Harley Davidson 2004 Touring Models. Service Manual — page 39
HOME
21. Cover rocker covers of front and rear cylinders with foam
f1684x3x
padding or bubble pack.
22. Cover lower frame tubes (both left and right side) with
2
foam padding or bubble pack. Split loom conduit or a half
4
shell of PVC tubing will also produce good results. Pro-
tection is necessary to prevent nicks or paint damage to
RIGHT
left frame tube and chafing, cutting or kinking of the
SIDE
brake line, wire cables and conduit at the top of the right
frame tube.
23. Wrap rear master cylinder reservoir with foam padding
or bubble pack.
3
24. Remove engine from BENCH STAND (HD-42310) or
ROLLING STAND (HD-43646A) and set on floor on right
1
side of chassis.
1CAUTION
The engine weighs approximately 165 pounds (74.8 kg).
Figure 3-17. Transmission Housing to Crankcase
Use a suitable lifting device, if necessary. Exercise cau-
Torque Sequence
tion to avoid personal injury.
25. Raise engine and install in chassis from right side of
vehicle setting front of crankcase onto front engine
c.
Standing on right side of engine, slide intake mani-
mounting bracket. Engine must be set forward far
fold/induction module toward installed position so
enough to clear two ring dowels in lower flange of trans-
that open-ended slots on flange adapters begin to
mission housing. Exercise caution to avoid contact with
engage allen head socket screws loosely installed
rear brake master cylinder reservoir and brake line, wire
on left side.
cables and conduit at top of lower right frame tube.
d.
Align fixed holes in flange adapters with those in
26. Move engine rearward to fully engage two ring dowels in
cylinder heads and start allen head socket screws.
For best results, use a long 1/4 inch ball allen head
lower flange of transmission housing.
socket with end driver 4 inches long.
27. Secure the engine as follows:
e.
Use the air cleaner backplate or INDUCTION SYS-
a. Hand tighten four bolts (with flat washers) to secure
TEM ALIGNMENT BRACKET
(P&A Part No.
transmission housing to rear of crankcase.
40054-01) to properly locate carburetor/induction
module. Proceed as follows:
b. Hand tighten two bolts (with flat washers) to secure
front of crankcase to front engine mounting bracket.
Backplate: Install two breather bolts to fasten back-
plate to front and rear cylinder heads. Install three
c. Tighten the four transmission housing to crankcase
T27 TORX screws to secure backplate to face of
bolts to 15 ft-lbs (20.3 Nm) in the sequence shown
carburetor/induction module.
in Figure 3-17.
Alignment bracket: Fitting pins on inboard side
NOTE
into holes in face of carburetor/induction module,
For best results, use Open End Crowfoot (Snap-On FC018)
install two breather bolts to fasten bracket to front
on upper left and upper right transmission housing to
and rear cylinder heads.
crankcase bolts.
f.
Tighten allen head socket screw in fixed holes of
d. Following the same sequence, final tighten the four
flange adapters until snug. Moving to left side of
transmission housing to crankcase bolts to 30-35 ft-
engine, tighten screws in slotted holes to 96-144 in-
lbs (40.7-47.5 Nm).
lbs (10.9-16.3 Nm).
e. Tighten the two crankcase to front engine mounting
g.
Remove breather bolts and T27 TORX screws to
bracket bolts to 33-38 ft-lbs (44.8-51.5 Nm).
remove backplate, if installed.
28. Install horn, top engine mounting bracket and stabilizer
h.
Tighten allen head socket screws in fixed holes of
link as an assembly. Proceed as follows:
flange adapters to 96-144 in-lbs (10.9-16.3 Nm).
a. Moving to right side of vehicle, turn hex head bolt to
i.
Remove breather bolts to remove alignment
secure stabilizer link to frame weldment. Tighten
bracket, if installed.
bolt to 18-22 ft-lbs (24-30 Nm).
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2004 Touring: Engine
HOME
b. On FLHR/C/S models, install elbow on post of oil
pressure switch. On FLHT/C/U and FLTR models,
install Packard connector to oil pressure sender .
c. Install new O-ring in groove on crank position sen-
sor body. Apply a very thin film of clean H-D 20W50
engine oil to O-ring before installation.
X-Acto Knife
d. Push sensor into bore aligning hole in sensor mount
with hole in spot face. Install allen head socket
Tang
screw (1/4 x 1 inch) and tighten to 90-120 in-lbs
(10.2-13.6 Nm).
e. Locate crankshaft position sensor connector [79], 2-
f1913x8x
place Mini-Deutsch, next to oil filter mount. Mate pin
and socket halves of connector.
Figure 3-18. Bend Tangs Outward on Socket Terminals
of Stator/Voltage Regulator Connector
35.
Install the voltage regulator. See Section 8.9 VOLTAGE
REGULATOR, INSTALLATION.
36.
Slide new clamp onto free end of breather hose behind
b. Install elbow terminals onto spade contacts at back
rear lifter cover. Install hose onto crankcase fitting.
of horn. Capture wire harness conduit in J-clamp.
Crimp clamp using HOSE CLAMP PLIERS (HD-97087-
65B).
c. Standing on left side of vehicle, install two hex head
bolts
(with flat washers) to secure top engine
37.
Slide new clamps onto free ends of oil hoses. Install
mounting bracket to front and rear cylinder heads.
hoses onto crankcase fittings. Crimp clamps.
Alternately tighten bolts to 35-40 ft-lbs (48-54 Nm).
38.
Install two allen head socket screws to secure oil hose
29.
Lower and remove jack under oil pan.
cover to transmission and engine housings. Longer
30.
Install conduit onto stator cables. For best results, feed
screw goes to engine housing. Alternately tighten
one socket terminal and cable through conduit at a time.
screws to 84-108 in-lbs (10-12 Nm).
31.
Install sockets into stator connector as follows:
39.
Install ignition coil and spark plug cables as follows:
a. Using a fingernail or a thin flat blade, like that on an
a. With the coil towers facing rear of vehicle, hold igni-
X-Acto knife, carefully bend the tangs outward away
tion coil and bracket at bottom of frame backbone.
from each terminal body. See Figure 3-18.
Pull sides of bracket outward and install on bosses
of front fuel tank mount. See Figure 3-11.
b. Feed each socket into wire end of stator connector
until it “clicks” in place.
b. Install electrical connector on left side of ignition
c. Verify that sockets will not back out of chambers. A
coil.
slight tug on each cable will confirm that it is locked.
c. Install spark plug cable to front cylinder onto left
32.
Install P-clip on stator cable conduit approximately five
side coil tower. Verify that spark plug cable is cap-
inches (127 mm) from socket housing. Slide P-clip over
tured in double-sided cable clip at bottom left side of
left side stud on lower frame crossmember. Properly ori-
frame backbone. Install new cable clip on T-stud if
ented, P-clip is positioned at front of stud with the open
damaged or missing.
side up and angled so that it is inline with the lower rail of
d. Install spark plug cable to rear cylinder onto right
the engine guard.
side coil tower. Verify that spark plug cable is cap-
33.
Uncoil main harness conduit and allow to hang below
tured in two single-sided cable clips at bottom left
lower frame tube at front of vehicle.
side of frame backbone. Install new cable clips on T-
studs if damaged or missing.
34.
Install oil pressure switch/sender and crankshaft position
sensor as follows:
40.
If equipped with cruise control, slide groove in cruise
cable end fitting over cap of wheel pin. Push on end fit-
a. Start oil pressure switch/sender into crankcase bore
ting until it snaps in place. Using slot, slip cruise cable
at the front right side of the crankcase. On FLHR/C/
housing into cable guide in throttle cable bracket. Install
S models, use a 15/16 inch Open End Crow Foot
new E-clip on sleeve at end of cruise cable housing.
(Snap-On FC30B) to tighten oil pressure switch to
96-120 in-lbs (11-14 Nm). On FLHT/C/U and FLTR
41.
Route idle and throttle control cables through J-clamp
models, use
1-1/16 inch Open End Crow Foot
fastened to right side of frame backbone.
(Snap-On FC34A) to tighten oil pressure sender to
same torque.
42.
Install idle and throttle control cables as follows:
2004 Touring: Engine
3-29
HOME
Carbureted: Install sleeve on throttle cable housing into
d. Start two exhaust flange nuts to secure rear header
shorter cable guide in throttle cable bracket. Drawing
pipe to studs of rear cylinder head.
throttle cable downward, fit barrel end into lower out-
e. Engaging transmission exhaust bracket, capture
board hole in throttle wheel. Install sleeve and spring on
front header pipe in transmission exhaust bracket
idle cable housing into longer cable guide inserting bar-
clamp. Use a channel lock to close clamp, if neces-
rel end into upper inboard hole in throttle wheel.
sary. Finger tighten clamp bolt (with flat washer and
Induction Module: Install sleeve on throttle cable hous-
locknut).
ing into shorter cable guide at top of throttle cable
NOTE
bracket. Drawing throttle cable downward, fit barrel end
into lower hole in throttle wheel. Install sleeve and spring
To ensure sealing integrity of TORCA clamps and prevent the
on idle cable housing into longer cable guide at bottom
possibility of leakage, Harley-Davidson recommends that
of throttle cable bracket inserting barrel end into upper
TORCA assemblies be discarded and replaced each time
hole in throttle wheel.
they are removed.
43. Tighten cables as necessary to keep barrel ends from
f.
Moving to left side of vehicle, slide new TORCA
clamp assembly onto crossover pipe.
dislodging. Verify that cables are seated in channel of
throttle wheel. Verify operation by turning throttle grip
g. Twist and push left side exhaust onto crossover
and observing cable action.
pipe.
44. Install connections to carburetor or induction module.
h. Start two bolts (with lockwashers) to secure left side
Standing on left side of vehicle, proceed as follows:
muffler to the lower saddlebag support rail.
Carbureted:
i.
Returning to left side of vehicle, position TORCA
clamp between rear header pipe and crossover
a. Moving to left side of vehicle, install electrical con-
pipe. Fit bracket tab into slot of TORCA clamp
nector to manifold absolute pressure (MAP) sensor
engaging stud in slot of exhaust support bracket.
at top of intake manifold.
Start Keps nut on stud.
b. Slide threaded portion of enrichener cable into slot
of mounting bracket. Flat on threads must face rear
CAUTION
of vehicle for script on enrichener knob to be right
side up. With the external tooth lockwasher and hex
Verify that the exhaust pipes do not contact the vehicle
nut positioned on the inboard side of the mounting
frame or any mounted components. Contact will cancel
bracket, tighten hex nut to 20-35 in-lbs (2.3-4.0
the effect of the rubber isolation mounts and transmit
Nm).
vibration to the rider via the vehicle frame.
Fuel Injected:
j.
Tighten the exhaust system as follows:
a. Install electrical connectors on fuel injectors.
● Using a long 1/2 inch swivel socket, tighten the top
nut of the front cylinder head exhaust flange to 9-18
b. Install manifold absolute pressure sensor and idle
in-lbs (1-2 Nm). Tighten the bottom nut to 100-120
air control connectors.
in-lbs (11.3-13.6 Nm). Final tighten the top nut to
c. Install intake air temperature sensor and throttle
100-120 in-lbs (11.3-13.6 Nm).
position sensor connectors.
● Tighten the bottom nut of the rear cylinder head
exhaust flange to 9-18 in-lbs (1-2 Nm). Tighten the
d. Moving to left side of vehicle, install connector to
top nut to
100-120 in-lbs (11.3-13.6 Nm). Final
engine temperature sensor at back of front cylinder.
tighten the bottom nut to 100-120 in-lbs (11.3-13.6
Pull boot over sensor to keep out dirt and debris.
Nm).
Install new cable strap to secure connector conduit
● Tighten the transmission exhaust bracket clamp bolt
to horn bracket.
to 60-96 in-lbs (6.8-10.8 Nm).
45. Install the primary chaincase. See Section
6.5 PRI-
● Tighten the two bolts (with lockwashers) to fasten
MARY CHAINCASE, INSTALLATION, steps 1-29.
right side muffler to lower saddlebag support rail.
46. Install exhaust system as follows:
● Tighten the two bolts (with lockwashers) to fasten
left side muffler to lower saddlebag support rail.
a. Install new gaskets in both the front and rear cylin-
● Verify that all exhaust pipes are in alignment and do
der head exhaust ports (with the tapered side out).
not contact the vehicle frame or mounted compo-
b. Place right side exhaust into position on vehicle and
nents.
start two exhaust flange nuts to secure front header
● Tighten the TORCA clamp between the rear header
pipe to studs of front cylinder head.
pipe and crossover pipe to 45-60 ft-lbs (61-81 Nm).
c. Start two bolts (with lockwashers) to secure right
● Tighten Keps nut securing bracket tab to exhaust
side muffler to the lower saddlebag support rail.
support bracket.
3-30
2004 Touring: Engine
HOME
COLD CHECK
HOT CHECK
f1254b3x
Figure 3-19. Engine Oil Dipstick
52.
Repeat steps 49-51 to install side cover, saddlebag and
CAUTION
fairing lower on left side of vehicle.
53.
Install the fuel tank. Proceed as follows:
Verify that the heat shields do not contact the vehicle
frame or any mounted components. Contact will cancel
Carbureted: See Section 4.7 FUEL TANK (CARBU-
the effect of the rubber isolation mounts and transmit
RETED), INSTALLATION
(AFTER COMPLETE
vibration to the rider via the vehicle frame.
REMOVAL), FLHT/C, or FLHR/S.
Fuel Injected: See Section
9.4 FUEL TANK (FUEL
NOTE
INJECTED), INSTALLATION
(AFTER COMPLETE
Position worm drive clamps so that screws are on the out-
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.
board side in the most accessible position.
54.
On Ultra models, hold locknut at bottom of fairing lower,
k. Open worm drive clamps and install heat shields as
and using a T40 TORX drive head, turn inside screw to
follows:
fasten assembly to engine guard clamp. Tighten screw
to 90-100 in-lbs (10.2-11.3 Nm). Repeat step on oppo-
● Over front header pipe (below exhaust port).
site side of vehicle.
● Over rear header pipe (below exhaust port).
55.
Adjust idle and throttle control cables as follows:
● Over front header pipe to rear header pipe connec-
tion (outboard of transmission side door).
Non-Cruise: See Section 2.21 THROTTLE CABLES
● Over rear header pipe to crossover pipe connection
(NON-CRUISE), ADJUSTMENT.
(above starter).
Cruise Equipped: See Section 8.30 CRUISE CON-
TROL (FLHRC, FLTR, FLHTCU), CABLE ADJUST-
l.
Position each worm drive clamp so that screw is on
MENT.
the outboard side in the most accessible position
and then tighten to 20-40 in-lbs (2.3-4.5 Nm).
NOTE
47.
Insert two allen head socket screws (with lockwashers
If oil pan was not drained, move to step 60.
and flat washers) through frame weldment into right side
front footboard brackets. For best results, approach from
56.
With vehicle resting on jiffy stand, add 3-1/2 quarts (3.3
left side of vehicle using a 3/8 inch ball allen with exten-
liters) engine oil as specified in Table 3-2. Use the proper
sion. Alternately tighten screws to 30-35 ft-lbs (41-48
grade of oil for the lowest temperature expected before
Nm).
the next oil change.
48.
Install the backplate and air cleaner. See Section 4.5
Table 3-2. Recommended Engine Oils
AIR CLEANER, INSTALLATION.
49.
On Ultra models, place fairing lower into position on right
Harley-
Lowest
Cold Weather
Harley-Davidson
side of vehicle. Holding T40 TORX screw inside fairing
Viscosity
Davidson
Ambient
Starts Below
Type
lower, install new rubber washer, clamp and locknut to
Rating
Temperature
50˚F (10˚C)
attach fairing bottom to engine guard. Do not tighten
SAE
Below 40˚F
HD Multi-grade
HD 360
Excellent
locknut.
10W40
(4˚C)
50.
Align barbed studs in right side cover with grommets in
SAE
Above 40˚F
HD Multi-grade
HD 360
Good
20W50
(4˚C)
frame downtubes and push firmly into place (no tools
SAE
Above 60˚F
required).
HD Regular Heavy
HD 360
Poor
50
(16˚C)
51.
Install right side saddlebag. See Section 2.25 SADDLE-
SAE
Above 80˚F
HD Extra Heavy
HD 360
Poor
BAG, INSTALLATION.
60
(27˚C)
2004 Touring: Engine
3-31
HOME
58. Perform engine oil level HOT CHECK as follows:
CAUTION
a. Ride vehicle until engine is at normal operating tem-
perature.
Oil level cannot be accurately measured on a cold
engine. For preride inspection, with motorcycle leaning
b. With the vehicle resting on the jiffy stand on level
on jiffy stand on level ground, oil should register on dip-
ground, allow engine to idle for 1-2 minutes. Turn
stick between arrows when engine is cold. Do NOT add
engine off.
oil to bring the level to the FULL mark on a COLD engine.
c. Wipe off the dipstick and insert it back into the oil
pan with the plug pushed completely into the fill
57. Perform engine oil level COLD CHECK as follows:
spout.
a. With the vehicle resting on the jiffy stand on level
d. Remove the dipstick and note the level of the oil.
ground, wipe off the dipstick and insert it back into
Add only enough oil to bring the level to the FULL
the oil pan with the plug pushed completely into the
mark on the dipstick. See Figure 3-19. Do not over-
fill spout.
fill.
59. Start engine and carefully check for oil leaks around
b. Remove the dipstick and note the level of the oil. Oil
level should register between the two arrows on the
drain plug and oil filter.
dipstick. See Figure 3-19. If oil level is at or below
the lower arrow, add only enough oil to bring the
level between the two arrows on the dipstick.
3-32
2004 Touring: Engine
HOME
TOP END OVERHAUL
3.9
DISASSEMBLY
1. Use low pressure spray to thoroughly clean exterior sur-
faces of engine prior to disassembly. Dirt caked on cool-
ing fins and other areas can fall into crankcase bore or
stick to subassemblies as parts are removed. Abrasive
particles can damage machined surfaces or plug oil pas-
sageways.
NOTE
Rocker cover and rocker housing bolts have both an internal
and external hex, which allows the bolts to be removed with
either a short 3/16 inch allen wrench (tight spaces), or a 7/16
inch socket or open end/box wrench (open spaces). See Fig-
ure 3-20. The internal hex is necessary if the engine is left in
the chassis for service. In these cases, the short 3/16 inch
allen wrench is indispensable when removing the rocker
f1603x3x
cover and rocker housing bolts on the left side of the engine
(particularly the rear) where there is close proximity to the
Figure 3-21. Remove Spring Cap Retainer
frame. A dimple or cavity cast into the left side of the upper
frame crossmember also aides in removing the rocker arm
4. Insert the blade of a small screwdriver into cast loop of
support plate assembly.
spring cap retainer (at top of upper push rod cover), and
while pushing down on spring cap, rotate bottom of
2. Alternately loosen the six rocker cover bolts following the
screwdriver toward outboard side to remove. See Figure
pattern shown in A of Figure 3-22. Remove the rocker
3-21. Repeat step on second push rod cover.
cover bolts.
5. Collapse upper and lower push rod covers.
NOTE
6. To remove the rocker arm support plate, both lifters of
It is assumed that each step performed on one cylinder is
the cylinder being serviced must be on the base circle
automatically repeated on the other.
(or lowest position) of the cam.
3. Remove the rocker cover and gasket. Discard the gas-
ket.
CAUTION
Removing the rocker arms with the valve train loaded
can result in bent push rods, damaged bushings or
warped support plate.
Internal Hex
Lock Patch
3/16 Inch Allen Wrench
To find the base circle, it is first necessary to rotate the
engine. Based on the level of disassembly required,
three methods of engine rotation are presented below.
a. With primary cover installed - With vehicle on center
stand, place the transmission in 5th gear and rotate
rear wheel in a clockwise direction (as viewed from
right side) until the base circle is found. See step
6(d) to find the base circle.
b. With primary cover removed
- Remove primary
External Hex
Captive
cover. Place the transmission in neutral. Fit a 1-1/2
7/16 Inch Open End Wrench
Washer
f1570x3x
inch socket on the compensating sprocket shaft nut.
Rotate nut in a counterclockwise direction until the
base circle is found. See step 6(d) to find the base
Figure 3-20. Rocker Cover Bolt (1-1/4 Inch)
circle.
2004 Touring: Engine
3-33
HOME
4
f2164x3x
5
1
3
f2163x3x
Breather
Assembly
2
1
FRONT
2
6
3
4
6
2
3
4
2
1
REAR
3
4
1
5
Remove Two Breather Assembly Bolts.
Alternately Loosen Four Rocker Arm Bolts
A
Loosen Six Rocker Cover Bolts.
B
1/4 Turn in Pattern Shown.
f2165x3x
2
f2166x3x
6
4
4
2
O-Ring
FRONT
1
3
3
5
1
3
5
1
3
1
REAR
2
4
2
6
4
Alternately Loosen Four Cylinder Head
Loosen Six Rocker Housing Bolts.
C
D
Bolts 1/4 Turn in Pattern Shown.
Figure 3-22. Top End Disassembly
3-34
2004 Touring: Engine
HOME
9.
When the rocker arm support plate bolts are free of the
cylinder head, lift the support plate assembly from the
rocker housing. See Section 3.11 SUBASSEMBLY SER-
VICE AND REPAIR, ROCKER ARM ASSEMBLY.
NOTE
Always service each cylinder separately. After the first cylin-
der is serviced the engine must be rotated to find the base
circle on the second cam. Service on the remaining cylinder
can then proceed.
10.
Remove the intake and exhaust push rods. Tag the push
rods as they are removed, so that they can be installed
f1527x3x
in their original locations. Also take note of their orienta-
tion to be able to discern top from bottom at time of
Figure 3-23. Sprocket Shaft Engine Rotation Tool
installation.
11.
Remove push rod covers from cylinder head and lifter
cover bores. Remove three O-rings from push rod cov-
CAUTION
ers and discard. If O-ring is missing from upper push rod
cover, be sure to dislodge it from the cylinder head bore.
Do not attempt to rotate engine by removing cam cover
and placing socket on crank or primary cam sprocket
12.
Using a crosswise pattern, remove the four allen head
flange bolt. Head of flange bolt can break off possibly
socket screws to release the lifter cover. Remove the
resulting in damage to flywheel or camshaft.
lifter cover and gasket. Discard the gasket.
13.
Remove the anti-rotation pin. Remove the hydraulic lift-
c. With engine mounted in engine stand - Fashion tool
ers. Tag lifters as they are removed, so that they can be
as follows: Obtain used or discarded compensating
installed in their original locations. Also take note of their
sprocket shaft extension (HD-40266-85). Weld a 13/
orientation (by observing location of the oil hole) to be
16 inch socket with a 1/2 inch drive to outboard side
able to discern front from rear at time of installation.
of extension. See Figure
3-23. Install tool on
14.
Place the lifters in clean plastic bags to keep out dust,
sprocket shaft and rotate in a counterclockwise
dirt and debris. See Section 3.11 SUBASSEMBLY SER-
direction until the base circle is found. See step 6(d)
VICE AND REPAIR, PUSH RODS/LIFTERS/COVERS.
to find the base circle.
15.
Remove O-ring from groove around breather baffle hole
d. Finding the base circle: Using one of the methods
in rocker housing. Discard the O-ring.
above, rotate engine until piston is at Top Dead
16.
Alternately loosen the six rocker housing bolts following
Center (TDC) of compression stroke. To accomplish
the pattern shown in C of Figure 3-22. Remove the
this, first raise lower push rod cover to access intake
rocker housing bolts.
lifter (inside hole of lifter cover). Place index finger
on top of the intake lifter. While rotating engine, feel
17.
Remove the rocker housing and gasket. Discard the
lifter rise (valve open) and fall (valve closed). Now
gasket.
place finger tightly over spark plug hole and rotate
engine again. In the compression stroke, air will be
CAUTION
forced out against your finger until the piston
reaches the TDC position. Stop engine rotation
To prevent distortion of the cylinder head, cylinder and
when the flow of air through the spark plug hole
cylinder studs, gradually loosen the cylinder head bolts
stops. Direct the beam of a small flashlight into
in the specified pattern.
spark plug hole to verify piston is at TDC. Both
18. Alternately loosen each of the four cylinder head bolts
intake and exhaust valves are now closed and the
just 1/4 turn following the pattern shown in D of Figure 3-
push rods are in the unloaded position (and should
22. Continue turning the bolts in these increments until
turn freely).
loose. Remove the cylinder head bolts.
7.
Remove two bolts to release breather assembly from the
NOTE
rocker arm support plate. See B of Figure 3-22. See
Save the cylinder head gasket if not damaged. The gasket is
Section 3.11 SUBASSEMBLY SERVICE AND REPAIR,
needed to install the CYLINDER TORQUE PLATES (HD-
BREATHER ASSEMBLY.
42324A) when measuring, boring or honing of the cylinder is
8.
Alternately loosen each of the four rocker arm support
required.
plate bolts just 1/4 turn following the pattern shown in B
19. Remove cylinder head and head gasket. See Section
of Figure
3-22. Continue turning the bolts in these
3.11 SUBASSEMBLY SERVICE AND REPAIR, CYLIN-
increments until loose.
DER HEAD.
2004 Touring: Engine
3-35
HOME
23. Remove O-ring seal from the bottom of the cylinder liner.
Discard O-ring seal. See Section 3.11 SUBASSEMBLY
SERVICE AND REPAIR, CYLINDER.
24. Remove O-ring from ring dowel on “downside” of cylin-
der deck. Discard the O-ring.
1CAUTION
Always wear proper eye protection when removing cir-
Claw
clips. Slippage may propel the ring with enough force to
cause eye injury.
Figure 3-24. Piston Pin Circlip
25. Verify that clean shop towels are properly positioned
Remover/Installer (Part No. HD-42317A)
over the crankcase bore to prevent the piston pin circlip
from falling into the crankcase.
f1635x3x
26. Remove the piston pin circlip as follows:
a. Insert the PISTON PIN CIRCLIP REMOVER/
INSTALLER (HD-42317A) into the piston pin bore
until claw on tool is positioned in slot of piston
(directly under circlip). See Figure 3-25.
b. Squeeze the handles of the tool together and pull
from bore. In the event that the circlip should fly out,
hold a shop towel over the bore during removal.
Remove circlip from claw and discard.
NOTE
It is not necessary to remove both piston pin circlips during
piston removal. Leave the second circlip in the pin bore.
Slot
27.
Remove the piston pin. If piston pin is difficult to remove,
use PISTON PIN REMOVER (HD-42320A). See Figure
3-26. Proceed as follows:
Figure 3-25. Remove Piston Pin Circlip
a. Remove acorn nut and spacer from rod end of tool.
b. Slide rod end through piston pin. Install spacer and
acorn nut to end of rod.
20. Raise the cylinder just enough to place clean shop tow-
c. Position rubber-coated tips of tool on flat each side
els under the piston. This will prevent any dirt or debris,
of pin bore.
such as broken ring pieces, from falling into the crank-
case bore.
d. Turn handle in a clockwise direction until piston pin
is pulled free of bore. See Figure 3-27.
CAUTION
28.
Remove the piston. Be sure to hold the rod shank
upright to prevent it from striking the crankcase. Place a
Exercise caution to avoid bending the cylinder studs.
piece of foam-type water pipe insulation around each
Even a slight bend or nick can cause a stress riser lead-
rod (about 3 inches long with a 2-1/4 inch O.D. and a 1
ing to stud failure.
inch I.D.) to prevent damage if contact should occur.
29.
Turn the piston over and mark the pin boss with the
21. Carefully remove the cylinder to avoid bending the cylin-
letters “F(ront)” or “R(ear)” to identify location. See Sec-
der studs. As the piston becomes free of the cylinder,
tion
3.11 SUBASSEMBLY SERVICE AND REPAIR,
hold it upright to prevent it from striking the studs or
PISTON and UPPER CONNECTING ROD.
dragging across the stud thread area. Mark the cylinder
“F(ront)” or “R(ear)” to identify location.
30.
If performing a top end overhaul only, see Section 3.11
SUBASSEMBLY SERVICE AND REPAIR, TOP END,
22. Slide plastic tubing, rubber hose or conduit over each
before proceeding to Section 3.9 TOP END OVERHAUL,
cylinder stud. Material approximately 6 inches (152 mm)
ASSEMBLY, which follows. If performing a complete
long with an I.D. of 1/2 inch (12.70 mm) will protect cylin-
engine overhaul, see Section
3.10 BOTTOM END
der studs and piston from damage.
OVERHAUL, DISASSEMBLY.
3-36
2004 Touring: Engine
HOME
5.
Insert piston pin through pin bore and upper connecting
rod bushing. Push pin until it contacts circlip installed in
opposite pin boss.
CAUTION
Do not reuse piston pin circlips. The circlips may weaken
during removal causing them to break or dislodge dur-
ing engine operation, a condition that will result in
engine damage.
6.
Place clean shop towels over the cylinder and lifter
Figure 3-26. Piston Pin Remover (Part No. HD-42320A)
bores to prevent the piston pin circlip from falling into the
crankcase. Verify that the circlip groove is clean and free
of dirt and grime.
Spacer and
Acorn Nut
Handle
7.
Install new piston pin circlip with the PISTON PIN CIR-
CLIP REMOVER/INSTALLER (HD-42317A). Proceed as
follows:
a. Slide circlip down nose of tool until it contacts claw.
Lightly squeeze handles of tool to capture circlip in
claw.
b. Releasing pressure on handles, rotate circlip so that
the end gap is centered at top of tool and then
recapture in claw.
c. Tilt the circlip forward until the end gap contacts
nose of tool. See upper frame of Figure 3-28.
d. Insert the tool into the piston pin bore until claw is
aligned with slot in piston.
Rubber Coated Tip
f1640x3x
e. Firmly push the tool into the piston pin bore until it
bottoms. Release handles and remove tool.
Figure 3-27. Remove Piston Pin
f.
Inspect the circlip to verify that it is fully seated in
the groove.
ASSEMBLY
CAUTION
NOTE
O-rings that are missing, distorted, pinched or otherwise
It is assumed that each step performed on one cylinder is
damaged will result in either oil leakage or low oil pres-
automatically repeated on the other.
sure. Use of the wrong O-ring will have the same results.
Since many O-rings are similar in size and appearance,
1. Slide plastic tubing, rubber hose or conduit over each
always use new O-rings keeping them packaged until
cylinder stud, if removed. Material approximately
6
use to avoid confusion.
inches (152 mm) long with an I.D. of 1/2 inch (12.70 mm)
will protect cylinder studs and piston from damage.
8. Install new O-ring over “downside” cylinder deck ring
dowel (that is, rear dowel on rear cylinder, front dowel on
2. Apply clean H-D 20W50 engine oil to piston pin, piston
front cylinder). Apply a very thin film of clean H-D 20W50
bosses and upper connecting rod bushing.
engine oil to O-ring before installation. Verify that O-ring
3. Remove water pipe insulation from rod shank.
is properly seated in groove.
4. Place piston over rod end so that the arrow stamped at
9. Install new O-ring seal at the bottom of the cylinder liner.
the top of the piston points toward the front of the
Apply a very thin film of clean H-D 20W50 engine oil to
engine.
O-ring before installation.
2004 Touring: Engine
3-37
HOME
b. With the forked end of the tool pointing towards the
f1564x3x
center of the engine and the adjustable knobs fac-
ing downward, capture shank of connecting rod in
fork. Lay tool on cylinder deck so that adjustable
knobs contact wall of cylinder bore.
c. Rotate engine until piston skirt is centered and
Circlip
firmly seated on top of support plate. See Figure 3-
30.
14. Install cylinder as follows:
a. Obtain the PISTON RING COMPRESSOR (HD-
96333-51C).
b. Fit tabs on pliers into slots of ring compressor band
(HD-96333-103). The arrow stamped on the band
indicates the side that faces up, so disregard the
f1636x3x
word “bottom.” Place band around piston. Press the
lever on the right side of the pliers to open the jaws
for band expansion.
c. Orient tool so that the top of the band is positioned
between the top compression ring and the piston
crown. Tightly squeeze handles of tool to compress
piston rings. The racheting action of the tool allows
release of the handles after the rings are com-
pressed.
Figure 3-28. Install Piston Pin Circlip
NOTE
Figure 3-29. Piston Support Plate (Part No. HD-42322)
Excessive lubrication of cylinder sleeve O-ring seal will result
in oil weepage between cylinder and crankcase as engine is
run, a condition that may be incorrectly diagnosed as an oil
Piston
leak.
Support Plate
10. Verify that the piston ring end gaps are properly stag-
gered. If necessary, see Section 3.11 SUBASSEMBLY
SERVICE AND REPAIR, PISTON.
11. Apply clean H-D 20W50 engine oil to piston, piston rings
and cylinder bore.
12. Remove plastic tubing or rubber hose from cylinder
studs. Rotate engine until piston is at top dead center. If
necessary, see step 31 for methods of engine rotation.
13. Install the PISTON SUPPORT PLATE (HD-42322). Pro-
ceed as follows:
a. Slide both adjustable knobs on tool down slots away
f1612x3x
from forked end. Tighten knobs when contact is
made with flats at end of slots.
Figure 3-30. Install Piston Support Plate
3-38
2004 Touring: Engine
HOME
h. Carefully set the cylinder over the two ring dowels in
the cylinder deck. Push down on the cylinder until it
is fully seated in the crankcase bore.
NOTE
To hold the first cylinder in position while installing the sec-
ond, install threaded cylinders
(HD-95952-1) from CON-
NECTING ROD CLAMPING TOOL (HD-95952-33B) onto
cylinder studs with the knurled side down. This will prevent
the piston rings from raising the cylinder as the engine is
rotated to bring the other piston into position for installation of
the second cylinder. See Figure 3-33.
Figure 3-31. Piston Ring Compressor
15. With the part number topside, place the head gasket
(Part No. HD-96333-51C)
over the two ring dowels in the upper flange of the cylin-
der.
16. Note that the word “Front” or “Rear” is cast into the top of
f1613x3x
Ring Compressor Band
(3-5/8 - 3-7/8 Inches)
the cylinder head to ensure proper installation. With the
Part No. HD-96333-103
indent in the cooling fins facing the right side of the
engine (for accommodation of the push rods and cov-
ers), carefully set the cylinder head over the two cylinder
ring dowels. To avoid damage to machined surfaces or
ring dowels, lower the cylinder head at an angle that
closely approximates the angle of the crankcase.
CAUTION
Thoroughly clean and lubricate the threads of the cylin-
der head bolts before installation. Friction caused by dirt
and grime will result in a false torque indication.
Pliers
Threaded
Cylinder
Figure 3-32. Install Cylinder
d.
Note that the cylinders should have been marked
with the letters
“F(ront)” or
“R(ear)” to identify
location. With the indent in the cooling fins facing
the right side of the engine, gently slide cylinder
over the cylinder studs and the piston crown resting
it on the top of the ring compressor band.
e.
Place the palms of both hands at the top of the cyl-
inder. Push down on the cylinder with a sharp, quick
motion to pass the piston ring area. See Figure 3-
32.
f.
Rotate the engine slightly to raise piston off support
plate. Remove pliers from band and then remove
band from around shank of connecting rod. Remove
piston support plate.
f1518b3x
g.
Remove shop towels from around the crankcase
Figure 3-33. Install Threaded Cylinders to Studs
bore exercising caution to keep out any dirt or
(Part No. HD-95952-1)
debris.
2004 Touring: Engine
3-39
HOME
17. Lightly oil threads and shoulders of cylinder head bolts
S
= Short Bolt
with clean H-D 20W50 engine oil.
L
= Long Bolt
A
FRONT
18. Start the cylinder head bolts onto the cylinder studs, two
L
short bolts on the left side of the engine, two long bolts
4
on the right.
S
2
19. Tighten the four cylinder head bolts as follows:
CAUTION
Improperly tightened cylinder head bolts may result in
gasket leaks, stud failure and distortion of the cylinder
and/or cylinder head.
a. Alternately turn each cylinder head bolt until finger
tight.
b. Tighten the cylinder head bolts to 120-144 in-lbs
(13.6-16.3 Nm) in the sequence shown in A of Fig-
1
3
ure 3-34.
S
L
c. Following the same sequence, tighten each bolt to
L
15-17 ft-lbs (20.3-23.1 Nm).
REAR
3
d. Using a grease pencil, mark a straight line on the
S
cylinder head bolt continuing the line over onto the
1
cylinder head. Using the marks as a guide, turn
each bolt 1/4 turn or 90 degrees. See B of Figure 3-
34. Be sure to tighten the cylinder head bolts in the
sequence shown in A of Figure 3-34.
NOTE
For best results, obtain Snap-on® Torque Angle Gauge
TA360.
20. Install a new rocker housing gasket on the cylinder head
flange.
2
S
4
CAUTION
L
f2166x3x
Even though all bolt holes (rocker housing, rocker arm
support plate and breather assembly) may appear to be
in alignment, the rocker housing gasket may be installed
B
upside down. An upside down gasket will result in an
open breather channel causing an oil leak when the vehi-
cle is started, possibly resulting in engine and/or prop-
erty damage.
21. Verify that the rocker housing gasket is installed cor-
rectly by noting that the breather channel is concealed.
See Figure 3-35.
22. With the indent facing forward, place the rocker housing
into position aligning the holes in the housing with those
in the gasket.
23. Apply a small dab of Loctite Medium Strength Thread-
locker 243 (blue) to threads of six rocker housing bolts.
f1583x3x
Start the rocker housing bolts, two long bolts on the left
side of the engine, four intermediate bolts in the interior.
Figure 3-34. Cylinder Head Torque Sequence
Alternately tighten the bolts to 120-168 in-lbs (13.6-18.9
and Bolt Size
Nm) in the pattern shown in Figure 3-36.
3-40
2004 Touring: Engine
HOME
f1577x3x
f1576x3x
Breather Channel Concealed
Breather Channel Exposed
CORRECT
WRONG
Figure 3-35. Install Rocker Housing Gasket (Rear Cylinder Shown)
L
S
= Short Bolt, 1 In.
NOTE
f2165x3x
I
= Intermediate Bolt, 1-1/4 In.
2
Rocker housing and rocker cover bolts have both an internal
I
L
= Long Bolt, 1-3/4 In.
6
and external hex, which allows the bolts to be installed with
4
either a short 3/16 inch allen wrench (tight spaces), or a 7/16
I
O-Ring
inch socket or open end/box wrench (open spaces). If the
engine is left in the chassis for service, the short 3/16 inch
allen wrench is indispensable when installing the rocker
housing and rocker cover bolts on the left side of the engine
FRONT
(particularly the rear) where there is close proximity to the
frame.
NOTE
If the engine was left in the chassis for service, final tighten
the rear left rocker housing bolt (rear cylinder) using a torque
I
wrench with a 1/4 inch drive. Since this tool may not be avail-
1
3
5
I
able in foot-pounds, tighten the bolt to 120-168 in-lbs.
L
3
Torque: 120-168 in-lbs
L
5
I
1
I
CAUTION
O-rings that are missing, distorted, pinched or otherwise
damaged will result in either oil leakage or low oil pres-
sure. Use of the wrong O-ring will have the same results.
Since many O-rings are similar in size and appearance,
REAR
always use new O-rings keeping them packaged until
use to avoid confusion.
24. Install new O-ring in groove around breather baffle hole
in rocker housing. Apply a thin film of clean H-D 20W50
engine oil to O-ring before installation. See Figure 3-36.
4
6
I
2
I
25. Install the hydraulic lifters in the crankcase bores with
L
the flats facing forward and rearward. To preserve exist-
Install Six Rocker Housing Bolts.
ing wear patterns, orientation of the oil hole (inboard or
outboard) should have been noted during disassembly.
Figure 3-36. Rocker Housing Torque Sequence
To avoid damage, do not drop lifters onto cam lobes.
and Bolt Size
2004 Touring: Engine
3-41
HOME
Do not install the spring cap retainers at this time. To
Anti-Rotation
ensure proper installation, take note of Table 3-3.
Pin
Lifter Cover
30. Install the push rods in their original positions. Be sure to
remove any tags that may have been used for marking
location and orientation. To ensure proper installation,
take note of Table 3-3. For example, if reassembling the
rear cylinder, slide the intake push rod (silver) through
the front hole in the rocker housing engaging the lifter
socket in the inside hole of the lifter cover. Slide the
exhaust push rod (black) through the rear hole in the
rocker housing engaging the lifter socket in the outside
hole of the lifter cover.
31. To install the rocker arm support plate, both lifters of the
cylinder being serviced must be on the base circle (or
lowest position) of the cam.
CAUTION
Installing the rocker arms and rotating the engine with
the valve train loaded can result in bent push rods and/
or valve damage.
Gasket
Ribs
f1606x3x
To find the base circle, it is first necessary to rotate the
Figure 3-37. Install Lifters and Lock Position
engine. Based on the level of disassembly, three meth-
With Anti-Rotation Pin
ods of engine rotation are presented below.
a. With primary cover installed - With vehicle on center
26. Place anti-rotation pin on the machined flat between the
stand, place the transmission in 5th gear and rotate
blocks cast into the crankcase. See Figure 3-37.
rear wheel in a clockwise direction (as viewed from
right side) until the base circle is found. See step
27. Install a new lifter cover gasket aligning the holes in the
31(d) to find the base circle.
gasket with those in the cover.
b. With primary cover removed
- Remove primary
CAUTION
cover. Place the transmission in neutral. Fit a 1-1/2
inch socket on the compensating sprocket shaft nut.
Movement or loss of the anti-rotation pin can result in
Rotate nut in a counterclockwise direction until the
lifter rotation causing catastrophic engine damage.
base circle is found. See step 31(d) to find the base
28. Install the lifter cover and start the four allen head socket
circle.
screws (1/4 x 1 inch). During installation, verify that the
anti-rotation pin is held in place by the ribs cast into the
CAUTION
inboard side of the lifter cover. See Figure 3-37. Tighten
the lifter cover screws to 90-120 in-lbs (10.2-13.6 Nm) in
Do not attempt to rotate engine by removing cam cover
a crosswise pattern.
and placing socket on crank or primary cam sprocket
29. Hand compress the push rod cover assembly and fit the
flange bolt. Head of flange bolt can break off possibly
O-ring end of the lower push rod cover into the lifter
resulting in damage to flywheel or camshaft.
cover bore. Expanding the assembly, fit the O-ring end of
the upper push rod cover into the cylinder head bore.
c. With engine mounted in engine stand - Fashion tool
as follows: Obtain used or discarded compensating
Table 3-3. Push Rod/Cover Locations
sprocket shaft extension (HD-40266-85). Weld a 13/
16 inch socket with a 1/2 inch drive to outboard side
Cylinder Head/
Cover and
Lifter Cover
of extension. See Figure
3-23. Install tool on
Cylinder
Rocker Housing
Push Rod*
Bore
sprocket shaft and rotate in a counterclockwise
Bore
direction until the base circle is found. See step
Intake
Inside
Rear
31(d) to find the base circle.
Front
Exhaust
Outside
Front
d. Finding the base circle: Using one of the methods
Intake
Inside
Front
above, rotate engine until piston is at Top Dead
Rear
Exhaust
Outside
Rear
Center (TDC) of compression stroke. To accomplish
* Push Rods Are Color Coded - Intake (Silver), Exhaust (Black)
3-42
2004 Touring: Engine
HOME
S
= Short Bolt, 1 In.
f2163x3x
f2164x3x
I
= Intermediate Bolt, 1-1/4 In.
Rocker Arm Torque:
L
= Long Bolt, 1-3/4 In.
18-22 ft-lbs
3
5
4
1
S
L
Breather
Assembly
Torque: 15-18 ft-lbs
Torque: 90-120 in-lbs
2
1
L
S
FRONT
2
6
4
3
L
S
6
L
2
3
4
S
2
1
L
S
REAR
3
1
4
L
5
S
A
Alternately Tighten Four Rocker Arm Bolts
B
Install Six Rocker Cover Bolts.
1/4 Turn in Pattern Shown.
Figure 3-38. Rocker Arm/Rocker Cover Torque Sequence and Bolt Size
this, first raise lower push rod cover to access intake
34. Alternately tighten each of the four rocker arm support
lifter (inside hole of lifter cover). Place index finger
plate bolts just 1/4 turn following the pattern shown in A
on top of the intake lifter. While rotating engine, feel
of Figure
3-38. Continue turning the bolts in these
lifter rise (valve open) and fall (valve closed). Now
increments until snug. Following the same numerical
place finger tightly over spark plug hole and rotate
sequence, tighten the bolts to 18-22 ft-lbs (24.4-29.8
engine again. In the compression stroke, air will be
Nm).
forced out against your finger until the piston
35. Alternately tighten the two breather assembly bolts to
reaches the TDC position. Stop engine rotation
90-120 in-lbs (10.2-13.6 Nm).
when the flow of air through the spark plug hole
stops. Direct the beam of a small flashlight into
NOTE
spark plug hole to verify piston is at TDC. Both
If the engine was left in the chassis for service, final tighten
intake and exhaust valves are now closed and the
the rocker arm support plate bolt on the rear left side of the
push rods are in the unloaded position.
rear cylinder using a 3/8 inch drive torque wrench with a 1/2
inch flank drive
“dog bone” torque adapter
(Snap-On
32.
Place the rocker arm support plate assembly into the
FRDH161). Since any extension can act as a torque multi-
rocker housing. Start the four rocker arm support plate
plier, the torque wrench must be perpendicular to the torque
bolts into the cylinder head.
adapter when the bolt is tightened. The 90 degree orientation
33.
Place breather assembly at top of rocker arm support
between the tools cancels the multiplier effect and prevents
plate. Apply a small dab of Loctite Medium Strength
the bolt from being over-tightened. If the adapter is kept inline
Threadlocker
243 (blue) to threads of two breather
with the torque wrench, the multiplier effect is in force and
assembly bolts. Start bolts into cylinder head.
distortion of the rocker housing will occur.
2004 Touring: Engine
3-43
HOME
39. Apply a small dab of Loctite Medium Strength Thread-
locker 243 (blue) to threads of six rocker cover bolts.
Start the rocker cover bolts, three short bolts on the left
side of the engine, three long bolts on the right. Tighten
the bolts to 15-18 ft-lbs (20.3-24.4 Nm) in the pattern
shown in B of Figure 3-38.
NOTE
If the engine was left in the chassis for service, final tighten
the three rocker cover bolts on the left side of the rear cylin-
der using a 3/8 inch drive torque wrench with a 7/16 inch
flank drive “dog bone” torque adapter (Snap-On FRDH141).
Since any extension can act as a torque multiplier, the torque
wrench must be perpendicular to the torque adapter when
the bolts are tightened. The 90 degree orientation between
the tools cancels the multiplier effect and prevents the bolts
from being over-tightened. If the adapter is kept inline with
the torque wrench, the multiplier effect is in force and distor-
tion of the rocker cover will occur.
f1604x3x
40.
If engine was left in the chassis for service, see Section
Figure 3-39. Install Spring Cap Retainer
3.6 ASSEMBLING MOTORCYCLE AFTER STRIPPING.
If engine was removed for service,
see
Section
3.8
INSTALLING ENGINE IN CHASSIS.
36. Lift up lower push rod covers and verify that both push
rods spin freely.
NOTE
Always service each cylinder separately. After the first cylin-
der is serviced the engine must be rotated to find the base
circle on the second cam. Service on the remaining cylinder
can then proceed.
37. Complete installation of the push rod covers as follows:
a. Verify that the O-ring ends of the upper and lower
push rod covers fit snugly into the cylinder head and
lifter cover bores.
b. Lodge the upper edge of spring cap retainer into the
cylinder head bore leaving the bottom edge free.
c. Insert blade of small screwdriver between bottom
edge of spring cap retainer and top of spring cap.
d. While simultaneously depressing spring cap with tip
of screwdriver, use forefinger to slide bottom edge
of spring cap retainer down shaft towards tip of
screwdriver blade. As spring cap reaches its full
length of travel, spring cap retainer should be in
approximate position against upper push rod cover.
See Figure 3-39.
NOTE
For best results, be sure that screwdriver, spring cap and
spring cap retainer are free of grease and oil.
e. Verify that spring cap retainer is seated tightly
against upper push rod cover.
38. Install a new rocker cover gasket on the rocker housing
flange. Place the rocker cover into position aligning the
holes in the cover with those in the gasket.
3-44
2004 Touring: Engine
HOME
BOTTOM END OVERHAUL
3.10
3.
Using a colored marker, mark the crank sprocket and
DISASSEMBLY
one of the links of the primary cam chain. Maintaining
the original direction of rotation during assembly may
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
prolong service life.
BLY. If only servicing cam compartment components,
4.
Remove the flange bolt and flat washer from the crank
see steps 1-11. If performing a complete engine over-
sprocket. See Figure 3-40.
haul, reference steps 1-29.
5.
Remove the flange bolt and flat washer from the primary
NOTE
cam sprocket.
NOTE
The cam support plate, lifter cover and crankshaft position
If too much loctite, or perhaps the wrong loctite, was used to
sensor mount all use the same short allen head socket screw
install the primary cam sprocket flange bolt, it may be very
(1/4 x 1 inch). Only the cam cover uses the longer screw (1/4
difficult to remove. In these cases, break down loctite using
x 1-1/4 inches). For ease of assembly, do not mix short and
heat from a small propane torch. Apply flame evenly around
long screws. Store long screws inside cam cover to avoid
bolt head in a circular motion, but not for so long as to turn
confusion. The short screws are interchangeable.
bolt blue. Do not direct heat at chain tensioner assembly and
other components or damage will result. Other methods of
2. Remove the ten allen head socket screws to release the
removal, such as use of a large breaker bar, also may result
cam cover. Remove and discard the cam cover gasket.
in damage to chain drive and other components.
Flange Bolt and
Flat Washer
Cleaning
Right
Plug
Crankcase Half
Front
Camshaft
Primary Cam
Sprocket
Primary
Cam Chain
Chain Guide
Primary Cam Chain
Tensioner
Crank
Sprocket
Oil Pressure
Flange Bolt and
Relief Valve
f2141x3x
Flat Washer
Figure 3-40. Cam Support Plate Assembly
2004 Touring: Engine
3-45
HOME
7.
Insert small pry bar (seal remover) between inboard side
of primary cam sprocket and cam support plate. Working
Tensioner
around its circumference, carefully ease primary cam
Unloader
sprocket off splines of rear camshaft until loose.
Slot
8.
Ease off crank sprocket with a slightly smaller pry bar
(seal remover). Remove the primary cam sprocket, pri-
mary cam chain and crank sprocket.
9.
Remove the primary cam sprocket spacer from the rear
camshaft.
Retention Pins
10.
Squeeze tabs to remove chain guide from between
blocks cast into cam support plate.
11.
Release the cam support plate from the oil pump flange.
Figure 3-41. Cam Chain Tensioner Unloader
Alternately loosen and then remove the four allen head
with Retention Pins (Part No. HD-42313)
socket screws following the pattern shown in B of Figure
3-50.
12.
Release the cam support plate from the crankcase
flange. Alternately loosen and then remove the six allen
head socket screws following the pattern shown in A of
Figure 3-50.
13.
Two ring dowels in crankcase flange locate cam support
plate (lower rear, upper front). See Figure 3-43. Insert
small pry bar (seal remover) between inboard side of
cam support plate and crankcase flange in area adja-
cent to ring dowels. Alternately work each side free and
then carefully ease cam support plate from end of crank-
shaft. See Section 3.11 SUBASSEMBLY SERVICE AND
REPAIR, CAM SUPPORT PLATE.
f1573b3x
O-Ring
Right
f2140x3x
Blind Hole
Crankcase Half
Ring
Figure 3-42. Retract Primary Cam Chain Tensioner
Dowel
1WARNING
Use extreme caution when operating propane torch.
Read the manufacturers instructions carefully before
use. Do not direct open flame or heat toward any fuel
system component. Extreme heat can cause fuel ignition
and explosion. Inadequate safety precautions could
result in death or serious injury.
6. Using the CAM CHAIN TENSIONER UNLOADER (HD-
42313), retract the primary cam chain tensioner as fol-
lows:
a. With the handle pointing toward the front of the cam
support plate, place cup of tool over spring coil. Cor-
rectly positioned, the slot in the tool should be adja-
cent to the hole in the tensioner. See Figure 3-42.
b. Rotate the handle of the tool in a counterclockwise
direction until the hole in the tensioner is aligned
O-Ring
with the hole in the boss of the cam support plate.
Ring
O-Ring
Dowel
Oil Feed Hole
Oil Pump
c. Insert a retention pin through the hole in the ten-
sioner and into the hole in the cam support plate.
Figure 3-43. Oil Pump Assembly
3-46
2004 Touring: Engine
HOME
1CAUTION
Do not pull the retention pin from the primary cam chain
tensioner after removal of the cam support plate. With
35-40 pounds of spring pressure behind the tensioner,
allowing it to accelerate through its full length of travel
will result in spring stretching and/or cracking of the ten-
sioner shoe. Furthermore, if the tensioner should con-
tact fingers or other parts of the hand, minor or
moderate injury may occur.
Figure 3-44. Crankshaft Guide (Part No. HD-42326A)
14. Remove O-ring from groove around oil feed hole in
crankcase flange
(directly below rear ring dowel).
Remove O-ring from groove around blind hole in boss
Water Pipe
f1644x3x
(directly above oil return hole in crankcase flange). Dis-
Insulation
card O-rings. See Figure 3-43.
15. Pull oil pump from crankshaft. Remove O-ring from out-
board side of oil pump housing. Remove O-ring from
scavenge port stub. Discard O-rings. See Section 3.11
Crankshaft
SUBASSEMBLY SERVICE AND REPAIR, OIL PUMP.
Guide
1WARNING
Be sure that stator mount flange (sprocket shaft side) is
NOT facing up when the case halves are separated or the
flywheel assembly will drop to the floor. Dropping the fly-
wheel assembly may result in parts damage and minor
or moderate injury.
16. Rotate crankcase in the engine stand so that the cam
cover flange is facing upward. Remove the nine crank-
case bolts in the left case half. Follow the sequence
shown in Figure 3-46.
Left
Crankcase Half
1CAUTION
f1645a3x
Crankshaft
Never move or lift the crankcase by grasping the cylin-
Guide
der studs. The crankcase is too heavy to be carried in
this manner and may be dropped. Dropping the crank-
case may result in parts damage and minor or moderate
injury.
17. Using pry points, loosen case halves. Lift right crank-
case half off end of crankshaft.
18. Remove O-rings from two ring dowels in split line face of
right case half. Discard the O-rings.
19. See Section
3.11 SUBASSEMBLY SERVICE AND
REPAIR, CRANKCASE.
ASSEMBLY
1. If removed, install left crankcase half in engine stand so
Crankshaft
Right
that the split line face is vertical.
Bearing
Crankcase Half
2. To prevent damage to the sprocket shaft bearing, slide
CRANKSHAFT GUIDE
(HD-42326A) over end of
Figure 3-45. Install Crankshaft Guide to Protect
sprocket shaft. Install flywheel assembly into left case
Crankshaft Bearing
half. Remove tool.
2004 Touring: Engine
3-47
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