Harley Davidson 2008 FLHTCUSE3 Model. Service Manual Supplement — page 4
4. Remove the spring retainer and inner and outer valve
sm02495
springs.
5. Slide the valve from the valve guide.
6. Using pliers, twist and remove the valve guide seal from
the top of the valve guide. Discard the valve guide seal.
2
7. Remove the spring seat from the cylinder head.
8. Mark the bottom of the valve "F(ront)" or "R(ear)" to
indicate the cylinder head from which it was removed.
Also, separate and tag tapered keepers, valve springs,
spring retainers and spring seats so that they are installed
on the same valve at time of assembly.
1
9. Repeat to remove the other valve.
2
10. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
sm04038
2
1
1. Holding fixture
2. Compressor
Figure 3-5.Valve Spring Compressor (Part No. HD-34736-B)
1.
14 mm end
2.
12 mm end
Figure 3-3. Cylinder Head Holding Fixture (Part No.
CLEANING
HD-39786-A)
1. Remove old gasket
material from cylinder head. Gasket
material left on sealing surfaces will cause leaks.
2. Remove all carbon deposits from combustion chamber
sm04039
and machined surfaces of cylinder head. Exercise caution
to avoid removing any metal material. For best results,
use an air tool with a worn wire brush. Scraping may result
in scratches or nicks.
3. To soften stubborn deposits, soak the cylinder head in a
chemical solution, such as GUNK HYDRO-SEAL or other
carbon and gum dissolving agent. Repeat last step as
necessary.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
4. Thoroughly clean the cylinder head, spring retainers,
tapered keepers, valves, inner and outer valve springs
and spring seats in a non-volatile cleaning solution or
solvent. Follow up with a thorough wash in hot soapy
Figure 3-4. Install Cylinder Head Holding Fixture in Vise
water. Blow dry with compressed air.
3-6 2008 FLHTCUSE3 Service: Engine
NOTES
•
If bead blasting is used, use walnut shells or other soft
cleaning materials.
Do not use glass or sand to bead blast surfaces exposed
to engine oil. Blasting materials can lodge in pores of the
•
Be aware that bead blasting materials may also enter
casting. Heat expansion releases this material which can
threaded holes adversely affecting fastener engagement
contaminate oil resulting in engine damage. (00534b)
and torque indication. Carefully cover all threaded holes
if bead blasting is employed.
sm04040
22
2
23
3
1
24
5
4
14
9
25
6
16
24
7
10
8
21
11
19
20
15
21
12
17
26
13
18
1. Automatic compression release (ACR)
14. Cylinder head gasket
2. Tapered keepers
15.
Cylinder
3. Spring retainer
16. Ring dowel
4. Outer spring
17. O-ring seal
5. Inner spring
18. Cylinder stud
6. Valve guide seal
19. Piston
7. Spring seat
20. Piston pin
8. Valve guide
21. Circlip (2)
9. Cylinder head bolt,
short (2)
22. Top compression ring
10. Cylinder head bolt,
long (2)
23.
Second compression ring
11. Cylinder head
24. Oil rail
12. Valve seat
25. Oil rail spacer
13. Valve
26. Screamin' Eagle nameplate
Figure 3-6. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)
2008 FLHTCUSE3 Service: Engine 3-7
INSPECTION
Valves
1. Replace the valve if there is evidence of burning or
PART NUMBER
TOOL NAME
cracking.
HD-34723
VALVE GUIDE HONE
2. Inspect the end of the valve stem for pitting or uneven
HD-34751
VALVE GUIDE CLEANING BRUSH
wear. Replace the valve if either of these conditions are
HD-48627
CYLINDER TORQUE PLATES
found.
HD-96796-47
VALVE SPRING TESTER
3. Inspect for burrs around the valve stem keeper groove.
Remove burrs with a fine tooth file if found.
Cylinder Head
4. To determine if the valve stem is excessively worn, see
1. Check for scratches and nicks on all gasket sealing sur-
VALVE GUIDES above.
faces.
Valve Springs
2. With the combustion chamber side facing upward, set a
straightedge diagonally across the length of the cylinder
1. Inspect springs for broken or discolored coils. Replace
head intersecting the upper and lower corners of the
springs if either of these conditions are found.
gasket surface. Slide a feeler gauge beneath the
2. Set the intake and exhaust valve springs on a level surface
straightedge to check the head for warpage. Checking the
and use a straightedge to check for proper squareness
opposite diagonal, repeat the procedure to verify that the
and height.
gasket surface is flat (especially if a head gasket was
blown). Discard the head if any low spot is
0.006
3. Check free length of inner and outer springs using a dial
inch (0.15 mm) or greater.
vernier caliper or load test with the VALVE SPRING
TESTER (Part No. HD-96796-47). Replace springs if free
NOTE
length or compression force do not meet specifications.
For good results, use one of the CYLINDER TORQUE
See 3.1 SPECIFICATIONS: ENGINE.
PLATES (Part No. HD-48627) in lieu of the straightedge. Lay
the upper plate flat on the machined surface of the head. As
Tapered Keepers
a preliminary check, see if the plate rocks from side to side. A
head on which the plate rocks is immediately suspect. Insert
1. Inspect parts for damage or rust pits. Replace as neces-
a feeler gauge between the plate and head at various locations
sary.
to see if warpage exceeds above specification.
2. Inspect inboard side of tapered keepers for excessive
3. Verify that oil passageways are open and clean.
wear. Upraised center must be pronounced and fit snugly
in valve stem groove. Place keepers into groove and verify
Valve Guides
that they grip tightly
without sliding.
1.
Inspect external surfaces for cracks (particularly the com-
Valve Seats
bustion chamber side). Replace the guide if any cracks
are found.
1.
Inspect seats for cracking, chipping or burning. Replace
seats if any evidence of these conditions are found.
2.
To verify cleanliness of valve guides, lightly hone using
the VALVE GUIDE HONE (Part No. HD-34723) and then
2.
Check seats for recession by measuring valve stem pro-
scrub with the VALVE GUIDE CLEANING BRUSH (Part
trusion.
No. HD-34751) to remove any dust or debris. Polish the
valve stem with fine emery cloth or steel wool to remove
carbon buildup, and then check valve stem to guide
clearance as follows:
a. Carefully measure the inside diameter of the valve
guide using an inside ball micrometer.
b. Measure the outside diameter of the valve stem with
an outside micrometer.
c. The clearance is the difference between the two
measurements. The valve stem and/or guide are
excessively worn if the clearance exceeds the limits
shown in Table 3-25. To determine if the guide is
excessively worn and must be replaced, repeat
measurements using a new valve.
Table 3-25. Service Wear Limits
VALVE
VALVE STEM TO GUIDE CLEARANCE
Intake
0.0038 in. (0.0965 mm)
Exhaust
0.0038 in. (0.0965 mm)
3-8 2008 FLHTCUSE3 Service: Engine
REPLACING VALVE GUIDES
sm04193
PART NUMBER
TOOL NAME
HD-34740
VALVE GUIDE AND VALVE GUIDE
SEAL HANDLE
HD-34740
VALVE GUIDE AND VALVE GUIDE
1
SEAL HANDLE
HD-34751
VALVE GUIDE CLEANING BRUSH
HD-39782-A
CYLINDER HEAD SUPPORT STAND
HD-39782-A
CYLINDER HEAD SUPPORT STAND
HD-39786
CYLINDER HEAD HOLDING FIXTURE
HD-39847
RATCHETING TAP HANDLE
HD-39847
RATCHETING TAP HANDLE
HD-39932
VALVE GUIDE REAMER
3
HD-39964
REAMER LUBRICANT
2
HD-39964
REAMER LUBRICANT
1. Intake seat adapter
2. Exhaust seat adapter
HD-48628
VALVE GUIDE INSTALLER
3. Cylinder head support stand
Removal
Figure 3-7. Cylinder Head Support Stand (HD-39782-A)
1. See Figure 3-7. Obtain the CYLINDER HEAD SUPPORT
STAND (Part No. HD-39782-A) and proceed as follows:
a. Insert sleeve of intake or exhaust seat adapter into
tube at top of support stand.
sm04041
b. Position cylinder head so that valve seat is centered
on seat adapter. Support stand ensures that valve
guide and seat are perpendicular. If perpendicularity
Figure 3-8. Valve Guide & Valve Guide Seal Handle
is not achieved, the cylinder head valve guide bore
(HD-34740)
will be damaged during the press procedure.
NOTE
Do not press out the valve guide from the bottom of the cylinder
head. Carbon buildup on the combustion chamber side of the
sm02498
guide can deeply gouge the cylinder head bore diminishing
the likelihood of achieving the proper interference fit and pos-
sibly requiring replacement of the cylinder head casting.
1
2. See Figure 3-8. At the top of the cylinder head, insert
VALVE GUIDE AND VALVE GUIDE SEAL HANDLE (Part
No. HD-34740) into valve guide bore until stopped by
shoulder.
3. See Figure 3-9. Center valve guide driver under ram of
arbor press. Apply pressure until valve guide drops free
of cylinder head. Discard the valve guide.
2
1. Valve guide driver
2. Cylinder head stand
Figure 3-9. Remove Valve Guide
2008 FLHTCUSE3 Service: Engine 3-9
Installation
Table 3-26. Oversized Valve Guides
1. Check valve guide to valve bore clearance.
VALVE GUIDE
IN.
MM
a. Measure the outside diameter of a new standard
valve guide.
Intake
0.001
0.025
0.002
0.05
b. Measure the cylinder head valve guide bore. The
valve guide should be 0.0020-0.0033 in. (0.051-0.084
0.003
0.08
mm) larger than the bore.
Exhaust
0.001
0.025
c. If clearance is not within specification, then select an
0.002
0.05
oversized valve guide. Refer to Table 3-26.
0.003
0.08
NOTE
Since some material is typically removed when the guide is
pressed out, it is normal to go to the next larger valve guide
sm02299
for the proper interference fit.
2.
See Figure 3-7 and Figure 3-10. Obtain the CYLINDER
HEAD SUPPORT STAND (Part No. HD-39782-A), VALVE
1
GUIDE AND VALVE GUIDE SEAL HANDLE (Part No. HD-
34740) and VALVE GUIDE INSTALLER (Part No. HD-
2
48628). Proceed as follows:
a. See Figure 3-10. Insert sleeve of intake or exhaust
seat adapter into tube at top of support stand. Position
cylinder head so that valve seat is centered on seat
1
adapter.
NOTE
Support stand ensures that valve guide and seat are per-
pendicular. If perpendicularity is not achieved, cylinder
head valve guide bore will be damaged during the press
2
procedure.
b. Apply petroleum jelly to lightly lubricate external sur-
faces of valve guide. Spread
lubricant so that thin film
covers entire surface area.
c. At top of cylinder head, start valve guide into bore.
d. Place installer sleeve over valve guide, and then insert
tapered end of valve guide driver into installer sleeve.
e. Center valve guide driver under ram of arbor press
and apply pressure only until valve guide is started
in bore and then back off ram slightly to allow guide
3
to center itself.
f.
Verify that support stand and driver are square.
Center driver under ram and press valve guide further
into bore, but then back off ram again to allow valve
1.
Valve guide driver
guide to find center.
2.
Valve guide installer sleeve
3.
Cylinder head stand
g. Repeat previous step and then apply pressure to
driver until installer sleeve contacts machined area
Figure 3-10. Install Valve Guide
of cylinder head.
NOTE
3.
See Figure 3-3. Obtain the CYLINDER HEAD HOLDING
Always back off ram to allow the valve guide to find center.
FIXTURE (Part No. HD-39786) and proceed as follows:
Pressing guide into cylinder head in one stroke can bend driver,
a. Thread the 12 mm end of the tool into the spark plug
break guide, distort cylinder head casting and/or damage cyl-
hole of the cylinder head.
inder head valve guide bore.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
3-10 2008 FLHTCUSE3 Service: Engine
NOTES
sm04043
•
Valve guides must be reamed to within
0.0005-0.0001
in. (0.013-0.0025 mm) of finished size.
•
For best results, do not push on reamer or apply pressure
to the reamer handle. While excessive pressure results in
a rough cut, bore will be tapered if pressure is not centrally
applied.
•
Never back reamer out of valve guide or bore will be
damaged.
4.
See Figure
3-11. Obtain the VALVE GUIDE
REAMER (Part No. HD-39932), RATCHETING TAP
HANDLE (Part No. HD-39847) and REAMER LUB-
RICANT (Part No. HD-39964). Proceed as follows:
a. Install tap handle (2) on reamer (1).
b. Apply a liberal amount of reamer lubricant to valve
guide bore and bit of reamer. Start bit of reamer into
bore at top of cylinder head.
c. See Figure 3-12. Placing thumb on drive socket of
Figure 3-12. Ream Valve Guide Bore
RATCHETING TAP HANDLE (Part No. HD-39847),
apply slight pressure on reamer while rotating in a
clockwise direction. Squirt additional lubricant onto
6.
See Figure 3-13. Clean valve guide bore with the VALVE
reamer and into guide as necessary.
GUIDE CLEANING BRUSH (HD-34751).
d. Continue rotating RATCHETING TAP HANDLE (Part
7.
See Figure 3-14. Obtain the 8 mm VALVE GUIDE FLEX
No. HD-39847) until entire bit has passed through
HONE (HD-34723) and REAMER LUBRICANT (Part
valve guide bore and shank of reamer rotates freely.
No. HD-39964). Proceed as follows:
e. Remove tap handle from reamer, and carefully pulling
a. Install hone in a high speed electric drill.
on bit, draw shaft of reamer out combustion chamber
b. Apply reamer lubricant to finishing stones of hone and
side of valve guide.
valve guide bore.
NOTE
c. Start finishing stones of hone into bore.
Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in
engine failure.
d. See Figure 3-15. Activating the drill, move the entire
length of the finishing stone arrangement forward and
5. Direct compressed air into the valve guide bore to remove
backward through the bore for 10 to 12 complete
any metal shavings or debris.
strokes. Work for a crosshatch pattern of approxim-
ately 60°.
sm04042
NOTE
Abrasive particles can damage machined surfaces and plug
oil passageways possibly resulting in engine failure.
8. Direct compressed air into the valve guide bore to remove
1
any debris and then clean with the VALVE GUIDE
CLEANING BRUSH
(Part No. HD-34751). See
Figure 3-13.
NOTE
Always verify valve stem to valve guide clearance after honing,
since a worn reamer may cut the bore undersize.
9. Measure the inside diameter of the valve guide with an
2
inside ball micrometer. Measure the outside diameter of
the valve stem with an outside micrometer. The valve stem
1. Valve guide reamer
may be excessively worn or the valve guide bore undercut
2. Ratcheting tap handle
if the clearance is not within the limits (low end preferable)
shown in Table 3-27.
Figure 3-11. Valve Guide Reamer and Ratcheting Tap
Handle
10. Using cleaning solvent, thoroughly clean valve guide bore.
Scrub valve guide bore with the VALVE GUIDE
CLEANING BRUSH (Part No. HD-34751).
2008 FLHTCUSE3 Service: Engine 3-11
sm04046
Table 3-27. New Parts Limits
VALVE
VALVE STEM TO GUIDE CLEARANCE
Intake
0.0011-0.0029 in. (0.028-0.074 mm)
Exhaust
0.0011-0.0029 in. (0.028-0.074 mm)
NOTE
For best results, use a thin engine oil and clean valve guide
bore with the type of swabs or patches found in gun cleaning
kits. Continue to wipe bore until clean cloth shows no evidence
of dirt or debris.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
Figure 3-15. Hone Valve Guide Bore
flow rates. (00061a)
11. Clean valves, cylinder head and valve seats in solvent.
Follow up with a thorough wash in hot soapy water. Blow
dry with low pressure compressed air.
sm04047
sm04044
Figure 3-13. Valve Guide Cleaning Brush
sm04045
Figure 3-14. 8mm Valve Guide Flex Hone
Figure 3-16. Scrub Valve Guide Bore
3-12 2008 FLHTCUSE3 Service: Engine
ASSEMBLY
PART NUMBER
TOOL NAME
Failure to install plastic capsule can cause the valve stem
HD-34736-B
VALVE SPRING COMPRESSOR
seal to catch the edge of the valve stem keeper groove.
The resulting damage can cause leakage around the valve
HD-34740
VALVE GUIDE AND VALVE GUIDE
stem, excessive oil consumption and valve sticking.
SEAL HANDLE
(00535b)
HD-34751
VALVE GUIDE CLEANING BRUSH
11. See Figure 3-17. Push on head of valve until it contacts
HD-39786
CYLINDER HEAD HOLDING FIXTURE
the valve seat. Placing finger at head of valve to keep
HD-48644
VALVE GUIDE SEAL INSTALLER
valve seated, slide plastic capsule over valve stem tip and
keeper groove.
1. Obtain the CYLINDER HEAD HOLDING FIXTURE (Part
No. HD-39786) and proceed as follows:
12. See Figure 3-18. Apply a very thin film of clean H-D 20W50
engine oil to capsule. Slide new valve guide seal over
a. Thread the 12 mm end of the tool into the spark plug
capsule and down valve stem until contact is made with
hole of the cylinder head.
top of valve guide. Remove capsule from valve stem tip.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
sm04048
2. Slide spring seat over valve guide until it contacts the
machined area on the cylinder head casting. Use a little
grease to hold the spring seat in position, if necessary.
NOTE
1
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).
3. Run the VALVE GUIDE CLEANING BRUSH (Part No. HD-
34751) through the valve guide bore to verify cleanliness.
4. Using TORCO MPZ or another suitable product, apply a
2
liberal amount of engine assembly lube to valve stem.
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
1. Plastic capsule
smoothly and seats properly.
2. Spring seat
7. Remove the valve and apply a second coat of assembly
Figure 3-17. Install Plastic Capsule on Valve Stem
lube to the valve stem. Install the valve in the valve guide.
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-
oughly clean external surface of valve guide until com-
pletely free of grease and oil.
NOTE
Do not apply LOCTITE to inside of valve guide seal or top of
valve guide or valve may stick to seal resulting in loss of com-
pression and valve sticking.
10. Obtain tube of LOCTITE RC/620 HIGH TEMPERATURE
RETAINING COMPOUND (green). Carefully apply Loctite
to valve guide seal seating surface on outside diameter
of valve guide. Exercise caution to keep compound out of
valve guide bore.
2008 FLHTCUSE3 Service: Engine 3-13
sm04049
sm04052
1
2
Figure 3-20. Seat Valve Guide Seal
1. Plastic capsule
sm04052
2. Valve guide seal
1
Figure 3-18. Install Valve Guide Seal
13.
See Figure
3-19. Obtain the VALVE GUIDE SEAL
INSTALLER (Part No. HD-48644) and proceed as follows:
2
a. Slide the installer tool over the valve guide seal using
valve stem as pilot. The tool bore allows insertion of
the valve stem, while the counterbore fits over the
valve guide seal.
b. See Figure 3-20. Using a small hammer, gently tap
the end of the tool until it lightly bottoms on the
3
installed spring seat. For best results, brace the cyl-
inder head to prevent movement during seal installa-
4
tion.
5
NOTES
•
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 sticking.
•
See Figure 3-21. If an arbor press is the preferred method
of valve guide seal installation, use the VALVE GUIDE
SEAL INSTALLER (Part No. HD-48644) with the VALVE
GUIDE AND VALVE GUIDE SEAL HANDLE (Part No. HD-
34740).
•
Do NOT remove valve after seal is installed. Removing
the valve after seal installation will cause the valve guide
6
seal to catch the edge of the valve stem keeper groove.
1.
Valve guide & valve guide seal handle
The resulting damage will lead to leakage around the valve
2.
Valve guide seal installer
stem, excessive oil consumption and valve sticking.
3.
Valve guide seal
4.
Valve
5.
Valve guide
sm04051
6.
Valve seat
Figure 3-21. Using Arbor Press to Install Valve Guide Seal
Figure 3-19. Valve Guide Seal Installer
14. Apply a liberal amount of assembly lube to valve stem tip
and keeper groove.
15. Install the inner and outer valve springs over the valve
guide. Fit the spring retainer on top of the inner and outer
3-14 2008 FLHTCUSE3 Service: Engine
valves springs. Like the spring seat, the smaller diameter
17. Tap the end of the valve stem once or twice with a soft
flange fits inside the inner valve spring. The larger diameter
mallet to ensure that tapered keepers are tightly seated
flange separates the inner and outer springs.
in the valve stem groove.
16. Obtain the VALVE SPRING COMPRESSOR (Part No. HD-
18. Repeat all previous steps to install the other valve compon-
34736-B) and proceed as follows:
ents.
a. Place tool over cylinder head so that the blunt end is
19. Verify that the copper seal washer is in place on the ACR.
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.
20. Apply three equally spaced dots of LOCTITE
246
THREADLOCKER MEDIUM STRENGTH/HIGH TEMPER-
b. Rotate forcing screw to compress valve springs.
ATURE around the lower third of the threads. Tighten to
11-15 ft-lbs
(14.9-20.3 Nm). See
8.16 AUTOMATIC
c. With the tapered side down, fit the keepers into the
COMPRESSION RELEASE.
valve stem groove. For best results, apply a dab of
grease to the inboard side of the keepers before
21. Release the cylinder head holding fixture from the vise
installation and use a magnetic rod for easy place-
and then remove the tool from the spark plug hole.
ment.
22. Cover the cylinder head to protect it from dust and dirt
d. Arranging tapered keepers so that the gaps are evenly
until time of installation.
spaced, turn forcing screw to release valve spring
compression.
INSTALLATION
NOTE
See Service Manual for cylinder head installation procedure.
Over-compressing the valve spring can damage the valve guide
seal resulting in leakage around the valve stem, excessive oil
consumption and valve sticking.
2008 FLHTCUSE3 Service: Engine 3-15
PISTONS
3.4
GENERAL
sm04055
See Figure 3-22. Though Twin Cam 110 pistons differ from
Twin Cam 96 in specification and appearance, piston service
procedures are the same except for measuring the nominal
diameter. See PISTON in SUBASSEMBLY SERVICE AND
REPAIR in the Service Manual. For service wear limits, refer
to Table 3-19.
MEASURING PISTON
1. Allow the piston to cool to room temperature.
2. See Figure 3-23. With a pencil or marker, mark the piston
on each side of the skirt across the thrust faces (perpen-
dicular to the piston pin bore) 0.394 in. (10 mm) from the
bottom edge.
NOTE
Set the piston skirt down on a level table and use a rule to
measure 0.394 in. (10 mm) high on the skirt.
3. Using a micrometer at the marks, measure the nominal
diameter of the piston.
4. Use a dial bore gauge to measure the piston ring travel
Figure 3-22. Twin-Cam 110 Piston
zone in the cylinder bore.
NOTE
For Cylinder Bore Measurement: See CYLINDER in SUB-
ASSEMBLY SERVICE AND REPAIR
in the Service Manual.
sm04056
5. Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).
Figure 3-23. 0.394 in. (10 mm)
3-16 2008 FLHTCUSE3 Service: Engine
BORING AND HONING CYLINDERS
3.5
INSPECTION
sm02506
3
PART NUMBER
TOOL NAME
HD-33446-B
CYLINDER TORQUE PLATES
TA360
SNAP-ON TORQUE ANGLE GAUGE
NOTE
Failure to use cylinder torque plates can produce measure-
ments that vary by as much as 0.001 in. (0.025 mm), possibly
resulting in the use of parts that are not suitable for service.
2
1.
See Figure 3-24. To simulate an assembled cylinder for
accurately measuring cylinder taper and out-of-round
4
1
conditions, as well as for boring, honing or deglazing,
1. Bolts
obtain the CYLINDER TORQUE PLATES (Part No. HD-
2. Lower plate
33446-B). Install the torque plates as follows:
3. Upper plate
a.
Remove o-ring seal from cylinder sleeve, if installed.
4. Vise grip step
b.
Place used head gasket over two dowel pins at top
Figure 3-24. Cylinder Torque Plates
of cylinder.
c.
Install brass jaws or shop towels around teeth of vise
to prevent damage to tool. Clamp stepped side of
NOTE
lower plate in vise with the simulated split line
Maximum cylinder wear occurs at the very top of top ring travel.
(machined strip) facing away.
Minimum wear occurs below ring travel. Failure to measure
the cylinder at these points may result in a faulty decision
d.
See Figure 3-25. Lightly oil threads and shoulders of
regarding the suitability of the cylinder for continued use.
four bolts (1) with clean H-D 20W50 engine oil. Slide
four bolts all the way through holes of lower plate (2)
2.
See Figure 3-27. Using an inside micrometer or dial bore
until washers contact outboard side.
gauge, check cylinder bore for out-of round and taper.
Proceed as follows:
e.
Slide cylinder down bolts with the indent in the cooling
fins facing upward.
a. At the top of the piston ring travel zone, starting about
0.50 in. (12.70 mm) or from the top of the cylinder,
f.
With the two dowel pins and head gasket in
place,
measure the cylinder diameter at two locations; par-
align holes in upper plate with ends of bolts. Blind
allel and perpendicular to the crankshaft. Record the
holes in upper plate accommodate dowel pins in cyl-
readings.
inder. Alternately tighten four bolts into upper plate in
a crosswise pattern until finger tight.
b. Repeat the two measurements at the center of the
piston ring travel zone.
g.
See Figure 3-26. Tighten the bolts to 120-144 in-
lbs (13.6-16.3 Nm) in the sequence shown.
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
15-17 ft-lbs (20.3-23.1 Nm).
d. Rebore the cylinder if the parallel and perpendicular
measurements at either the top, middle or bottom of
i.
Using a grease pencil, mark a straight line on one of
the bore vary by more than
0.002 in. (0.051 mm).
the bolts continuing the line over onto the lower plate.
This indicates an out-of-round condition.
Repeat step for remaining three bolts.
e. Rebore the cylinder if the top, middle and bottom bore
j.
Using the marks as a guide, turn each bolt 1/4 turn
diameters either parallel or perpendicular to the
or 90°. Be sure to tighten the bolts in the sequence
crankshaft vary by more than 0.002 in. (0.051 mm).
shown in Figure 3-26.
This indicates excessive taper.
NOTE
3.
Continue with cylinder service.
For best results, obtain SNAP-ON TORQUE ANGLE
GAUGE (Part No. TA360).
a. If cylinders are not scuffed or scored and are not worn
beyond the service limits, see Deglazing Cylinder in
k. For purposes of inspection, remove the assembly
the Service Manual.
from the vise and place on bench top.
b. If cylinders are worn beyond the service limits, then
they must be rebored and/or honed to accept the next
standard oversize piston. See 3.5 BORING AND
HONING CYLINDERS, Cylinder Bore Finished Size.
2008 FLHTCUSE3 Service: Engine 3-17
sm02530
sm02532
2
1
3
1. Bolt (4)
2. Lower plate
3. Vise
Figure 3-25. Attaching Cylinder Torque Plates
Figure 3-27. Measure for Out-of-Round and Taper
sm02531
CYLINDER BORE FINISHED SIZE
3
4
1. For cylinder removal, cleaning, inspection, boring and
honing and installation, see CYLINDER in the Service
Manual.
2. Refer to Table 3-28. Bore the cylinder to
0.003 in. (0.08
mm) under the desired finished size. See BORING and
HONING CYLINDER in the Service Manual.
2
1
An incorrect cross hatch pattern or too fine a hone will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00538b)
3. Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing must
be done with the torque plates attached. All honing must
be done from the bottom (crankcase end) of the cylinder.
Figure 3-26. Cylinder Torque Plate Bolt Sequence
Work for a 60° crosshatch pattern.
4. Stop frequently to examine the cylinder bore and/or take
measurements. Remember, a precise 60° cross hatch
pattern in the piston travel area is important.
Failure to remove all abrasive particles may result in pre-
mature cylinder, piston and ring wear and engine failure.
(00537b) .
5. Thoroughly wash the cylinder bore with liquid dish soap
and warm water to remove all abrasive particles and
residual girt. Continue cleaning until a clean cloth shows
no evidence or dirt or debris.
6. Immediately apply a thin film of clean engine oil to a clean
white paper towel and thoroughly wipe the inside of the
cylinder to prevent the cylinder bore from rusting.
3-18 2008 FLHTCUSE3 Service: Engine
NOTE
sm04057
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.
7. With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See
INSPECTION under PISTON in Service Manual.
8. For cylinder installation, see CYLINDER in Service Manual.
PISTON ORIENTATION
See Figure 3-28. When replacing a piston, orient the piston so
that the etched arrow on the top of the piston faces forward.
Figure 3-28. Piston Orientation Arrow (arrow points to front
of engine)
Table 3-28. Oversize Pistons and Cylinder Bores
PISTON
CYLINDER BORE FINISHED SIZE
TYPE
SIZE
MINIMUM
MAXIMUM
Standard
STD
4.0000 in. (101.6 mm)
4.0005 in. (101.613 mm)
Oversize
0.005 in. (0.13 mm)
4.0050 in. (101.727 mm)
4.0055 in. (101.740 mm)
0.010 in. (0.25 mm)
4.0100 in. (101.854 mm)
4.0105 in. (101.867 mm)
2008 FLHTCUSE3 Service: Engine 3-19
CRANKCASE ASSEMBLY
3.6
GENERAL
sm04059
With the exception of the top center crankcase bolt, crankcase
service is identical to original equipment. See the Service
1
Manual for complete procedure.
ASSEMBLY
1
PART NUMBER
TOOL NAME
HD-39361-B
SPROCKET SHAFT OIL SEAL
2
INSTALLER
HD-42326-A
CRANKSHAFT GUIDE
HD-97225-55C
SPROCKET SHAFT BEARING
INSTALLER
1. Install left crankcase half in engine stand so that the split
line face is vertical.
2. See Figure 3-29. To prevent damage to the sprocket shaft
(roller) bearing, slide CRANKSHAFT GUIDE (Part No. HD-
42326-A) over end of sprocket shaft.
3
3. Slide flywheel assembly into left case half and remove
tool.
4. Tip crankcase in engine stand so that flywheel pinion shaft
is pointing straight up.
NOTE
O-rings that are missing, distorted, pinched or otherwise dam-
aged will result in either oil leakage or low oil pressure.
Use
of
4
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 use to avoid confusion.
5. Install new o-rings over two ring dowels in split line face
2
of right case half.
5
6. Apply a small bead of sealant approximately 0.056 in. (1.4
mm) wide to the split line face. For best results, use High-
Performance Sealant (gray), (Part No. HD-99650-02).
7. To prevent damage to the crankshaft (roller) bearing, slide
CRANKSHAFT GUIDE (Part No. HD-42326-A) over end
1.
Water pipe insulation
of crankshaft until it contacts shoulder on shaft.
2.
Crankshaft guide
3.
Left crankcase
8. See Figure 3-30. Slide bearing in right crankcase half over
4.
Crankshaft bearing
end of crankshaft to mate case halves. Remove tool.
5.
Right crankcase
Figure 3-30. Crankshaft Guide
sm04058
NOTE
See Figure 3-31. The center upper bolt (1) is longer than the
remaining eight crankcase bolts. If any of the other bolts are
installed in that position, the threads will not engage the threads
in the crankcase and the bolt will spin. If the center upper bolt
is installed in a different location, the head of the bolt will be
standing above the crankcase.
Figure 3-29. Crankshaft Guide
3-20 2008 FLHTCUSE3 Service: Engine
9. Start the nine crankcase bolts and tighten:
sm04060
1
a. Alternately turn each crankcase bolt until finger tight.
b. In sequence, tighten the crankcase bolts to 10 ft-
lbs (13.6 Nm).
4
c. In sequence, tighten each bolt to 15-19 ft-lbs (20.3-
5
25.8 Nm).
10. Rotate crankcase in the engine stand so that the stator
8
mount flange (sprocket shaft side) is facing upward.
7
11. Slide thrust washer over sprocket shaft with "THIS SIDE
OUT" facing out (and the chamfer inboard).
NOTE
If using OE part without markings, orient as required to preserve
existing wear pattern.
2
12.
To install new oil seal into bearing bore, obtain pilot, Nice
bearing, large flat washer and handle from SPROCKET
3
SHAFT BEARING INSTALLER (Part No. HD-97225-55C)
and proceed as follows:
9
6
a. Verify that seal lip garter spring is in place on both
sides of seal.
Figure 3-31. Crankcase Torque Sequence (left side)
b. Thread pilot onto sprocket shaft until contact is made
with shoulder.
c. With the lettering facing outside, slide oil seal over
sm04061
pilot until it contacts bearing bore.
d. See Figure 3-32. Slide SPROCKET SHAFT OIL SEAL
INSTALLER (Part No. HD-39361-B) over pilot
until it
contacts oil seal.
e. Slide Nice bearing and large flat washer over pilot
until contact is made with seal installer.
f.
Thread handle onto pilot shaft.
g. See Figure 3-33. Rotate handle in a clockwise direc-
Figure 3-32. Sprocket Shaft Oil Seal Installer
tion until oil seal installer makes firm contact with
crankcase stator mount.
h. Remove handle, flat washer, Nice bearing, seal
installer and pilot from sprocket shaft.
13.
Slide sprocket shaft spacer over end of sprocket shaft.
Push spacer into oil seal until seated against bearing race.
2008 FLHTCUSE3 Service: Engine 3-21
sm02348
1
1
1. Seal Installer
Figure 3-33. Sprocket Shaft Oil Seal Installer
3-22 2008 FLHTCUSE3 Service: Engine
OIL COOLER
3.7
OPERATION
REMOVAL
For engine oil flow through the engine, See ENGINE OIL FLOW
PART NUMBER
TOOL NAME
under GENERAL INFORMATION in Touring Models Service
HD-97087-65B
HOSE CLAMP PLIERS
Manual.
See Figure 3-34. The flow of oil to the cooler is controlled by
1. Cover the front fender to protect finish.
a thermostat in an adapter located between the oil filter and
2. Place a container under the motorcycle to catch excess
the filter mount.
oil.
Under pressure from the crankcase, engine oil flows from the
NOTE
crankcase oil filter mount into a passage in the oil cooler
Dispose of oil in accordance with local regulations.
adapter. The thermostat is located across the supply and return
ports. It consists of a temperature sensitive element com-
3. See Figure 3-35. Remove the fasteners (1) and washers
pressed between a spring and a threaded plug.
(2) securing the oil cooler (3) and cover (4) to the frame
mounting bracket (5) and pull the cooler and cover forward.
When the engine oil temperature is below 200° F (93° C), an
open thermostat allows the largest percentage of engine oil in
4. Use the HOSE CLAMP PLIERS (Part No. HD-97087-65B)
the supply port to pass through to the return port and then to
to cut the clamps (6) at the oil hoses (7, 8) at the oil cooler
the oil filter. A smaller percentage flows through the supply
adapter (9).
hose to the oil cooler.
5. Remove the oil cooler with cover.
When oil temperature exceeds 200° F (93° C), the thermostat
6. The oil cooler should be inspected for dirt and debris.
closes and all the oil flows through the supply port and hose
to the oil cooler.
7. See Figure 3-34. If removing the hoses from the oil cooler,
cut clamps on the supply and return hoses.
The oil circulates through the finned tubes of the cooler to dis-
sipate heat and returns to the oil cooler adapter through a
INSTALLATION
return hose.
The oil is filtered before returning to the crankcase.
PART NUMBER
TOOL NAME
HD-97087-65B
HOSE CLAMP PLIERS
NOTE
Regardless of whether the thermostat is closed or open, oil is
1. If
replacing the hoses, install new hose clamps on the
always pressurized in the oil cooler adapter, the oil
cooler
ends of the hoses.
supply hose, the oil cooler and the oil return hose.
2. Push the supply and return hoses over the expanded tubes
At every service interval, the oil cooler fins should be checked
on the oil cooler.
for dirt and debris.
3. Use HOSE CLAMP PLIERS (Part No. HD-97087-65B) to
clamp the hoses to the oil cooler.
sm04062
4. Holding the cover over the cooler, install on the mounting
bracket. Tighten fasteners to 80-110 in-lbs (9.2-12.4 Nm).
5. See Figure 3-35. Push the oil hoses into the fittings on the
oil cooler adapter.
NOTE
Verify that the protective cap is in place on the frame stud in
the path of the oil hoses.
6. Use HOSE CLAMP PLIERS (Part No. HD-97087-65B) to
clamp the hoses to the oil cooler adapter.
7. Check oil level and add oil if required.
8. After running engine, inspect oil cooler hose fittings for
leaks.
Figure 3-34. Oil Cooler
2008 FLHTCUSE3 Service: Engine 3-23
sm04063
6
7
9
8
3
4
5
2
1
1. Fastener (3)
2. Washer (3)
3. Oil cooler
4. Cover
5. Mounting bracket
6. Hose clamp (4)
7. Return oil hose
8. Supply oil hose
9. Oil cooler adapter
Figure 3-35. Oil Cooler
3-24 2008 FLHTCUSE3 Service: Engine
OIL COOLER ADAPTER
3.8
REMOVAL
sm04065
PART NUMBER
TOOL NAME
HD-42311
OIL FILTER WRENCH
3
HD-97087-65B
HOSE CLAMP PLIERS
1. Place a container under motorcycle to catch excess oil.
2. Bend a cardboard funnel and fit to motorcycle to route
fluid away from regulator and oil cooler toward the con-
tainer.
3. Use OIL FILTER WRENCH (Part No. HD-42311) to
remove the oil filter.
1
4. Use HOSE CLAMP PLIERS (Part No. HD-97087-65B) to
remove the clamps from the oil hoses at the adapter.
2
5. See Figure 3-36. Remove the oil filter adapter (1).
6. Remove the oil cooler adapter (2) with the gasket (3).
DISASSEMBLY
1. Inspection cover
1. See Figure 3-37. Inspect the crankcase mating surface
2. Gasket
and, if necessary, remove any old gasket material.
3. Positioning flange
2. Remove the inspection cover (1) and gasket.
Figure 3-37. Oil Cooler Adapter
3. Remove the two oil cooler line fittings.
ASSEMBLY
NOTE
Replace the oil cooler adapter if the thermostat is not func-
1. Install the inspection passage cover and new gasket.
tioning.
2. Apply one drop LOCTITE 246 THREADLOCKER MEDIUM
4. Clean the oil filter mount surface of old filter gasket
STRENGTH/HIGH TEMPERATURE to the fasteners and
material.
tighten to 90-120 in-lbs (10.2-13.6 Nm).
5. Clean the oil passages in solvent.
3. See Figure 3-38. Install the supply (1) and return (2) port
6. Inspect the oil passages and the oil cooler mount.
oil line fittings.
a. Finger tighten.
sm04064
b. From finger tight, turn 2-3 more turns.
3
INSTALLATION
2
PART NUMBER
TOOL NAME
HD-97087-65B
HOSE CLAMP PLIERS
1
NOTE
To avoid cross threading tapped holes, exercise care when
starting oil filter adapter.
1. See Figure 3-37. Match the positioning flanges (3) on the
oil cooler adapter to the oil filter mount.
1. Oil filter adapter
NOTE
2. Oil cooler adapter
The oil cooler adapter will only fit in one location.
3. Gasket
2. Apply LOCTITE
246 THREADLOCKER MEDIUM
Figure 3-36. Oil Cooler Adapter
STRENGTH/HIGH TEMPERATURE to the threads of the
oil filter adapter.
3. Holding the adapter in place, thread the oil filter adapter
fitting through the adapter with the internal hex facing
outward. Tighten to 18-22 ft-lbs (24.4-27.3 Nm).
4. Install the oil hoses with new clamps.
2008 FLHTCUSE3 Service: Engine 3-25
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