Harley Davidson 2004 Touring Models. Service Manual — page 42
HOME
f1599x3x
Ram
Driver
Remover
Installer
Remover Side
Side
Side
Down
Support
Tube
Driver
Figure 3-103. Crankshaft Bushing Remover/Installer
(Part No. HD-42315)
Support
Tube
REMOVE
3.
Turn cam support plate over so that secondary cam
CRANKSHAFT
chain side is facing upward.
BUSHING
4.
Start new bushing into bore with the knurled edge top-
side. Be sure that hole in bushing is aligned with oil hole
in bushing bore.
Crankshaft
f1600x3x
Driver
Bushing
Installer Side
Knurled Side Up
Down
CAUTION
If the crankshaft bushing is pressed in from the primary
cam chain side, or from the secondary cam chain side
with the knurled edge of the bushing down, the bushing
bore will be damaged. Damage to the bore requires
replacement of the cam support plate.
5.
Center crankshaft bushing bore over support tube.
6.
Insert installer side of driver into bushing. See lower
frame of Figure 3-104.
Ensure Oil
Hole Alignment
7. Press on driver until collar of tool makes firm contact
with cam support plate.
INSTALL
8. Ream the crankshaft bushing following the directions
CRANKSHAFT
below.
BUSHING
Figure 3-104. Remove/Install Crankshaft Bushing
Reaming Crankshaft Bushing
in Cam Support Plate
NOTE
A new crankshaft bushing must be reamed for proper size
a. From flywheel compartment side, carefully insert
and alignment. If crankcase halves are not split, ream the
tapered end of reamer pilot into crankshaft bearing
bushing using a spare right case half to avoid further engine
until it stops. See left frame of Figure 3-106.
disassembly.
b. Slide reamer through pilot starting bit into crank-
1. Slide cam support plate onto two ring dowels in crank-
shaft bushing in cam support plate. Do not apply
case flange.
lubricant to reamer or bushing. Ream the bushing
dry or cut will not be accurate.
2. Install six allen head socket screws (1/4 x 1 inch) to
secure cam support plate to crankcase flange. Alter-
c. Install handle/drive socket on reamer lug. See right
nately tighten screws until snug.
frame of Figure 3-106.
3. Obtain the CRANKSHAFT BUSHING REAMER (HD-
d. Placing thumb on drive socket, apply slight pressure
42316) and REAMER HANDLE/DRIVE SOCKET (HD-
on reamer while rotating handle/drive socket in a
43645). Proceed as follows:
clockwise direction.
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f.
Remove handle/drive socket, and carefully pulling
on bit, draw shaft of reamer out of bushing on cam
Handle/Drive Socket
side of crankcase.
g. Remove pilot from crankshaft bearing. Tap on pilot
using a soft rubber mallet, if necessary.
Pilot
4.
Remove the allen head socket screws to release the
cam support plate from the crankcase flange.
CAUTION
Abrasive particles can damage machined surfaces and
plug oil passages possibly resulting in engine failure.
Reamer
5. Using a small screwdriver, carefully pry cleaning plug
from top of cam support plate. Thoroughly flush right
Figure 3-105. Crankshaft Bushing Reamer (Part No. HD-
crankcase half and cam support plate in cleaning sol-
42316) and Handle/Drive Socket (Part No. HD-43645)
vent to remove any metal shavings or debris. Blow dry
with compressed air. Install cleaning plug in cam support
plate replacing O-ring if torn or damaged.
CAUTION
For best results, do not push on reamer or apply pres-
Camshafts/Camshaft Bearings
sure to the reamer handle. While excessive pressure
Removal
results in a rough cut, bushing bore will be tapered if
pressure is not centrally applied.
1.
Place cup of CAM CHAIN TENSIONER UNLOADER
(HD-42313) over spring coil of secondary cam chain ten-
e. Continue rotating handle/drive socket until entire bit
sioner positioning finger on tool between tensioner and
has passed through bushing and shank of reamer
shoe. See Figure 3-107. Rotate tool in a counterclock-
rotates freely in the bore.
wise direction inserting retention pin through hole in
boss on primary cam chain side of cam support plate.
Pin engages hooks on tensioner to hold it in the
CAUTION
retracted position. For best results, place cam support
Never back reamer out flywheel side of crankcase or
plate in a vise using brass jaw inserts to prevent casting
crankshaft bushing will be damaged.
damage.
Install pilot and reamer from flywheel side of case.
Install handle/drive socket on reamer.
Right Crankcase
Handle/
Reamer
Half
Drive Socket
Crankshaft
Bearing
Pilot
f1619x3x
f1611x3x
Figure 3-106. Ream Crankshaft Bushing
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Press out camshafts (with bearings).
Finger
Ram
Camshaft
Driver
Tensioner
Unloader
Shoe
Retention
Pin
f1637x3x
Parallel
Figure 3-107. Retract Secondary Cam Chain Tensioner
Blocks
f1623x3x
1WARNING
Remove bearing from front camshaft.
Always wear proper eye protection when removing re-
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
Forcing
worn. Slippage may propel the ring with enough force to
Screw
cause eye injury.
3/8-16 Inch
2. Remove retaining ring from groove at end of front cam-
Bolt
shaft. Discard retaining ring.
with Flat Washer
3. Remove four T20 TORX screws to free bearing retainer
plate from inboard side of cam support plate.
Bridge
4. Using a colored marker, mark one of the links of the sec-
ondary cam chain. Maintaining the original direction of
rotation during assembly may prolong service life of
Hardened
chain.
Plug
Bearing
5. With the primary cam chain side facing upward, place
cam support plate on parallel blocks under ram of arbor
press.
6. Obtain the CAMSHAFT/CAMSHAFT BEARING RE-
MOVER/INSTALLER (HD-43644). See Figure 3-108.
Wedge
Attachment
Support Block
Front
Camshaft
f1611x3x
Figure 3-109. Remove Camshafts/Front Cam Bearing
CAUTION
Camshaft Driver
Bearing Pilot/Driver
Since the bearing fit to the camshafts is tighter than its
fit in the support plate, any attempt to remove the cam-
Figure 3-108. Camshaft/Camshaft Bearing
shafts without the bearings will result in damage to the
Remover/Installer (Part No. HD-43644)
cam support plate and bearing retainer plate, if installed.
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f1806x3x
Pull Bearing Inner Race and Thrust Washer
A
From Rear Cam. Remove O-Ring if Present.
Thrust
Washer
Inner
Shop
Race
Rag
Box Wrench
5/8 Inch
NOTE
Although the vane has been eliminated
from the cam sprocket on production
motorcycles, the service part retains the
vane to retrofit earlier models having a
camshaft position sensor.
Box Wrench
Inner
9/16 Inch
Race
Shop
Thrust
Rag
Washer
Install O-Ring and Thrust Washer.
B
Press Bearing Inner Race Onto Rear Cam.
f1807x3x
Figure 3-110. Remove/Install Bearing Inner Race (With O-Ring and Thrust Washer) Onto Rear Camshaft
CAUTION
camshafts (with attached bearings) from the cam sup-
port plate. See upper frame of Figure 3-109.
Cam bearings may be a loose fit in the cam support
plate. To avoid possible damage, be aware that camshaft
8.
Remove secondary cam chain from cam sprockets.
and bearing assemblies may drop out at start of press
9.
If reusing front camshaft, remove bearing as follows:
procedure.
7. Fit cups of camshaft driver over ends of front and rear
a. Position WEDGE ATTACHMENT (HD-95637-46A)
camshafts, so that contact is made with the bearing
on inboard side of front camshaft bearing and turn
inner races. Centering driver under ram at a point mid-
hex nuts an equal number of turns to draw halves of
way between the camshafts, simultaneously press both
wedge together.
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b. Obtain two 3/8-16 inch bolts 3-1/2 inches long (with
flat washers). Install flat washers on bolts. Obtain
O-Ring
Thrust Washer
bridge, forcing screw and hardened plug from
MAINSHAFT BEARING INNER RACE PULLER/
INSTALLER (HD-34902B).
c. Slide one bolt into channel on each side of bridge
so that flat washer is between bridge and bolt head.
Thread bolts into wedge attachment an equal num-
ber of turns.
d. Sparingly apply graphite lubricant to threads of forc-
ing screw to prolong service life and ensure smooth
operation. Start forcing screw into center hole of
Bearing Inner Race
bridge.
Roller Bearing
f1805x3x
CAUTION
Figure 3-111. Rear Cam Roller Bearing Kit (P/N 8983)
Failure to use hardened plug may result in damage to
forcing screw and/or camshaft.
2.
Install O-ring, thrust washer and bearing inner race onto
e. Place cupped side of hardened plug against end of
rear camshaft as follows:
camshaft. Thread forcing screw into bridge until the
steel ball at the end of the screw makes firm contact
a. To properly locate thrust washer, first install O-ring
with hardened plug.
in grinding relief groove. Groove is on the splined
end between the machined area and the secondary
f.
Verify that the tool assembly is square so that the
cam sprocket. Exercise caution to avoid stretching
bearing is not cocked during removal. See lower
or breaking the O-ring. Since the O-ring is not sold
frame of Figure 3-109. Turn forcing screw until bear-
separately, damage will require purchase of a new
ing is pulled free of camshaft. Discard bearing.
roller bearing kit.
10.
If reusing rear camshaft, remove roller bearing assembly
as follows:
CAUTION
a. Slide roller bearing from end of rear camshaft.
Since bearing is a loose fit on cam, no pressing
The thrust washer will be offset to one side if the O-ring
tools are required.
is not installed in the grinding relief groove. Damage to
the bearing cage can occur if the thrust washer is not
b. Install tools as you would to remove the bearing
properly centered.
from the front camshaft, but position cup of wedge
inboard of the thrust washer.
b. Slide thrust washer down rear camshaft until cen-
c. Wrap a shop rag around camshaft to get a firm grip
tered over O-ring in grinding relief groove.
and also to protect hand from sharp edges of
c. Slide bearing inner race down rear camshaft until
sprocket.
contact is made with shoulder of machined area.
d. Using a 5/8 inch box wrench, turn forcing screw until
d. Install primary cam sprocket spacer and sprocket
bearing inner race and thrust washer are pulled free
on camshaft and secure using thicker flat washer
of camshaft. See A of Figure 3-110. A light interfer-
and long flange bolt.
ence fit allows the parts to be removed with little
effort. Discard inner race and thrust washer.
NOTE
e. If present, remove O-ring from grinding relief groove
If not enough of the splined shaft is exposed to install the
in camshaft. Groove is on the splined end between
sprocket, leave out the spacer and proceed to step 2(e).
the machined area and the secondary cam
Once the bearing inner race has been started onto the
sprocket. Discard O-ring.
machined area, remove the flange bolt, washer and sprocket,
and then reassemble using the spacer. Repeat step 2(e) to
NOTE
fully install bearing inner race.
Since the O-ring is not used in production, it will only be
found if the cams were serviced at the dealer level.
e. Wrap a shop rag around camshaft to get a firm grip
and also to protect hand from sharp edges of
sprocket. Using a 9/16 inch box wrench, turn flange
Installation
bolt in a clockwise direction. Bearing inner race is
1.
Obtain new rear cam roller bearing kit (Part No. 8983).
fully installed when it makes firm contact with the
See Figure 3-111.
thrust washer. See B of Figure 3-110.
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7.
Apply a small dab of Loctite Medium Strength Thread-
locker 243 (blue) to threads of four bearing retainer plate
Roller Bearing
Ball Bearing
Rear Cam
Front Cam
screws. Using a T20 TORX drive head, secure bearing
retainer plate to cam support plate. Tighten screws to
20-30 in-lbs (2.3-3.4 Nm) in a crosswise pattern. Verify
that hole in retainer plate is properly aligned with sec-
ondary cam chain oiler.
8.
Place cam support plate back on support block, if
removed. Block properly supports inner races of bear-
ings as camshafts are installed.
9.
Align pin stamped timing lines on teeth of secondary
cam sprockets
(outboard faces). See Figure
3-113.
f1804x3x
Using a colored marker, carefully mark the timing line
locations on the inboard side of the sprocket teeth.
Figure 3-112. Cam Bearings
These marks are needed to observe proper orientation
of the camshafts when they are pressed into the bear-
f.
Verify that the thrust washer is locked in place and
ings.
cannot be rotated. If necessary, install shaft in vise
using brass jaw inserts, and further tighten flange
10.
Place the secondary cam chain around the sprockets of
bolt until the desired result is achieved.
both the front and rear camshafts. To maintain the origi-
nal direction of rotation, be sure that the colored mark
g. Remove flange bolt, flat washer, sprocket and
placed on the chain link during disassembly is facing
spacer.
opposite the cam support plate during installation.
CAUTION
11.
Orient the camshafts so that they are positioned on
opposite ends of the chain, and then verify that the col-
Always install new bearings. Only use genuine Harley-
ored marks placed on the inboard side of the sprocket
Davidson bearings. Reusing old bearings or using bear-
teeth are still in alignment.
ings from a supplier other than Harley-Davidson will
result in engine damage.
12.
Maintaining the position of the camshafts on the chain
with the colored marks in alignment, place the sprocket
3. Obtain the CAMSHAFT/CAMSHAFT BEARING RE-
ends of the camshafts into the bearings.
MOVER/INSTALLER (HD-43644).
4. With the secondary cam chain side facing upward, place
cam support plate on support block, so that outer races
of bearings are properly supported. Note that one corner
Front
of the support block is contoured to accommodate the
Camshaft
chain guide blocks cast into the front of the support
Rear
plate.
Camshaft
5. Center new bearing over bearing bore with the lettered
side up. Slide pilot shaft of bearing driver through
bearing into hole of support block.
NOTE
Be aware that the front and rear cam bearings are not inter-
changeable. The rear bearing is the roller type, while the front
is the ball bearing kind. See Figure 3-112.
6. Center bearing driver under ram of arbor press. Press
on driver until bearing makes firm contact with counter-
bore in cam support plate. See upper frame of Figure 3-
114. Repeat steps to install second bearing.
NOTE
Pin Stamped
Timing Lines
f2067x3x
Bearings may be a press to loose fit. If deemed necessary,
clean bearing OD and apply Loctite Low Strength Thread-
Figure 3-113. Align Timing Lines on Teeth
locker 243 (Blue) before installation, but exercise caution to
of Camshaft Sprockets
avoid getting compound on rollers or bearing ID.
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NOTE
Press bearings into cam support plate.
Do not mix camshafts during the press procedure. The rear
Bearing
camshaft, which can be identified by the splined shaft, must
Pilot/Driver
go into the roller bearing at the rear of the cam support plate.
Bearing
13. Place cup of camshaft driver over end of front camshaft
only.
Support
CAUTION
Block
Verify that splined end of rear camshaft has been started
into support block. Damage to the camshaft and/or sup-
port block can occur if end of camshaft catches top of
block during the press procedure.
NOTE
f1618x3x
To reduce the likelihood of such contact occuring, use 7/8
Center front camshaft under ram. Start front cam-
inch drill bit to enlarge rear cam bore in support block. For
shaft into cam bearing.
best results, radius top inside edge of bore after drilling.
Ram
Camshaft
CAUTION
Driver
Be sure that the tensioner shoe is clear of the secondary
cam chain during the press procedure. Contact can
result in damage that requires replacement of the ten-
Front
Support
Camshaft
sioner assembly.
Block
14. Center end of front camshaft under ram and slowly apply
pressure to driver just to start front camshaft into bear-
ing ID. See center frame of Figure 3-114.
CAUTION
If rear camshaft is not properly aligned, edge of installed
f1822x3x
inner race can catch on bearing rollers. Bearing damage
can result if contact occurs during the press procedure.
While applying pressure to front camshaft, wiggle
rear camshaft to guide inner race between bearing
15. Slowly apply pressure to driver on front camshaft, while
rollers.
wiggling rear camshaft as necessary to guide inner race
between bearing rollers. See lower frame of Figure 3-
Rear
114.
Camshaft
16. When inner race on rear cam is started into roller bear-
ing, apply pressure to driver until front camshaft is fully
seated. If necessary, keep finger pressure at top of rear
camshaft to ensure that assembly remains square and
inner race moves to installed position in roller bearing.
17. Since the pin stamped timing lines on the secondary
sprockets cannot be observed once the camshafts are
pressed into the bearings, note that the outboard ends of
the shafts have a second set of timing lines (although
they may be somewhat difficult to see). Using a straight-
edge, verify that these timing lines are in alignment. See
Figure 3-115. If they are not, then the camshafts must be
removed and reinstalled (with a new bearing set).
f1821x3x
Figure 3-114. Install Cam Bearings/Camshafts
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Cam Chain Tensioners
Rear
Front
Camshaft
Camshaft
Removal
1CAUTION
Do not pull the retention pins from the primary or sec-
ondary cam chain tensioners with the chains and
sprockets removed. With 35-40 pounds of spring pres-
sure behind the tensioner, allowing it to accelerate
through its full length of travel will cause spring stretch-
ing and/or cracking of the tensioner shoe, damage which
requires replacement of the assembly. Furthermore, if
the tensioner should contact fingers or other parts of the
hand, minor or moderate injury may occur.
1. If retracted, hold the cam chain tensioner with the CAM
CHAIN TENSIONER UNLOADER (HD-42313), pull the
retention pin and ease the assembly into the unloaded
position.
Pin Stamped
f2068x3x
Timing Lines
1WARNING
Figure 3-115. Verify Alignment of Timing Lines
Always wear proper eye protection when removing re-
on Ends of Camshafts
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
cause eye injury.
1WARNING
2.
Remove retaining ring from groove in tensioner post.
Discard retaining ring.
Always wear proper eye protection when installing re-
taining rings. Use the correct retaining ring pliers. Verify
3.
Slide cam chain tensioner assembly from post disengag-
that the tips of the pliers are not damaged or excessively
ing spring pin from hole in cam support plate.
worn. Slippage may propel the ring with enough force to
cause eye injury.
Installation
18. With the sharp edge out, install new retaining ring in
1.
Slide cam chain tensioner assembly onto post inserting
groove at end of front camshaft.
spring pin into hole in cam support plate.
f1676x3x
Acceptable Wear
Unacceptable Wear
Unacceptable Wear
Continue use of the tensioner shoe
Replace the tensioner shoe assembly
Replace the tensioner shoe assembly
assembly (and chain) if worn to a depth
(and chain) if worn to a depth that is
(and chain) if there is any evidence of
that is less than half the thickness of the
equal to or greater than half the thick-
melting, burning or cracking.
shoe material.
ness of the shoe material.
Figure 3-116. Cam Chain Tensioner Shoe Wear
2004 Touring: Engine
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3. Slide spring into bypass port until seated in open side of
piston.
4. Start new roll pin into hole in cam support plate. Com-
press spring using the blade of a small screwdriver.
5. Holding spring compressed, tap roll pin into cam support
plate until it approaches pin hole on opposite side.
6. Remove screwdriver to release spring. Verify that spring
is straight and square in bore.
7. Using a 1/8 inch punch with a small hammer, carefully
tap roll pin until flush with casting.
6908
8. Install primary cam chain tensioner assembly. See CAM
CHAIN TENSIONERS, INSTALLATION, in this section.
Figure 3-117. Oil Pressure Relief Valve Assembly
Cam Needle Bearings
1WARNING
Removal
Always wear proper eye protection when installing re-
1. Obtain the CAMSHAFT NEEDLE BEARING RE-
taining rings. Use the correct retaining ring pliers. Verify
MOVER/INSTALLER (HD-42325).
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
2. Remove four button fasteners from threaded holes in
support plate, if installed. See Figure 3-118.
cause eye injury.
2. With the sharp edge out, install new retaining ring in
3. Sparingly apply graphite lubricant to threads of collet to
groove of post. Verify that the ring is fully seated in the
prolong service life and ensure smooth operation.
groove.
4. Slide collet through support plate so that threaded end
3. If retracted prior to disassembly, place cup of CAM
exits stamped side of plate.
CHAIN TENSIONER UNLOADER
(HD-42313) over
5. Aligning two large holes in support plate with needle
spring coil of cam chain tensioner assembly. Retract the
bearing bores, hang right side of plate on ring dowel in
tensioner inserting a retention pin through hole in boss
crankcase flange.
on the primary cam chain side of cam support plate.
Oil Pressure Relief Valve
f1303x2x
Graphite
Lubricant
Removal
Button
1. Before removal, see CLEANING AND INSPECTION in
Hex Nut
Fastener (4)
this section.
Nice
2. Remove primary cam chain tensioner assembly. See
Bearing
CAM CHAIN TENSIONERS, REMOVAL.
Support
Plate
3. Secure the cam support plate in a vise with access to
the roll pin. Be sure to install a pair of brass jaw inserts in
the vise to avoid damage to the casting.
Pilot
4. Using a 1/8 inch punch with a small hammer, carefully
tap roll pin from pin hole in cam support plate. Discard
roll pin.
5. Remove spring and piston from bypass port.
Flat
Washer
Installation
Installer
Collet
1.
Secure the cam support plate in a vise. Install a pair of
Shaft
Collet
Threaded End
Expandable End
brass jaw inserts to avoid damage to the casting.
2.
Lubricate piston with clean H-D 20W50 engine oil. Slide
piston into bypass port with the open side facing out-
Figure 3-118. Camshaft Needle Bearing Remover/Installer
(HD-42325)
ward.
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6.
Align four holes at corners of support plate with threaded
Install support plate with collet.
holes in crankcase flange. Install button fasteners in
Install Nice bearing, flat washer and hex nut.
these holes to secure support plate to crankcase. See
upper frame of Figure 3-119.
Support
Button
7.
Center expandable end of collet in bearing bore and
Plate
Fastener
slide Nice bearing and flat washer on threaded end.
Start hex nut on threaded end.
8.
Push expandable end of collet through bearing bore into
flywheel compartment. Feel for inside edge of needle
Nice
Ring Dowel
bearing using end of collet and then back off slightly.
Bearing
Hole
9.
Holding collet to prevent lateral movement, finger tighten
hex nut until Nice bearing contacts support plate.
10.
Using a 7/16 inch open end wrench, hold flat on collet to
prevent rotation. Using a second 7/16 inch open end
Flat
wrench, expand collet by turning hex at end of shaft in a
Washer
clockwise direction. See center frame of Figure 3-119.
Collet
Expandable end of collet makes contact with needle
Threaded End
bearing ID.
Hex
11.
Using a 15/16 inch open end wrench, turn hex nut in a
Nut
f1586x3x
clockwise direction until bearing is free. If necessary,
hold flat on collet to prevent rotation. See lower frame of
Holding flat, turn hex in a
f1587x3x
Figure 3-119.
clockwise direction to expand collet.
12.
Remove four button fasteners and pull support plate
from crankcase.
13.
Holding flat on collet, turn hex at end of shaft in a coun-
terclockwise direction to close collet. Remove and dis-
card needle bearing.
14.
Remove hex nut, flat washer and Nice bearing from
threaded end of collet. Pull collet from support plate.
15.
Return to step 1 to remove second needle bearing.
Installation
Hex
Flat
1.
Obtain the CAMSHAFT NEEDLE BEARING RE-
MOVER/INSTALLER (HD-42325).
2.
Sparingly apply graphite lubricant to threads of installer
shaft to prolong service life and ensure smooth opera-
tion.
3.
Thread installer shaft into stamped side of support plate
Turn hex nut in a clockwise direction
to remove bearing.
until threads begin to emerge from opposite side.
4.
Install pilot at end of installer shaft.
5.
Place new needle bearing on pilot with lettered side fac-
ing shoulder.
6.
Aligning two large holes in support plate with needle
bearing bores, hang right side of plate on ring dowel in
crankcase flange.
7.
Align four holes at corners of support plate with threaded
holes in crankcase flange. Install button fasteners in
these holes to secure support plate to crankcase. See
upper frame of Figure 3-120.
8.
Using 15/16 inch open end wrench, turn hex at end of
installer shaft in a clockwise direction until resistance is
felt. See lower frame of Figure 3-120.
9.
Turn end of installer shaft in a counterclockwise direction
until pilot is free of needle bearing bore.
f1588x3x
Figure 3-119. Remove Cam Needle Bearing
2004 Touring: Engine
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a. Measure distance from edge of cam support plate
Install support plate with installer shaft (and pilot).
to inboard side of piston. Insert straight stiff wire into
unplugged hole outboard of roll pin until it bottoms,
Support
and then mark and measure wire. With piston fully
Plate
Button
seated in the bore, depth should be approximately
Fastener
2.25 inches (57.15 mm). If it is not, continue with
step 1(b).
b. Remove oil pressure relief valve. See OIL PRES-
SURE RELIEF VALVE, REMOVAL, in this section.
Ring Dowel
c. Inspect spring for stretching, kinking or distortion.
Hole
d. Inspect piston and bore for burrs, scoring or other
damage. Look for steel particles or aluminum chips.
Replace cam support plate and piston if any of
these conditions are found.
e. Install piston in bore and measure running clear-
ance. If running clearance exceeds
0.003 inch
(0.076 mm), install new piston and remeasure.
Replace cam support plate if running clearance still
Installer
exceeds specification.
Shaft
f1589x3x
2.
Clean cam support plate as follows:
Turn hex on installer shaft in a clockwise direction
to install bearing.
a. Using a small screwdriver, carefully pry cleaning
plug from cam support plate. See Figure 3-121.
b. Thoroughly flush cam support plate with a non-vola-
tile cleaning solution or solvent and then blow dry
with low pressure compressed air.
c. Reinstall cleaning plug replacing O-ring if damaged
or deteriorated.
d. Verify that all oil holes are clean and open.
CAUTION
Exercise caution to avoid enlarging the oil holes or oil
pressure will be adversely affected.
Installation
f1590x3x
1.
See Section 3.10 BOTTOM END OVERHAUL, ASSEM-
BLY, steps 12-29.
Figure 3-120. Install Cam Needle Bearing
2.
Remove wireforms to release hydraulic lifters.
3.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
steps 29-39.
10.
Remove four button fasteners and pull support plate and
installer shaft from crankcase.
11.
Remove pilot from installer shaft. Unthread installer
shaft from support plate.
12.
Return to step 1 to install second needle bearing.
13.
Thread four button fasteners into threaded holes in sup-
port plate to prevent loss.
Cleaning and Inspection
1.
Inspect oil pressure relief valve as follows:
NOTE
If diagnosing low oil pressure, start with step 1(a). If diagnos-
6891
ing high oil pressure, then begin with step 1(b).
Figure 3-121. Remove Cleaning Plug
3-98
2004 Touring: Engine
HOME
OIL PUMP
Inner Gerotor
Outer Gerotor
Removal
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-11.
NOTE
When removing the cam support plate, it is not necessary to
disturb the lifter assemblies if a method is devised to prevent
the hydraulic lifters from dropping into the cam compartment.
Wear
One such method is provided in the following step. Leaving
Limit
the lifter assemblies intact simplifies the procedure, since the
lifter cover, gasket, anti-rotation pin and hydraulic lifters can
be left in place.
f1563x3x
2. Fashion lifter holding tool as follows:
a. Obtain a large binder clip (available at any office
Figure 3-123. Measure Gerotor Sets for Wear
supply store). Squeeze wireforms to remove from
binder clip. See upper frame of Figure 3-102.
b. Compress wireform slightly and insert free ends into
2.
Thoroughly dry all parts with low pressure compressed
outer and inner lifter cover bores so that legs
air. Verify that all oil passages are clean and open.
engage walls of both hydraulic lifter sockets. See
3.
Look for scoring, gouging or cracking caused by foreign
lower frame of Figure 3-102.
material that may have passed through the oil pump.
3. See Section 3.10 BOTTOM END OVERHAUL, DISAS-
4.
Look for grooves or scratches on the cam support plate,
SEMBLY, steps 1-15.
which serves as the outboard side of the oil pump.
5.
Check for excessive wear or damage on lobes of outer
Cleaning and Inspection
gerotors and between lobes on inner gerotor.
6.
Mesh pieces of one gerotor set together as shown in
1. Clean all parts in a non-volatile cleaning solution or sol-
Figure 3-123. Use a feeler gauge to determine clear-
vent.
ance between tips of lobes on inner and outer gerotors.
The maximum allowable clearance is
0.004 inch
(0.10 mm). Replace gerotor set if clearance exceeds
specification. Inspect second gerotor set in the same
Oil Pump
O-Ring
manner.
Housing
7.
Measure thickness of inner gerotor of one set with a
micrometer. Measure the outer gerotor of the same set.
Wide
Replace the gerotor set if the difference exceeds 0.001
Gerotor Set
inch (0.025 mm). Inspect second gerotor set in the same
(Scavenge)
manner.
Wave
8.
Assemble the oil pump. Verify that feed gerotors stand
Washer
Narrow
proud of the oil pump surface 0.080-0.090 inch (2.03-
Gerotor Set
2.29 mm). If measurement is less than 0.080 inch (2.03
(Feed)
mm), remove feed gerotor set and reassemble using
new wave washer. Repeat measurement and replace oil
pump body if still not within specification.
O-Ring
Separator
Plate
Installation
1.
See Section 3.10 BOTTOM END OVERHAUL, ASSEM-
Separator
BLY, steps 11-29.
Plate
f1530b3x
2.
Remove wireforms to release hydraulic lifters.
3.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
Figure 3-122. Oil Pump Assembly
steps 29-39.
2004 Touring: Engine
3-99
HOME
Legend:
f2070x3x
1.
Crankshaft Bearing
2.
Ring Dowel
3.
Cam Needle Bearing
4.
Oil Inlet Fitting
5.
Oil Outlet Fitting
6.
Crankcase Breather Fitting
7.
Right Crankcase Half
8.
O-Ring
9.
Piston Jet
10.
T20 TORX Screw
11.
Lock Ring
12.
Sprocket Shaft Bearing
13.
O-Ring
14.
Ring Dowel
15.
Plug
16.
O-Ring
17.
Oil Filter Mount
18.
Oil Filter Adapter
19.
Flat Washer
20.
Bolt
28
21.
Lockplate
22.
Oil Filter
27
23.
Crankcase Bolt
24.
Ring Dowel
25.
O-Ring
26.
Left Crankcase Half
29
27.
Thrust Washer
28.
Oil Seal
29.
Sprocket Shaft Spacer
26
25
24
6
7
12
11
23
9
10
5
8
4
13
3
14
19
2
20
21
1
18
15
16
22
17
Figure 3-124. Crankcase Assembly (Exploded View)
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2004 Touring: Engine
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CRANKCASE
3
1.
Ram
2.
Pilot/Driver
Removal
3.
Support Tube
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-29.
“A”
End Up
2. See Section 3.10 BOTTOM END OVERHAUL, DISAS-
SEMBLY, steps 1-18.
1
f2126x3x
Disassembly/Assembly
2
RIGHT CRANKCASE HALF
Crankshaft Bearing
Removal
1CAUTION
Never move or lift the crankcase by grasping the cylin-
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.
1.
See Figure 3-125. Obtain CRANKSHAFT/SPROCKET
SHAFT BEARING REMOVER/INSTALLER PILOT/
DRIVER
(B-45655) and CRANKSHAFT/SPROCKET
SHAFT BEARING REMOVER/INSTALLER SUPPORT
Figure 3-126. Remove Crankshaft Bearing
TUBE (HD-42720-5).
2.
Place support tube on hydraulic press table with the “A”
4.
Slide pilot/driver through bearing into support tube.
end up. The ends of the support tube are stamped “A”
and “B” to ensure proper orientation.
5.
Center pilot/driver under ram of press. Apply pressure to
3.
With the outboard side of the right crankcase half facing
pilot/driver until bearing is free. See Figure 3-126.
upward, position crankshaft bearing bore over support
6.
Remove right crankcase half, pilot/driver and bearing
tube.
from support tube. Discard bearing.
Support Tube
Installation
Part No. HD-42720-5
1.
See Figure 3-125. Obtain CRANKSHAFT/SPROCKET
SHAFT BEARING REMOVER/INSTALLER PILOT/
DRIVER
(B-45655) and CRANKSHAFT/SPROCKET
SHAFT BEARING REMOVER/INSTALLER SUPPORT
TUBE (HD-42720-5).
2.
Turn support tube over so that the “B” end is up. The
ends of the support tube are stamped “A” and “B” to
ensure proper orientation.
3.
With the outboard side of the right crankcase half facing
Pilot/Driver
upward, position crankshaft bearing bore over support
Part No. B-45655
d0687x3x
tube.
4.
Obtain new crankshaft bearing and apply a thin film of
Figure 3-125. Crankshaft/Sprocket Shaft Bearing
clean engine oil to O.D.
Pilot/Driver and Support Tube
2004 Touring: Engine
3-101
HOME
Installation
3
1. Ram
2. Pilot/Driver
CAUTION
3. Support Tube
4. Crankshaft Bearing
O-rings that are missing, distorted, pinched or otherwise
“B”
damaged will result in either oil leakage or low oil pres-
End Up
sure. Use of the wrong O-ring will have the same results.
Since many O-rings are similar in size and appearance,
always use new O-rings keeping them packaged until
1
use to avoid confusion.
f2127x3x
2
1.
Install new O-ring in groove of jet mounting flange. Apply
a very thin film of clean H-D 20W50 engine oil to O-ring
before installation.
4
2.
Apply Loctite Low Strength Threadlocker 222 (purple) to
threads of two T20 TORX screws.
3.
With the jet pointed upward, install TORX screws to
secure piston jet to crankcase. Tighten screws to 25-35
in-lbs (2.8-4.0 Nm).
LEFT CRANKCASE HALF
Sprocket Shaft Bearing
Removal
Figure 3-127. Install Crankshaft Bearing
1CAUTION
Never move or lift the crankcase by grasping the cylin-
der studs. The crankcase is too heavy to be carried in
5.
Start crankshaft bearing into bore with the lettered side
this manner and may be dropped. Dropping the crank-
up. Lubricate leading edge of bearing before placement.
case may result in parts damage and minor or moderate
6.
Slide pilot/driver through bearing into support tube.
injury.
7.
Center pilot/driver under ram of press. Apply pressure to
pilot/driver until resistance is felt and bearing bottoms in
1WARNING
support tube. See Figure 3-127.
Do NOT rotate left crankcase half in the engine stand so
8.
Remove pilot/driver and right crankcase half from sup-
the stator mount flange (sprocket shaft side) is facing up
port tube.
or the flywheel assembly will drop to the floor. Dropping
the flywheel assembly may result in parts damage and
minor or moderate injury.
1.
Holding flywheel assembly so that it does not drop out of
Piston Jets
left crankcase half, rotate cradle so that engine is upright
and crankshaft and sprocket shaft are horizontal.
Removal
2.
Carefully slide flywheel assembly out of left crankcase
1.
Remove two T20 TORX screws to free piston jet from
half.
crankcase.
3.
Remove left crankcase half from engine stand and move
2.
Remove O-ring from groove in mounting flange of jet.
to bench area. Remove thrust washer from outboard
Discard O-ring.
side of crankcase by pulling it past the oil seal. Set thrust
washer aside for inspection or reuse.
4.
Using a suitable drift, tap oil seal from bearing bore. Dis-
card oil seal.
3-102
2004 Touring: Engine
HOME
f2136x3x
1
f2132x3x
2
1
2
4
3
3
f2129x3x
f2129x3x
1.
Ram
1. Ram
3
2.
Pilot/Driver
3
2. Pilot/Driver
3.
Support Tube (“A” end up)
3. Support Tube (“A” end up)
4.
Sprocket Shaft Bearing
Figure 3-128. Remove Sprocket Shaft Bearing
Figure 3-129. Install Sprocket Shaft Bearing
5.
See Figure 3-125. Obtain CRANKSHAFT/SPROCKET
Installation
SHAFT BEARING REMOVER/INSTALLER SUPPORT
TUBE (HD-42720-5) and CRANKSHAFT/SPROCKET
1CAUTION
SHAFT BEARING REMOVER/INSTALLER PILOT/
DRIVER (B-45655).
Never move or lift the crankcase by grasping the cylin-
der studs. The crankcase is too heavy to be carried in
6.
Place left crankcase half on work bench with inboard
this manner and may be dropped. Dropping the crank-
side of facing upward.
case may result in parts damage and minor or moderate
7.
Using the tip of a flat blade screwdriver, carefully lift end
injury.
of lock ring out of groove in bearing bore. Working the
1.
See Figure 3-125. Obtain CRANKSHAFT/SPROCKET
screwdriver around the edge, lift the lock ring up and out
SHAFT BEARING REMOVER/INSTALLER SUPPORT
of the groove. Be careful not to damage the lip of the
TUBE (HD-42720-5) and CRANKSHAFT/SPROCKET
groove during removal.
SHAFT BEARING REMOVER/INSTALLER PILOT/
8.
Place support tube on hydraulic press table with the “A”
DRIVER (B-45655).
end up. The ends of the support tube are stamped “A”
2.
Place support tube on hydraulic press table with the “A”
and “B” to ensure proper orientation.
end up. The ends of the support tube are stamped “A”
9.
With the outboard side of the left crankcase half facing
and “B” to ensure proper orientation.
upward, position sprocket shaft bearing bore over sup-
3.
With inboard side of the left crankcase half facing
port tube. See Figure 3-128.
upward, position sprocket shaft bearing bore over sup-
port tube.
10.
Slide pilot/driver through bearing into support tube.
4.
See Figure 3-129. Obtain new sprocket shaft bearing
11.
Center pilot/driver under ram of press. Apply pressure to
and apply a thin film of clean engine oil to O.D.
pilot/driver until bearing is free.
5.
Start sprocket shaft bearing into bearing bore with the
12.
Remove left crankcase half, pilot/driver and bearing from
lettered side down. Lubricate leading edge of bearing
support tube. Discard bearing.
before placement.
2004 Touring: Engine
3-103
HOME
6.
Slide pilot/driver through bearing into support tube.
Hold-Down
7.
Center pilot/driver under ram of press. Apply pressure to
Clamp
pilot/driver until bearing lightly bottoms in the bore.
8.
Remove left crankcase half and pilot/driver from support
tube.
9.
Place left crankcase half on work bench with inboard
side of facing upward.
10. Obtain new lock ring and work into groove in bearing
bore. Be careful not to damage the lip of the groove dur-
ing installation. Verify that lock ring is fully seated in the
groove.
Locating Pin
NOTE
If lock ring will not fit into groove, bearing bore may not have
Figure 3-130. Flywheel Fixture (Part No. HD-44358)
been properly cleaned and/or bearing may not be fully
seated in the bore.
f2154x3x
1
Sprocket Shaft Bearing Inner Race
2
Removal
3
1.
If reusing flywheel, remove bearing inner race and thrust
washer as follows:
a. Obtain FLYWHEEL SUPPORT FIXTURE
(HD-
44358). See Figure 3-130. Install brass jaws or
shop towels around teeth of vise to prevent damage
7
4
to tool. Clamp tool in vise with the round hole top-
side.
b. Insert crankshaft end through hole resting flywheel
assembly on fixture. Slide knurled locating pin down
slot in tool to engage crank pin hole. Hand tighten
6
5
locating pin.
c. Slide hold-down clamp down slot to engage inboard
side of right flywheel half, and then hand tighten
knurled nut at bottom to secure. Repeat step to
secure hold-down clamp on opposite side of fly-
wheel.
NOTE
For proper clamping force, hold-down clamp must not be
tilted. Rotate hex on outboard stud until clamp is level.
d. Position WEDGE ATTACHMENT (HD-95637-46A)
on inboard side of thrust washer and turn hex nuts
an equal number of turns to draw halves of wedge
together.
1.
Forcing Screw
4.
Hardened Plug
2.
3/8-16 Inch Bolt
5.
Wedge Attachment
CAUTION
with Flat Washer
6.
Bearing Inner Race
Install wedge attachment only so far as necessary to
3.
Bridge
7.
Sprocket Shaft
ensure positive contact with thrust washer. Installing
tool with more contact than absolutely necessary will
Figure 3-131. Remove Inner Race From Sprocket Shaft
result in damage to flywheel.
e. Obtain two 3/8-16 inch bolts 6-1/2 inches long (with
flat washers). Install flat washers on bolts. Obtain
f.
Slide one bolt into channel on each side of bridge
bridge, forcing screw and hardened plug from
so that flat washer is between bridge and bolt head.
MAINSHAFT BEARING INNER RACE PULLER/
Thread bolts into wedge attachment an equal num-
INSTALLER (HD-34902B).
ber of turns.
3-104
2004 Touring: Engine
HOME
f2265x3x
1. Install Thrust Washer and Bearing Inner Race On
Sprocket Shaft. Assemble Tool.
1
2
3
4
Figure 3-132. Sprocket Shaft Timken Bearing
Cone Installer (Part No. HD-97225-55B)
6
5
7
g. Sparingly apply graphite lubricant to threads of forc-
ing screw to prolong service life and ensure smooth
operation. Start forcing screw into center hole of
bridge.
CAUTION
f2152x3x
Failure to use hardened plug may result in damage to
forcing screw and/or sprocket shaft.
2. Press Bearing Inner Race Onto Sprocket Shaft.
h. Place cupped side of hardened plug against end of
sprocket shaft. Thread forcing screw into bridge until
f2153x3x
the steel ball at the end of the screw makes firm
contact with hardened plug.
i.
Using the Robinair Heat Gun (HD-25070), uniformly
heat the bearing inner race for about 30 seconds
using a circular motion.
NOTE
To faciliate removal without heat, apply a light penetrating oil
to shaft and leading edge of bearing inner race.
1WARNING
Never use both heat and penetrating oil. Use only one or
the other. Excessive heat can cause the penetrating oil
1. Pilot Shaft
5.
Sleeve
to ignite resulting in flames or fire. Inadequate safety
2. Handle
6.
Inner Race
precautions can result in death or serious injury.
3. Flat Washer
7.
Thrust Washer
4. Nice Bearing
j.
Turn forcing screw until thrust washer and bearing
inner race move approximately 1/8 inch (3.2 mm).
Figure 3-133. Press Inner Race Onto Sprocket Shaft
k. Turn hex nuts an equal number of turns to separate
halves of WEDGE ATTACHMENT.
CAUTION
l.
After bottoming thrust washer on shaft, reposition
WEDGE ATTACHMENT
(HD-95637-46A) on
Install wedge attachment only so far as necessary to
inboard side of bearing inner race. Turn hex nuts an
ensure positive contact with bearing inner race. Install-
equal number of turns to draw halves of wedge
ing tool with more contact than absolutely necessary
together.
will result in damage to flywheel.
2004 Touring: Engine
3-105
HOME
f2266x3x
9
8
7
6
5
3
4
2
5.
Bearing
1. Flywheel Assembly
6.
Left Crankcase Half
2. Thrust Washer
7.
Thrust Washer
3. Inner Race
8.
Oil Seal
1
4. Lock Ring
9.
Spacer
Figure 3-134. Sprocket Shaft Bearing Assembly
m. Verify that the tool assembly is square, so that the
NOTE
bearing inner race is not cocked during removal.
To faciliate installation without heat, apply a light penetrating
See Figure 3-131.
oil to shaft and leading edge of bearing inner race.
n. Using the Robinair Heat Gun (HD-25070), uniformly
heat the bearing inner race for about 30 seconds
using a circular motion.
1WARNING
Never use both heat and penetrating oil. Use only one or
NOTE
the other. Excessive heat can cause the penetrating oil
To faciliate removal without heat, apply a light penetrating oil
to ignite resulting in flames or fire. Inadequate safety
to shaft and leading edge of bearing inner race.
precautions can result in death or serious injury.
o. Turn forcing screw until bearing inner race is pulled
4.
Obtain the SPROCKET SHAFT TIMKEN BEARING
free of sprocket shaft.
CONE INSTALLER (HD-97225-55B). See Figure 3-132.
p. Remove thrust washer from sprocket shaft.
Assemble tool as described below.
a. Thread pilot onto sprocket shaft until contact is
2.
Discard thrust washer and bearing inner race.
made with shoulder.
b. Sparingly apply graphite lubricant to threads of pilot
Installation
shaft to prolong service life and ensure smooth
1.
Place new thrust washer over sprocket shaft with the ink
operation.
stamp facing outside
(and the chamfer on the ID
c. Slide sleeve over pilot until it contacts bearing inner
inboard).
race.
2.
Place new bearing inner race on bench top. Using the
Robinair Heat Gun (HD-25070), uniformly heat bearing
d. Slide Nice bearing and large flat washer over pilot
inner race for about 60 seconds using a circular motion.
until contact is made with sleeve.
3.
Wearing suitable gloves to protect hands from burns,
e. Thread handle onto pilot shaft. See upper frame of
place heated bearing inner race over sprocket shaft.
Figure 3-133.
3-106
2004 Touring: Engine
HOME
5. Rotate handle of tool in a clockwise direction until bear-
5.
Check ring dowels for looseness, wear or damage.
ing inner race bottoms against thrust washer. See lower
Replace as necessary.
frame of Figure 3-133.
6.
Use a file to carefully remove any nicks or burrs from
6. Remove handle, flat washer, Nice bearing, sleeve and
machined surfaces.
pilot from sprocket shaft.
7.
Clean out tapped holes and clean up damaged threads.
8.
Check the top of the crankcase for flatness with a
Cylinder Studs
straightedge and feeler gauge. Replace if warped.
Removal
1. Thread a 3/8”-16 nut onto cylinder stud.
Installation
2. Thread a second nut onto stud until it contacts the first.
1.
See Section 3.10 BOTTOM END OVERHAUL, ASSEM-
3. Placing wrench on first nut installed, remove stud from
BLY, steps 1-29.
cylinder deck.
2.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
Installation
steps 1-39.
1. Hand start stud in cylinder deck with the collar side
down.
2. Install steel ball bearing into unused cylinder head bolt.
Position head bolt on end of stud.
3. Using an air gun, tighten stud until collar almost contacts
cylinder deck.
4. Leaving cylinder head bolt installed, hand tighten stud to
10-20 ft-lbs (14-27 Nm).
Pipe Plug and Oil Fittings
Removal
1. Turn hex on oil fittings in a counterclockwise direction
until free.
2. Turn pipe plug in a counterclockwise direction until free.
Installation
1. Apply Loctite Pipe Sealant with Teflon 565 to threads.
2. Turn hex on oil fittings in a clockwise direction until snug.
Tighten fittings to 120-168 in-lbs (13.6-18.9 Nm).
3. Install pipe plug. Tighten pipe plug to 120-168 in-lbs
(13.6-18.9 Nm).
Cleaning and Inspection
1. Scrape old gasket material from the crankcase flanges.
Old gasket material left on mating surfaces will cause
leaks.
2. Clean all parts in a non-volatile cleaning solution or sol-
vent.
3. Thoroughly dry all parts with low pressure compressed
air.
4. Verify that all oil holes and passageways are clean and
open.
2004 Touring: Engine
3-107
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