Harley Davidson 2005 touring models. Service repair manual — page 69
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RIDER BACKREST
2.14
REMOVAL
INSTALLATION
1.
See Figure 2-30. Spread the seat covering at the base of
1.
See Figure 2-32. Spread the seat opening to expose the
the backrest exposing the two spring loaded support
keyed backrest support bracket.
arms.
2.
See Figure 2-31. Using two hands, squeeze together the
10566
spring loaded support arms.
10564
1
2
1.
Support arms
2.
Spring
Figure 2-30. Removable Rider Backrest
3.
Pull upward to remove the backrest from the bracket.
Figure 2-32. Backrest Installation
10565
2.
Squeeze together the two spring loaded support arms
on the backrest.
3.
See Figure 2-33. Insert the support arms into the keyed
support bracket.
4.
Test to assure the seat is secured into the bracket.
NOTE
The backrest is spring loaded to assist the passenger in get-
ting on and off the vehicle.
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Figure 2-31. Backrest Removal-Spring Loaded
Support Arms
2
1.
Seat
2.
Keyed support bracket
Figure 2-33. Backrest Mounting Bracket
2-28
2005 FLHTCSE2: Chassis
HOME
REMOVABLE PASSENGER BACKREST
2.15
REMOVAL
INSTALLATION
1.
Remove the saddlebags. See SADDLEBAG, REMOVAL
NOTE
in Touring Models Service Manual.
Install all fasteners finger-tight until instructed to tighten to
2.
See Figure 2-34. Push in the spring-loaded locking latch
specified torque.
and pull the swivel latch rearward on the passenger
1.
Cover filler strip to protect finish.
backrest.
2.
See Figure 2-36. Install docking assembly mounting
3.
Lift the backrest off by lifting upward and then toward the
bracket
(25) and upper saddlebag mounting bracket
rear of the motorcycle.
(15). Secure with screw (16) and washer (17).
4.
See Figure 2-36. Remove bolt (10), washer (9) and front
3.
Install screw (18), lock washer (19) and flat washer (20).
backrest docking bushing (8).
4.
Install backrest docking points bracket (7). Secure with
5.
Remove bolt (14), washer (13), rear backrest docking
screw (14), washer (13), rear backrest docking bushing
bushing (12), washer (11), nut (6) and backrest docking
(12), washer (11) and lock nut (6).
points bracket (7).
5.
Install front backrest docking bushing (8) with screw (10)
6.
Remove screw (18), lock washer (19) and washer (20).
and washer (9) through the backrest docking points
7.
Remove bolt (21), lock washer (22), front Tour-Pak dock-
bracket into the frame.
ing bushing (23) and spacer (24).
6.
Install spacer (24), front Tour-Pak docking bushing (23),
8.
Cover filler strip to protect finish and remove screw (16)
lock washer (22) and bolt (21).
and washer (17).
7.
Align mounting hole in upper saddlebag mounting
9.
Remove upper saddlebag mounting bracket (15) and
bracket (15) with saddlebag.
docking assembly mounting bracket (25).
10. Repeat for opposite side.
10986
11. Inspect all parts and replace as required.
10707
1
Figure 2-35. Passenger Backrest Docking Points
2
1.
Rear latch (2)
2.
“C” bracket guides (2)
Figure 2-34. Detachable Passenger Backrest
2005 FLHTCSE2: Chassis
2-29
HOME
8.
Tighten the following fasteners:
10. Install passenger backrest by sliding bracket c-guides
a. Screw (18) to 15-20 ft-lbs (20.4-27.1 Nm).
onto front backrest docking bushing, and pushing down
on the rear of the bracket with latches aligned to rear
b. Screw (16) to 15-20 ft-lbs (20.4-27.1 Nm).
backrest docking bushings until they rotate and lock into
c. Screw (10) to 15-20 ft-lbs (20.4-27.1 Nm).
position.
d. Screw (14) to 15-20 ft-lbs (20.4-27.1 Nm).
11. Check that passenger backrest is locked in place before
e. Screw (21) to 15-20 ft-lbs (20.4-27.1 Nm).
operating motorcycle.
9.
Repeat for opposite side.
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12
14
1.
Screw (3)
14.
Screw (2)
2.
Spacer (3)
15.
Upper saddlebag mounting bracket (2)
3.
Backrest mounting bracket
16.
Screw (2)
4.
Passenger backrest assembly
17.
Washer (4)
5.
Backrest pad
18.
Screw (2)
6.
Lock nut (2)
19.
Lock washer (2)
7.
Backrest docking points bracket (2)
20.
Washer (2)
8.
Front backrest docking bushing (2)
21.
Screw (2)
9.
Washer (2)
22.
Lock washer (2)
10. Screw (2)
23.
Front Tour-Pak docking bushing (2)
11. Washer (2)
24.
Spacer (2)
12. Rear backrest docking bushing (2)
25.
Docking assembly mounting bracket (2)
13. Washer (2)
Figure 2-36. Passenger Backrest Components
2-30
2005 FLHTCSE2: Chassis
HOME
REMOVABLE TOUR-PAK
2.16
GENERAL
10989
The FLHTCSE2 is equipped with a Removable Tour-Pak
assembly. When using the Removable Passenger Backrest
assembly
(see
2.15 REMOVABLE PASSENGER BACK-
REST), the Removable Tour-Pak must be detached from the
vehicle.
REMOVAL
1.
Remove the saddlebags. See SADDLEBAG, REMOVAL
in Touring Models Service Manual.
NOTE
See Figure 2-37. Tour-Pak power cable connector is located
between seat and fender strut cover on left side of vehicle.
Figure 2-38. Disconnecting Tour-Pak
2.
See Figure 2-38. Disconnect Tour-Pak power cable con-
Power Cable Connector
nector.
3.
See Figure 2-39. Unscrew and disconnect Tour-Pak
antenna cable coaxial connector (1).
10943
4.
See Figure 2-40. Push in the spring-loaded locking latch
1
and pull the swivel latch rearward on the Tour-Pak
bracket.
5.
Lift the Tour-Pak off by lifting upward and then toward the
rear of the motorcycle.
2
10989
3
1.
Coaxial connector
2.
Coaxial adapter
3.
Antenna chassis mount
Figure 2-39. Disconnecting Antenna Cable
10691
Figure 2-37. Tour-Pak Power Cable Connector
Figure 2-40. Unlatching Tour-Pak Mounting Bracket
(Tour-Pak removed for Clarity)
2005 FLHTCSE2: Chassis
2-31
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DISASSEMBLY
Mounting Bracketry (on Vehicle)
1.
See Figure 2-42. Remove screw (3), docking point bush-
ing (4), washer (5) and nut (10) from rear docking point
Tour-Pak
bracket (11).
2.
Remove screw (3), washer (18), docking point bushing
CAUTION
(4), washer (19) and nut (10) securing front docking
point bracket (23) to docking point mounting bracket
When disassembling Tour-Pak from mounting bracket,
(20).
be careful to avoid damaging painted surfaces.
3.
Remove screw (21), washer (12), docking point bushing
1.
Place Tour-Pak on a clean, soft cloth or mat, being care-
(22) and front docking point bracket (23).
ful not to damage painted surfaces.
4.
Remove two screws (16), washers (17), saddlebag filler
2.
See Figure 2-41. Unscrew and remove five nuts (6),
strip (26) and washer (27).
washers (2) and screws (1).
5.
Remove docking point mounting bracket (20) as follows:
3.
Remove Tour-Pak (7), support tube (3) and five saddle
a. Remove screw (6), lockwasher (7), docking point
spacers (4) from detachable mounting bracket (5).
bushing (8) and spacer (9).
b. Loosen, but do not remove, screw (14).
pd0222
c. Remove screw (13), lockwasher (7), washer (12)
and rear docking point bracket (11).
d. Remove screw (14), washer (15), docking point
mounting bracket
(20), upper rear saddlebag
mounting bracket (24) and washer (15).
6.
Repeat steps 1-5 on opposite side of vehicle.
1
ASSEMBLY
2
Mounting Bracketry (on Vehicle)
NOTE
Install all fasteners finger-tight until instructed to tighten to
3
specified torque.
7
1.
See Figure 2-42. Install docking point mounting bracket
(20) as follows:
a. Install washer (15), upper rear saddlebag mounting
4
bracket (24), docking point mounting bracket (20),
washer (15) and screw (14).
b. Install rear docking point bracket (11), washer (12),
lockwasher (7) and screw (13).
c. Install spacer (9), docking point bushing (8), lock-
washer (7) and screw (6).
5
2.
Temporarily mount saddlebag, position upper rear sad-
dlebag mounting bracket with mounting hole in saddle-
bag and tighten screw (14) to 15-20 ft-lbs (20.4-27.1
6
Nm). Remove saddlebag.
3.
Install washer (27), saddlebag filler strip (26), two wash-
ers (17) and two screws (16).
1.
Screw, 1/4-20 x 2-1/4 in. (5)
4.
Install front docking point bracket
(23), docking point
2.
Washer 1/4 in. inside dia. (10)
bushing (22), washer (12) and screw (21).
3.
Support tube
4.
Saddle spacer (5)
5.
Detachable Mounting Bracket
6.
Locknut, Nylon cap, 1/4-20 (5)
7.
Tour-Pak
Figure 2-41. Removable Tour-Pak Assembly
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2005 FLHTCSE2: Chassis
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19
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16
17
16
1.
Tour-Pak
15. Washer (4)
2.
Detachable mounting bracket
16. Screw (4)
3.
Screw (4)
17. Washer (4)
4.
Docking point bushing (4)
18. Washer (2)
5.
Washer (2)
19. Washer (2)
6.
Screw (2)
20. Docking point mounting bracket (2) (right side
7.
Lockwasher (4)
shown)
8.
Docking point bushing (2)
21. Screw (2)
9.
Spacer (2)
22. Docking point bushing (2)
10.
Locknut (4)
23. Front docking point bracket (2)
11.
Rear docking point bracket (2) (right side shown)
24. Upper rear saddlebag mounting bracket (2)
12.
Washer (4)
25. Support bracket (2) (right side shown)
13.
Screw (2)
26. Saddlebag filler strip (2) (right side shown)
14.
Screw (2)
27. Washer (2)
Figure 2-42. Removable Tour-Pak Mounting Components
2005 FLHTCSE2: Chassis
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HOME
5.
Attach front docking point bracket (23) to docking point
mounting bracket (20) with screw (3), washer (18) dock-
CAUTION
ing point bushing (4), washer (19) and nut (10).
When assembling Tour-Pak and mounting bracket, be
6.
Install screw (3), docking point bushing (4), washer (5)
careful to avoid damaging painted surfaces.
and nut (10) to rear docking point bracket (11).
1.
See Figure 2-44. Place Tour-Pak on its front surface on a
7.
Tighten the following docking point mounting bracket
clean, soft cloth or mat, being careful not to damage
(20) fasteners:
painted surfaces.
a. Screw (6) to 15-20 ft-lbs (20.4-27.1 Nm).
2.
See Figure 2-41. Locate five screws (1), ten washers (2),
b. Screw (13) to 15-20 ft-lbs (20.4-27.1 Nm).
five saddle spacers (4), five locknuts (6), detachable
c. Screw (3) to 15-20 ft-lbs (20.4-27.1 Nm).
mounting bracket (5) and support tube (3).
8.
Tighten screw (21) to 15-20 ft-lbs (20.4-27.1 Nm).
3.
See Figure 2-45. Insert one screw with washer through
9.
Tighten screw (3) on rear docking point bracket (11) to
rear-most hole in Tour-Pak bottom. Slide support tube
15-20 ft-lbs (20.4-27.1 Nm).
onto screw.
10. Tighten two screws (16) to 15-20 ft-lbs (20.4-27.1 Nm).
Tour-Pak
10704
NOTE
See Figure 2-43. Detachable mounting bracket has two sets
of holes for mounting Tour-Pak. The rear set of holes will be
used to mount the Tour-Pak.
10767
Figure 2-44. Positioning Tour-Pak for Assembly
Mount Tour-Pak
in rear holes
10705
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Figure 2-43. Detachable Mounting Bracket
2
3
5
1.
Support tube
2.
Saddle spacer
3.
Screw and locknut
4.
Washer
5.
Tour-Pak (front surface facing down)
Figure 2-45. Mounting Support Tube
2-34
2005 FLHTCSE2: Chassis
HOME
4.
Install one saddle spacer onto screw with curved surface
INSTALLATION
of spacer facing support tube. Install washer and lock-
nut. Finger-tighten locknut only.
NOTE
5.
Install screws and washers in other four locations,
See Figure 2-47. The removable Tour-Pak assembly mounts
through Tour-Pak bottom and support tube. Install sad-
on the two rear docking points (2) on each side of the vehicle.
dle spacers on screws with curved surface of each
spacer facing support tube.
1.
See Figure 2-47. Install Tour-Pak mounting bracket by
6.
See Figure 2-46. Slide detachable mounting bracket (1)
sliding bracket c-guides onto forward-most of two rear
onto screws with bracket latches facing rear of Tour-Pak.
docking bushings (2), and pushing down on the rear of
the bracket with latches aligned to rear docking points
7.
Install washers and locknuts
(2,
3). Tighten all five
until they rotate and lock into position.
screws and locknuts to 96-120 in-lbs (10.8-13.5 Nm).
10987
10768
2
2
3
4
1
1.
Passenger backrest docking bushings
2.
Tour-Pak bracket docking bushings
Figure 2-47. Tour-Pak and Passenger
1
Backrest Docking Points
2.
Check that mounting bracket is locked in place before
5
operating vehicle.
1.
Detachable mounting bracket
3.
See Figure
2-48. Locate Tour-Pak power connector
2.
Screw and locknut (4)
between seat and fender strut cover on left side of
3.
Washer (4)
motorcycle.
4.
Saddle spacer (4)
5.
Tour-Pak (front surface facing down)
10988
Figure 2-46. Detachable Mounting Bracket
Figure 2-48. Tour-Pak Power Connector
2005 FLHTCSE2: Chassis
2-35
HOME
4.
See Figure 2-49. Plug Tour-Pak harness into power con-
5.
See Figure 2-51. Make certain that coaxial adapter (2) is
nector and tuck cable assembly between seat and
securely finger-tightened into the antenna chassis
fender strut cover.
mount (3).
10989
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1
2
3
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10679
1.
Coaxial connector
2.
Coaxial adapter
3.
Antenna chassis mount
Figure 2-49. Connecting Tour-Pak Power Cable
Figure 2-51. Connecting Antenna Cable
(Tour-Pak Installed)
NOTE
6.
Pull enough coaxial cable from Tour-Pak to reach coaxial
See Figure 2-50. With the radio antenna mast mounted on
adapter on antenna chassis mount, allowing for a small
the Tour-Pak antenna mount, the coaxial adapter shown in
amount of slack in cable.
the figure allows connecting the antenna cable to the chassis
antenna mount. With Tour-Pak removed, the adapter may be
7.
Screw coaxial cable connector (1) into coaxial adapter
removed and antenna mast threaded directly onto the chas-
on antenna chassis mount. Finger-tighten securely.
sis antenna mount.
pd0220
Figure 2-50. Coaxial Adapter
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2005 FLHTCSE2: Chassis
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RADIO ANTENNA
10680
Removal
See Figure 2-52. Loosen set screw (2) with allen wrench (4)
and unscrew antenna mast (1) from antenna Tour-Pak mount
1
(3).
Installation
See Figure 2-52. Screw antenna mast (1) into antenna
2
mount (3) on Tour-Pak and tighten set screw (2) with allen
wrench (4).
3
4
1.
Antenna mast
2.
Set screw
3.
Antenna Tour-Pak mount
4.
Allen wrench
Figure 2-52. Installing Antenna on Tour-Pak
2005 FLHTCSE2: Chassis
2-37
HOME
SADDLEBAG SUPPORTS
2.17
6.
Remove screw (7), washer (2) and upper front saddle-
REMOVAL
bag bracket (8).
7.
See Figure
2-42. Follow procedures under
2.16
1WARNING
REMOVABLE TOUR-PAK, DISASSEMBLY to remove
the following items:
To prevent accidental vehicle start-up, which could
a. Front docking point bracket (23),
cause death or serious injury, remove maxi-fuse before
b. Docking point mounting bracket (20),
proceeding. (00251a).
c. Rear docking point bracket (11),
1.
See Touring Models Service Manual and remove the fol-
lowing items:
d. Upper rear saddlebag bracket (24).
a. Saddlebags.
8.
See Figure 2-54. Remove support bracket (5) and trim.
b. Left and right side covers.
9.
Repeat REMOVAL steps 2-10 for opposite side.
c. Maxi-Fuse.
2.
See Figure 2-53. See Figure 2-54. Remove two screws
INSTALLATION
(14), washers (15) and spacer (4) securing saddlebag
filler strip (3) to vehicle. Remove filler strip.
1.
See Figure 2-54. Position support bracket (5) and trim
on vehicle.
2.
See Figure
2-42. Follow procedures under
2.16
10765
REMOVABLE TOUR-PAK, ASSEMBLY to install the fol-
lowing items (tighten all fasteners to torque specified in
procedure):
a. Upper rear saddlebag bracket (24),
b. Rear docking point bracket (11),
c. Docking point mounting bracket (20),
d. Front docking point bracket (23).
3.
See Figure 2-54. Install screw (7), washer (2) and upper
front saddlebag bracket (8). Temporarily mount saddle-
bag, position upper front saddlebag mounting bracket
lined up with mounting hole in saddlebag and tighten
screw to 15-20 ft-lbs (20.4-27.1 Nm). Remove saddle-
bag.
4.
Loosely attach rear of saddlebag support bracket (12) to
support bracket (5) with two screws (13) and locknuts
(6).
Figure 2-53. Removing Filler Strip
5.
Attach front of saddlebag support bracket to vehicle
frame with screw (11) and locknut (10). Tighten screw to
3.
Remove two screws (18) and lockwashers (19) securing
15-20 ft-lbs (20.4-27.1 Nm).
muffler (16) to saddlebag support bracket (12). Remove
6.
Tighten screws securing rear of saddlebag support
muffler mounting bracket (20) and rubber mount (17).
bracket to 15-20 ft-lbs (20.4-27.1 Nm).
4.
Remove screw (11) and locknut (10) securing front of
7.
Install rubber mount
(17) onto saddlebag support
saddlebag support bracket to vehicle frame.
bracket. Slide muffler mounting bracket (20) into rubber
5.
Remove two screws (13) and locknuts (6) securing rear
mount.
of saddlebag support bracket to support bracket (5).
Remove saddlebag support bracket from vehicle.
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2005 FLHTCSE2: Chassis
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14
14
15
16
11
1.
Upper rear saddlebag bracket (2)
11. Screw (2)
2.
Washer (6)
12. Saddlebag support bracket (2) (right side shown)
3.
Saddlebag filler strip (2)
13. Screw (4)
4.
Spacer (2)
14. Screw (4)
5.
Support bracket (2) (right side shown)
15. Washer (4)
6.
Locknut (4)
16. Muffler (2)
7.
Screw (4)
17. Rubber mount (2)
8.
Upper front saddlebag bracket (2)
18. Screw (4)
9.
Receptacle (9)
19. Lockwasher (4)
10. Locknut (2)
20. Muffler mounting bracket (2)
Figure 2-54. Saddlebag Support Components
8.
Attach muffler (16) to muffler mounting bracket with two
10. Repeat INSTALLATION steps 1-9 for opposite side.
screws (18) and lockwashers (19). Tighten to 96-144 in-
11. See Touring Models Service Manual and install the fol-
lbs (10-9-16.3 Nm).
lowing items:
9.
Install saddlebag filler strip
(3) with washer (4), two
a. Maxi-Fuse.
screws (14) and washers (15). Tighten to 15-20 ft-lbs
b. Left and right side covers.
(20.4-27.1 Nm).
c. Saddlebags.
2005 FLHTCSE2: Chassis
2-39
HOME
MUFFLER END CAP
2.18
REPLACEMENT
10553
1.
See Figure 2-55. Loosen and remove three fasteners
holding muffler end cap in place. Remove end cap.
2.
Install muffler end cap, align holes. Install and tighten
fasteners.
Figure 2-55. Muffler End Cap Fastener Locations
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2005 FLHTCSE2: Chassis
ENGINE
3
Table Of Contents
SUBJECT
PAGE NO.
3.1 Specifications
3-1
3.2 Service Wear Limits
3-3
3.3 Torque Values (table)
3-5
3.4 Breather Assembly
3-6
3.5 Rocker Housing
3-7
3.6 Cylinder Heads
3-10
3.7 Pistons
3-24
3.8 Boring and Honing Cylinders
3-25
3.9 Cams and Timing Marks
3-26
3.10 Flywheel/Connecting Rod Assembly
3-27
3.11 Oil Vent Line
3-30
3.12 Oil Cooler Operation
3-31
3.13 Oil Cooler
3-34
3.14 Oil Filter Mount
3-35
3.15 Thermostat
3-37
NOTE
This section provides information unique to FLHTCSE2 model motorcycles. Any informa-
tion not presented in this supplement can be found in the Touring Models Service Manual.
HOME
SPECIFICATIONS
3.1
GENERAL
MANUFACTURING TOLERANCES
Table 3-4. Rocker Arms
Table 3-1. Engine-General
ITEM
INCHES
MM
ITEM
SPECIFICATION
Shaft fit in bushing
Number of cylinders
2
0.0005-0.0020
0.013-0.051
(loose)
Type
4-cycle, 45˚ V-twin, air-cooled
End clearance
0.003-0.013
0.08-0.033
100 ft-lbs (138 Nm)
Torque
@ 3500 RPM
Bushing fit in rocker arm
0.002-0.004
0.051-0.102
Bore
3.875 in. (98.425 mm)
(tight)
Stroke
4.375 in. (111.125 mm)
Piston displacement (approx.)
103 cu. in. (1690 cc)
Compression ratio
9.0:1
Table 3-5. Rocker Arm Shafts
Combustion chamber
Hemispherical
Twin cams, chain driven with
ITEM
INCHES
MM
Cam system
spring loaded tensioners
Shaft fit in rocker arm
Max. sustained engine speed
5800 RPM
0.0007-0.0022
0.018-0.056
support plate (loose)
Idle speed
1000 RPM ± 50
Weight
165 lbs (74.8 kg)
Table 3-6. Hydraulic Lifters
Table 3-2. Ignition System
ITEM
INCHES
MM
Fit in crankcase (loose)
0.0008-0.0020
0.02-0.05
ITEM
SPECIFICATION
Sequential, non waste spark,
Type
MAP-N control
Ignition timing:
Table 3-7. Cylinder Heads
20˚-30˚
1050 RPM (hot idle)
ITEM
INCHES
MM
Spark plug size
12 mm
Spark plug type
Harley-Davidson 6R12
Valve guide in head (tight)
0.0020-0.0033
0.051-0.084
Spark plug gap
0.038-0.043 in. (0.97-1.09 mm)
Valve seat in head (tight)
0.003-0.0045
0.076-0.114
Spark plug torque
12-18 ft-lbs (16.3-24.4 Nm)
Head gasket surface
0.0-0.006
0.0-0.0152
(flatness)
Table 3-3. Oiling System
Table 3-8. Valves
ITEM
SPECIFICATION
Twin gerotor, dual scavenge, crank mounted
ITEM
INCHES
MM
Pump
and driven, internal oil pump, dry sump
Fit in guide (exhaust)
0.0015-0.0033
0.038-0.084
30-38 psi (207-262 kN/m2) at
Pressure
2000 RPM and normal operating temperature
Fit in guide (intake)
0.0008-0.0026
0.020-0.066
of 230˚ F (110˚ C)
Seat width
0.040-0.062
1.02-1.58
10 micron media,
Filtration
filtered between pump and engine
Stem protrusion from
1.990-2.024
50.55-51.41
cylinder head boss
Cooling
Thermostat controlled oil cooler
2005 FLHTCSE2: Engine
3-1
HOME
Table 3-9. Valve Spring Assembly
Table 3-12. Flywheels
ITEM
PRESSURE
DIMENSION
ITEM
INCHES
MM
Closed
165 lbs (75 kg).
1.820 in (46.2 mm).
Runout
0.000-0.010
0.0-0.254
(flywheels at rim)
Open
416 lbs (189 kg)
1.290 in. (32.7 mm)
Runout
Free length
n/a
2.210 in (56.1 mm)
0.000-0.002
0.0-0.051
(shaft at flywheel)
End play
0.003-0.010
0.076-0.254
Table 3-10. Pistons
ITEM
INCHES
MM
Table 3-13. Crankshaft Sprocket
Shaft Bearing
Fit in cylinder
0.0014-0.0025
0.036-0.064
Ring end gap:
ITEM
INCHES
MM
Top compression ring
0.010-0.020
0.254-0.508
Roller bearing fit (loose)
0.0002-0.0015
0.005-0.038
2nd compression ring
0.014-0.024
0.3556-0.6096
Crankshaft runout
0.0-0.003
0.0-0.076
Oil control ring
0.010-0.050
0.25-1.27
Bearing fit in
0.0038-0.0054
0.097-0.137
crankcase (tight)
Ring side clearance:
Top compression ring
0.0012-0.0037
0.030-0.094
Bearing inner race on
0.0001-0.0010
0.0025-0.0254
crankshaft (tight)
2nd compression ring
0.0012-0.0037
0.030-0.094
Oil control ring
0.0031-0.0091
0.079-0.231
Piston pin fit (loose)
0.0002-0.0005
0.005-0.013
Table 3-11. Connecting Rods
ITEM
INCHES
MM
Piston pin fit (loose)
0.0003-0.0007
0.008-0.018
Side play between
0.005-0.015
0.13-0.38
flywheels
Connecting rod to
0.0004-0.0017
0.0102-0.0432
crankpin (loose)
3-2
2005 FLHTCSE2: Engine
HOME
SERVICE WEAR LIMITS
3.2
GENERAL
Table 3-18. Cylinders
REPLACE IF WEAR EXCEEDS
Wear limits can be used as a guide when deciding whether to
ITEM
reuse engine parts. Replace used parts whenever the follow-
INCHES
MM
ing wear limits are exceeded.
Taper
0.002
0.051
Out of round
0.002
0.051
Table 3-14. Rocker Arm/Rocker Shafts
Warpage of gasket or
0.006
0.152
REPLACE IF WEAR EXCEEDS
O-ring surfaces: top
ITEM
Warpage of gasket or
INCHES
MM
0.004
0.102
O-ring surfaces: base
Shaft fit in bushing
0.0035
0.089
(loose)
End clearance
0.025
0.635
Table 3-19. Cylinder Bore
Shaft fit in rocker arm
0.0035
0.089
support plate (loose)
REPLACE IF WEAR EXCEEDS
ITEM
INCHES
MM
Standard
3.877
98.48
Table 3-15. Hydraulic Lifters
0.005 in. oversize
3.882
98.60
REPLACE IF WEAR EXCEEDS
0.010 in. oversize
3.887
98.73
ITEM
INCHES
MM
Fit in crankcase
0.003
0.08
Table 3-20. Pistons
Roller fit
0.0015
0.038
Roller end clearance
0.015
0.38
REPLACE IF
WEAR EXCEEDS
ITEM
INCHES
MM
Table 3-16. Cam Support Plate
Fit in cylinder (loose)
0.003
0.076
REPLACE IF WEAR EXCEEDS
Piston pin fit (loose)
0.0008
0.020
ITEM
Top compression
0.030
0.762
INCHES
MM
Ring
2nd compression
0.034
0.863
0.080-0.090
2.03-2.29
end gap
Cam chain
Oil control ring rails
0.050
1.27
tensioner shoe
1/2 thickness of shoe
Top compression
0.0045
0.11
Warpage
0.010
0.25
Ring
side
2nd compression
0.0045
0.11
Crankshaft bushing fit
0.0008-0.001
0.0203-0.0254
clearance
Oil control ring rails
0.010
0.25
Table 3-17. Cylinder Heads
REPLACE IF
ITEM
INCHES
MM
Valve guide (tight)
Less than 0.002
Less than 0.051
Valve seat (tight)
Less than 0.002
Less than 0.051
Head warpage
Greater than 0.006
Greater than 0.152
2005 FLHTCSE2: Engine
3-3
HOME
Table 3-21. Connecting Rods
Table 3-24. Breather Assembly
REPLACE IF WEAR EXCEEDS
REPLACE IF WEAR EXCEEDS
ITEM
ITEM
INCHES
MM
INCHES
MM
Piston pin fit (loose)
0.001
0.025
Breather cover warpage
0.005
0.13
Side play between
Breather baffle warpage
0.005
0.13
0.020
0.51
flywheels
Fit on crankpin (loose)
0.002
0.05
Table 3-25. Valve Stem to Guide Clearance
REPLACE IF WEAR EXCEEDS
ITEM
Table 3-22. Flywheels
INCHES
MM
Intake
0.0035
0.089
REPLACE IF WEAR EXCEEDS
ITEM
Exhaust
0.0040
0.102
INCHES
MM
Flywheel runout at rim
0.015
0.381
Shaft runout at
0.003
0.076
flywheel
End play
0.010
0.254
Table 3-23. Crankshaft Sprocket
Shaft Bearing
REPLACE IF
ITEM
INCHES
MM
Bearing fit (loose)
Greater than 0.0015
Greater than 0.038
Crankshaft runout
Greater than 0.003
Greater than 0.076
Bearing fit in
0.0038-0.0054
0.097-0.137
crankcase (tight)
Bearing inner race on
Less than 0.0001
Less than 0.0254
crankshaft (tight)
3-4
2005 FLHTCSE2: Engine
HOME
TORQUE VALUES
3.3
ITEM
TORQUE
NOTES
Chrome oil vent line nut
60-80 in-lbs
6.8-9.0 Nm
page 3-30
Oil cooler to mounting backet
80-110 in-lbs
9.1-12.4 Nm
page 3-34
Oil filter adapter
12-16 ft-lbs
16.3-21.7 Nm
page 3-36
Oil filter mount screw
130-150 in-lbs
14.7-16.9 Nm
page 3-36
LOCTITE Thread Seal-
Oil pressure switch
96-144 in-lbs
10.8-16.3 Nm
ant, page 3-34
Oil spout fitting
130-150 in-lbs
14.7-16.9 Nm
page 3-30
Oil vent line crankcase fitting
130-150 in-lbs
14.7-16.9 Nm
page 3-30
Rocker housing bolts
120-168 in-lbs
13.6-19.0 Nm
page 3-9
Thermostat plug
15-20 ft-lbs
20.4-27.1 Nm
page 3-36, 3-37
Transfer passage cover
90-120 in-lbs
10.2-13.6 Nm
page 3-36
2005 FLHTCSE2: Engine
3-5
HOME
BREATHER ASSEMBLY
3.4
REMOVAL
INSTALLATION
See TOP END OVERHAUL in the Touring Models Service
See TOP END OVERHAUL in the Touring Models Service
Manual.
Manual.
NOTE
f1531x4x
If breather style is different from that illustrated, see
1
2
BREATHER ASSEMBLY under TOP END under SUBAS-
SEMBLY SERVICE AND REPAIR, in the Touring Models Ser-
vice Manual.
3
4
DISASSEMBLY
5
1.
See Figure 3-1. Remove two fasteners from breather
assembly.
2.
Remove breather cover and gasket. Discard cover gas-
ket.
6
7
3.
Remove the breather baffle and gasket. Discard gasket.
4.
Pull filter element from bore on inboard side of breather
8
baffle. Discard filter element.
5.
Pull stem of umbrella valve from hole at top of breather
baffle. Discard umbrella valve.
CLEANING AND INSPECTION
1WARNING
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye injury.
Wear safety glasses when working with compressed air.
Never use your hand to check for air leaks or to deter-
1.
Fastener
mine air flow rates. (00061a)
2.
Breather cover
3.
Cover gasket
1.
Clean all parts in a non-volatile cleaning solution or sol-
4.
Umbrella valve
vent.
5.
Breather baffle
2.
Thoroughly dry all parts with low pressure compressed
6.
Filter element
air.
7.
Breather baffle gasket
8.
Rocker arm support plate
ASSEMBLY
Figure 3-1. Breather Components
1.
See Figure 3-1. Insert stem of new umbrella valve
through center hole at top of breather baffle. Use dena-
tured alcohol or glass cleaner to lubricate stem. Care-
fully pull rubber bead on stem through hole in baffle.
Verify that rubber bead is pulled completely through hole
and resides on bottom side of baffle.
2.
Press new filter element into bore at bottom of baffle
Hole in filter element accommodates umbrella valve
stem.
3.
Place breather baffle gasket on a clean flat surface.
Aligning holes, place breather baffle, cover gasket and
breather cover on top. Slide two screws through stackup
to keep assembly together until time of installation.
3-6
2005 FLHTCSE2: Engine
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