Harley Davidson 2005 touring models. Service repair manual — page 14
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3.
Remove the rocker arms from the rocker arm support
ROCKER ARM ASSEMBLY
plate. Mark the rocker arms to indicate location.
Removal
Cleaning and Inspection
1.
See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-9.
1.
Clean all parts in a non-volatile cleaning solution or sol-
vent. Thoroughly dry with low pressure compressed air.
Disassembly
2.
Check rocker arms for uneven wear or pitting where con-
tact is made with the valve stem tips. Check for concave
1.
Remove the four bolts from the rocker arm support plate.
wear where rocker arms contact the push rod ends.
If necessary, slightly wiggle the two bolts on the push rod
Replace rocker arm if excessive wear is found at either
side (right) to disengage them from the notches in the
location.
rocker arm shafts.
3.
Verify that oil holes in rocker arms and rocker arm sup-
2.
Using a hammer and brass drift, tap left side of rocker
port plate are clean and open.
arm shafts so that the notched ends exit the rocker arm
support plate first. Mark the shafts so that they are
4.
Inspect rocker arm shafts for scratches, burrs, scoring or
installed in their original locations at time of assembly.
excessive wear. Replace as necessary.
A
B
C
D
Figure 3-58. Measure Rocker Arm Assembly for Wear
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5.
Measure the inside diameter of the rocker arm support
plate bore. See A of Figure 3-58. Measure the outside
Remove Bushings.
diameter of the rocker arm shaft where it fits in the bore.
See B of Figure 3-58. Repeat the measurement on
opposite side of support plate and shaft. Replace the
shaft or support plate if any measurement equals or
exceeds 0.0035 inch (0.089 mm).
Driver
Discarded Shaft
6.
Measure the inside diameter of the rocker arm bushing.
See C of Figure 3-58. Measure the outside diameter of
the rocker arm shaft where it rides in the bushing. See D
of Figure 3-58. Repeat the measurement on opposite
side of rocker arm and shaft. Replace the shaft or bush-
ings if any measurement equals or exceeds 0.0035 inch
(0.089 mm).
7.
To replace rocker arm bushings, proceed as follows:
NOTE
9/16”-18 Tap
Remove, install and ream one bushing at a time.
6916
a. Obtain a 9/16”-18 (14.29 mm) tap. Turn tap into
bushing until tight. Place rocker arm under ram of
arbor press with tap at bottom. Slide a discarded
Install Bushings.
rocker arm shaft through open end of rocker arm
until contact is made with tap. Using shaft as driver
(and untapped bushing as pilot), press against shaft
until both tap and bushing are free. See upper
Driver
frame of Figure 3-59.
b. Using a suitable driver, press new bushing into side
of rocker arm until flush with casting. See center
frame of Figure 3-59. Be sure to orient bushing so
that split line faces top of rocker arm.
CAUTION
Never back reamer out of rocker arm or new bushing will
be damaged.
c. Lock rocker arm in a vise using brass jaw inserts or
shop towels to prevent casting damage. Insert
6922
tapered end of ROCKER ARM BUSHING REAMER
(HD-94804-57) into old bushing in rocker arm. Note
that old bushing on drive side of reamer serves as
pilot. See lower frame of Figure 3-59. Rotate reamer
Ream Bushings.
until new bushing on far side is reamed, and then
continuing in the same direction, draw drive side of
reamer from new bushing.
Bushing Reamer
d. Repeat steps 7(a) thru 7(c) to remove, install and
Part No. HD-94804-57
ream second bushing.
Assembly
1. Place the rocker arms into position on the rocker arm
support plate.
2. Push the un-notched ends of the rocker arm shafts into
the right side of the support plate and then into the
rocker arms. As they approach their fully installed posi-
tions, rotate the shafts so that the notches are aligned
with the bolt holes in the support plate.
6923
Figure 3-59. Replace Rocker Arm Bushings
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3.
To check for proper end play, insert a feeler gauge
between the rocker arm and support plate. See Figure 3-
60. Repeat measurement on other rocker arm. Replace
the rocker arm, rocker arm support plate, or both if end
play exceeds 0.025 inch (0.635 mm).
4.
Install the four bolts in the rocker arm support plate. For
proper assembly, remember that the two bolts on the
push rod side (right) must engage the notches in the
rocker arm shafts.
Installation
1.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
steps 31-39.
6917
Figure 3-60. Check End Play
3-58
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PUSH RODS/LIFTERS/COVERS
Spring Cap
Retainer
O-Ring
Removal
Small
1.
See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-14.
Disassembly
1. With the exception of the lifter covers, all parts should
have been disassembled and marked during the
Spring Cap
removal procedure. Disassemble the lifter covers as fol-
lows:
Spring
a. Separate upper and lower push rod covers.
b. Remove O-ring from seat at bottom of lower push
Flat
O-Ring
rod cover. Discard O-ring.
Washer
Intermediate
c. Remove O-ring from seat at top of upper push rod
cover. Slide O-ring, flat washer, spring and spring
cap from body of upper push rod cover. Discard O-
rings.
Upper
Push Rod
Cover
Cleaning and Inspection
Flared End
1. Scrape old gasket material from the lifter cover flange.
Old gasket material left on mating surfaces will cause
leaks.
2. With the exception of the hydraulic lifters, clean all parts
in a non-volatile cleaning solution or solvent. Verify that
the O-ring seats and contact surfaces of the push rod
covers are completely clean.
Lower
3. Thoroughly dry all parts with low pressure compressed
Push Rod
air. Verify that all oil holes are clean and open.
Cover
4. Verify that the hydraulic lifter rollers turn freely and are
free of flat spots, scuff marks and pitting. If flat spots
exist, examine the cam lobe on which the lifter operates.
5. Inspect the lifter socket for signs of wear. Verify that the
plunger of the hydraulic lifter is fully extended up against
the C-clip. Use index finger to pump plunger to verify
O-Ring
lifter operation.
Large
f1584x3x
6. Examine the push rods. Replace any push rods that are
bent, dented, broken or discolored. Replace the rod if
Figure 3-61. Push Rod Cover Assembly
the ball ends show signs of excessive wear or damage.
7. Cover all parts with a clean plastic sheet to protect them
CAUTION
from dust and dirt.
O-rings that are missing, distorted, pinched or otherwise
Assembly
damaged will result in either oil leakage or low oil pres-
sure. Use of the wrong O-ring will have the same results.
1. With the exception of the lifter covers, all parts will be
Since many O-rings are similar in size and appearance,
assembled during the installation procedure. Assemble
always use new O-rings keeping them packaged until
the lifter covers as follows:
use to avoid confusion.
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a. Obtain three new o-rings- small, intermediate and
d. Fit the straight end of the upper push rod cover into
large.
the flared end of the lower push rod cover.
b. Install small O-ring on seat at the top of the upper
e. Install large O-ring on seat at bottom of lower push
push rod cover.
rod cover.
NOTE
Apply a very thin film of clean H-D 20W50 engine oil to O-
Installation
rings before installation.
1.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
c. Slide the spring cap, spring, flat washer and inter-
steps 25-39.
mediate size O-ring onto the body of the upper push
rod cover. Move parts up body until spring cap con-
tacts upper O-ring seat.
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NOTES
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Legend:
1.
Tapered Keepers
2.
Spring Retainer
1
3.
Valve Spring
4.
Spring Seat/Valve Stem Seal
5.
Valve Guide
7
2
6.
Valve Guide Collar
7.
Cylinder Head Bolt
8.
Cylinder Head Bolt
3
9.
Cylinder Head
10.
Valve Seat
11.
Valve
12.
Cylinder Head Gasket
4
8
13.
Cylinder
14.
Ring Dowel
5
15.
O-Ring Seal
16.
Cylinder Stud
6
17.
Piston
18.
Piston Pin
19.
Circlip
20.
Top Compression Ring
21.
Second Compression Ring
22.
Oil Rail
9
23.
Oil Rail Spacer
10
11
12
14
20
22
13
21
22
19
23
18
17
19
15
16
f2291x3x
Figure 3-62. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)
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CYLINDER HEAD
Removal
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-11 and 15-19.
Disassembly
1. Before proceeding with the disassembly procedure,
determine if cylinder head reconditioning is necessary.
Figure 3-65. Valve Spring Compressor
Proceed as follows:
(Part No. HD-34736B)
a. Raise valve ports of cylinder head to strong light
source. If light is visible around edges of seats, then
move to step 2 to recondition cylinder head.
f1648x3x
b. Fill ports at top of cylinder head with solvent. Wait
ten full seconds and then check for leakage into
combustion chamber. If solvent leakage into com-
bustion chamber is evident, then move to step 2 to
recondition cylinder head.
14mm End
12mm End
Figure 3-63. Cylinder Head Holding Fixture
Figure 3-66. Compress Valve Springs
(Part No. HD-39786)
2.
Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
f2292x3x
39786) and proceed as follows:
a. Note that both ends of the fixture are threaded, one
end at 14mm and the other at 12mm. Thread the
12mm end of the tool into the spark plug hole of the
cylinder head.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position). See Figure
3-64.
3.
Obtain the VALVE SPRING COMPRESSOR
(HD-
34736B) and proceed as follows:
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.
Cylinder Head
See Figure 3-66.
Holding Fixture
b. Rotate forcing screw to compress valve spring.
c. If spring retainer has not broken free of tapered
keepers, give head of tool a sharp tap with a soft
mallet. Using magnetic rod or small screwdriver,
Figure 3-64. Install Cylinder Head Holding Fixture in Vise
remove the keepers from the valve stem groove.
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d. Rotate forcing screw to release the valve spring
4.
Thoroughly clean the cylinder head, spring retainers,
compression.
tapered keepers, valves and valve springs in a non-vola-
tile cleaning solution or solvent. Follow up with a thor-
4.
Remove the spring retainer and valve spring.
ough wash in hot soapy water. Blow dry with
compressed air.
5.
Slide the valve from the valve guide.
6.
Twist and remove the valve stem seal/spring seat from
Inspection
the top of the valve guide. Discard the valve stem seal/
spring seat.
Cylinder Head
1.
Check for scratches and nicks on all gasket sealing sur-
7.
Mark the bottom of the valve “F(ront)” or “R(ear)” to indi-
faces.
cate the cylinder head from which it was removed. Also,
separate and tag the tapered keepers, valve spring and
2.
With the combustion chamber side facing upward, set a
spring retainer so that they are installed on the same
straightedge diagonally across the length of the cylinder
valve at time of assembly.
head intersecting the upper and lower corners of the
gasket surface. Slide a feeler gauge beneath the
8.
Repeat steps 3-7 to remove the other valve components.
straightedge to check the head for warpage. Checking
the opposite diagonal, repeat the procedure to verify that
9.
Release the cylinder head holding fixture from the vise
the gasket surface is flat (especially if a head gasket was
and then remove the tool from the spark plug hole.
blown). Discard the head if any low spot is 0.005 inch
(0.13 mm) or greater.
Cleaning and Inspection
NOTE
For good results, use one of the CYLINDER TORQUE
Cleaning
PLATES (HD-42324A) in lieu of the straightedge. Lay the
upper plate flat on the machined surface of the head. As a
1.
Remove old gasket material from cylinder head. Gasket
preliminary check, see if the plate rocks from side to side. A
material left on sealing surfaces will cause leaks.
head on which the plate rocks is immediately suspect. Insert
a feeler gauge between the plate and head at various loca-
2.
Remove all carbon deposits from combustion chamber
tions to see if warpage exceeds above specification.
and machined surfaces of cylinder head. Exercise cau-
tion to avoid removing any metal material. For best
3.
Verify that oil passageways are open and clean.
results, use an air tool with a worn wire brush. Scraping
may result in scratches or nicks.
Valve Guides
3. To soften stubborn deposits, soak the cylinder head in a
1.
Inspect external surfaces for cracks
(particularly the
chemical solution, such as GUNK HYDRO-SEAL or
combustion chamber side). Replace the guide if any
other carbon and gum dissolving agent. Repeat step 2
cracks are found.
as necessary.
2.
To verify cleanliness of valve guides, lightly hone bore
using the VALVE GUIDE HONE (B-45525) and then
CAUTION
scrub with the VALVE GUIDE CLEANING BRUSH (HD-
34751) to remove any dust or debris. Polish the valve
Do not use glass or sand to bead blast surfaces exposed
stem with fine emery cloth or steel wool to remove car-
to the engine oil. Bead blasting materials become lodged
bon buildup, and then check valve stem to guide clear-
in the pores of the casting where they cannot be
ance as follows:
removed through ordinary cleaning methods. Only after
Carefully measure the inside diameter of the valve guide
the engine is put into use will heat expansion cause this
using an inside ball micrometer. Measure the outside
material to be released, and the resulting oil contamina-
diameter of the valve stem with an outside micrometer.
tion will accelerate wear and lead to engine failure. If
The valve stem and/or guide are excessively worn if the
bead blasting must be employed, use wallnut shells or
clearance exceeds the limits shown in Table 3-5. Repeat
other soft non-damaging abrasive that can be digested
measurements with a new valve to determine if the
in the engine oil.
guide must be replaced.
Table 3-5. Service Wear Limits
CAUTION
Be aware that bead blasting materials may also enter
Valve
Valve Stem to Guide Clearance
threaded holes adversely affecting fastener engagement
Intake
0.0038 inch (0.0965 mm)
and torque indication. Carefully cover all threaded holes
if bead blasting is employed.
Exhaust
0.0038 inch (0.0965 mm)
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Tapered Keepers
1.
Inspect parts for damage or rust pits. Replace as neces-
Intake Seat
sary.
Adapter
2.
Inspect inboard side of tapered keepers for excessive
Part No. HD-39782A-3
Cylinder Head
wear. Upraised center must be pronounced and fit
Support Stand
snugly in valve stem groove. Place keepers into groove
and verify that they grip tightly without sliding.
Valve Seats
1.
Inspect seats for cracking, chipping or burning. Replace
seats if any evidence of these conditions are found.
Exhaust Seat
2.
Check seats for recession by measuring valve stem pro-
Adapter
trusion. See VALVE AND SEAT REFACING in this sec-
Part No. HD-39782A-4
tion, steps 5-6.
Figure 3-67. Cylinder Head Support Stand
VALVE GUIDE REPLACEMENT
(Part No. HD-39782A)
Removal
NOTE
Valve Guide
If valve guide replacement is necessary, always install new
Driver
guide before refacing valve seat.
1.
Obtain the CYLINDER HEAD SUPPORT STAND (HD-
39782A) and proceed as follows:
a. Insert sleeve of intake or exhaust seat adapter into
tube at top of support stand. See Figure 3-67.
Valve Guide
Installer Sleeve
b. Position cylinder head so that valve seat is centered
on seat adapter. Support stand ensures that valve
guide and seat are perpendicular. If perpendicular-
Figure 3-68. Valve Guide Driver (Part No. B-45524-1) and
ity is not achieved, the cylinder head valve guide
Valve Guide Installer Sleeve (Part No. B-45524-2A)
bore will be damaged during the press procedure.
Valves
f2325x3x
1. Replace the valve if there is evidence of burning or
Ram
cracking.
Valve Guide
Driver
2. Inspect the end of the valve stem for pitting or uneven
wear. Replace the valve if either of these conditions are
found.
3. Inspect for burrs around the valve stem keeper groove.
Remove burrs with a fine tooth file if found.
4. To determine if the valve stem is excessively worn, see
INSPECTION, VALVE GUIDES, step 2.
Valve Springs
1. Inspect springs for broken or discolored coils. Replace
springs if either of these conditions are found.
2. Set the intake and exhaust valve springs on a level sur-
face and use a straightedge to check for proper square-
ness and height.
Cylinder Head
3. Check free length of springs using a dial vernier caliper
Support Stand
or load test with the VALVE SPRING TESTER (HD-
96796-47). Replace springs if free length or compres-
sion force do not meet specifications. See Section 3.1
Figure 3-69. Remove Valve Guide
SPECIFICATIONS.
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a.
Insert sleeve of intake or exhaust seat adapter into
tube at top of support stand. Position cylinder head
A
B
C
so that valve seat is centered on seat adapter. Sup-
port stand ensures that valve guide and seat are
perpendicular. If perpendicularity is not achieved,
cylinder head valve guide bore will be damaged dur-
ing the press procedure.
b.
Insert valve guide collar into installer sleeve so that
it is squarely seated on the counterbore. Insert
valve guide into sleeve until it makes contact with
collar. Center assembly under ram of arbor press
and apply pressure to valve guide until it bottoms in
sleeve. Remove valve guide with collar from installer
Figure 3-70.
Install Collar on Valve Guide
sleeve. See Figure 3-70.
c.
Apply Vaseline to lightly lubricate external surfaces
of valve guide. Spread lubricant so that thin film cov-
CAUTION
ers entire surface area.
Do not press out the valve guide from the bottom of the
d.
At top of cylinder head, start valve guide into bore.
cylinder head. Carbon buildup on the combustion cham-
Orient valve guide so that end farthest from the col-
ber side of the guide can deeply gouge the cylinder head
lar goes into the cylinder head. See C of Figure 3-
bore diminishing the likelihood of achieving the proper
70.
interference fit and possibly requiring replacement of
the cylinder head casting.
e.
Place installer sleeve over valve guide so that coun-
2.
At the top of the cylinder head, insert VALVE GUIDE
terbore makes contact with installed collar, and then
DRIVER (B-45524-1) into valve guide bore until stopped
insert tapered end of valve guide driver into sleeve.
by shoulder.
f.
Center valve guide driver under ram of arbor press
3.
Center valve guide driver under ram of arbor press.
and apply pressure only until valve guide is started
Apply pressure until valve guide drops free of cylinder
in bore and then back off ram slightly to allow guide
head. Discard the valve guide. Remove collar at top of
to center itself. See Figure 3-71.
cylinder head. Discard collar. See Figure 3-69.
NOTE
Collar is not present on OEM intake valve guides.
f2324x3x
Valve Guide
Installation
Driver
Valve Guide
1.
Measure the outside diameter of a new standard valve
Installer Sleeve
guide, and then measure the cylinder head valve guide
bore. The valve guide should be 0.0020-0.0033 inch
(0.051-0.084 mm) larger than the bore.
If clearance is not within specification, then select one of
the following oversize guides - 0.001 inch (0.025 mm),
0.002 inch (0.05 mm) or 0.003 inch (0.08 mm).
NOTE
Since some material is typically removed when the guide is
pressed out, it is normal to go to the next larger size for the
proper interference fit.
2.
Measure cylinder head bore and outside diameter of
selected oversize guide to verify correct interference fit.
Cylinder Head
Support Stand
3.
Obtain the CYLINDER HEAD SUPPORT STAND (HD-
39782A), VALVE GUIDE DRIVER
(B-45524-1) and
VALVE GUIDE INSTALLER SLEEVE (B-45524-2A). Pro-
Figure 3-71. Install Valve Guide
ceed as follows:
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2005 Touring: Engine
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b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
NOTE
Valve Guide
Reamer
Valve guides must be reamed to within 0.0005 - 0.0001 inch
(0.013 - 0.0025 mm) of finished size.
5.
Obtain the VALVE GUIDE REAMER
(B-45523),
REAMER T-HANDLE (HD-39847) and REAMER LUBRI-
CANT (HD-39964). Proceed as follows:
Reamer
a. Install T-handle on reamer.
T-Handle
b. Apply a liberal amount of reamer lubricant to valve
guide bore and bit of reamer. Start bit of reamer into
Figure 3-72. Valve Guide Reamer (Part No. B-45523) and
bore at top of cylinder head.
Reamer T-Handle (Part No. HD-39847)
c. Placing thumb on drive socket of reamer T-handle,
apply slight pressure on reamer while rotating in a
f2293x3x
clockwise direction. See Figure 3-73. Squirt addi-
tional lubricant onto reamer and into guide as nec-
essary.
Valve Guide
Reamer
CAUTION
For best results, do not push on reamer or apply pres-
sure to the reamer handle. While excessive pressure
Reamer
results in a rough cut, bore will be tapered if pressure is
T-Handle
not centrally applied.
d. Continue rotating reamer T-handle until entire bit
has passed through valve guide bore and shank of
reamer rotates freely.
CAUTION
Never back reamer out of valve guide or bore will be
damaged.
Figure 3-73. Ream Valve Guide Bore
e. Remove T-handle from reamer, and carefully pulling
on bit, draw shaft of reamer out combustion cham-
ber side of valve guide.
CAUTION
Always back off ram to allow the valve guide to find cen-
CAUTION
ter. Pressing guide into cylinder head in one stroke can
bend driver, break guide, distort cylinder head casting
Abrasive particles can damage machined surfaces and
and/or damage cylinder head valve guide bore.
plug oil passageways possibly resulting in engine fail-
ure.
g. Verify that support stand and driver are square.
Center driver under ram and press valve guide fur-
6.
Direct compressed air into the valve guide bore to
ther into bore, but then back off ram again to allow
remove any metal shavings or debris.
valve guide to find center.
7.
Clean valve guide bore with the VALVE GUIDE CLEAN-
h. Repeat step 3(g) and then apply pressure to driver
ING BRUSH (HD-34751).
until installer sleeve contacts machined area of cyl-
inder head.
8.
Obtain the VALVE GUIDE HONE
(B-45525) and
REAMER LUBRICANT (HD-39964). Proceed as follows:
4. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
a. Install hone in a high speed electric drill.
39786) and proceed as follows:
a. Thread the 12mm end of the tool into the spark plug
b. Apply reamer lubricant to finishing stones of hone
hole of the cylinder head.
and valve guide bore.
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the valve stem with an outside micrometer. The valve
stem may be excessively worn or the valve guide bore
undercut if the clearance is not within the limits (low end
preferable) shown in Table 3-6.
Table 3-6. New Parts Limits
Valve
Valve Stem to Guide Clearance
Intake
0.001 - 0.003 inch (0.0254-0.0762 mm)
Exhaust
0.001 - 0.003 inch (0.0254-0.0762 mm)
Figure 3-74. Valve Guide Hone (Part No. B-45525)
11. Using cleaning solvent, thoroughly clean cylinder head
and valve guide bore. Scrub valve guide bore with the
f2295x3x
VALVE GUIDE CLEANING BRUSH (HD-34751). For
best results, use a thin engine oil and clean valve guide
bore with the type of swabs or patches found in gun
cleaning kits. Continue to wipe bore until clean cloth
shows no evidence of dirt or debris. Follow up with a
thorough wash in hot soapy water. Blow dry with com-
pressed air.
Figure 3-75. Hone Valve Guide Bore
Figure 3-76. Valve Guide Brush (Part No. HD-34751)
c. Start finishing stones of hone into bore.
d. Activating the drill, move the entire length of the fin-
f2294x3x
ishing stone arrangement forward and backward
through the bore for 10 to 12 complete strokes. See
Figure
3-75. Work for a crosshatch pattern of
approximately 60˚.
CAUTION
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine fail-
ure.
9.
Direct compressed air into the valve guide bore to
remove any debris and then clean with the VALVE
GUIDE CLEANING BRUSH (HD-34751). See Figure 3-
77.
NOTE
Always verify valve stem to valve guide clearance after hon-
ing, since a worn reamer may cut the bore undersize.
10. Measure the inside diameter of the valve guide with an
inside ball micrometer. Measure the outside diameter of
Figure 3-77. Scrub Valve Guide Bore
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Do not remove any more metal than is necessary to
clean up and true the valve face. Removing metal
f2296x3x
reduces the service life of the valve. The amount of
grinding needed to retrue the valve is a clear indication
of its condition. Discard the valve if it cannot be quickly
Dial Vernier
refaced while maintaining a good margin. Valves that do
Caliper
not clean up quickly are either warped, excessively worn
or too deeply pitted to be used.
Obtain a new valve if grinding leaves the margin less
than 0.0313 inch (0.795 mm). A valve in this condition
does not seat normally, burns easily and may crack or
cause pre-ignition.
3.
Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
39786) and proceed as follows:
a. Thread the 12mm end of the tool into the spark plug
hole of the cylinder head.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
4.
Obtain the NEWAY VALVE SEAT CUTTER SET (HD-
35758A) and cut valve seat angle to 46°.
NOTE
Do not remove any more metal than is necessary to clean up
the seat (that is, to provide a uniform finish and remove pit-
ting).
5.
From the bottom of the cylinder head, insert the valve
stem into the valve guide. Push on bottom of valve until it
contacts the valve seat.
f2298x3x
6.
Placing finger at bottom of valve to keep valve seated,
Figure 3-78. Measure Valve Stem Protrusion
use a dial vernier caliper to check the distance from the
top of the valve stem to the machined area on the cylin-
der head. See Figure 3-78.
VALVE AND SEAT REFACING
Seat wear and valve refacing causes the valve stem pro-
trusion to change. If valve stem protrusion exceeds
NOTE
2.039 inches (51.79 mm), but is less than 2.069 inches
(52.55 mm), obtain the short service replacement valve.
Verify correct valve stem to valve guide clearance before
refacing. See Table 3-6. If new guides must be installed,
Service replacement valves are 0.030 inch (0.76 mm)
shorter than the standard valve.
complete that task before refacing valves and seats.
If protrusion exceeds 2.069 inches (52.55 mm), then use
1. Hold the valve firmly against a wire wheel in a bench
the existing valve, but replace the valve seat.
grinder. Remove all carbon deposits from the valve
head, face and stem, but exercise caution to avoid
removing any metal. Carbon left on the stem may affect
CAUTION
alignment in the valve refacer. Polish the valve stem with
steel wool or crocus cloth to remove any marks that
Do not shorten the valve by grinding on the end of the
might be left by the wire wheel.
stem. Grinding replaces the hardened case with mild
steel which results in accelerated wear.
2. Install valve (both intake and exhaust) in a valve refacer
set to a 45 degree angle. The valve refacer is required
7.
Remove valve from cylinder head. Apply magic marker
equipment, since accuracy in matching the angle of the
or similar product to valve seat and allow to thoroughly
valve face with the angle of the valve seat is critical.
dry.
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f1655x3x
Head
Seat
60˚
0.040-0.062 in.
(1.02-1.57 mm)
Valve
31˚
46˚ Cutting
Margin
Figure 3-79. Valve Lapping Tool (Part No. HD-96550-36A)
45˚ Grinding
0.0313 in.
(0.795 mm)
6873
Figure 3-81. Valve Seat Angles
11.
Inspect the contact pattern on the valve seat to be sure
area is 0.040-0.062 inch (1.02-1.57 mm) wide and con-
tacts the valve two-thirds of the way towards the outer
edge of the valve face. See Figure 3-81. If necessary,
modify the seat pattern as follows:
Valve Lapping
Tool
a. Use the 31° angle cutter to lower the valve seat sur-
face and reduce its width.
b. Use the 60° angle cutter to raise the valve seat sur-
face and reduce its width.
c. Use the 46° angle cutter to widen the valve seat sur-
face.
12.
Using a magic marker, mark three equally spaced verti-
cal lines across the valve face and then insert the valve
Figure 3-80. Oscillate Tool to Create Contact Area
back into the cylinder head.
13.
Attach suction cup of VALVE LAPPING TOOL (HD-
8.
Insert the valve stem into the valve guide. Push on bot-
96550-36A) to valve head, and holding shank of tool
tom of valve until it contacts the valve seat.
between the palms of both hands, oscillate the tool back
and forth a few times.
9.
Obtain the VALVE LAPPING TOOL (HD-96550-36A) and
proceed as follows:
14.
Remove the valve and perform a final inspection of the
contact pattern. If necessary, return to step 11.
a. Attach suction cup at end of tool to valve head.
15.
Remove the valve from the cylinder head. Use contact
b. Holding shank of tool between the palms of both
cleaner to thoroughly clean magic marker and/or dye
hands, oscillate the tool back and forth a few times.
from valve face and seat, if present.
See Figure 3-80.
16.
Release the cylinder head holding fixture from the vise
10.
Remove the valve from the cylinder head and carefully
and then remove the tool from the spark plug hole.
inspect the mating surfaces under a good light.
17.
To confirm quality of valve and seat refacing work, pro-
Inspection of the valve seat should show an unbroken
ceed as follows:
contact area of uniform width. If the seat is not concen-
a. Insert valve in guide, and holding valve to seat,
tric with the valve guide, then the cutter will remove more
raise port to strong light source. If light is visible
material in one spot than another. Carbon deposits may
around edge of seat, then valves and seats must be
have caused the guide to be pressed in crooked, the
reconditioned.
guide may be cracked, or the cutter blade or cutter pilot
have not have been properly cleaned.
b. Holding valve to seat, fill port at top of cylinder head
with solvent. Wait ten full seconds and then check
NOTE
for leakage into combustion chamber. If solvent
If the results are not acceptable, then recut the valve seat or
leakage into combustion chamber is evident, then
replace the valve guide.
valves and seats must be reconditioned.
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f2297x3x
CAUTION
Failure to install plastic capsule will cause the valve
Plastic
Capsule
stem seal to catch the edge of the valve stem keeper
groove. The resulting damage will lead to leakage around
the valve stem, excessive oil consumption and valve
sticking.
7.
Push on bottom of valve until it contacts the valve seat.
Placing finger at bottom of valve to keep valve seated,
slide plastic capsule over valve stem tip and keeper
groove. See Figure 3-82.
8.
Apply a very thin film of clean H-D 20W50 engine oil to
capsule.
9.
Obtain new valve stem seal and spring seat. Assemble
parts as shown in Figure 3-83.
Figure 3-82. Lubricate Plastic Capsule
10. Slide valve stem seal/spring seat over capsule and down
valve stem until contact is made with top of valve guide
18. Clean valves, cylinder head and valve seats in solvent.
and machined area of cylinder head casting. Remove
Follow up with a thorough wash in hot soapy water. Blow
capsule from valve stem tip.
dry with compressed air.
CAUTION
Assembly
Removing the valve after seal installation will cause the
valve stem seal to catch the edge of the valve stem
1. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
keeper groove. The resulting damage will lead to leakage
39786) and proceed as follows:
around the valve stem, excessive oil consumption and
valve sticking.
a. Thread the 12mm end of the tool into the spark plug
hole of the cylinder head.
11. Apply a liberal amount of assembly lube to valve stem tip
and keeper groove.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
NOTE
8702
A
At the time of disassembly, all parts should have been
marked or tagged so that they are installed on the same
valve (and in the same head).
2. Run the VALVE GUIDE CLEANING BRUSH (HD-34751)
through the valve guide bore to verify cleanliness.
3. Using TORCO MPZ or another suitable product, apply a
liberal amount of engine assembly lube to valve stem.
8703
8704
B
C
4. From the bottom of the cylinder head, insert the valve
stem into the valve guide.
5. To distribute the assembly lube evenly around the valve
stem and guide, hand spin the valve as it is installed.
Work the valve back and forth in the bore to verify that it
slides smoothly and seats properly.
6. Remove the valve and apply a second coat of assembly
lube to the valve stem. Install the valve in the valve
guide.
Figure 3-83. Valve Stem Seal/Spring Seat Assembly
2005 Touring: Engine
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12. With the smaller diameter coils topside, install the valve
Installation
spring over the valve guide. Place the spring retainer on
top of the valve spring.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps
13. Obtain the VALVE SPRING COMPRESSOR
(HD-
15-24 and 29-39.
34736B) and proceed as follows:
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the spring retainer.
CAUTION
Over-compressing the valve spring can damage the
valve stem seal resulting in leakage around the valve
stem, excessive oil consumption and valve sticking.
b. Rotate forcing screw to compress valve spring.
c. With the tapered side down, fit the keepers into the
valve stem groove. For best results, apply a dab of
grease to the inboard side of the keepers before
installation and use a magnetic rod for easy place-
ment.
d. Arranging tapered keepers so that the gaps are
evenly spaced, turn forcing screw to release valve
spring compression.
14. Tap the end of the valve stem once or twice with a soft
mallet to ensure that tapered keepers are tightly seated
in the valve stem groove.
15. Repeat steps 1-14 to install the other valve components.
16. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
17. Cover the cylinder head to protect it from dust and dirt
until time of installation.
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2005 Touring: Engine
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CYLINDER
Removal
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-11 and 15-24.
Cleaning and Inspection
CLEANING
1.
Scrape old gasket material from the machined surface at
the top of the cylinder. Old gasket material left on the
Figure 3-84. Cylinder Torque Plates
mating surface will cause leaks.
(Part No. HD-42324A)
2.
Clean cylinder in a non-volatile cleaning solution or sol-
vent. Thoroughly dry with low pressure compressed air.
Verify that oil passageways are clean and open.
Lower Plate
A
Bolts
3.
Inspect the cylinder bore for defects or damage in the
ring travel area. Replace cylinders that are severely
scored, scuffed, scratched, burnt or gouged.
4.
Using Magnaflux Dye Penetrant, inspect the cylinder for
cracks. If no cracks are found, thoroughly wash cylinder
to remove traces of dye.
5.
Use a file to carefully remove any nicks or burrs from the
machined surfaces of the cylinder.
6.
Using a feeler gauge and the CYLINDER TORQUE
PLATES (HD-42324A), check the machined surfaces for
flatness. Proceed as follows:
a. Lay gasket side of the upper plate (without vise grip)
Vise
flat against the head gasket surface.
b. As a preliminary check, see if the plate rocks from
f2075x3x
side to side. A cylinder on which the plate rocks is
immediately suspect.
c. Insert a feeler gauge between the plate and cylinder
3
B
Upper Plate
at various locations.
4
d. The head gasket surface must be flat within 0.006
inch (0.15 mm).
e. Now turn the cylinder upside down and lay the seal
side of the lower plate (with vise grip) flat against
the O-ring seal surface. Repeat steps 6(b) and 6(c).
f.
The O-ring seal surface must be flat within 0.004
inch (0.102 mm).
g. Replace the cylinder (and piston) if either surface is
not within specification.
INSPECTION
CAUTION
2
Failure to use the cylinder torque plates can produce
1
measurements that vary by as much as 0.001 inch (0.025
f2074x3x
mm), possibly resulting in the use of parts that are not
suitable for service.
Figure 3-85. Install Cylinder to Torque Plates
2005 Touring: Engine
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1.
To simulate an assembled cylinder for accurately mea-
suring cylinder taper and out-of-round conditions, as well
f1686x3x
as for boring, honing or deglazing, obtain the CYLIN-
DER TORQUE PLATES (HD-42324A). Install the torque
plates as follows:
a.
Remove O-ring seal from cylinder sleeve, if
installed.
b.
Place used head gasket over two ring dowels at top
of cylinder.
c.
Install brass jaws or shop towels around teeth of
vise to prevent damage to tool. Clamp stepped side
of lower plate in vise with the simulated split line
(machined strip) facing away.
d.
Lightly oil threads and shoulders of four bolts with
clean H-D 20W50 engine oil. Slide bolts all the way
through holes of lower plate. See A of Figure 3-85.
e.
Slide cylinder down bolts with the indent in the cool-
ing fins facing upward.
f.
With the head gasket in place, align holes in upper
plate with ends of bolts. Blind holes in upper plate
accommodate ring dowels in cylinder. Alternately
tighten four bolts into upper plate until finger tight.
Figure 3-86. Measure for Out-of-Round and Taper
g.
Tighten the bolts to 120-144 in-lbs (13.6-16.3 Nm)
in the sequence shown in B of Figure 3-85.
c. Repeat the measurements again at the bottom of
h.
Following the same sequence, tighten each bolt to
the bore at a point below the piston ring travel zone.
15-17 ft-lbs (20.3-23.1 Nm).
d. Rebore the cylinder if the parallel and perpen-
i.
Using a grease pencil, mark a straight line on one of
dicular measurements at either the top, middle or
the bolts continuing the line over onto the lower
bottom of the bore vary by more than 0.002 inch
plate. Repeat step for remaining three bolts. Using
(0.051 mm), which indicates an out-of-round condi-
the marks as a guide, turn each bolt 1/4 turn or 90
tion.
degrees. Be sure to tighten the bolts in the
sequence shown in B of Figure 3-85.
Rebore the cylinder if the top, middle and bottom
bore diameters either parallel or perpendicular to
NOTE
the crankshaft vary by more than 0.002 inch (0.051
mm), which indicates excessive taper.
For
best results, obtain Snap-on® Torque Angle Gauge
TA360.
CAUTION
j.
For purposes of inspection, remove the assembly
from the vise and place on bench top.
Maximum cylinder wear occurs at the very top of top ring
travel. Minimum wear occurs below ring travel. Failure to
2.
See Figure 3-86. Using an inside micrometer or dial bore
measure the cylinder at these points may result in a
gauge, check cylinder bore for out-of round and taper.
faulty decision regarding the suitability of the cylinder
Proceed as follows:
for continued use.
a. At the top of the piston ring travel zone (starting
3.
If cylinders are not scuffed or scored, and are not worn
about 0.50 inch or 12.70 mm from the top of the cyl-
beyond the service limits described under step 2(d), see
inder), measure the cylinder diameter at two loca-
DEGLAZING CYLINDER on the next page.
tions- parallel and perpendicular to the crankshaft.
Write the readings down.
On the other hand, if cylinders are worn beyond the ser-
vice limits, then they must be rebored and/or honed to
b. Repeat the two measurements at the center of the
accept the next standard oversize piston. See BORING
piston ring travel zone.
AND HONING CYLINDER on the next page.
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2005 Touring: Engine
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DEGLAZING CYLINDER
2.
Hone the cylinder to its finished size using a 280 grit
rigid hone.
NOTE
3.
Stop frequently to examine the cylinder bore and/or take
Deglazing removes wear patterns, minor scuff marks and
scratches without enlarging the bore diameter.
measurements. Remember, a precise 60˚ cross hatch
pattern in the piston travel area is important.
1. Lightly swab the cylinder bore with a cloth dipped in
clean engine oil.
4.
Thoroughly wash the cylinder bore with liquid dishwash-
ing soap and warm water to remove all abrasive parti-
2. Obtain a 240 grit flexible ball-type deglazing tool with a
cles and residual grit. Continue cleaning until a clean
bristle tip or finishing stone arrangement able to produce
cloth shows no evidence or dirt or debris.
a 60˚ cross hatch pattern.
3. Install the deglazing tool in a slow-speed drill. The speed
Table 3-7. Oversize Pistons
at which the tool rotates determines the speed at which
it must be stroked up and down the bore to produce the
Cylinder Bore
desired cross hatch pattern.
Piston
Finished Size
4. Starting at the bottom of the cylinder, move the deglaz-
3.7500 - 3.7505 in.
ing tool up and down the entire length of the cylinder
Standard
(95.250 - 95.263 mm)
bore for 10 to 12 complete strokes.
0.005 In. (0.13 mm)
3.7550 - 3.7555 in.
5. Stop to examine the cylinder bore and/or take measure-
Oversize
(95.377 - 95.390 mm)
ments. A precise 60˚ cross hatch pattern in the piston
travel area is the most important.
0.010 In. (0.25 mm)
3.7600 - 3.7605 in.
Oversize
(95.504 - 95.517 mm)
CAUTION
Example: A 0.005 in. (0.13 mm) oversize piston will have
the proper running clearance with a cylinder bore size of
The angular cross hatch pattern ensures an even flow of
3.7550 - 3.7555 in. (95.377 - 95.390 mm).
oil onto the cylinder walls and promotes longer cylinder,
piston and ring life. An Improper crosshatch pattern will
result in insufficient oil retention and possible piston
5.
Hot rinse the cylinder and dry with moisture free com-
seizure and/or high oil consumption.
pressed air. Immediately apply a thin film of clean engine
oil to prevent rusting.
CAUTION
6.
With the cylinder at room temperature, check the piston
Failure to remove all abrasive particles may result in pre-
clearance in the cylinder in which the piston will run. See
mature cylinder, piston and ring wear and possible
PISTON, INSPECTION, step 5.
engine failure.
6. Thoroughly wash the cylinder bore with liquid dishwash-
ing soap and warm water to remove all abrasive parti-
Installation
cles and residual grit. Continue cleaning until a clean
cloth shows no evidence or dirt or debris.
1.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
7. Hot rinse the cylinder and dry with moisture free com-
steps 8-24 and 29-39.
pressed air. Immediately apply a thin film of clean engine
oil to prevent rusting.
8. With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See
PISTON, INSPECTION, step 5.
BORING AND HONING CYLINDER
1. Bore the cylinder to 0.003 inch (0.08 mm) under the
desired finished size. See Table 3-7.
CAUTION
An improper crosshatch pattern or too fine a hone will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption.
2005 Touring: Engine
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