Harley Davidson 2005 touring models. Service repair manual — page 11
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EXHAUST SYSTEM
2.36
NOTE
REMOVAL
TORCA muffler clamps have eliminated the need for silicone
or graphite tape during assembly. To ensure sealing integrity
1.
Remove saddlebags. See Section 2.25 SADDLEBAG,
of muffler clamps and prevent the possibility of leakage, Har-
REMOVAL.
ley-Davidson recommends that muffler clamp assemblies be
2.
See Figure 2-195. Open worm drive clamps to remove
discarded and replaced each time they are removed.
six heat shields from exhaust pipes. Mark the location of
the heat shields to ensure proper assembly.
3.
Using a bungee cord, tie the muffler on the left side of
INSTALLATION
the vehicle to the lower saddlebag support rail.
4.
Remove the exhaust flange nuts to release the front and
NOTE
rear header pipes from the cylinder head studs. For best
Always loosely assemble exhaust system on vehicle before
results, use impact wrench with long 1/2 inch swivel
following tightening procedure. Assemble as follows:
socket.
1.
Install new gaskets in both the front and rear cylinder
5.
See Figure 2-194. Loosen the four TORCA clamps as
head exhaust ports (with the tapered side out).
follows:
Right side of vehicle
2.
Install transmission exhaust bracket onto transmission
side door, if removed.
● front header pipe to rear header pipe
● rear header pipe to right side muffler
3.
Install front header pipe exhaust flange onto front cylin-
der head. Start flange nuts on cylinder head studs.
Left side of vehicle
4.
Engaging transmission exhaust bracket, capture front
● rear header pipe to crossover pipe
header pipe in transmission exhaust bracket clamp. Use
● crossover pipe to left side muffer
a channel lock to close clamp, if necessary. Finger
NOTE
tighten clamp bolt (with flat washer and locknut).
To facilitate removal, spray PB Blaster or other suitable pene-
5.
Slide a new TORCA clamp onto free end of front header
trating oil in and around joints of exhaust pipes. For best
pipe.
results, be sure to allow sufficient time for the penetrating oil
6.
Install rear header pipe onto rear cylinder head and front
to work.
header pipe. Start flange nuts on cylinder head studs.
6.
Remove four bolts (with lockwashers) to detach left and
Move TORCA clamp into position between front and rear
right side mufflers from the lower saddlebag support
header pipes.
rails.
7.
Slide new TORCA clamps onto free ends of rear header
7.
Standing on right side of vehicle, remove muffler from Y-
pipe. TORCA clamp to crossover pipe is special in that it
shaped rear header pipe.
has slot for bracket tab to exhaust support bracket.
8.
Remove Keps nut and pull bracket tab and stud from
8.
Slide right side muffler onto rear header pipe. Finger
slots in TORCA clamp and exhaust support bracket.
tighten two bolts (with lockwashers) to attach muffler to
9.
Remove Y-shaped rear header pipe from front header
lower saddlebag support rail. Place TORCA clamp into
pipe, crossover pipe (to left side muffler) and rear cylin-
position between rear header pipe and right side muffler.
der head. Remove bracket tab from slot in TORCA
9.
Moving to left side of vehicle, install crossover pipe onto
clamp.
remaining end of rear header pipe (above starter). Place
10.
Remove bolt (with flat washer and locknut) from trans-
TORCA clamp into position between rear header pipe
mission exhaust bracket clamp on front header pipe.
and crossover pipe.
Use a channel lock to open clamp and then remove from
10.
Fit bracket tab into slot of TORCA clamp engaging stud
header pipe and transmission exhaust bracket. Remove
in slot of exhaust support bracket. Start Keps nut on
front header pipe exhaust flange from front cylinder
stud.
head.
11.
Slide new TORCA clamp onto free end of crossover
11.
Moving to left side of vehicle, remove crossover pipe
pipe.
from left side muffler.
12.
Using a bungee cord, tie left side muffler to lower sad-
12.
Remove bungee cord to release left side muffler from
dlebag support rail. Install left side muffler on crossover
lower saddlebag support rail.
pipe. Place TORCA clamp into position between cross-
13.
Remove and discard gaskets from front and rear
over pipe and left side muffler. Finger tighten bolts to
exhaust ports. Discard TORCA clamp bolt assemblies-
attach muffler to saddlebag support rail.
one time usage only.
2-156
2005 Touring: Chassis
HOME
b. Tighten the bottom nut of the rear cylinder head
CAUTION
exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the
top nut to
100-120 in-lbs (11.3-13.6 Nm). Final
Verify that the exhaust pipes do not contact the vehicle
tighten the bottom nut to 100-120 in-lbs (11.3-13.6
frame or any mounted components. Contact will cancel
Nm).
the effect of the rubber isolation mounts and transmit
c. Tighten the transmission exhaust bracket clamp bolt
vibration to the rider via the vehicle frame.
to 60-96 in-lbs (6.8-10.8 Nm).
13. Tighten the exhaust system as follows:
d. Tighten the two bolts (with lockwashers) to fasten
the right side muffler to the lower saddlebag support
a. Tighten the top nut of the front cylinder head
rail.
exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the
bottom nut to 100-120 in-lbs (11.3-13.6 Nm). Final
e. Tighten the two bolts (with lockwashers) to fasten
tighten the top nut to
100-120 in-lbs (11.3-13.6
the left side muffler to the lower saddlebag support
Nm).
rail.
Left
Muffler
Crossover
Rubber
TORCA
Pipe
Mount
Clamp
Screw
Saddlebag Support
Rail Bracket
Bracket
Lock
Tab
Washer
Keps
Nut
TORCA
Exhaust
Clamp
Support Bracket
(Special)
Right
Muffler
Cylinder Head
TORCA
Gasket
Clamp
Circlip
Transmission
Exhaust Bracket
Exhaust
Clamp
Flange
Nut
Rear
Header Pipe
TORCA
Clamp
Front
Header Pipe
Transmission
f1153b2x
Exhaust Bracket
Figure 2-194. Exhaust System (without Heat Shields)
2005 Touring: Chassis
2-157
HOME
Heat
Shields
Left Muffler
Crossover
Pipe
Right Muffler
Heat
Shields
Rear
Header Pipe
Worm Drive
Clamps
Front
Header Pipe
Heat
Shields
f1154b2x
Figure 2-195. Heat Shields
f.
Verify that all exhaust pipes are in alignment and do
15. Open worm drive clamps and install six heat shields on
not contact the vehicle frame or mounted compo-
exhaust pipes as marked during removal. See Figure 2-
nents.
195. Position each clamp so that screw is on the out-
board side in the most accessible position and then
g. Tighten the four TORCA clamps to 45-60 ft-lbs (61-
tighten to 20-40 in-lbs (2.3-4.5 Nm).
81 Nm) in the following order:
● crossover pipe to left side muffer
CAUTION
● rear header pipe to right side muffer
Verify that the heat shields do not contact the vehicle
● front header pipe to rear header pipe
frame or any mounted components. Contact will cancel
● rear header pipe to crossover pipe
the effect of the rubber isolation mounts and transmit
vibration to the rider via the vehicle frame.
14. Tighten Keps nut securing bracket tab to exhaust sup-
port bracket.
16. Remove bungee cord from left side muffler.
17. Install saddlebags. See Section
2.25 SADDLEBAG,
INSTALLATION.
2-158
2005 Touring: Chassis
ENGINE
3
Table Of Contents
SUBJECT
PAGE NO.
3.1 Specifications
3-1
Manufacturing Tolerances
3-1
3.2 Service Wear Limits
3-3
3.3 General Information
3-5
3.4 How To Use This Section
3-14
3.5 Stripping Motorcycle For Service
3-16
3.6 Assembling Motorcycle After Stripping
3-18
3.7 Removing Engine From Chassis
3-21
3.8 Installing Engine In Chassis
3-26
3.9 Top End Overhaul
3-33
Disassembly
3-33
Assembly
3-37
3.10 Bottom End Overhaul
3-45
Disassembly
3-45
Assembly
3-47
3.11 Subassembly Service And Repair
3-55
Breather Assembly
3-55
Rocker Arm Assembly
3-56
Push Rods/Lifters/Covers
3-59
Cylinder Head
3-63
Cylinder
3-73
Piston
3-77
Upper Connecting Rod
3-82
Cam Support Plate
3-87
Oil Pump
3-99
Crankcase
3-101
Flywheel/Connecting Rod Assembly
3-108
HOME
SPECIFICATIONS
3.1
MANUFACTURING TOLERANCES
Hydraulic Lifter
IN.
MM
Fit in crankcase (loose)
0.0008-0.0020
0.02-0.05
General
Number of cylinders
2
Cylinder Head
IN.
MM
Type
4-cycle, 45˚V2, air-cooled
85 ft-lbs (115.2 Nm)
Valve guide in head (tight)
0.0020-0.0033
0.051-0.084
Torque
@ 3000 rpm
Valve seat in head (tight)
0.003-0.0045
0.076-0.114
Bore
3.75 in. (95.25 mm)
Head gasket surface
0-0.006
0-0.0152
Stroke
4.00 in. (101.6 mm)
(flatness)
Piston displacement (approx.)
88 cu. in. (1450 cc)
Compression ratio
9.0:1
Valve
IN.
MM
Combustion chamber
5.187 cu. in. (85 cc) bathtub
Fit in guide: exhaust
0.001-0.003
0.0254-0.0762
Twin cams, chain driven with
Cam system
Fit in guide: intake
0.001-0.003
0.0254-0.0762
spring loaded tensioners
Seat width
0.040-0.062
1.02-1.58
Max. sustained engine speed
5500 rpm
Stem protrusion from
Idle speed
1000 rpm +/- 50
2.005-2.039
50.93-51.79
cylinder head boss
Weight
165 lbs (74.8 kg)
Valve Spring
IN.
MM
Ignition System
135 lbs
61.2 kg
Sequential, non waste spark,
Closed
Type
@ 1.850 in.
@ 47.0 mm
MAP-N control
312 lbs
141.5 kg
Ignition timing:
Open
20o-30o
@ 1.300 in.
@ 33.0 mm
1050 rpm (Hot Idle)
Free length
2.325 in.
59.1 mm
Spark plug size
12 mm
Spark plug type
Harley-Davidson 6R12
Spark plug gap
0.038-0.043 in. (0.97-1.09 mm)
Piston
IN.
MM
Spark plug torque
12-18 ft-lbs (16-24 Nm)
Fit in cylinder:
Early Style Piston
0.0006-0.0017
0.015-0.043
Late Style Piston
0.0014-0.0025
0.036-0.064
Oiling System
Ring end gap:
Twin gerotor, dual scavenge, crank mounted
Top compression ring
0.010-0.020
0.25-0.51
Pump
and driven, internal oil pump, dry sump
2nd compression ring
0.014-0.024
0.36-0.61
30-38 psi (207-262 kN/m2) at
Pressure
2000 rpm and normal operating temperature
Oil control ring
0.010-0.050
0.25-1.27
of 230o F (110o C)
Ring side clearance:
10 micron media,
Filtration
Top compression ring
0.0012-0.0037
0.030-0.094
filtered between pump and engine
2nd compression ring
0.0012-0.0037
0.030-0.094
Rocker Arm
IN.
MM
Oil control ring
0.0031-0.0091
0.079-0.23
Shaft fit in bushing
0.0005-0.0020
0.013-0.051
Piston pin fit (loose)
0.0002-0.0005
0.005- 0.013
(loose)
End clearance
0.003-0.013
0.08-0.33
Connecting Rod
IN.
MM
Bushing fit in rocker arm
0.002-0.004
0.051-0.102
(tight)
Piston pin fit (loose)
0.0007-0.0012
0.018-0.030
Side play between
Rocker Arm Shaft
IN.
MM
0.005-0.015
0.13-0.38
flywheels
Shaft fit in rocker arm
Connecting rod to
0.0007-0.0022
0.018-0.056
0.0004-0.0017
0.0102-0.0432
support plate (loose)
crankpin (loose)
2005 Touring: Engine
3-1
HOME
MANUFACTURING TOLERANCES (CONT.)
TORQUE VALUES
Flywheel
IN.
MM
Item
ft/in-lbs
NM
Runout
Breather assembly bolts
90-120 in-lbs
10-14 Nm
0.000-0.010
0.000-0.254
(flywheels at rim)
Cam cover screws
125-155 in-lbs
14-18 Nm
Runout
0.000-0.002
0.000-0.051
Cam cover plate screws
20-30 in-lbs
2.3-3.4 Nm
(shaft at flywheel)
Cam support plate screws
90-120 in-lbs
10-14 Nm
End play
0.003-0.010
0.076-0.254
Bearing retainer plate
20-30 in-lbs
2-3 Nm
screws
Crankshaft/Sprocket
15 ft-lbs,
20.3 Nm,
IN.
MM
Shaft Bearings
Crank sprocket flange bolt
loosen one full
loosen one full
turn, 24 ft-lbs
turn, 32.5 Nm
Bearing fit (loose)
0.0002-0.0015
0.005-0.038
15 ft-lbs,
20.3 Nm,
Crankshaft runout
0.0-0.003
0.0-0.076
Primary cam sprocket
loosen one full
loosen one
Bearing fit in
flange bolt
turn, 34 ft-lbs
full turn, 46.1
0.0038-0.0054
0.097-0.137
crankcase (tight)
Nm
Bearing inner race on
Crank position sensor
90-120 in-lbs
10.2-13.6 Nm
0.0004-0.0014
0.010-0.036
screw
crankshaft (tight)
Piston jet screws
25-35 in-lbs
2.8-4.0 Nm
Transmission housing to
15 ft-lbs,
20 Nm,
crankcase bolts
30-35 ft-lbs
41-48 Nm
Crankcase to front engine
33-38 ft-lbs
45-52 Nm
mounting bracket bolts
10 ft-lbs,
14 Nm,
Crankcase bolts
15-19 ft-lbs
20-26 Nm
120-144 in-lbs,
13.6-16.3 Nm,
Cylinder head bolts
15-17 ft-lbs
20.3-23.1 Nm
+ 90o turn
+ 90o turn
Cylinder studs
10-20 ft-lbs
14-27 Nm
Engine oil drain plug
14-21 ft-lbs
19-28 Nm
Lifter cover screws
90-120 in-lbs
10-14 Nm
Oil pan screws
84-132 in-lbs
9.5-14.9 Nm
Oil filter
1/2-3/4 turn after gasket contact
Oil filter mount
12-16 ft-lbs
16-22 Nm
Crankcase oil fittings/plugs
120-168 in-lbs
13.6-18.9 Nm
Oil hose cover screws
84-108 in-lbs
10-12 Nm
Oil pressure switch/sender
96-120 in-lbs
11-14 Nm
Rocker arm support
18-22 ft-lbs
24-30 Nm
plate bolts
Rocker cover bolts
15-18 ft-lbs
20-24 Nm
Rocker housing bolts
120-168 in-lbs
13.6-18.9 Nm
Spark plugs
12-18 ft-lbs
16-24 Nm
Stator screws
55-75 in-lbs
6.2-8.5 Nm
Upper engine mounting
bracket:
To cylinder heads
35-40 ft-lbs
48-54 Nm
To top stabilizer link
18-22 ft-lbs
24-30 Nm
Engine temperature
120-180 in-lbs
13.6-20.3 Nm
sensor
Intake flange adapter
96-144 in-lbs
10.9-16.3 Nm
screws
Exhaust flange adapter
100-120 in-lbs
11.3-13.6 Nm
nuts
3-2
2005 Touring: Engine
HOME
SERVICE WEAR LIMITS
3.2
GENERAL
REPLACE IF
Wear limits can be used as a guide when deciding whether to
Cylinder Bore
IN.
MM
reuse engine parts. Replace used parts whenever the follow-
ing wear limits are exceeded.
Standard
More than 3.752
More than 95.301
0.005 in. oversize
More than 3.757
More than 95.428
REPLACE IF
Rocker Arm/
0.010 in. oversize
More than 3.762
More than 95.555
Rocker Arm Shaft
IN.
MM
Shaft fit in bushing (loose)
More than 0.0035
More than 0.089
REPLACE IF
End clearance
More than 0.025
More than 0.635
Piston
IN.
MM
Shaft fit in rocker arm
More than 0.0035
More than 0.089
support plate (loose)
Fit in cylinder (loose)
More than 0.003
More than 0.076
Piston pin fit (loose)
More than 0.0008
More than 0.020
Ring end gap
REPLACE IF
Top compression
More than 0.030
More than 0.76
Hydraulic Lifter
IN.
MM
2nd compression
More than 0.034
More than 0.86
Fit in crankcase
More than 0.003
More than 0.08
Oil control ring rails
More than 0.050
More than 1.27
Roller fit
More than 0.0015
More than 0.038
Ring side clearance
Roller end clearance
More than 0.015
More than 0.38
Top compression
More than 0.0045
More than 0.11
2nd compression
More than 0.0045
More than 0.11
Oil control ring rails
More than 0.010
More than 0.25
REPLACE IF
Cam Support Plate
IN.
MM
REPLACE IF
Connecting Rod
More than 0.090
More than 2.29
Cam chain
IN.
MM
tensioner shoe wear
1/2 thickness of shoe
Piston pin fit (loose)
More than 0.002
More than 0.051
Crankshaft bushing fit
Less than 0.0008
Less than 0.0203
in cam support plate
Side play between
More than 0.020
More than 0.508
flywheels
Crankshaft bushing
More than 0.8545
More than 21.704
maximum ID
Fit on crankpin (loose)
More than 0.002
More than 0.051
REPLACE IF
REPLACE IF
Flywheel
Cylinder Head
IN.
MM
IN.
MM
Runout (flywheels at rim)
More than 0.015
More than 0.381
Valve guide in head (tight)
Less than 0.002
Less than 0.051
Runout (shaft at flywheel)
More than 0.005
More than 0.127
Valve seat in head (tight)
Less than 0.002
Less than 0.051
End play
More than 0.010
More than 0.254
Head warpage
More than 0.006
More than 0.152
REPLACE IF
Crankshaft/Sprocket
REPLACE IF
Shaft Bearings
Cylinder
IN.
MM
IN.
MM
Bearing to shaft
More than 0.0015
More than 0.038
Taper
More than 0.002
More than 0.051
clearance
Out of round
More than 0.002
More than 0.051
Shaft runout
More than 0.003
More than 0.076
Warpage of gasket or
Bearing fit in
More than 0.006
More than 0.152
Less than 0.0038
Less than 0.097
O-ring surfaces: top
crankcase (tight)
Warpage of gasket or
Bearing inner race
More than 0.004
More than 0.102
Less than 0.0004
Less than 0.010
O-ring surfaces: base
on shaft (tight)
2005 Touring: Engine
3-3
HOME
SERVICE WEAR LIMITS (CONT.)
REPLACE IF
Breather Assembly
IN.
MM
Breather cover warpage
More than 0.005
More than 0.13
Breather baffle warpage
More than 0.005
More than 0.13
REPLACE IF
Valve Stem to
Guide Clearance
IN.
MM
Intake
More than 0.0038
More than 0.0965
Exhaust
More than 0.0038
More than 0.0965
3-4
2005 Touring: Engine
HOME
GENERAL INFORMATION
3.3
FUEL
LUBRICATION
Use a good quality leaded or unleaded gasoline (91 pump
octane or higher). Octane rating is usually posted on the
CHECKING ENGINE OIL LEVEL
pump.
CAUTION
CAUTION
Oil level cannot be accurately measured on a cold
Using gasolines with alcohol additives (such as metha-
engine. For preride inspection, with motorcycle leaning
nol) can cause rubber components within the fuel sys-
on jiffy stand on level ground, oil should register on dip-
tem to fail or result in engine damage.
stick between arrows when engine is cold. Do NOT add
oil to bring the level to the FULL mark on a COLD engine.
GASOLINE/ALCOHOL BLENDS
1. Perform engine oil level COLD CHECK as follows:
Harley-Davidson motorcycles were designed to give the best
a. With the vehicle resting on the jiffy stand on level
performance using unleaded gasoline. Some fuel suppliers
ground, wipe off the dipstick and insert it back into
sell gasoline/alcohol blends as a fuel. The type and amount
the oil pan with the plug pushed completely into the
of alcohol added to the fuel is important.
fill spout.
● DO NOT USE GASOLINES CONTAINING METHANOL.
b. Remove the dipstick and note the level of the oil. Oil
Using gasoline/methanol blends will result in starting
level should register between the two arrows on the
and driveablility deterioration and damage to critical fuel
dipstick. See Figure 3-1. If oil level is at or below the
system components.
lower arrow, add only enough oil to bring the level
● ETHANOL is a mixture of 10% ethanol (Grain alcohol)
between the two arrows on the dipstick.
and 90% unleaded gasoline. Gasoline/ethanol blends
2. Perform engine oil level HOT CHECK as follows:
can be used in your motorcycle if the ethanol content
a. Ride vehicle until engine is at normal operating tem-
does not exceed 10%.
perature.
● REFORMULATED OR OXYGENATED GASOLINES
b. With the vehicle resting on the jiffy stand on level
(RFG):
“Reformulated gasoline” is a term used to
ground, allow engine to idle for 1-2 minutes. Turn
describe gasoline blends that are specifically designed
engine off.
to burn cleaner than other types of gasoline. Your motor-
cycle will run normally using this type of gas.
c. Wipe off the dipstick and insert it back into the oil
pan with the plug pushed completely into the fill
You may find that some gasoline blends adversely affect the
spout.
starting, driveability or fuel efficiency of your bike. If you
experience one or more of these problems, we recommend
d. Remove the dipstick and note the level of the oil.
you try a different brand of gasoline or gasoline with a higher
Add only enough oil to bring the level to the FULL
octane rating.
mark on the dipstick. See Figure 3-1. Do not overfill.
COLD CHECK
HOT CHECK
f1254b3x
Figure 3-1. Engine Oil Dipstick
2005 Touring: Engine
3-5
HOME
5.
Remove the oil filter as follows:
a. Obtain the OIL FILTER WRENCH (HD-42311). The
tool allows easy removal of the oil filter without risk
of damage to the crankshaft position sensor or
cable.
b. Place the jaws of the wrench over the oil filter with
the tool oriented vertically. See Figure 3-3.
c. Using a 3/8 inch drive with a 4 inch extension, turn
wrench in a counterclockwise direction. Do not use
with air tools.
Figure 3-2. Oil Filter Wrench (Part No. HD-42311)
NOTE
Use OIL FILTER WRENCH (HD-44067) if HD-42311 is not
f1641x3x
available.
6.
Clean the oil filter mount flange of any old gasket mate-
rial.
7.
Lubricate gasket with clean engine oil and install new oil
filter on filter mount. Hand tighten oil filter 1/2-3/4 turn
after gasket first contacts filter mounting surface. Do
NOT use OIL FILTER WRENCH for oil filter installation.
NOTE
Use of the Premium 10 micron synthetic media oil filter is
highly recommended, Part No. 63798-99 (Chrome) or 63731-
99 (Black).
8. Install engine oil drain plug with O-ring. Tighten plug to
14-21 ft-lbs (19-28 Nm).
9.
With vehicle resting on jiffy stand, add 3-1/2 quarts (3.3
liters) engine oil as specified in Table 3-1. Use the proper
grade of oil for the lowest temperature expected before
the next oil change.
Figure 3-3. Remove Engine Oil Filter
Table 3-1. Recommended Engine Oils
Harley-
Lowest
Cold Weather
CHANGING ENGINE OIL AND FILTER
Harley-Davidson
Viscosity
Davidson
Ambient
Starts Below
Type
Rating
Temperature
50˚F (10˚C)
NOTE
SAE
Below 40˚F
At the 1000 mile (1600 km) service interval, and at every
HD Multi-grade
HD 360
Excellent
10W40
(4˚C)
5000 mile (8000 km) service interval thereafter, change the
SAE
Above 40˚F
engine oil and engine oil filter. If motorcycle is ridden hard,
HD Multi-grade
HD 360
Good
20W50
(4˚C)
under dusty conditions or in cold weather, change engine oil
SAE
Above 60˚F
HD Regular Heavy
HD 360
Poor
and filter more often.
50
(16˚C)
SAE
Above 80˚F
1. Ride vehicle until engine is at normal operating tempera-
HD Extra Heavy
HD 360
Poor
60
(27˚C)
ture.
2. Locate oil filler plug/dipstick on right side of vehicle at top
of transmission case. To remove the oil filler plug, pull
CAUTION
steadily while moving plug back and forth.
Oil level cannot be accurately measured on a cold
3. Locate oil drain plug at front left side of the oil pan.
engine. For preride inspection, with motorcycle leaning
Remove the oil drain plug and allow oil to drain com-
on jiffy stand on level ground, oil should register on dip-
pletely.
stick between arrows when engine is cold. Do NOT add
oil to bring the level to the FULL mark on a COLD engine.
4. Inspect the oil drain plug O-ring for cuts, tears or signs of
deterioration. Replace as necessary.
10. Perform engine oil level COLD CHECK as follows:
3-6
2005 Touring: Engine
HOME
a. With the vehicle resting on the jiffy stand on level
ground, wipe off the dipstick and insert it back into
CAUTION
the oil pan with the plug pushed completely into the
Check the engine oil level if the oil pressure indicator
fill spout.
lamp remains illuminated. If the oil level is normal, stop
b. Remove the dipstick and note the level of the oil. Oil
the engine immediately. Do not ride the vehicle until the
level should register between the two arrows on the
probem is located and corrected.
dipstick. See Figure 3-1. If oil level is at or below the
lower arrow, add only enough oil to bring the level
If the indicator lamp is not extinguished, it may be the result
between the two arrows on the dipstick.
of a low oil level or diluted oil supply. In freezing weather, the
oil feed and return lines can clog with ice or sludge. A defect
11.
Perform engine oil level HOT CHECK as follows:
in the lamp wiring, faulty oil pressure switch/sender, dam-
aged oil pump, plugged oil filter element, incorrect oil viscos-
a. Ride vehicle until engine is at normal operating tem-
ity, broken or weak spring in the oil pressure relief valve and/
perature.
or damaged or incorrectly installed O-rings in the engine may
b. With the vehicle resting on the jiffy stand on level
also cause the indicator lamp to remain on.
ground, allow engine to idle for 1-2 minutes. Turn
To troubleshoot the problem, always check the engine oil
engine off.
level first. If the oil level is OK, determine if oil returns to the
c. Wipe off the dipstick and insert it back into the oil
pan from the oil return hose. If oil does not return, shut off the
pan with the plug pushed completely into the fill
engine until the problem is located and corrected.
spout.
To check the engine oil pressure, proceed as follows:
d. Remove the dipstick and note the level of the oil.
Add only enough oil to bring the level to the FULL
1.
Verify engine oil level. See CHECKING ENGINE OIL
mark on the dipstick. See Figure 3-1. Do not overfill.
LEVEL in this section.
12.
Start engine and carefully check for oil leaks around
2.
Locate the oil pressure switch/sender at the front right
drain plug and oil filter.
side of the crankcase.
3.
On FLHR/C/S models, pull elbow from post of oil pres-
sure switch. On FLHT/C/U and FLTR models, pull exter-
WINTER LUBRICATION
nal latch outward and use rocking motion to remove
Packard connector from oil pressure sender.
Combustion in an engine produces water vapor. During start-
4.
On FLHR/C/S models, use a 15/16 inch Open End Crow
ing and warm-up in cold weather, especially in freezing tem-
peratures, the vapor condenses to water before the
Foot (Snap-On FC30B) to remove oil pressure switch
crankcase is hot enough to exhaust it through the breather
from crankcase. On FLHT/C/U and FLTR models, use 1-
system. If the engine is run long enough for the crankcase to
1/16 inch Open End Crow Foot (Snap-On FC34A) to
become thoroughly heated, the water returns to vapor and is
remove oil pressure sender.
then exhausted.
5.
Start OIL PRESSURE GAUGE ADAPTER (HD-96921-
110) into crankcase bore. Using a 5/8 inch open end/box
An engine used for only short trips, and seldom allowed to
wrench, turn adapter until snug. See Figure 3-4.
thoroughly warm up, accumulates increasing amounts of
water in the oil pan. Water mixed with oil forms a sludge that
6.
Moving to left side of vehicle, route banjo fitting and hose
causes accelerated engine wear. In freezing temperatures,
of OIL PRESSURE GAUGE
(HD-96921-52B) over
the water becomes slush or ice, which may clog oil lines and
shifter lever and oil filter to right side of engine. See Fig-
result in engine failure.
ure 3-5.
Always change the engine oil more often in winter. If the
7.
Slide washer on banjo bolt and insert through banjo fit-
engine is used for short runs, change the oil even more fre-
ting on gauge. Install second washer on bolt and thread
quently. The farther below freezing the temperature drops the
into adapter until snug.
more often the oil should be changed.
8.
Run vehicle or simulate road running until engine is at
normal operating temperature, approximately
230o F.
(110o C.). Gauge reading will not be accurate if engine is
OIL PRESSURE INDICATOR LAMP
not completely warmed.
9.
Verify that oil pressure is 30-38 psi (207-262 kN/m2) at
The red OIL PRESSURE indicator lamp illuminates to indi-
2000 rpm.
cate improper circulation of the engine oil. The lamp illumi-
nates when the ignition is first turned on (before the engine is
10.
Remove banjo bolt (and washers) from adapter. Remove
started), but should be extinguished once the engine is run-
gauge from vehicle and then remove adapter from
ning.
crankcase.
2005 Touring: Engine
3-7
HOME
ENGINE OIL FLOW
Gauge
CAUTION
The oiling system is carefully designed for optimum effi-
ciency. All oil holes and passageways are specially
sized. Exercise caution to avoid enlarging oil holes dur-
ing cleaning. Any modification of the oiling system will
adversely affect oil pressure or cooling and lubrication
Banjo
Adapter
efficiency.
Bolt
Part No. HD-96921-110
Oil Feed (Figures 3-6, 3-7)
Washers
Oil flows from the oil pan through a passageway at the front
of the transmission housing into a flexible hose clamped to
Figure 3-4. Oil Pressure Gauge
the lower fitting (A1) at the rear right side of the crankcase.
(Part No. HD-96921-52B)
Running through a passageway in the crankcase, the oil exits
a hole in the crankcase flange (B2) and enters a hole on the
f1646x3x
inboard side of the cam support plate. Passing through a
channel in the cam support plate (A3), the oil enters the feed
side of the oil pump. See OIL PUMP OPERATION. The feed
Adapter
gerotors of the pump direct the flow up a second channel in
the cam support plate (A4).
A drilling in this channel connects to a pressure relief valve
mounted in the bypass port of the cam support plate (A5).
When the oil pressure exceeds the setting of the valve spring
Oil
Filter
(35 psi), the orifice opens to bypass excess oil back to the
feed side of the pump (A3).
Oil not returned to the feed side exits a hole on the inboard
side of the cam support plate and passes through a hole in
the crankcase flange (B6). Flowing through a passageway in
the crankcase, where a reading is taken by the oil pressure
sender (B7), the oil exits the lower hole in the oil filter mount
(D8).
Figure 3-5. Install Adapter and Oil Pressure Gauge
After circulating through the oil filter, the flow of oil is directed
back into the crankcase through the upper hole in the oil filter
mount (D9). Exiting a passageway in the crankcase through
NOTE
a hole in the crankcase flange (B10), the flow of oil reenters
If reusing oil pressure switch/sender, apply Loctite Pipe Seal-
the cam support plate.
ant with Teflon 565 to threads.
Filtered oil is then routed to the top and bottom ends of the
engine, as described below.
11. Start oil pressure switch/sender into crankcase bore.
12. On FLHR/C/S models, use a 15/16 inch Open End Crow
Top End (Figures 3-6, 3-7)
Foot (Snap-On FC30B) to tighten oil pressure switch to
96-120 in-lbs (11-14 Nm). On FLHT/C/U and FLTR
Oil passes through a channel in the cam support plate exiting
models, use 1-1/16 inch Open End Crow Foot (Snap-On
the inboard side through two holes near the top (A11, A12).
FC34A) to tighten oil pressure sender to same torque.
Entering two holes in the crankcase flange (B13, B14), one
leading to the front cylinder and the other to the rear, the oil
13. On FLHR/C/S models, install elbow on post of oil pres-
travels through passageways in the crankcase to the hydrau-
sure switch. On FLHT/C/U and FLTR models, install
lic lifter bores (D15).
Packard connector to oil pressure sender.
Exiting a hole in each lifter bore (E16), the oil flows around
NOTE
the lifter and enters a hole at the side of the lifter body. As the
If wire socket terminal requires replacement, see APPENDIX
chamber inside the lifter body is filled, the push rod socket
B.5 SEALED BUTT SPLICE CONNECTORS.
rises to achieve the no-lash fit of the valve train components.
The flow of oil then exits a hole centered in the lifter socket
14. Test oil pressure switch/sender for proper operation.
and runs up the hollow push rods.
3-8
2005 Touring: Engine
HOME
f1581b3x
A
Cam Support Plate
12
11
26
4
38
36
1
3
5
Crankshaft
Bushing
13
14
10
B
24
23
7
37
6
2
f1573b3x
Oil Pump
35
25
Cam Needle Bearings
C
Crankshaft
Bearing
34
f1580b3x
Figure 3-6. Engine Oil Flow - Cam Support Plate/Right Crankcase Half
2005 Touring: Engine
3-9
HOME
NOTE
Oil spray from each piston jet also enters a hole at the bottom
Note that there is one additional hole drilled into the inside
of each pin boss (O30) for lubrication of the piston pin.
lifter bores- while the oblong hole circulates oil around the
Another hole at the top of the connecting rod (D31) allows a
lifter body as described, the round hole (E17) feeds oil to the
portion of the oil to reach the upper rod bushing.
piston jets in the flywheel compartment.
Surplus oil falls back to the bottom of the flywheel compart-
Exiting holes at the top of the hollow push rods, oil enters a
ment where it collects in the sump area (P32). Oil in the
hole at the bottom of the intake and exhaust rocker arms.
sump is drawn to the cam compartment through an internal
Lubricating the rocker arm bushings, oil flows down the
channel (P33, C34) that connects with the second scavenge
rocker arm shafts and exits a pin hole in the outboard side of
lobe of the oil pump (B35).
each rocker arm housing (F18) where it sprays the valve
springs and the top of the valve stem.
Oil Return (Figures 3-6, 3-8)
Oil runs down to the low side of the rocker housing and
enters the exhaust valve spring pocket where a drain hole
The “dual kidney” designation given to the oil pump refers to
(G19) leads to a passageway in the cylinder head casting.
its two scavenging functions, whereby it simultaneously
Oil exits the bottom of the cylinder head and passes through
draws oil from both the cam and flywheel compartments.
a ring dowel (H20) on the “down side” of the cylinder flange.
The oil runs through a vertical passageway in the cylinder,
Oil sucked up by the scavenge lobes passes through the
passes through a second ring dowel on the “down side” of
scavenge gerotors of the oil pump and is directed through a
the cylinder deck (I21) and enters the left crankcase half.
return channel in the cam support plate (A36). See OIL
PUMP OPERATION.
Flowing through a horizontal passageway in the left crank-
case half (J22), oil runs through a third ring dowel (K23) to
Exiting a hole on the inboard side of the cam support plate,
the right crankcase half where it travels through another pas-
the oil enters a hole in the crankcase flange (B37).
sageway before emptying into the cam compartment (B23,
B24).
The oil flows through a passageway in the crankcase and
Oil collecting in the cam compartment is picked up by one of
exits the upper fitting at the rear right side of the crankcase
two scavenge lobes on the oil pump (B25).
(A38). Passing through a flexible hose connection, the flow of
oil runs through a passageway at the front of the transmis-
Bottom End (Figures 3-6, 3-7, 3-8)
sion housing (Q39) before emptying into the oil pan at the
front of the baffle (R40).
Oil travels down the center passage of the cam support plate
(A26) and sprays out through pin holes on each side of the
The oil flows to the rear of the oil pan along each side of the
casting to lubricate both the primary and secondary cam
chains. Oil also passes through a hole in the crankshaft
baffle. Spring tension holds the unit tight against the bottom
of the pan to prevent oil from entering or escaping around the
bushing where the flow enters a drilling in the crankshaft
(L27).
perimeter of the baffle. At the back of the oil pan, the oil
enters the open side of the baffle where it is redirected for-
Oil runs down the center of the crankshaft and then up a
ward. The baffle plates slow the circulation of the oil through
cross drilling into the right side of the flywheel. The flow exits
the pan to enhance cooling.
a drilling in the crank pin bore, enters the crank pin and then
sprays out through three holes to lubricate the lower rod
Oil pickup occurs in the front compartment of the baffle
bearing set.
where a passageway in the casting (S41) directs the flow
The oil splash and mist created by the action of the flywheel
upward. Passing through a second passageway in the trans-
lubricates the crankshaft bearing and the camshaft needle
mission housing (Q42), the flow of oil enters the flexible hose
bearings in the right crankcase half. This same action serves
connection (A1) to repeat the circuit.
to lubricate the sprocket shaft bearing in the left crankcase
half (M28).
Also note that a third flexible hose clamped to a fitting behind
the rear lifter cover connects the cam compartment with the
Since the oil mist also lubricates the cylinder walls, three
oil filler spout. This crankcase breather connection provides
holes on each side of the piston (in the area of the third ring
the pressure balance necessary for oil circulation.
land) evacuate excess oil scraped from the walls on the pis-
ton downstroke.
Oil Pump Operation
The piston jets (N29), which receive a supply of oil from the
intake lifter bores, spray the underside of the piston for cool-
The oil pump consists of a housing containing two gerotor
ing of the piston crown and skirt area. A check valve in each
gear sets, one feed and the other scavenge. Driven by the
jet opens only when the oil pressure reaches 12-15 psi, at
crankshaft, the feed gerotor set distributes oil to the engine,
which point the engine is operating above idle speed. At idle
while the scavenge gerotor set draws oil from the cam and
speeds (9-12 psi), the valve remains closed to prevent over
flywheel compartments and returns it to the oil pan.
oiling and to ensure proper system operating pressure.
3-10
2005 Touring: Engine
HOME
15
D
31
H
20
9
8
E
I
17
16
21
F
J
22
18
G
K
19
23
Figure 3-7. Engine Oil Flow - Top End
2005 Touring: Engine
3-11
HOME
L
P
27
32
33
M
Q
28
42
39
40
N
R
29
O
30
S
41
Figure 3-8. Engine Oil Flow - Bottom End
3-12
2005 Touring: Engine
HOME
Each gerotor gear set has two parts, an inner and outer gero-
tor. The inner and outer gerotors have fixed centers that are
f1562x3x
slightly offset to one another. Also, the inner gerotor has one
Seal
less tooth.
As the crankshaft rotates, the cavity between the inner and
Inner
outer gerotors on the inlet side of the pump increases in vol-
Oil In
Gerotor
ume. This creates a vacuum causing oil to be drawn in. The
cavity continues to increase until the volume is equivalent to
that of the missing tooth on the inner gerotor. Also note that
the inlet and outlet sides of the pump are sealed by the tips
A
and lobes of the inner and outer gerotors. See A of Figure 3-
9.
Continued rotation moves the pocket of oil to the outlet side
of the pump. In this area, the cavity decreases in volume as
the gerotor teeth mesh causing the oil to be squeezed out the
Outer
discharge port. As the cavity on the outlet side is emptied, a
Gerotor
second seal formed by the tips and lobes of the inner and
outer gerotors prevents oil on the outlet side (high pressure)
from being transferred to the inlet side (low pressure). See B
of Figure 3-9.
In operation, the gerotors provide a continuous flow of oil.
See C of Figure 3-9.
Breather Operation
Oil Out
NOTE
The crankcase breather system relieves crankcase pressure
B
produced by the downstroke of the pistons and allows crank-
case vapors vacated from each cylinder to be directed into
the air filter element. Through effective recirculation of crank-
case vapors, the system serves to eliminate the pollutants
Seal
normally discharged from the crankcase.
As each piston pushes downward on its power and intake
stroke, displaced air in the flywheel compartment is vented
through the crankshaft bearing into the cam compartment
and then up the push rod covers into the rocker housing.
Air rushes under the rocker arm support plate, which is ele-
vated slightly, and passes through an opening at the bottom
of the plate to enter the breather baffle compartment.
C
In the baffle compartment, the flow of air passes upward
through the oil filter gauze, where the oil is removed from the
air. Two pin holes in the rocker arm support plate act as drain
holes to rid the baffle compartment of the oil separated from
the air.
Passing through the oil filter gauze, the flow of air passes
through the umbrella valve into the breather compartment.
Figure 3-9. Gerotor Operation
The flaps of the umbrella valve only allow air to be vented
one way, rising to allow the passage of air, but then falling
back into place to seal the vent holes as the flow of air stops.
Flowing
through the cylinder head passageway, the
air
passes through a drilling in the air cleaner backplate bolt and
In the breather compartment, the flow of air reverses direc-
then through a breather tube into the air filter element.
tion passing downward through holes aligned in the breather
baffle, rocker arm support plate and rocker housing. Exiting
NOTE
the rocker housing, the air enters a passageway cast into the
top of the cylinder head. Proper orientation of the rocker
Air cleaner mounting without installation of the breather
housing gasket is critical for effective sealing of this passage-
tubes allows crankcase vapors to be vented into the atmo-
way.
sphere in violation of legal emissions standards.
2005 Touring: Engine
3-13
HOME
HOW TO USE THIS SECTION
3.4
GENERAL
TOP END SERVICE
Three basic levels of service are presented in this section:
Engine in Chassis
Engine Removed
top end overhaul, bottom end overhaul and subassembly ser-
vice and repair. The manner in which these instructions are
used depends upon the level of disassembly required.
Stripping
Removing Engine
Motorcycle for
From Chassis.
Service.
Top End Overhaul
Top End Overhaul,
Top End Overhaul,
Disassembly.
If servicing only cylinder head components, pistons, cylinders
Disassembly.
and/or upper rod bushings, see Section 3.5 STRIPPING
Subassembly
MOTORCYCLE FOR SERVICE, and then proceed to Section
Subassembly
Service and Repair-
3.9 TOP END OVERHAUL, DISASSEMBLY. During top end
Service and Repair-
Top End.
disassembly, the engine may be left in the chassis for ser-
Top End.
vice.
Top End Overhaul,
Top End Overhaul,
Assembly.
NOTE
Assembly.
If the engine is to be removed from the chassis, see Section
Installing Engine
3.7 REMOVING ENGINE FROM CHASSIS in lieu of Section
Assembling
In Chassis.
3.5 STRIPPING MOTORCYCLE FOR SERVICE.
Motorcycle After
In the top end disassembly instructions, references are made
Stripping.
to Section 3.11 SUBASSEMBLY SERVICE AND REPAIR for
service of all top end subassemblies.
BOTTOM END SERVICE
To rebuild the engine after a top end overhaul is complete,
perform the steps under Section 3.9 TOP END OVERHAUL,
Engine in Chassis
Engine Removed
ASSEMBLY, immediately following the disassembly instruc-
tions. Then, refer to Section 3.6 ASSEMBLING MOTORCY-
Cam
Flywheel Compartment
CLE AFTER STRIPPING to complete the project.
Compartment.
or Complete Engine
Overhaul.
NOTE
Stripping
For clarity, all artwork in this section shows the engine
Motorcycle for
removed from the chassis for service.
Removing Engine
Service.
From Chassis.
Top End Overhaul,
Bottom End Overhaul
Top End Overhaul,
Disassembly,
Disassembly.
Bottom end service may require either partial or complete
Steps 1-11.
disassembly of the engine. Servicing components in the cam
Bottom End
Bottom End
compartment requires only partial disassembly, while servic-
Overhaul,
Overhaul,
ing those in the flywheel compartment requires complete dis-
Disassembly.
Disassembly,
assembly. An easy rule to remember is that any time the
Steps 1-14.
crankcase halves must be split, complete disassembly needs
Subassembly
Service and Repair-
to occur. The cam compartment can be accessed through
Subassembly
Top End.
removal of the cam cover making complete engine disassem-
Service and Repair-
bly unnecessary.
Bottom End.
Subassembly
During bottom end service that requires complete disassem-
Service and Repair-
Bottom End
bly, the engine must be removed from the chassis and placed
Bottom End.
Overhaul,
in an engine stand. To begin, see Section 3.7 REMOVING
Assembly,
ENGINE FROM CHASSIS.
Bottom End
Steps 12-29.
Overhaul,
After the motorcycle has been stripped and the engine
Assembly.
Top End Overhaul,
removed, follow all of the steps under Section 3.9 TOP END
Assembly,
OVERHAUL, DISASSEMBLY. When finished, continue with
Top End Overhaul,
Steps 29-39.
disassembly of the bottom half by performing those steps
Assembly.
listed under Section 3.10 BOTTOM END OVERHAUL, DIS-
Assembling
ASSEMBLY.
Installing Engine
Motorcycle After
In Chassis.
Stripping.
Figure 3-10. Top/Bottom End Service
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2005 Touring: Engine
HOME
As with the top end disassembly instructions, references are
For example, if just installing new cams, then refer to Section
made to Section
3.11 SUBASSEMBLY SERVICE AND
3.11 SUBASSEMBLY SERVICE AND REPAIR, CAM SUP-
REPAIR for service of bottom end subassemblies.
PORT PLATE.
Since it is standard practice to inspect and clean all oil pas-
The steps under Section 3.9 TOP END OVERHAUL and Sec-
sages when the engine is completely disassembled, a
tion 3.10 BOTTOM END OVERHAUL that need to be fol-
detailed explanation of the engine oil circuit is presented
lowed for the removal and installation of the cam support
under Section 3.3 GENERAL INFORMATION, ENGINE OIL
plate are given.
FLOW.
Furthermore, detailed instructions for disassembling, clean-
To rebuild the engine after a bottom end overhaul is com-
ing, inspecting, replacing and assembling cam support plate
plete, perform the steps under Section 3.10 BOTTOM END
components are provided.
OVERHAUL, ASSEMBLY, and then proceed to Section 3.9
TOP END OVERHAUL, ASSEMBLY, to rebuild the upper
end.
Once the engine is assembled, refer to Section 3.8 INSTALL-
ING ENGINE IN CHASSIS to complete the project.
The flow charts on the preceding page show how the same
subsections are used for various levels of service.
Subassembly Service and Repair
Finally, if the task entails servicing of only one particular sub-
assembly, then move directly to Section 3.11 SUBASSEM-
BLY SERVICE AND REPAIR for all service instructions.
2005 Touring: Engine
3-15
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