Harley Davidson 2004 Touring Models. Service Manual — page 41
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bore with the type of swabs or patches found in gun
cleaning kits. Continue to wipe bore until clean cloth
shows no evidence of dirt or debris. Follow up with a
thorough wash in hot soapy water. Blow dry with com-
pressed air.
VALVE AND SEAT REFACING
NOTE
Verify correct valve stem to valve guide clearance before
Figure 3-74. Valve Guide Hone (Part No. HD-34723)
refacing. See Table 3-6. If new guides must be installed,
complete that task before refacing valves and seats.
f1661x3x
1. Hold the valve firmly against a wire wheel in a bench
grinder. Remove all carbon deposits from the valve
head, face and stem, but exercise caution to avoid
removing any metal. Carbon left on the stem may affect
alignment in the valve refacer. Polish the valve stem with
steel wool or crocus cloth to remove any marks that
might be left by the wire wheel.
Figure 3-75. Hone Valve Guide Bore
Figure 3-76. Valve Guide Brush (Part No. HD-34751)
NOTE
Always verify valve stem to valve guide clearance after hon-
f1660x3x
ing, since a worn reamer may cut the bore undersize.
10. Measure the inside diameter of the valve guide with an
inside ball micrometer. Measure the outside diameter of
the valve stem with an outside micrometer. The valve
stem may be excessively worn or the valve guide bore
undercut if the clearance is not within the limits (low end
preferable) shown in Table 3-6.
Table 3-6. New Parts Limits
Valve
Valve Stem to Guide Clearance
Intake
0.0008 - 0.0026 inch (0.020-0.066 mm)
Exhaust
0.0015 - 0.0033 inch (0.038-0.084 mm)
11. Using cleaning solvent, thoroughly clean cylinder head
and valve guide bore. Scrub valve guide bore with the
VALVE GUIDE CLEANING BRUSH (HD-34751). For
best results, use a thin engine oil and clean valve guide
Figure 3-77. Scrub Valve Guide Bore
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a. Thread the 12mm end of the tool into the spark plug
hole of the cylinder head.
f1662x3x
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
Dial Vernier
4.
Obtain the NEWAY VALVE SEAT CUTTER SET (HD-
Caliper
35758A) and cut valve seat angle to 46°.
NOTE
Do not remove any more metal than is necessary to clean up
the seat (that is, to provide a uniform finish and remove pit-
ting).
5.
From the bottom of the cylinder head, insert the valve
stem into the valve guide. Push on bottom of valve until it
contacts the valve seat.
6.
Placing finger at bottom of valve to keep valve seated,
use a dial vernier caliper to check the distance from the
top of the valve stem to the machined area on the cylin-
der head. See Figure 3-78.
Seat wear and valve refacing causes the valve stem pro-
trusion to change. If valve stem protrusion exceeds
2.034 inches (51.66 mm), but is less than 2.064 inches
(52.43 mm), obtain the short service replacement valve.
Service replacement valves are 0.030 inch (0.76 mm)
shorter than the standard valve.
If protrusion exceeds 2.064 inches (52.43 mm), then use
the existing valve, but replace the valve seat.
CAUTION
Do not shorten the valve by grinding on the end of the
f1663x3x
stem. Grinding replaces the hardened case with mild
steel which results in accelerated wear.
Figure 3-78. Measure Valve Stem Protrusion
7.
Remove valve from cylinder head. Apply magic marker
or similar product to valve seat and allow to thoroughly
dry.
2.
Install valve (both intake and exhaust) in a valve refacer
8.
Insert the valve stem into the valve guide. Push on bot-
set to a 45 degree angle. The valve refacer is required
tom of valve until it contacts the valve seat.
equipment, since accuracy in matching the angle of the
valve face with the angle of the valve seat is critical.
9.
Obtain the VALVE LAPPING TOOL (HD-96550-36A) and
proceed as follows:
Do not remove any more metal than is necessary to
a. Attach suction cup at end of tool to valve head.
clean up and true the valve face. Removing metal
reduces the service life of the valve. The amount of
b. Holding shank of tool between the palms of both
grinding needed to retrue the valve is a clear indication
hands, oscillate the tool back and forth a few times.
of its condition. Discard the valve if it cannot be quickly
See Figure 3-80.
refaced while maintaining a good margin. Valves that do
not clean up quickly are either warped, excessively worn
10. Remove the valve from the cylinder head and carefully
or too deeply pitted to be used.
inspect the mating surfaces under a good light.
Inspection of the valve seat should show an unbroken
Obtain a new valve if grinding leaves the margin less
contact area of uniform width. If the seat is not concen-
than 0.0313 inch (0.795 mm). A valve in this condition
tric with the valve guide, then the cutter will remove more
does not seat normally, burns easily and may crack or
material in one spot than another. Carbon deposits may
cause pre-ignition.
have caused the guide to be pressed in crooked, the
3.
Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
guide may be cracked, or the cutter blade or cutter pilot
39786) and proceed as follows:
have not have been properly cleaned.
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f1655x3x
Head
Seat
60˚
0.040-0.062 in.
(1.02-1.57 mm)
Valve
Figure 3-79. Valve Lapping Tool (Part No. HD-96550-36A)
46˚ Cutting
31˚
Margin
45˚ Grinding
0.0313 in.
(0.795 mm)
6873
Figure 3-81. Valve Seat Angles
14.
Remove the valve and perform a final inspection of the
contact pattern. If necessary, return to step 11.
15.
Remove the valve from the cylinder head. Use contact
cleaner to thoroughly clean magic marker and/or dye
Valve Lapping
Tool
from valve face and seat, if present.
16.
Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
17.
To confirm quality of valve and seat refacing work, pro-
ceed as follows:
a. Insert valve in guide, and holding valve to seat,
raise port to strong light source. If light is visible
around edge of seat, then valves and seats must be
Figure 3-80. Oscillate Tool to Create Contact Area
reconditioned.
b. Holding valve to seat, fill port at top of cylinder head
NOTE
with solvent. Wait ten full seconds and then check
If the results are not acceptable, then recut the valve seat or
for leakage into combustion chamber. If solvent
replace the valve guide.
leakage into combustion chamber is evident, then
valves and seats must be reconditioned.
11. Inspect the contact pattern on the valve seat to be sure
area is 0.040-0.062 inch (1.02-1.57 mm) wide and con-
18.
Clean valves, cylinder head and valve seats in solvent.
tacts the valve two-thirds of the way towards the outer
Follow up with a thorough wash in hot soapy water. Blow
edge of the valve face. See Figure 3-81. If necessary,
dry with compressed air.
modify the seat pattern as follows:
a. Use the 31° angle cutter to lower the valve seat sur-
face and reduce its width.
Assembly
b. Use the 60° angle cutter to raise the valve seat sur-
face and reduce its width.
1.
Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
39786) and proceed as follows:
c. Use the 46° angle cutter to widen the valve seat sur-
face.
a. Thread the 12mm end of the tool into the spark plug
12. Using a magic marker, mark three equally spaced verti-
hole of the cylinder head.
cal lines across the valve face and then insert the valve
b. Clamp tool in vise at a 45 degree angle (or one that
back into the cylinder head.
offers a comfortable working position).
13. Attach suction cup of VALVE LAPPING TOOL (HD-
2.
Slide spring seat over valve guide until it contacts the
96550-36A) to valve head, and holding shank of tool
between the palms of both hands, oscillate the tool back
machined area on the cylinder head casting. Use a little
grease to hold the spring seat in position, if necessary.
and forth a few times.
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f1664x3x
Plastic
Capsule
Figure 3-82. Valve Stem Seal Installer
(Part No. HD-34643A)
Spring
NOTE
Seat
At the time of disassembly, all parts should have been
marked or tagged so that they are installed on the same
valve (and in the same head).
Install plastic capsule.
3. Run the VALVE GUIDE CLEANING BRUSH (HD-34751)
f1665x3x
through the valve guide bore to verify cleanliness.
4. Using TORCO MPZ or another suitable product, apply a
Plastic
liberal amount of engine assembly lube to valve stem.
Capsule
5. From the bottom of the cylinder head, insert the valve
stem into the valve guide.
6. To distribute the assembly lube evenly around the valve
stem and guide, hand spin the valve as it is installed.
Work the valve back and forth in the bore to verify that it
slides smoothly and seats properly.
7. Remove the valve and apply a second coat of assembly
lube to the valve stem. Install the valve in the valve
guide.
Valve Stem Seal
8. Retract the valve so that the stem is not visible above the
top of the valve guide.
9. Using isopropyl alcohol or other suitable degreaser, thor-
Install valve stem seal.
oughly clean external surface of valve guide until com-
pletely free of grease and oil.
Valve Stem
CAUTION
Seal Installer
Do not apply Loctite to inside of valve stem seal or top of
valve guide or valve may stick to seal resulting in loss of
compression and valve sticking.
10. Obtain tube of Loctite RC/620 (green) High Temperature
Retaining Compound. Carefully apply Loctite to valve
stem seal seating surface on outside diameter of valve
guide. Exercise caution to keep compound out of valve
guide bore.
CAUTION
Failure to install plastic capsule will cause the valve
Tap installer to seat valve stem seal.
f1666x3x
stem seal to catch the edge of the valve stem keeper
groove. The resulting damage will lead to leakage around
the valve stem, excessive oil consumption and valve
Figure 3-83. Install Valve Stem Seal
sticking.
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11. Push on bottom of valve until it contacts the valve seat.
Placing finger at bottom of valve to keep valve seated,
f1654x3x
slide plastic capsule over valve stem tip and keeper
Valve Guide
groove. See upper frame of Figure 3-83.
Driver
12. Apply a very thin film of clean H-D 20W50 engine oil to
capsule. Slide new valve stem seal over capsule and
down valve stem until contact is made with top of valve
guide. See center frame of Figure 3-83. Remove cap-
sule from valve stem tip.
Valve Stem
Seal Installer
CAUTION
To avoid damaging the valve stem seal and/or cracking
the valve guide, always use the proper valve stem seal
installer tool. Use of an ordinary socket will damage the
Valve Stem
seal or guide, resulting in leakage around the valve
Seal
stem, excessive oil consumption and valve sticking.
13. Obtain the VALVE STEM SEAL INSTALLER
(HD-
Valve
34643A) and proceed as follows:
Valve Guide
a. Slide the installer tool over the valve stem seal
using valve stem as pilot. The tool bore allows inser-
tion of the valve stem, while the counterbore fits
over the valve stem seal.
CAUTION
Repeated blows on installer after seal is in place will
cause seal distortion resulting in leakage around the
valve stem, excessive oil consumption and valve stick-
Valve
ing.
Seat
b. Using a small hammer, gently tap the end of the tool
until it lightly bottoms on the installed spring seat.
See lower frame of Figure 3-83. For best results,
brace the cylinder head with chest area to prevent
movement during seal installation.
Figure 3-84. Using Arbor Press to Install Valve Stem Seal
NOTE
If an arbor press is the preferred method of valve stem seal
installation, use the VALVE STEM SEAL INSTALLER (HD-
16. Obtain the VALVE SPRING COMPRESSOR
(HD-
34643A) with the VALVE GUIDE DRIVER (HD-34740). See
34736B) and proceed as follows:
Figure 3-84.
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
CAUTION
forcing screw is seated on the valve spring retainer.
Removing the valve after seal installation will cause the
valve stem seal to catch the edge of the valve stem
CAUTION
keeper groove. The resulting damage will lead to leakage
around the valve stem, excessive oil consumption and
Over-compressing the valve spring can damage the
valve sticking.
valve stem seal resulting in leakage around the valve
stem, excessive oil consumption and valve sticking.
14. Apply a liberal amount of assembly lube to valve stem tip
and keeper groove.
b. Rotate forcing screw to compress valve springs.
15. Install the inner and outer valve springs over the valve
c. With the tapered side down, fit the keepers into the
guide. Fit the spring retainer on top of the inner and
valve stem groove. For best results, apply a dab of
outer valves springs. Like the spring seat, the smaller
grease to the inboard side of the keepers before
diameter flange fits inside the inner valve spring. The
installation and use a magnetic rod for easy place-
larger diameter flange separates the inner and outer
ment.
springs.
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d. Arranging tapered keepers so that the gaps are
Installation
evenly spaced, turn forcing screw to release valve
spring compression.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps
14-24 and 29-39.
17. Tap the end of the valve stem once or twice with a soft
mallet to ensure that tapered keepers are tightly seated
in the valve stem groove.
18. Repeat steps 1-17 to install the other valve components.
19. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
20. Cover the cylinder head to protect it from dust and dirt
until time of installation.
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CYLINDER
Removal
1.
See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-11 and 15-24.
Cleaning and Inspection
CLEANING
1.
Scrape old gasket material from the machined surface at
the top of the cylinder. Old gasket material left on the
Figure 3-85. Cylinder Torque Plates
mating surface will cause leaks.
(Part No. HD-42324A)
2.
Clean cylinder in a non-volatile cleaning solution or sol-
vent. Thoroughly dry with low pressure compressed air.
Verify that oil passageways are clean and open.
Lower Plate
A
Bolts
(with Flat Washers)
3.
Inspect the cylinder bore for defects or damage in the
ring travel area. Replace cylinders that are severely
scored, scuffed, scratched, burnt or gouged.
4.
Using Magnaflux Dye Penetrant, inspect the cylinder for
cracks. If no cracks are found, thoroughly wash cylinder
to remove traces of dye.
5.
Use a file to carefully remove any nicks or burrs from the
machined surfaces of the cylinder.
6.
Using a feeler gauge and the CYLINDER TORQUE
PLATES (HD-42324A), check the machined surfaces for
flatness. Proceed as follows:
a. Lay gasket side of the upper plate (without vise grip)
Vise
flat against the head gasket surface.
b. As a preliminary check, see if the plate rocks from
f2075x3x
side to side. A cylinder on which the plate rocks is
immediately suspect.
c. Insert a feeler gauge between the plate and cylinder
3
B
Upper Plate
at various locations.
4
d. The head gasket surface must be flat within 0.006
inch (0.15 mm).
e. Now turn the cylinder upside down and lay the seal
side of the lower plate (with vise grip) flat against
the O-ring seal surface. Repeat steps 6(b) and 6(c).
f.
The O-ring seal surface must be flat within 0.004
inch (0.102 mm).
g. Replace the cylinder (and piston) if either surface is
not within specification.
INSPECTION
CAUTION
2
Failure to use the cylinder torque plates can produce
1
measurements that vary by as much as 0.001 inch (0.025
f2074x3x
mm), possibly resulting in the use of parts that are not
suitable for service.
Figure 3-86. Install Cylinder to Torque Plates
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1.
To simulate an assembled cylinder for accurately mea-
suring cylinder taper and out-of-round conditions, as well
f1686x3x
as for boring, honing or deglazing, obtain the CYLIN-
DER TORQUE PLATES (HD-42324A). Install the torque
plates as follows:
a.
Remove O-ring seal from cylinder sleeve, if
installed.
b.
Place used head gasket over two ring dowels at top
of cylinder.
c.
Install brass jaws or shop towels around teeth of
vise to prevent damage to tool. Clamp stepped side
of lower plate in vise with the simulated split line
(machined strip) facing away.
d.
Slide four bolts
(with flat washers) all the way
through holes of lower plate until washers contact
outboard side. See A of Figure 3-86.
e.
Slide cylinder down bolts with the indent in the cool-
ing fins facing upward.
f.
With the head gasket in place, align holes in upper
plate with ends of bolts. Blind holes in upper plate
accommodate ring dowels in cylinder. Alternately
tighten four bolts into upper plate in a crosswise pat-
tern until snug.
Figure 3-87. Measure for Out-of-Round and Taper
g.
Tighten the bolts to 84-108 in-lbs (9.5-12.2 Nm) in
the sequence shown in B of Figure 3-86.
c. Repeat the measurements again at the bottom of
the bore at a point below the piston ring travel zone.
h.
Following the same sequence, tighten each bolt to
12-14 ft-lbs (16.3-18.9 Nm).
d. Rebore the cylinder if the parallel and perpen-
dicular measurements at either the top, middle or
i.
Using a grease pencil, mark a straight line on one of
the bolts continuing the line over onto the lower
bottom of the bore vary by more than 0.002 inch
(0.051 mm), which indicates an out-of-round condi-
plate. Repeat step for remaining three bolts. Using
the marks as a guide, turn each bolt 1/4 turn or 90
tion.
degrees. Be sure to tighten the bolts in the
Rebore the cylinder if the top, middle and bottom
sequence shown in B of Figure 3-86.
bore diameters either parallel or perpendicular to
the crankshaft vary by more than 0.002 inch (0.051
NOTE
mm), which indicates excessive taper.
For best results, obtain Snap-on® Torque Angle Gauge
TA360.
CAUTION
j.
For purposes of inspection, remove the assembly
Maximum cylinder wear occurs at the very top of top ring
from the vise and place on bench top.
travel. Minimum wear occurs below ring travel. Failure to
measure the cylinder at these points may result in a
2. See Figure 3-87. Using an inside micrometer or dial bore
faulty decision regarding the suitability of the cylinder
gauge, check cylinder bore for out-of round and taper.
for continued use.
Proceed as follows:
a. At the top of the piston ring travel zone (starting
3.
If cylinders are not scuffed or scored, and are not worn
about 0.50 inch or 12.70 mm from the top of the cyl-
beyond the service limits described under step 2(d), see
inder), measure the cylinder diameter at two loca-
DEGLAZING CYLINDER on the next page.
tions- parallel and perpendicular to the crankshaft.
On the other hand, if cylinders are worn beyond the ser-
Write the readings down.
vice limits, then they must be rebored and/or honed to
b. Repeat the two measurements at the center of the
accept the next standard oversize piston. See BORING
piston ring travel zone.
AND HONING CYLINDER on the next page.
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DEGLAZING CYLINDER
2.
Hone the cylinder to its finished size using a 280 grit
rigid hone.
NOTE
3.
Stop frequently to examine the cylinder bore and/or take
Deglazing removes wear patterns, minor scuff marks and
scratches without enlarging the bore diameter.
measurements. Remember, a precise 60˚ cross hatch
pattern in the piston travel area is important.
1. Lightly swab the cylinder bore with a cloth dipped in
clean engine oil.
4.
Thoroughly wash the cylinder bore with liquid dishwash-
ing soap and warm water to remove all abrasive parti-
2. Obtain a 240 grit flexible ball-type deglazing tool with a
cles and residual grit. Continue cleaning until a clean
bristle tip or finishing stone arrangement able to produce
cloth shows no evidence or dirt or debris.
a 60˚ cross hatch pattern.
3. Install the deglazing tool in a slow-speed drill. The speed
Table 3-7. Oversize Pistons
at which the tool rotates determines the speed at which
it must be stroked up and down the bore to produce the
Cylinder Bore
Piston
desired cross hatch pattern.
Finished Size
4. Starting at the bottom of the cylinder, move the deglaz-
3.7500 - 3.7505 in.
ing tool up and down the entire length of the cylinder
Standard
(95.250 - 95.263 mm)
bore for 10 to 12 complete strokes.
0.005 In. (0.13 mm)
3.7550 - 3.7555 in.
5. Stop to examine the cylinder bore and/or take measure-
Oversize
(95.377 - 95.390 mm)
ments. A precise 60˚ cross hatch pattern in the piston
travel area is the most important.
0.010 In. (0.25 mm)
3.7600 - 3.7605 in.
Oversize
(95.504 - 95.517 mm)
CAUTION
Example: A 0.005 in. (0.13 mm) oversize piston will have
the proper running clearance with a cylinder bore size of
The angular cross hatch pattern ensures an even flow of
3.7550 - 3.7555 in. (95.377 - 95.390 mm).
oil onto the cylinder walls and promotes longer cylinder,
piston and ring life. An Improper crosshatch pattern will
result in insufficient oil retention and possible piston
5.
Hot rinse the cylinder and dry with moisture free com-
seizure and/or high oil consumption.
pressed air. Immediately apply a thin film of clean engine
oil to prevent rusting.
CAUTION
6.
With the cylinder at room temperature, check the piston
Failure to remove all abrasive particles may result in pre-
clearance in the cylinder in which the piston will run. See
mature cylinder, piston and ring wear and possible
PISTON, INSPECTION, step 5.
engine failure.
6.
Thoroughly wash the cylinder bore with liquid dishwash-
ing soap and warm water to remove all abrasive parti-
Installation
cles and residual grit. Continue cleaning until a clean
cloth shows no evidence or dirt or debris.
1.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
7.
Hot rinse the cylinder and dry with moisture free com-
steps 8-24 and 29-39.
pressed air. Immediately apply a thin film of clean engine
oil to prevent rusting.
8.
With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See
PISTON, INSPECTION, step 5.
BORING AND HONING CYLINDER
1.
Bore the cylinder to 0.003 inch (0.08 mm) under the
desired finished size. See Table 3-7.
CAUTION
An improper crosshatch pattern or too fine a hone will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption.
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6.
Using Magnaflux Dye Penetrant, inspect the piston for
PISTON
surface cracks. Pay special attention to the area around
the pin bores, ring lands and oil drain holes beneath the
piston crown. If no cracks are found, thoroughly wash
Removal
piston to remove traces of dye.
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-11 and 15-29.
Inspection
1.
Lightly oil a good piston pin and insert it into the piston
pin bore to feel for the proper interference fit. The pin
Disassembly
should slide in and out without binding, but also without
pivoting or rocking. Replace piston and/or pin if clear-
Piston Rings, Removal
ance exceeds 0.0008 in. (0.020 mm).
2.
Carefully inspect the pistons for damage or excessive
1WARNING
wear. Discard pistons with cracked, broken or bent ring
lands. Check the piston skirt for cracks, gouges, deep
Always wear proper eye protection when removing the
scratches or heavy scoring. Check the piston heads for
compression rings. Slippage may propel the ring with
evidence of burning, etching or melting. Look for marks
enough force to cause eye injury.
or imprints caused by contact with valves. Pistons with
superficial wear marks, minor scratching or mild scoring
1. Carefully remove first and second compression rings
may continue to be used.
using the proper piston ring expander (Snap-On PRS8).
3.
Run your index finger around the edge of the piston
2. Using your fingers, remove the top and bottom oil rails
crown to feel for dings, nicks or burrs. Lightly file the
from the third ring groove. Remove the expander spring.
edge of the crown to remove any defects.
3. Discard the piston rings.
CAUTION
Cleaning and Inspection
Worn ring grooves result in high oil consumption and
blow-by of exhaust gases. Blow-by of exhaust gases
Cleaning
contaminates the engine oil supply with acids and
leaves sludge in the crankcase. It also reduces engine
CAUTION
efficiency by weakening the combustion seal necessary
for efficient transfer of energy to the piston.
Do not sand blast or glass bead blast pistons. Bead
blasting rounds off ring lands and will result in oil con-
4.
Measure the piston ring side clearance as follows:
tamination leading to accelerated wear.
a. Insert the edge of a new ring into the piston ring
groove. Insert a feeler gauge between the upper
1. To remove all carbon and combustion deposits, soak the
surface of the ring and the ring land. See Figure 3-
pistons in a special detergent that will not corrode alumi-
88.
num. Maintain the temperature of the cleaning solution
well below 212o F. (100o C.).
2. Thoroughly rinse the pistons and dry with moisture free
6906
compressed air.
3. Clean the oil drain holes leading from the oil control ring
groove to the underside of the piston crown. Run a small
bristle brush through the passageways to ensure their
cleanliness, but be careful not to damage or enlarge the
holes. Do not use a wire brush.
4. Verify that all other oil holes are clean and open.
CAUTION
Exercise care to avoid scratching the sides of the piston
ring grooves.
5. Thoroughly clean the three piston ring grooves of all car-
bon deposits. A broken compression ring properly
ground to a sharp chisel-like edge may be used for this
purpose.
Figure 3-88. Measure Piston Ring Side Clearance
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NOTE
On late style pistons, the measurement is taken on the bare
aluminum to avoid measuring errors. An oval-shaped open-
EARLY STYLE
ing is present on each side of the piston for proper placement
of the micrometer. See upper frame of Figure 3-90. Since the
FULLY COATED
oval openings are too small for a standard flat anvil microme-
No Bare
ter, which would result in measuring errors, use a 3-4 inch
Aluminum
blade or ball anvil style micrometer, or a 4-5 inch micrometer
with spherical ball anvil adapters. See lower frame of Figure
3-90.
f2114x3x
c. Using a grease pencil, mark the top, middle and
bottom of the piston ring travel zone in the cylinder
bore. Measure at markings in cylinder parallel and
perpendicular to crankshaft.
CAUTION
Do not check piston running clearance immediately after
honing or deglazing cylinder. Since heat will cause mea-
surements to vary by as much as 0.0002 inch (0.005 mm),
both piston and cylinder must be at room temperatures.
d. Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).
LATE STYLE
f1685x3x
Figure 3-89. Measure Early Style Piston for
Running Clearance
b. Since the grooves wear unevenly, repeat this check
at several locations around the piston groove cir-
cumference.
Bare
Aluminum
c. Discard the piston if the side clearance of either
compression ring exceeds 0.0045 in. (0.11 mm).
Discard the piston if the oil control ring side clear-
ance exceeds 0.010 in. (0.25 mm).
f2113x3x
5.
Measure the running clearance on fully coated early
style pistons as follows:
NOTE
Check the piston clearance in the cylinder in which the piston
4-5 Inch
will run. The torque plates must be installed on the cylinder
Micrometer
and it must be deglazed and suitable for continued service.
a. Holding outside micrometer, measure piston skirt
diameter across the thrust faces (perpendicular to
pin bore). Start below the bottom ring land and
move micrometer towards bottom of skirt. Microme-
ter will be loose, then tight (about 1/2 inch from bot-
tom), and then loose again. See lower frame of
Figure 3-89.
Spherical Ball
b. Measure the piston skirt at the tightest spot and
Anvil Adapters
f2109x3x
then transfer that measurement to the dial bore
gauge.
Figure 3-90. Measure Late Style Piston for
Running Clearance
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2004 Touring: Engine
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NOTE
Ring end gap dimensions also apply to oversize rings.
Replace ring if end gap exceeds specification. If end gap is
under specification, filing is permissible.
3.
Use compressed air to remove any dirt or dust that may
have settled in the oil drain holes and piston ring
grooves.
4.
Install piston rings as follows:
a.
Apply clean H-D 20W50 engine oil to three piston
ring grooves.
b.
Install expander spring into third ring groove. Spiral
bottom oil rail into space below expander spring
positioning the gap 90 degrees from the gap in the
6905
expander spring. Spiral top oil rail into space above
expander spring positioning gap 180 degrees from
the gap in the bottom oil rail.
Figure 3-91. Measure Ring End Gap
Assembly
Piston Rings, Installation
4
3
NOTE
Always use new piston rings. Piston rings take a definite set
and must not be reused if the engine has been operated.
FRONT
Always deglaze (or hone) the cylinder before installing new
rings. Ring sets are available to fit oversize pistons.
1. Before placing each ring on the piston, perform the fol-
lowing check.
CAUTION
2
1
5
Insufficient ring end gap may cause the ends to abut at
engine operating temperatures, resulting in ring break-
2
1
5
age, cylinder scuffing and/or piston seizure.
CAUTION
REAR
Excessive ring end gap results in high oil consumption
and blow-by of exhaust gases. While blow-by contami-
nates the oil supply and leaves sludge in the crankcase,
it also reduces engine efficiency by weakening the com-
bustion seal necessary for efficient transfer of energy to
the piston.
4
3
2. Insert the new ring into the cylinder, square it in the bore
using the top of the piston and measure the ring end gap
with a feeler gauge. See Figure 3-91. Do not use the ring
1.
Expander spring
if the end gap does not fall within the following specifica-
2.
Bottom oil rail
tions.
3.
Top oil rail
f2066x3x
Table 3-8. Ring End Gap
4.
Second compression ring
5.
Top compression ring
Ring Type
Ring End Gap
Top compression ring
0.010 in. (0.25 mm) - 0.020 in. (0.51 mm)
Figure 3-92. Piston Ring Gap Alignment
2nd compression ring
0.014 in. (0.36 mm) - 0.024 in. (0.61 mm)
Oil control ring rails
0.010 in. (0.25 mm) - 0.050 in. (1.27 mm)
2004 Touring: Engine
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Installation
CAUTION
1.
See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
Use the proper piston ring spreader to prevent excessive
steps 1-23 and 28-37.
ring twist and expansion. Over expansion may cause the
ring to crack opposite the ring gap. Damaged or dis-
torted rings result in blow-by of exhaust gases,
increased oil consumption and lower service life on
valves and other components.
CAUTION
Installing the second compression ring upside down will
cause oil to be scraped up into the combustion chamber
resulting in excessive oil consumption and low service
life on valves and other components.
c. Using the proper piston ring expander (Snap-On
PRS8), carefully install the second compression
ring making sure that the dot (punch mark) near the
ring gap faces the piston crown. Rotate the ring so
the gap is 90 degrees from the gap in the top oil rail.
d. Carefully install the top compression ring using the
proper piston ring expander
(Snap-On PRS8).
Rotate the ring so the gap is 180 degrees from the
gap in the second compression ring.
e. Rotate the three piston rings using the palms of
both hands. The rings must rotate freely without
sticking.
f.
Verify that the ring gaps are still properly staggered.
See Figure 3-92.
3-80
2004 Touring: Engine
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NOTES
2004 Touring: Engine
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HOME
UPPER CONNECTING ROD
Removal
1.
See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-11 and 15-29.
Disassembly/Assembly
Threaded
NOTE
Cylinders
Service of connecting rods is limited to replacement of the
Part No. HD-95952-1
upper bushing. Damage to connecting rods or lower bushing
service requires replacement of the flywheel assembly.
Figure 3-93. Connecting Rod Clamping Tool
(Part No. HD-95952-33B)
Upper Connecting Rod Bushing
f1597x3x
Removal
Threaded
NOTE
Cylinder
Replace the upper rod bushing if the piston pin to rod bush-
ing clearance exceeds 0.002 inch (0.051 mm).
CAUTION
Place clean shop towels in and around the crankcase
bore to prevent chips and shavings from falling into the
crankcase.
1.
Obtain the CONNECTING ROD CLAMPING TOOL (HD-
95952-33B) and proceed as follows:
a. Slide clamp over connecting rod so that slots
engage cylinder head studs. See Figure 3-94. Exer-
cise caution to avoid scratching or bending studs.
b. With the knurled side up, install threaded cylinders
(HD-95952-1) onto studs to secure position of
Clamp
Thumbscrew
clamp.
c. Alternately turn each clamp thumbscrew a few turns
to gradually fix position of connecting rod. Turning
Figure 3-94. Install Connecting Rod Clamping Tool
only one thumbscrew will move rod off-center, while
tightening second thumbscrew can cause rod to flex
f.
Thread the hex cylinder onto rod until assembly is
or bend.
snug. See upper frame of Figure 3-96.
2.
Obtain the CONNECTING ROD BUSHING REMOVER/
INSTALLER (HD-95970-32D) and proceed as follows:
g. Holding nut at end of threaded rod with a 5/8 inch
box wrench, turn hex cylinder with a 5/8 inch socket
a. Sparingly apply graphite lubricant to threads of rod
until bushing is free.
to prolong service life and ensure smooth operation.
h. Unthread hex cylinder from rod. Remove flat
b. Slide receiver cup (HD-95984-99) onto threaded rod
washer, Nice bearing and driver. Remove threaded
with the closed side facing hex nut.
rod from bushing bore.
c. Insert threaded rod through upper rod bushing.
i.
Remove bushing from receiver cup and discard.
d. Slide remover side of driver (HD-95986-99) down
threaded rod. The driver is stamped to ensure
Installation
proper orientation.
e. Slide Nice bearing and flat washer down threaded
1.
Obtain the CONNECTING ROD BUSHING REMOVER/
rod until it contacts driver.
INSTALLER (HD-95970-32D) and proceed as follows:
3-82
2004 Touring: Engine
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Receiver
Driver
Driver
Cup
Part No. HD-95986-99
Nice
Remover Side
Bearing
Hex
Cylinder
Receiver Cup
Part No. HD-95984-99
Figure 3-95. Connecting Rod Bushing Remover/Installer
Flat
(Part No. HD-95970-32D)
Washer
a.
Slide receiver cup (HD-95984-99) onto threaded rod
Connecting
Rod
Threaded
with the closed side facing hex nut.
Rod
b.
Insert threaded rod through upper rod bushing bore.
Remover Stackup
c.
Slide new bushing down threaded rod. Start bush-
f1601x3x
ing into bore. Verify that center of slot in bushing is
f1602x3x
aligned with oil hole at top of rod. Also, be sure that
Upper Rod
bushing is square in bore and not cocked. See cen-
Bushing
ter frame of Figure 3-96.
Oil Hole
Driver
d.
Slide installer side of driver (HD-95986-99) down
Installer Side
threaded rod until shoulder contacts bushing. The
driver is stamped to ensure proper orientation.
e.
Slide Nice bearing and flat washer down threaded
rod until it contacts driver.
f.
Thread the hex cylinder onto rod until assembly is
snug.
g.
Holding nut at end of threaded rod with a 5/8 inch
box wrench, turn hex cylinder with a 5/8 inch socket
until collar on driver bottoms against connecting
rod. See lower frame of Figure 3-96.
Slot
h.
Unthread hex cylinder from rod and remove flat
Installer Stackup
washer, Nice bearing and driver. Remove threaded
rod from bushing bore, but exercise caution to avoid
scratching or gouging bushing.
f1598x3x
Reaming Upper Rod Bushing
1. Obtain the CONNECTING ROD BUSHING REAMER
(HD-42318) and REAMER HANDLE/DRIVE SOCKET
(HD-43645). Proceed as follows:
a. Carefully insert bit of reamer into upper connecting
rod bushing. Do not apply lubricant to reamer or
bushing. Ream the bushing dry or cut will not be
accurate.
b. Install handle/drive socket on reamer lug. See Fig-
ure 3-98.
c. Placing thumb on drive socket, apply slight pressure
on reamer while rotating handle/drive socket in a
clockwise direction.
Hold hex nut on threaded rod with 5/8 inch box.
Turn cylinder hex with 5/8 inch socket.
Figure 3-96. Remove/Install Connecting Rod Bushing
2004 Touring: Engine
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HOME
2.
Using contact cleaner or cleaning solvent, thoroughly
wipe upper connecting rod and bushing of any metal
Handle/Drive Socket
shavings or debris.
Honing Upper Rod Bushing
Reamer
1. Obtain the CONNECTING ROD BUSHING HONE (HD-
42569) and REAMER LUBRICANT (HD-39964). Pro-
ceed as follows:
a. Install hone in a high speed electric drill.
b. Apply reamer lubricant to finishing stones of hone
Figure 3-97. Connecting Rod Bushing Reamer (Part No.
and inside of upper connecting rod bushing.
HD-42318) and Handle/Drive Socket (Part No. HD-43645)
c. Start finishing stones of hone into bushing.
d. Activating the drill, move the entire length of the fin-
f1642x3x
ishing stone arrangement forward and backward
through the bushing bore for 10 to 12 complete
strokes. See Figure 3-100. Work for a crosshatch
pattern of approximately 60˚.
CAUTION
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine fail-
ure.
Figure 3-98. Ream Connecting Rod Bushing
CAUTION
For best results, do not push on reamer or apply pres-
Figure 3-99. Connecting Rod Bushing Hone
sure to the reamer handle. While excessive pressure
(Part No. HD-42569)
results in a rough cut, bushing bore will be tapered if
pressure is not centrally applied.
f1643x3x
d. Continue rotating handle/drive socket until entire bit
has passed through bushing and shank of reamer
rotates freely in the bore.
CAUTION
Never back reamer out of connecting rod or bushing will
be damaged.
e. Remove handle/drive socket, and carefully pulling
on bit, draw shaft of reamer out of connecting rod
bushing.
CAUTION
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine fail-
ure.
Figure 3-100. Hone Connecting Rod Bushing
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2004 Touring: Engine
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2. Using contact cleaner or cleaning solvent, thoroughly
Installation
wipe upper connecting rod and bushing of any metal
shavings or debris. Continue wiping until a clean cloth
See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps
shows no evidence of dirt or debris.
1-24 and 29-39.
3. Lightly oil a good piston pin and insert it into the upper
connecting rod bushing bore to feel for the proper inter-
ference fit. The pin should slide in and out of the bushing
without binding, but also without pivoting or rocking.
4. Remove shop towels exercising caution that shavings,
chips and other debris do not fall into crankcase.
2004 Touring: Engine
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Legend:
1.
T20 TORX Screw
17.
Roll Pin
2.
Cam Position Sensor Cover
18.
Oil Pressure Relief Valve Piston
3.
Screw
19.
Valve Spring
4.
Cam Cover
20.
Chain Guide
5.
Cam Cover Gasket
21.
Screw
6.
Primary Cam Chain
22.
Cam Support Plate
47
7.
Flange Bolt
23.
Secondary Cam Chain Tensioner
8.
Flat Washer
24.
Retaining Ring
9.
Primary Cam Sprocket
25.
O-Ring
10.
Spacer
26.
Cleaning Plug
11.
Retaining Ring
27.
Retaining Ring
12.
Primary Cam Chain Tensioner
46
13.
Flange Bolt
14.
Flat Washer
15.
Crank Sprocket
16.
Crankshaft Bushing
35
45
33
43
36
41
34
44
30
32
40
38
42
28
39
39
27
31
37
29
28.
Rear Cam (Roller) Bearing
29.
Front Cam (Ball) Bearing
30.
Bearing Retainer Plate
26
31.
T20 TORX Screw
32.
Secondary Cam Chain
33.
Roller Bearing Inner Race
34.
Thrust Washer
25
23
35.
O-Ring
24
36.
Rear Camshaft
37.
Front Camshaft
38.
Feed Gerotor Set
39.
Separator Plate
40.
Wave Washer
20
41.
Scavenge Gerotor Set
42.
O-Ring
43.
Oil Pump Housing
44.
O-Ring (Scavenge Port Stub)
19
45.
O-Ring (Oil Feed Hole)
18
22
46.
O-Ring (Blind Hole)
47.
Right Crankcase Half
4
5
8
7
10
21
17
11
12
9
13
16
2
15
14
6
1
3
f2143x3x
Figure 3-101. Cam Support Plate/Oil Pump Assemblies (Exploded View)
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2004 Touring: Engine
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2. Center support tube under ram of arbor press.
BOTTOM END
3. Center crankshaft bushing in cam support plate over
support tube. Be sure that the primary cam chain side of
the cam support plate is facing upward.
CAM SUPPORT PLATE
CAUTION
Removal
If the crankshaft bushing is pressed out the primary cam
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
chain side, the bore will be damaged by the knurled edge
BLY, steps 1-11.
of the bushing. Damage to the bore requires replace-
ment of the cam support plate.
NOTE
When removing the cam support plate, it is not necessary to
4. Insert remover side of driver into crankshaft bore so that
disturb the lifter assemblies if a method is devised to prevent
shoulder on tool is seated on edge of bushing. See
the hydraulic lifters from dropping into the cam compartment.
upper frame of Figure 3-104.
One such method is provided in the following step. Leaving
5. Press on driver until collar of tool contacts cam support
the lifter assemblies intact simplifies the procedure, since the
plate. Remove bushing from support tube and discard.
lifter cover, gasket, anti-rotation pin and hydraulic lifters can
be left in place.
Installation
2. Fashion lifter holding tool as follows:
1.
Obtain the CRANKSHAFT BUSHING REMOVER/
a. Obtain a large binder clip (available at any office
INSTALLER (HD-42315).
supply store). Squeeze wireforms to remove from
2.
Center support tube under ram of arbor press.
binder clip. See upper frame of Figure 3-102.
b. Compress wireform slightly and insert free ends into
outer and inner lifter cover bores so that legs
engage walls of both hydraulic lifter sockets. See
f1596x3x
lower frame of Figure 3-102.
Binder Clip
3. See Section 3.10 BOTTOM END OVERHAUL, DISAS-
SEMBLY, steps 1-14.
Wireform
Disassembly/Assembly
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-
f1595x3x
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
Wireform
hand, minor or moderate injury may occur.
NOTE
If the retention pins interfere with cleaning or service proce-
dures, hold the retracted cam chain tensioner with the CAM
CHAIN TENSIONER UNLOADER (HD-42313), pull the
retention pin and ease the assembly into the unloaded posi-
tion.
Crankshaft Bushing
Removal
1. Obtain the CRANKSHAFT BUSHING REMOVER/
INSTALLER (HD-42315).
Figure 3-102. Fashion Tool to Hold Hydraulic Lifters
2004 Touring: Engine
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