Harley Davidson 2005 touring models. Service repair manual — page 13

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23. Remove O-ring seal from the bottom of the cylinder liner.

Discard O-ring seal. See Section 3.11 SUBASSEMBLY

SERVICE AND REPAIR, CYLINDER.

24. Remove O-ring from ring dowel on “downside” of cylin-

der deck. Discard the O-ring.

1CAUTION

Always wear proper eye protection when removing cir-

Claw

clips. Slippage may propel the ring with enough force to

cause eye injury.

Figure 3-24. Piston Pin Circlip

25. Verify that clean shop towels are properly positioned

Remover/Installer (Part No. HD-42317A)

over the crankcase bore to prevent the piston pin circlip

from falling into the crankcase.

f1635x3x

26. Remove the piston pin circlip as follows:

a. Insert the PISTON PIN CIRCLIP REMOVER/

INSTALLER (HD-42317A) into the piston pin bore

until claw on tool is positioned in slot of piston

(directly under circlip). See Figure 3-25.

b. Squeeze the handles of the tool together and pull

from bore. In the event that the circlip should fly out,

hold a shop towel over the bore during removal.

Remove circlip from claw and discard.

NOTE

It is not necessary to remove both piston pin circlips during

Slot

piston removal. Leave the second circlip in the pin bore.

27.

Remove the piston pin. If piston pin is difficult to remove,

use PISTON PIN REMOVER (HD-42320A). See Figure

3-26. Proceed as follows:

Figure 3-25. Remove Piston Pin Circlip

a. Remove acorn nut and spacer from rod end of tool.

b. Slide rod end through piston pin. Install spacer and

acorn nut to end of rod.

20. Raise the cylinder just enough to place clean shop tow-

els under the piston. This will prevent any dirt or debris,

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

such as broken ring pieces, from falling into the crank-

of pin bore.

case bore.

d. Turn handle in a clockwise direction until piston pin

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

CAUTION

28.

Remove the piston. Be sure to hold the rod shank

upright to prevent it from striking the crankcase. Place a

Exercise caution to avoid bending the cylinder studs.

piece of foam-type water pipe insulation around each

Even a slight bend or nick can cause a stress riser lead-

rod (about 3 inches long with a 2-1/4 inch O.D. and a 1

ing to stud failure.

inch I.D.) to prevent damage if contact should occur.

21. Carefully remove the cylinder to avoid bending the cylin-

29.

Turn the piston over and mark the pin boss with the

der studs. As the piston becomes free of the cylinder,

letters “F(ront)” or “R(ear)” to identify location. See Sec-

hold it upright to prevent it from striking the studs or

tion

3.11 SUBASSEMBLY SERVICE AND REPAIR,

dragging across the stud thread area. Mark the cylinder

PISTON and UPPER CONNECTING ROD.

“F(ront)” or “R(ear)” to identify location.

30.

If performing a top end overhaul only, see Section 3.11

SUBASSEMBLY SERVICE AND REPAIR, TOP END,

22. Slide plastic tubing, rubber hose or conduit over each

before proceeding to Section 3.9 TOP END OVERHAUL,

cylinder stud. Material approximately 6 inches (152 mm)

ASSEMBLY, which follows. If performing a complete

long with an I.D. of 1/2 inch (12.70 mm) will protect cylin-

engine overhaul, see Section

3.10 BOTTOM END

der studs and piston from damage.

OVERHAUL, DISASSEMBLY.

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5. Insert piston pin through pin bore and upper connecting

rod bushing. Push pin until it contacts circlip installed in

opposite pin boss.

CAUTION

Do not reuse piston pin circlips. The circlips may weaken

during removal causing them to break or dislodge dur-

ing engine operation, a condition that will result in

engine damage.

Place clean shop towels over the cylinder and lifter

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

bores to prevent the piston pin circlip from falling into the

crankcase. Verify that the circlip groove is clean and free

of dirt and grime.

Spacer and

Acorn Nut

Handle

Install new piston pin circlip with the PISTON PIN CIR-

CLIP REMOVER/INSTALLER (HD-42317A). Proceed as

follows:

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

Lightly squeeze handles of tool to capture circlip in

claw.

b. Releasing pressure on handles, rotate circlip so that

the end gap is centered at top of tool and then

recapture in claw.

c. Tilt the circlip forward until the end gap contacts

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

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

aligned with slot in piston.

Rubber Coated Tip

f1640x3x

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

Figure 3-27. Remove Piston Pin

bottoms. Release handles and remove tool.

Inspect the circlip to verify that it is fully seated in

the groove.

ASSEMBLY

CAUTION

NOTE

O-rings that are missing, distorted, pinched or otherwise

It is assumed that each step performed on one cylinder is

damaged will result in either oil leakage or low oil pres-

automatically repeated on the other.

sure. Use of the wrong O-ring will have the same results.

Since many O-rings are similar in size and appearance,

Slide plastic tubing, rubber hose or conduit over each

always use new O-rings keeping them packaged until

cylinder stud, if removed. Material approximately

use to avoid confusion.

inches (152 mm) long with an I.D. of 1/2 inch (12.70 mm)

will protect cylinder studs and piston from damage.

8. Install new O-ring over “downside” cylinder deck ring

dowel (that is, rear dowel on rear cylinder, front dowel on

Apply clean H-D 20W50 engine oil to piston pin, piston

front cylinder). Apply a very thin film of clean H-D 20W50

bosses and upper connecting rod bushing.

engine oil to O-ring before installation. Verify that O-ring

Remove water pipe insulation from rod shank.

is properly seated in groove.

Place piston over rod end so that the arrow stamped at

9. Install new O-ring seal at the bottom of the cylinder liner.

the top of the piston points toward the front of the

Apply a very thin film of clean H-D 20W50 engine oil to

engine.

O-ring before installation.

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

f1564x3x

center of the engine and the adjustable knobs fac-

ing downward, capture shank of connecting rod in

fork. Lay tool on cylinder deck so that adjustable

knobs contact wall of cylinder bore.

c. Rotate engine until piston skirt is centered and

Circlip

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

30.

14. Install cylinder as follows:

a. Obtain the PISTON RING COMPRESSOR (HD-

96333-51E).

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

(HD-96333-103). The arrow stamped on the band

indicates the side that faces up, so disregard the

f1636x3x

word “bottom.” Place band around piston. Press the

lever on the right side of the pliers to open the jaws

for band expansion.

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

between the top compression ring and the piston

crown. Tightly squeeze handles of tool to compress

piston rings. The racheting action of the tool allows

release of the handles after the rings are com-

pressed.

Figure 3-28. Install Piston Pin Circlip

NOTE

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

Excessive lubrication of cylinder sleeve O-ring seal will result

in oil weepage between cylinder and crankcase as engine is

run, a condition that may be incorrectly diagnosed as an oil

Piston

leak.

Support Plate

10. Verify that the piston ring end gaps are properly stag-

gered. If necessary, see Section 3.11 SUBASSEMBLY

SERVICE AND REPAIR, PISTON.

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

and cylinder bore.

12. Remove plastic tubing or rubber hose from cylinder

studs. Rotate engine until piston is at top dead center. If

necessary, see step 31 for methods of engine rotation.

13. Install the PISTON SUPPORT PLATE (HD-42322). Pro-

ceed as follows:

a. Slide both adjustable knobs on tool down slots away

f1612x3x

from forked end. Tighten knobs when contact is

made with flats at end of slots.

Figure 3-30. Install Piston Support Plate

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

the cylinder deck. Push down on the cylinder until it

is fully seated in the crankcase bore.

NOTE

To hold the first cylinder in position while installing the sec-

ond, install threaded cylinders

(HD-95952-1) from CON-

NECTING ROD CLAMPING TOOL (HD-95952-33B) onto

cylinder studs with the knurled side down. This will prevent

the piston rings from raising the cylinder as the engine is

rotated to bring the other piston into position for installation of

the second cylinder. See Figure 3-33.

Figure 3-31. Piston Ring Compressor

15. With the part number topside, place the head gasket

(Part No. HD-96333-51E)

over the two ring dowels in the upper flange of the cylin-

der.

16. Note that the word “Front” or “Rear” is cast into the top of

f1613x3x

Ring Compressor Band

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

the cylinder head to ensure proper installation. With the

Part No. HD-96333-103

indent in the cooling fins facing the right side of the

engine (for accommodation of the push rods and cov-

ers), carefully set the cylinder head over the two cylinder

ring dowels. To avoid damage to machined surfaces or

ring dowels, lower the cylinder head at an angle that

closely approximates the angle of the crankcase.

CAUTION

Thoroughly clean and lubricate the threads of the cylin-

der head bolts before installation. Friction caused by dirt

and grime will result in a false torque indication.

Pliers

Threaded

Cylinder

Figure 3-32. Install Cylinder

Note that the cylinders should have been marked

with the letters

“F(ront)” or

“R(ear)” to identify

location. With the indent in the cooling fins facing

the right side of the engine, gently slide cylinder

over the cylinder studs and the piston crown resting

it on the top of the ring compressor band.

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

inder. Push down on the cylinder with a sharp, quick

motion to pass the piston ring area. See Figure 3-

32.

Rotate the engine slightly to raise piston off support

plate. Remove pliers from band and then remove

band from around shank of connecting rod. Remove

piston support plate.

f1518b3x

Remove shop towels from around the crankcase

Figure 3-33. Install Threaded Cylinders to Studs

bore exercising caution to keep out any dirt or

(Part No. HD-95952-1)

debris.

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17. Lightly oil threads and shoulders of cylinder head bolts

= Short Bolt

with clean H-D 20W50 engine oil.

= Long Bolt

FRONT

18. Start the cylinder head bolts onto the cylinder studs, two

short bolts on the left side of the engine, two long bolts

on the right.

19. Tighten the four cylinder head bolts as follows:

CAUTION

Improperly tightened cylinder head bolts may result in

gasket leaks, stud failure and distortion of the cylinder

and/or cylinder head.

a. Alternately turn each cylinder head bolt until finger

tight.

b. Tighten the cylinder head bolts to 120-144 in-lbs

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

ure 3-34.

c. Following the same sequence, tighten each bolt to

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

REAR

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

cylinder head bolt continuing the line over onto the

cylinder head. Using the marks as a guide, turn

each bolt 1/4 turn or 90 degrees. See B of Figure 3-

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

sequence shown in A of Figure 3-34.

NOTE

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

TA360.

20. Install a new rocker housing gasket on the cylinder head

flange.

CAUTION

f2166x3x

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.

21. Verify that the rocker housing gasket is installed cor-

rectly by noting that the breather channel is concealed.

See Figure 3-35.

22. With the indent facing forward, place the rocker housing

into position aligning the holes in the housing with those

in the gasket.

23. Apply a small dab of Loctite Medium Strength Thread-

locker 243 (blue) to threads of six rocker housing bolts.

f1583x3x

Start the rocker housing bolts, two long bolts on the left

side of the engine, four intermediate bolts in the interior.

Figure 3-34. Cylinder Head Torque Sequence

Alternately tighten the bolts to 120-168 in-lbs (13.6-18.9

and Bolt Size

Nm) in the pattern shown in Figure 3-36.

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f1577x3x

f1576x3x

Breather Channel Concealed

Breather Channel Exposed

CORRECT

WRONG

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

= Short Bolt, 1 In.

f2165x3x

= Intermediate Bolt, 1-1/4 In.

NOTE

= Long Bolt, 1-3/4 In.

If the engine was left in the chassis for service, use the

ROCKER HOUSING WRENCH (HD-47248) to start the

rocker housing bolts. With both an external and internal hex,

O-Ring

the bolts also can be installed with either a 7/16 inch socket

or open end/box wrench (open spaces), or a short 3/16 inch

allen wrench (tight spaces). For best results, final tighten the

FRONT

bolts on the left side of the engine (where there is close prox-

imity to the frame) to 120-168 in-lbs using a torque wrench

with a 1/4 inch drive.

CAUTION

O-rings that are missing, distorted, pinched or otherwise

Torque: 120-168 in-lbs

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.

24. Install new O-ring in groove around breather baffle hole

in rocker housing. Apply a thin film of clean H-D 20W50

REAR

engine oil to O-ring before installation. See Figure 3-36.

25. Install the hydraulic lifters in the crankcase bores with

the flats facing forward and rearward. To preserve exist-

ing wear patterns, orientation of the oil hole (inboard or

outboard) should have been noted during disassembly.

To avoid damage, do not drop lifters onto cam lobes.

Install Six Rocker Housing Bolts.

26. Place anti-rotation pin on the machined flat between the

Figure 3-36. Rocker Housing Torque Sequence

blocks cast into the crankcase. See Figure 3-37.

and Bolt Size

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Do not install the spring cap retainers at this time. To

Anti-Rotation

ensure proper installation, take note of Table 3-3.

Pin

Lifter Cover

30. Install the push rods in their original positions. Be sure to

remove any tags that may have been used for marking

location and orientation. To ensure proper installation,

take note of Table 3-3. For example, if reassembling the

rear cylinder, slide the intake push rod (silver) through

the front hole in the rocker housing engaging the lifter

socket in the inside hole of the lifter cover. Slide the

exhaust push rod (black) through the rear hole in the

rocker housing engaging the lifter socket in the outside

hole of the lifter cover.

31. To install the rocker arm support plate, both lifters of the

cylinder being serviced must be on the base circle (or

lowest position) of the cam.

CAUTION

Installing the rocker arms and rotating the engine with

the valve train loaded can result in bent push rods and/

Gasket

Ribs

f1606x3x

or valve damage.

Figure 3-37. Install Lifters and Lock Position

To find the base circle, it is first necessary to rotate the

With Anti-Rotation Pin

engine. Based on the level of disassembly, three meth-

ods of engine rotation are presented below.

27. Install a new lifter cover gasket aligning the holes in the

a. With primary cover installed - With vehicle on center

gasket with those in the cover.

stand, place the transmission in 5th gear and rotate

rear wheel in a clockwise direction (as viewed from

CAUTION

right side) until the base circle is found. See step

31(d) to find the base circle.

Movement or loss of the anti-rotation pin can result in

lifter rotation causing catastrophic engine damage.

b. With primary cover removed

- Remove primary

cover. Place the transmission in neutral. Fit a 1-1/2

28. Install the lifter cover and start the four allen head socket

inch socket on the compensating sprocket shaft nut.

screws (1/4 x 1 inch). During installation, verify that the

Rotate nut in a counterclockwise direction until the

anti-rotation pin is held in place by the ribs cast into the

base circle is found. See step 31(d) to find the base

inboard side of the lifter cover. See Figure 3-37. Tighten

circle.

the lifter cover screws to 90-120 in-lbs (10.2-13.6 Nm) in

a crosswise pattern.

CAUTION

29. Hand compress the push rod cover assembly and fit the

O-ring end of the lower push rod cover into the lifter

Do not attempt to rotate engine by removing cam cover

cover bore. Expanding the assembly, fit the O-ring end of

and placing socket on crank or primary cam sprocket

the upper push rod cover into the cylinder head bore.

flange bolt. Head of flange bolt can break off possibly

resulting in damage to flywheel or camshaft.

Table 3-3. Push Rod/Cover Locations

c. With engine mounted in engine stand - Obtain the

Cylinder Head/

Cover and

Lifter Cover

ENGINE ROTATION WRENCH (HD-47257). See

Cylinder

Rocker Housing

Push Rod*

Bore

Figure 3-23. Install tool on sprocket shaft and rotate

Bore

in a counterclockwise direction until the base circle

Intake

Inside

Rear

is found. See step 31(d) to find the base circle.

Front

Exhaust

Outside

Front

d. Finding the base circle: Using one of the methods

Intake

Inside

Front

Rear

above, rotate engine until piston is at Top Dead

Exhaust

Outside

Rear

Center (TDC) of compression stroke. To accomplish

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

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= Short Bolt, 1 In.

f2163x3x

f2164x3x

= Intermediate Bolt, 1-1/4 In.

Rocker Arm Torque:

= Long Bolt, 1-3/4 In.

18-22 ft-lbs

Breather

Assembly

Torque: 15-18 ft-lbs

Torque: 90-120 in-lbs

FRONT

REAR

Alternately Tighten Four Rocker Arm Bolts

Install Six Rocker Cover Bolts.

1/4 Turn in Pattern Shown.

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

this, first raise lower push rod cover to access intake

34. Alternately tighten each of the four rocker arm support

lifter (inside hole of lifter cover). Place index finger

plate bolts just 1/4 turn following the pattern shown in A

on top of the intake lifter. While rotating engine, feel

of Figure

3-38. Continue turning the bolts in these

lifter rise (valve open) and fall (valve closed). Now

increments until snug. Following the same numerical

place finger tightly over spark plug hole and rotate

sequence, tighten the bolts to 18-22 ft-lbs (24.4-29.8

engine again. In the compression stroke, air will be

Nm).

forced out against your finger until the piston

35. Alternately tighten the two breather assembly bolts to

reaches the TDC position. Stop engine rotation

90-120 in-lbs (10.2-13.6 Nm).

when the flow of air through the spark plug hole

stops. Direct the beam of a small flashlight into

NOTE

spark plug hole to verify piston is at TDC. Both

If the engine was left in the chassis for service, final tighten

intake and exhaust valves are now closed and the

the rocker arm support plate bolt on the rear left side of the

push rods are in the unloaded position.

rear cylinder using a 3/8 inch drive torque wrench with a 1/2

inch flank drive

“dog bone” torque adapter

(Snap-On

32.

Place the rocker arm support plate assembly into the

FRDH161). Since any extension can act as a torque multi-

rocker housing. Start the four rocker arm support plate

plier, the torque wrench must be perpendicular to the torque

bolts into the cylinder head.

adapter when the bolt is tightened. The 90 degree orientation

33.

Place breather assembly at top of rocker arm support

between the tools cancels the multiplier effect and prevents

plate. Apply a small dab of Loctite Medium Strength

the bolt from being over-tightened. If the adapter is kept inline

Threadlocker

243 (blue) to threads of two breather

with the torque wrench, the multiplier effect is in force and

assembly bolts. Start bolts into cylinder head.

distortion of the rocker housing will occur.

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39. Apply a small dab of Loctite Medium Strength Thread-

locker 243 (blue) to threads of six rocker cover bolts.

Start the rocker cover bolts, three short bolts on the left

side of the engine, three long bolts on the right. Tighten

the bolts to 15-18 ft-lbs (20.3-24.4 Nm) in the pattern

shown in B of Figure 3-38.

NOTE

If the engine was left in the chassis for service, final tighten

the three rocker cover bolts on the left side of the rear cylin-

der using a 3/8 inch drive torque wrench with a 7/16 inch

flank drive “dog bone” torque adapter (Snap-On FRDH141).

Since any extension can act as a torque multiplier, the torque

wrench must be perpendicular to the torque adapter when

the bolts are tightened. The 90 degree orientation between

the tools cancels the multiplier effect and prevents the bolts

from being over-tightened. If the adapter is kept inline with

the torque wrench, the multiplier effect is in force and distor-

tion of the rocker cover will occur.

f1604x3x

40.

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

Figure 3-39. Install Spring Cap Retainer

3.6 ASSEMBLING MOTORCYCLE AFTER STRIPPING.

If engine was removed for service,

see

Section

3.8

INSTALLING ENGINE IN CHASSIS.

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

rods spin freely.

NOTE

Always service each cylinder separately. After the first cylin-

der is serviced the engine must be rotated to find the base

circle on the second cam. Service on the remaining cylinder

can then proceed.

37. Complete installation of the push rod covers as follows:

a. Verify that the O-ring ends of the upper and lower

push rod covers fit snugly into the cylinder head and

lifter cover bores.

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

cylinder head bore leaving the bottom edge free.

c. Insert blade of small screwdriver between bottom

edge of spring cap retainer and top of spring cap.

d. While simultaneously depressing spring cap with tip

of screwdriver, use forefinger to slide bottom edge

of spring cap retainer down shaft towards tip of

screwdriver blade. As spring cap reaches its full

length of travel, spring cap retainer should be in

approximate position against upper push rod cover.

See Figure 3-39.

NOTE

For best results, be sure that screwdriver, spring cap and

spring cap retainer are free of grease and oil.

e. Verify that spring cap retainer is seated tightly

against upper push rod cover.

38. Install a new rocker cover gasket on the rocker housing

flange. Place the rocker cover into position aligning the

holes in the cover with those in the gasket.

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BOTTOM END OVERHAUL

3.10

3. Using a colored marker, mark the crank sprocket and

DISASSEMBLY

one of the links of the primary cam chain. Maintaining

the original direction of rotation during assembly may

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

prolong service life.

BLY. If only servicing cam compartment components,

4. Remove the flange bolt and flat washer from the crank

see steps 1-11. If performing a complete engine over-

sprocket. See Figure 3-40.

haul, reference steps 1-29.

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

cam sprocket.

NOTE

The cam support plate and lifter cover use the same short

If too much loctite, or perhaps the wrong loctite, was used to

allen head socket screw (1/4 x 1 inch). Only the cam cover

install the primary cam sprocket flange bolt, it may be very

uses the longer screw (1/4 x 1-1/4 inches). For ease of

difficult to remove. In these cases, break down loctite using

assembly, do not mix short and long screws. Store long

heat from a small propane torch. Apply flame evenly around

screws inside cam cover to avoid confusion. The short

bolt head in a circular motion, but not for so long as to turn

screws are interchangeable.

bolt blue. Do not direct heat at chain tensioner assembly and

other components or damage will result. Other methods of

2. Remove the ten allen head socket screws to release the

removal, such as use of a large breaker bar, also may result

cam cover. Remove and discard the cam cover gasket.

in damage to chain drive and other components.

Flange Bolt and

Flat Washer

Cleaning

Right

Plug

Crankcase Half

Front

Camshaft

Primary Cam

Sprocket

Primary

Cam Chain

Chain Guide

Primary Cam Chain

Tensioner

Crank

Sprocket

Oil Pressure

Flange Bolt and

Relief Valve

f2141x3x

Flat Washer

Figure 3-40. Cam Support Plate Assembly

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Insert small pry bar (seal remover) between inboard side

of primary cam sprocket and cam support plate. Working

Tensioner

around its circumference, carefully ease primary cam

Unloader

sprocket off splines of rear camshaft until loose.

Slot

Ease off crank sprocket with a slightly smaller pry bar

(seal remover). Remove the primary cam sprocket, pri-

mary cam chain and crank sprocket.

Remove the primary cam sprocket spacer from the rear

camshaft.

Retention Pins

10.

Squeeze tabs to remove chain guide from between

blocks cast into cam support plate.

11.

Release the cam support plate from the oil pump flange.

Figure 3-41. Cam Chain Tensioner Unloader

Alternately loosen and then remove the four allen head

with Retention Pins (Part No. HD-42313)

socket screws following the pattern shown in B of Figure

3-50.

12.

Release the cam support plate from the crankcase

flange. Alternately loosen and then remove the six allen

head socket screws following the pattern shown in A of

Figure 3-50.

13.

Two ring dowels in crankcase flange locate cam support

plate (lower rear, upper front). See Figure 3-43. Insert

small pry bar (seal remover) between inboard side of

cam support plate and crankcase flange in area adja-

cent to ring dowels. Alternately work each side free and

then carefully ease cam support plate from end of crank-

shaft. See Section 3.11 SUBASSEMBLY SERVICE AND

REPAIR, CAM SUPPORT PLATE.

f1573b3x

O-Ring

Right

f2140x3x

Blind Hole

Crankcase Half

Ring

Figure 3-42. Retract Primary Cam Chain Tensioner

Dowel

1WARNING

Use extreme caution when operating propane torch.

Read the manufacturers instructions carefully before

use. Do not direct open flame or heat toward any fuel

system component. Extreme heat can cause fuel ignition

and explosion. Inadequate safety precautions could

result in death or serious injury.

6. Using the CAM CHAIN TENSIONER UNLOADER (HD-

42313), retract the primary cam chain tensioner as fol-

lows:

a. With the handle pointing toward the front of the cam

support plate, place cup of tool over spring coil. Cor-

rectly positioned, the slot in the tool should be adja-

cent to the hole in the tensioner. See Figure 3-42.

b. Rotate the handle of the tool in a counterclockwise

direction until the hole in the tensioner is aligned

O-Ring

with the hole in the boss of the cam support plate.

Ring

O-Ring

Dowel

Oil Feed Hole

Oil Pump

c. Insert a retention pin through the hole in the ten-

sioner and into the hole in the cam support plate.

Figure 3-43. Oil Pump Assembly

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1CAUTION

Do not pull the retention pin from the primary cam chain

tensioner after removal of the cam support plate. With

35-40 pounds of spring pressure behind the tensioner,

allowing it to accelerate through its full length of travel

will result in spring stretching and/or cracking of the ten-

sioner shoe. Furthermore, if the tensioner should con-

tact fingers or other parts of the hand, minor or

moderate injury may occur.

Figure 3-44. Crankshaft Guide (Part No. HD-42326A)

14. Remove O-ring from groove around oil feed hole in

crankcase flange

(directly below rear ring dowel).

Remove O-ring from groove around blind hole in boss

Water Pipe

f1644x3x

(directly above oil return hole in crankcase flange). Dis-

Insulation

card O-rings. See Figure 3-43.

15. Pull oil pump from crankshaft. Remove O-ring from out-

board side of oil pump housing. Remove O-ring from

scavenge port stub. Discard O-rings. See Section 3.11

Crankshaft

SUBASSEMBLY SERVICE AND REPAIR, OIL PUMP.

Guide

1WARNING

Be sure that stator mount flange (sprocket shaft side) is

NOT facing up when the case halves are separated or the

flywheel assembly will drop to the floor. Dropping the fly-

wheel assembly may result in parts damage and minor

or moderate injury.

16. Rotate crankcase in the engine stand so that the cam

cover flange is facing upward. Remove the nine crank-

case bolts in the left case half. Follow the sequence

shown in Figure 3-46.

Left

Crankcase Half

1CAUTION

f1645a3x

Crankshaft

Never move or lift the crankcase by grasping the cylin-

Guide

der studs. The crankcase is too heavy to be carried in

this manner and may be dropped. Dropping the crank-

case may result in parts damage and minor or moderate

injury.

17. Using pry points, loosen case halves. Lift right crank-

case half off end of crankshaft.

18. Remove O-rings from two ring dowels in split line face of

right case half. Discard the O-rings.

19. See Section

3.11 SUBASSEMBLY SERVICE AND

REPAIR, CRANKCASE.

ASSEMBLY

1. If removed, install left crankcase half in engine stand so

Crankshaft

Right

that the split line face is vertical.

Bearing

Crankcase Half

2. To prevent damage to the sprocket shaft bearing, slide

CRANKSHAFT GUIDE

(HD-42326A) over end of

Figure 3-45. Install Crankshaft Guide to Protect

sprocket shaft. Install flywheel assembly into left case

Crankshaft Bearing

half. Remove tool.

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Rotate crankcase in the engine stand so that the stator

mount flange (sprocket shaft side) is facing upward.

Install service thrust washer on sprocket shaft with the

ink stamp facing out (and the chamfer inboard). If using

OE part without markings, orient as required to preserve

existing wear pattern.

To install new oil seal into bearing bore, obtain pilot,

Nice bearing, large flat washer and handle from

SPROCKET SHAFT TIMKEN BEARING CONE

INSTALLER (HD-97225-55B) and proceed as follows:

a. Verify that seal lip garter spring is in place on both

sides of seal.

b. Thread pilot onto sprocket shaft until contact is

made with shoulder.

c. With the lettering facing outside, slide oil seal over

pilot until it contacts bearing bore.

d. Slide SPROCKET SHAFT OIL SEAL INSTALLER

(HD-39361A) over pilot until it contacts oil seal. See

Figure 3-47.

f1585x3x

Figure 3-46. Crankcase Torque Sequence

(Left Side View)

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

Figure 3-47. Sprocket Shaft Oil Seal Installer

use to avoid confusion.

(Part No. HD-39361A)

3. Install new O-rings over two ring dowels in split line face

of right case half.

4. Apply a small bead of sealant approximately 0.056 inch

f1882x3x

(1.4 mm) wide to the split line face. For best results, use

High-Performance Sealant (gray), Part No. HD-99650-

02.

5. To prevent damage to the crankshaft bearing, place

CRANKSHAFT GUIDE (HD-42326A) over end of crank-

shaft. Mate case halves sliding bearing in right crank-

case half over end of crankshaft. Remove tool. See

Figure 3-45.

Sprocket Shaft

Oil Seal Installer

6. Start the nine crankcase bolts and tighten as follows:

a. Alternately turn each crankcase bolt until finger

tight.

b. Tighten the crankcase bolts to 10 ft-lbs (13.6 Nm) in

the sequence shown in Figure 3-46.

c. Following the same sequence, tighten each bolt to

15-19 ft-lbs (20.3-25.8 Nm).

Figure 3-48. Install

Oil Seal In Bore

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e. Slide Nice bearing and large flat washer over pilot

until contact is made with seal installer.

Rear

Front

Camshaft

Thread handle onto pilot shaft.

g. Rotate handle in a clockwise direction until oil seal

installer makes firm contact with crankcase stator

mount. See Figure 3-48.

h. Remove handle, flat washer, Nice bearing, seal

installer and pilot from sprocket shaft.

9. Slide sprocket shaft spacer over end of sprocket shaft.

Push spacer into oil seal until seated against bearing

race.

10. Rotate crankcase in the engine stand so that the cam

cover flange is facing upward.

11. Install oil pump as follows:

Pin Stamped

f2068x3x

Timing Lines

CAUTION

Figure 3-49. Verify Alignment of Timing Lines

O-rings that are missing, distorted, pinched or otherwise

on Front and Rear Camshafts

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

CAUTION

use to avoid confusion.

O-rings that are missing, distorted, pinched or otherwise

a. Install new O-ring on scavenge port stub of oil

damaged will result in either oil leakage or low oil pres-

pump housing. Apply a very thin film of clean H-D

sure. Use of the wrong O-ring will have the same results.

20W50 engine oil to O-ring before installation.

Since many O-rings are similar in size and appearance,

always use new O-rings keeping them packaged until

b. Slide oil pump housing onto crankshaft fitting O-ring

use to avoid confusion.

on scavenge port stub into crankcase bore at back

of cam compartment. Firmly push on scavenge port

g. Install new O-ring in groove on outboard side of oil

stub with thumb to be sure that it is snug in bore.

pump housing. See Figure 3-43. Apply a very thin

Inspect O-ring on stub to verify that it is not pinched

film of clean H-D 20W50 engine oil to O-ring before

or distorted.

installation.

c. Separate the gerotor gears into two sets, one wide

12. Install new O-ring in groove around oil feed hole in

(scavenge) and the other narrow (feed).

crankcase flange (directly below rear ring dowel). Install

new O-ring around blind hole in boss (directly above oil

NOTE

return hole in crankcase flange). Apply a thin film of H-D

Lubricate parts with clean H-D 20W50 engine oil during

20W50 engine oil to O-rings before installation.

assembly.

13. If not retracted, place cup of CAM CHAIN TENSIONER

UNLOADER (HD-42313) over spring coil of secondary

d. Fit the smaller of the wide gerotor gears into the

cam chain tensioner positioning finger on tool between

larger. Slide the wide gerotor set down the crank-

tensioner and shoe. Rotate tool in a counterclockwise

shaft until it bottoms in the oil pump housing.

direction inserting retention pin through hole in boss on

e. Slide the first of two separator plates down the

primary cam chain side of cam support plate. Pin

crankshaft until it contacts the wide gerotor set.

engages hooks on tensioner to hold it in the retracted

Install wave washer and second separator plate.

position. For best results, place cam support plate in a

vise using brass jaw inserts to prevent casting damage.

Fit the smaller of the narrow gerotor gears into the

larger. Slide the narrow gerotor set down the crank-

14. Lubricate cam needle bearings with clean H-D 20W50

shaft until it contacts the separator plate.

engine oil.

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CAM SUPPORT PLATE

OIL PUMP

f1581b3x

Figure 3-50. Cam Support Plate/Oil Pump Torque Sequence

15.

Using a straightedge, verify that the pin stamped timing

d. Alternately snug and then tighten the screws in

lines on the ends of the front and rear camshafts are in

holes 3 and 4 to 40-45 in-lbs (4.5-5.1 Nm).

alignment (although they may be somewhat difficult to

e. Remove the alignment tool from hole 1. Install the

see). See Figure 3-49. If necessary, rotate camshafts in

allen head socket screw and tighten to 40-45 in-lbs

order to make this observation.

(4.5-5.1 Nm).

16.

Aligning bushing in cam support plate with end of crank-

Repeat step 18(e) to replace alignment tool in hole

shaft, slide cam support plate over crankshaft onto two

2 with allen head socket screw.

ring dowels in crankcase flange. Use a rubber mallet to

fully seat cam support plate on ring dowels.

g. Final tighten all four screws to 90-120 in-lbs (10.2-

13.6 Nm). Use the pattern shown in B of Figure 3-

17.

Install the six allen head socket screws (1/4 x 1 inch) to

50. Numbers cast adjacent to the bolt holes also

secure the cam support plate to the crankcase flange.

indicate the oil pump torque sequence.

Tighten screws to 90-120 in-lbs (10.2-13.6 Nm) in the

pattern shown in A of Figure 3-50.

NOTE

18.

Secure the cam support plate to the oil pump flange as

If only realigning the oil pump, first loosen all screws following

follows:

the pattern shown in B of Figure 3-50. Remove screws from

holes 1 and 2 and then follow the alignment procedure start-

a. Start two allen head socket screws (1/4 x 1 inch)

ing at step 18(b).

into holes 3 and 4. See B of Figure 3-50.

b. Obtain two ALIGNMENT TOOLS used to install lifter

19. Pull retention pin from hole in cam support plate to

guides on Evolution engines (HD-33443). Loosely

release secondary cam chain tensioner.

install alignment tools in holes 1 and 2.

20. Squeeze tabs and install chain guide between blocks

c. While rotating the engine, alternately snug and then

cast into cam support plate.

tighten the alignment tools to 40-45 in-lbs (4.5-5.1

21. Install primary cam sprocket spacer onto rear camshaft.

Nm).

22. If using the original cam support plate, camshafts, pri-

NOTE

mary cam sprocket, crank sprocket and flywheel assem-

For methods of engine rotation, see Section 3.9 TOP END

bly, then move to step 23. However, if any of these parts

OVERHAUL, DISASSEMBLY, step 7.

have been replaced, then proceed as follows:

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a. Install primary cam sprocket onto splines of rear

camshaft. Install long flange bolt with thicker flat

washer to secure sprocket to end of camshaft.

b. Install crank sprocket onto crankshaft. Install short

flange bolt with smaller diameter flat washer (that is,

washer from bulk inventory) to secure sprocket to

end of crankshaft.

NOTE

Use of smaller diameter flat washer with crank sprocket

flange bolt allows room on sprocket face for placement of

straightedge under step 22(e).

c. To prevent rotation, position the CRANKSHAFT/

CAMSHAFT SPROCKET LOCKING TOOL (HD-

f2142x3x

42314) between the crank and primary cam sprock-

ets. See Figure 3-52. The handle of the tool is

Figure 3-53. Check Alignment of Crank and

stamped “Crank” and “Cam” to ensure proper orien-

Primary Cam Sprocket Faces

tation. Tighten the crank and primary cam sprocket

flange bolts to

15 ft-lbs

(20.3 Nm). Remove the

sprocket locking tool.

e. Place a straightedge across the crank and primary

cam sprocket faces. Try to insert a 0.010 inch feeler

d. Push on rear camshaft to remove end play.

gauge between the straightedge and each sprocket

face. See Figure 3-53. If the feeler gauge does not

fit at either location, then proceed to step 22(f).

On the other hand, if the crank sprocket is “proud”

(that is, rises above the face of the primary cam

sprocket) more than 0.010 inch, remove the flange

bolt and primary cam sprocket, and noting the part

number stamped on the existing spacer, replace it

with the next larger size. See spacer sizes listed in

Table 3-4. Replace the spacer with the next smaller

size only if the primary cam sprocket is “proud”

(rises above the face of the crank sprocket) more

than 0.010 inch. Return to step 21 to repeat the

Figure 3-51. Crankshaft/Camshaft Sprocket Locking Tool

check with the new spacer installed.

(Part No. HD-42314)

Table 3-4. Primary Cam Sprocket Spacers

Spacer Size

H-D Part Number

0.287

25722-00

0.297

25723-00

0.307

25721-00

0.317

25719-00

0.327

25717-00

0.337

25725-00

Sprocket

Remove both crank and primary cam sprockets.

Locking Tool

Discard smaller diameter flat washer obtained from

f2139x3x

bulk inventory.

Figure 3-52. Lock Crank and Primary Cam Sprockets

23. Install the primary cam chain and sprocket assembly as

Before Tightening Flange Bolts

follows:

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NOTE

Crank

If the punch marks are not in alignment, then the sprockets

Primary Cam

Sprocket

must be removed and reinstalled. The vehicle will not run

Sprocket

properly if the sprockets are misaligned by even one tooth.

NOTE

Both crank and primary cam sprocket flange bolts are spe-

cially hardened, while the flat washers are of a special diam-

eter and thickness. Therefore, use only genuine Harley-

Davidson parts when replacement is necessary. The crank

and primary cam sprocket flange bolts and flat washers are

NOT interchangeable.

25. Install crank sprocket and primary cam sprocket flange

bolts and flat washers as follows:

NOTE

Exercise caution to avoid mixing oil on washer with thread-

locker on bolt or sealing integrity may be compromised.

Apply a thin film of clean H-D 20W50 engine oil to

both sides of flat washers.

Install thinner flat washer on short flange bolt.

Punch Marks

f2138x3x

Install thicker flat washer on long flange bolt.

Apply Loctite Primer

7649

(P/N

98968-99) to

Figure 3-54. Verify Alignment of Crank and

threads of flange bolts.

Primary Cam Sprocket Punch Marks

Apply one drop of Loctite High Strength Thread-

locker 262 (red) to threads of flange bolts.

a. Place the primary cam sprocket in the cam chain.

Hold the sprocket allowing the chain to hang loose.

Install short flange bolt with thinner flat washer to

Rotate the sprocket so that the punch mark on the

secure crank sprocket to end of crankshaft.

sprocket root faces straight downward.

Install long flange bolt with thicker flat washer to

secure primary cam sprocket to end of camshaft.

NOTE

To maintain the original direction of rotation, verify that the

Position CRANKSHAFT/CAMSHAFT SPROCKET

colored mark placed on the chain link and crank sprocket is

LOCKING TOOL (HD-42314) between the crank

facing away from the cam support plate during installation.

and primary cam sprockets to prevent rotation. See

Figure 3-52. The handle of the tool is stamped

b. Place the crank sprocket in the opposite end of the

“Crank” and “Cam” to ensure proper orientation.

chain with the punch mark on the sprocket tooth fac-

Alternately tighten the crank and primary cam

ing straight upward.

sprocket flange bolts to 15 ft-lbs (20.3 Nm).

c. Maintaining the position of the sprockets on the

Loosen each flange bolt one full turn.

chain with the punch marks in alignment, start the

primary cam sprocket onto the splines of the rear

Tighten the crank sprocket flange bolt to 24 ft-lbs

camshaft. Apply a thin film of clean H-D 20W50

(32.5 Nm).

engine oil to the splines before installation.

Tighten the primary cam sprocket flange bolt to 34

d. Maintaining the position of the crank sprocket on the

ft-lbs (46.1 Nm).

chain, rotate the primary cam sprocket in a clock-

Remove the sprocket locking tool.

wise direction until the flat on the crank sprocket is

aligned with the flat on the crankshaft. Install the

crank sprocket.

1CAUTION

24. Rotate the primary cam sprocket in a clockwise direction

Ease the primary cam chain tensioner into the unloaded

until the punch mark on the root is aligned with the

position using the proper tool. Do not pull the retention

punch mark on the crank sprocket tooth. Lay a straight-

pin to unload the tensioner or the pin may be damaged.

edge across the centerline of the crank and primary cam

Furthermore, if the tensioner should contact fingers or

sprocket flange bolt holes to verify that the punch marks

other parts of the hand, minor or moderate injury may

are in alignment. See Figure 3-54.

occur.

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26. Hold the retracted primary cam chain tensioner with the

CAM CHAIN TENSIONER UNLOADER (HD-42313),

pull retention pin from hole in cam support plate and

Torque: 125-155 in-lbs

ease the assembly into the unloaded position.

27. Apply clean H-D 20W50 engine oil to crank and primary

cam sprockets.

CAUTION

Before cam cover installation, verify cleanliness of blind

holes in the crankcase flange. Tightening screws with

dirt, water or oil in the holes can cause the casting to

crack or break. Damage to the casting requires replace-

ment of the right crankcase half.

28. Align holes in new cam cover gasket with those in the

crankcase flange.

29. Install the cam cover using ten allen head socket screws

(1/4 x 1-1/4 inches). Alternately tighten screws to 125-

155 in-lbs (14.1-17.5 Nm) following the pattern shown in

Figure 3-55.

f1616b3x

30. If performing a complete engine overhaul, see Section

3.9 TOP END OVERHAUL, ASSEMBLY, steps 1-39. If

Figure 3-55. Cam Cover Torque Sequence

only cam compartment components were serviced, just

see steps 29-39.

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Legend:

Bolt

24.

Upper Push Rod Cover

Bolt

25.

Spring Cap Retainer

Rocker Cover

26.

Spring Cap

Rocker Cover Gasket

27.

Spring

Breather Bolt

28.

Flat Washer

Breather Cover

29.

O-Ring

Breather Cover Gasket

30.

Lower Push Rod Cover

Umbrella Valve

31.

O-Ring

Breather Baffle

32.

Lifter Cover Screw

10.

Filter Element

33.

Lifter Cover

11.

Breather Baffle Gasket

34.

Anti-Rotation Pin

12.

Rocker Arm Bolt

35.

Lifter Cover Gasket

13.

Rocker Arm Support Plate

36.

Hydraulic Lifter

14.

Rocker Arm Bushing

37.

Push Rod

15.

Rocker Arm

16.

Rocker Arm Shaft

17.

Rocker Arm

18.

Breather Baffle O-Ring

19.

Rocker Housing Bolt

20.

Rocker Housing Bolt

21.

Rocker Housing

22.

Rocker Housing Gasket

23.

O-Ring

f2239x3x

Figure 3-56. Rocker Arm/Breather/Lifter Assemblies (Exploded View)

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SUBASSEMBLY SERVICE AND REPAIR

3.11

TOP END

f2176x3x

BREATHER ASSEMBLY

Removal

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-7.

Disassembly

1. Remove two bolts and lift breather assembly from rocker

arm support plate. See Figure 3-57.

2. Remove the breather cover and gasket. Remove the

breather baffle and gasket. Discard gaskets.

Pull filter element from bore on inboard side of breather

baffle. Pull stem of umbrella valve from hole at top of

breather baffle. Discard both filter element and umbrella

valve.

Cleaning and Inspection

1. Clean all parts in a non-volatile cleaning solution or sol-

vent.

2. Thoroughly dry all parts with low pressure compressed

air.

Bolt

3. Set a straightedge diagonally across the length of the

Breather Cover

Breather Baffle

breather cover intersecting the opposite corners of the

Cover Gasket

Filter Element

gasket surface. Slide a feeler gauge beneath the

Umbrella Valve

Breather Baffle Gasket

straightedge to check the breather cover for warpage.

Repeat the step checking the opposite diagonal. Discard

Figure 3-57. Breather Assembly

the breather cover if any low spot exceeds 0.005 inch

(0.13 mm).

4. Repeat step

3 to inspect the gasket surface of the

breather baffle for flatness. Discard the breather baffle if

any low spot exceeds 0.005 inch (0.13 mm).

Place breather baffle gasket on a clean flat surface.

Aligning holes, place breather baffle, cover gasket and

Assembly

breather cover on top. Slide two screws through stackup

to keep assembly together until time of installation.

1. Insert stem of new umbrella valve through center hole at

top of breather baffle. Carefully pull rubber bead on stem

through hole in baffle. Use denatured alcohol or glass

cleaner to lubricate stem, if necessary. Verify that rubber

Installation

bead is pulled completely through hole and resides on

1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

bottom side of baffle.

steps 33-39.

2. Press new filter element into bore at bottom of baffle.

Hole in filter element accommodates umbrella valve

stem.

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Harley Davidson 2005 touring models. Service repair manual — page 13

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