the inner valve spring. The
larger diameter flange separates the inner and outer
springs.
16. Obtain the VALVE SPRING COMPRESSOR
(HD-
34736B) and proceed as follows:
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.
CAUTION
Over-compressing the valve spring can damage the
valve stem seal resulting in leakage around the valve
stem, excessive oil consumption and valve sticking.
b. Rotate forcing screw to compress valve springs.
c. With the tapered side down, fit the keepers into the
valve stem groove. For best results, apply a dab of
grease to the inboard side of the keepers before
installation and use a magnetic rod for easy place-
ment.
d. Arranging tapered keepers so that the gaps are
evenly spaced, turn forcing screw to release valve
spring compression.
17. Tap the end of the valve stem once or twice with a soft
mallet to ensure that tapered keepers are tightly seated
in the valve stem groove.
18. Repeat all previous steps to install the other valve com-
ponents.
19. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
20. Cover the cylinder head to protect it from dust and dirt
until time of installation.
2005 FLHTCSE2: Engine
3-23
HOME
PISTONS
3.7
GENERAL
f2113x4x
FLHTCSE2 pistons differ from those of other touring models
in specification and appearance. However, piston service
procedures are the same as those found in the Touring Mod-
els Service Manual. See PISTON on SUBASSEMBLY SER-
VICE AND REPAIR in the Touring Models Service Manual.
For service wear limits, refer to Table 3-20. and Table 3-19.
NOTE
The piston is measured on the bare aluminum to avoid mea-
suring errors. An oval-shaped spot is present on each side of
the piston for proper placement of the micrometer. See upper
1
frame of Figure 3-33. Since the oval openings are too small
for a standard flat anvil micrometer, which would result in
measuring errors, use a 4-5 inch micrometer with spherical
ball anvil adapters. See lower frame of Figure 3-33.
f2109x3x
9974
2
3
1.
Oval opening
2.
4-5 inch micrometer
3.
Spherical ball anvil adapters
Figure 3-33. FLHTCSE2 Piston Measurement
Figure 3-32. FLHTCSE2 Piston Orientation Arrow
(arrow points to front of engine)
3-24
2005 FLHTCSE2: Engine
HOME
BORING AND HONING CYLINDERS
3.8
5.
Thoroughly wash the cylinder bore with liquid dish soap
CYLINDER BORE FINISHED SIZE
and warm water to remove all abrasive particles and
residual girt. Continue cleaning until a clean cloth shows
1.
For cylinder removal, cleaning, inspection, boring and
no evidence or dirt or debris.
honing and installation, see CYLINDER in the Touring
6.
Immediately apply a thin film of clean engine oil to a
Models Service Manual.
clean white paper towel and thoroughly wipe the inside
2.
Refer to Table 3-28. Bore the cylinder to 0.003 in. (0.08
of the cylinder. This prevents the cylinder bore from rust-
mm) under the desired finished size. See BORING and
ing.
HONING CYLINDER in the Touring Models Service
NOTE
Manual. Refer to Table 3-28.
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
CAUTION
remains white. The cylinder is now clean.
An improper crosshatch pattern or too fine a hone will
7.
With the cylinder at room temperature, check the piston
result in insufficient oil retention and possible piston
clearance in the cylinder in which the piston will run. See
seizure and/or high oil consumption.
INSPECTION under PISTON in Touring Models Service
Manual.
3.
Hone the cylinder to its finished size using a 280 grit
rigid hone followed by a 240 grit flexible ball hone. Hon-
8.
For cylinder installation, see CYLINDER in Touring Mod-
ing must be done with the torque plates attached. All
els Service Manual.
honing must be done from the bottom (crankcase end of
the cylinder. Work for a 60˚ crosshatch pattern.
4.
Stop frequently to examine the cylinder bore and/or take
measurements. Remember, a precise 60˚ cross hatch
pattern in the piston travel area is important.
Table 3-28. Oversize Pistons/Cylinder Bores
PISTON
CYLINDER BORE FINISHED SIZE
TYPE
SIZE
MINIMUM
MAXIMUM
Standard
STD
3.8750 in. (98.4250 mm)
3.8755 in. (98.438 mm)
0.005 in. (0.13 mm)
3.8800 in. (98.552 mm)
3.8805 in. (98.565 mm)
Oversize
0.010 in. (0.25 mm)
3.8850 in. (98.679 mm)
3.8855 in. (98.692 mm)
2005 FLHTCSE2: Engine
3-25
HOME
CAMS AND TIMING MARKS
3.9
GENERAL
FLHTCSE2 cams differ from those of other touring models in
specification and appearance. However, cam service proce-
dures are the same as those found in the Touring Models
Service Manual. See Camshafts and Camshaft Bearings
under CAM SUPPORT PLATE under SUBASSEMBLY SER-
VICE AND REPAIR in the Touring Models Service Manual.
f1607a3x
2
1
1.
Rear camshaft punch mark
2.
Front camshaft punch mark
Figure 3-34. FLHTCSE2 Cam Timing Marks
3-26
2005 FLHTCSE2: Engine
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