Harley Davidson 2018 softail models. Service manual — page 15
NOTE
Abrasive particles can damage machined surfaces or plug oil passageways. Clean parts before disassembly to prevent
component damage.
1. Use low-pressure compressed air to clean exterior
surfaces of engine.
2. Disconnect negative battery cable. See Main Fuse.
3. Remove seat. See Remove.
4. Remove fuel tank. See Prepare.
5. Remove spark plug cables. See Remove.
6. Remove air cleaner. See Remove.
7. Remove air cleaner backplate assembly. See Prepare.
8. Remove upper front engine mount. See Prepare.
9. Remove oil cooler upper screw. See Prepare.
10. Remove upper cooling lines. See Prepare.
11. Disconnect electrical connectors.
a. Rear cylinder: Knock sensor and ACR.
b. Front cylinder: ACR.
12. Remove spark plugs. See Prepare.
13. Remove upper rocker covers. See Prepare.
14. Remove breathers. See Prepare.
1. See Lower Rocker Cover. Remove lower rocker cover.
a. Remove five screws.
b. Lift off from cylinder head.
c. Engine in chassis: Remove from left side.
2. Discard gasket.
3. Clean threadlocker from all screws and threaded holes. See Cleaning Fastener Threads in Cleaning.
a. Cover exposed internal engine area to prevent contamination from loosened threadlocker.
1. Install new gasket.
2. See Figure 1. Install lower rocker cover.
a. Engine in chassis: Install from left side.
b. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to 5-7
screw threads.
c. Start four screws and the stud.
d. Tighten in sequence shown to 10.2-13.6 N·m
(90-120 in-lbs).
Figure 1. Lower Rocker Cover
1. Install breathers. See Prepare.
2. Install upper rocker covers. See Prepare.
3. Install spark plugs. See Prepare.
4. Connect electrical connectors.
a. Rear cylinder: Knock sensor and ACR.
b. Front cylinder: ACR.
5. Install upper cooling lines. See Prepare.
6. Install oil cooler upper screw. See Prepare.
7. Install upper front engine mount. See Prepare.
8. Install air cleaner backplate assembly. See Prepare.
9. Install air cleaner. See Remove.
10. Install spark plug cables. See Remove.
11. Install fuel tank. See Prepare.
12. Install seat. See Remove.
13. Connect negative battery cable. See Main Fuse.
NOTE
Abrasive particles can damage machined surfaces or plug oil passageways. Clean parts before disassembly to prevent
component damage.
1. Use low-pressure compressed air to clean exterior
surfaces of engine.
2. Disconnect negative battery cable. See Main Fuse.
3. Remove seat. See Remove.
4. Remove fuel tank. See Prepare.
5. Remove spark plug cables. See Remove.
6. Remove upper front engine mount. See Prepare.
7. Remove oil cooler upper screw. See Prepare.
8. Remove upper cooling lines. See Prepare.
9. Disconnect electrical connectors.
a. Rear cylinder: Knock sensor and ACR.
b. Front cylinder: ACR.
10. Remove left side spark plugs. See Prepare.
11. Remove upper rocker covers. See Prepare.
1. Remove rocker arms.
a. Set piston at TDC on the compression stroke.
b. See Figure 1. Alternately loosen screws (3) until
screws can be turned by hand.
c. Remove screws.
d. Remove rocker shaft (1) and rocker arm (4).
e. Repeat with remaining rocker arm.
1
Shaft
2
Head casting
3
Screw
4
Rocker arm
Figure 1. Remove Rocker Arms
1. Clean all parts.
2. Inspect for wear. Replace or repair as necessary.
a. Measure rocker arm bore.
b. Measure rocker arm shaft for excessive wear.
c. Inspect valve contact areas for excessive wear.
d. Inspect pushrod pocket for excessive wear.
e. Verify that oil holes in rocker arms are clean and open.
1.
Set piston at approximate BDC on the power stroke.
2.
Install rocker arms.
a. Verify that lifters are on the base circle of the
camshaft lobe.
b. See Remove Rocker Arms. Install rocker arm (4)
and rocker shaft (1).
c. Verify that rocker shaft is seated in both towers.
d. Install screws (3).
e. Alternately tighten screws to pull rocker shaft down
evenly.
f. Tighten to 31.2-36.6 N·m (23-27 ft-lbs).
g. Repeat with remaining rocker arms.
3.
Allow lifters to bleed down. When lifters have bled down,
pushrods can be rotated by hand.
NOTE
Do not rotate crankshaft until lifters have bled down.
Rotating crankshaft sooner could result in valve-to-
piston contact resulting in damage.
4.
Check valve lash after lifters have bled down.
a. Position crankshaft at TDC of compression stroke. All
valves will be closed.
b. While holding rocker arm against valves, attempt to
slide a feeler gauge between each valve stem tip and
the rocker arm.
c. The maximum allowable lash on a common rocker
arm is 0.2 mm (0.008 in). A measurement in excess
requires disassembly and repair of cylinder head
assembly.
1. Install upper rocker covers. See Prepare.
2. Install spark plugs. See Prepare.
3. Connect electrical connectors.
a. Rear cylinder: Knock sensor and ACR.
b. Front cylinder: ACR.
4. Install upper cooling lines. See Prepare.
5. Install oil cooler upper screw. See Prepare.
6. Install upper front engine mount. See Prepare.
7. Install spark plug cables. Remove.
8. Install fuel tank. See Prepare.
9. Install seat. See Remove.
10. Connect negative battery cable. See Main Fuse.
NOTE
Abrasive particles can damage machined surfaces or plug oil passageways. Clean parts before disassembly to prevent
component damage.
1. Use low-pressure compressed air to clean exterior
surfaces of engine.
2. Disconnect negative battery cable. See Main Fuse.
3. Remove seat. See Remove.
4. Remove fuel tank. See Prepare.
5. Remove spark plug cables. See Remove.
6. Remove air cleaner. See Remove.
7. Remove air cleaner backplate assembly. See Prepare.
8. Remove upper front engine mount. See Prepare.
9. Remove oil cooler cover and upper screw. See Prepare.
10. Remove upper cooling lines. See Prepare.
11. Disconnect electrical connectors.
a. Rear cylinder: Knock sensor and ACR.
b. Front cylinder: ACR
12. Remove spark plugs. See Prepare.
13. Remove upper rocker covers. See Prepare.
14. Remove rocker arms. See Prepare.
NOTE
Mark parts for location and orientation during removal.
1. Remove pushrods.
2. Remove pushrod covers using 94086-09 (PUSHROD COVER RETAINER INSTALLATION AND REMOVAL
TOOL).
a. See Figure 1. Alternately, insert the blade of a screwdriver in tab (1) of spring cap retainer.
b. While pushing down on spring cap (2), rotate bottom of retainer outboard.
3. Remove pushrod covers.
a. Collapse upper and lower pushrod covers.
4. Disassemble pushrod cover assemblies.
a. Discard three O-rings.
5. See Figure 2. Remove lifter covers.
a. Remove four screws (1).
b. Remove the lifter cover (2) and gasket (3). Discard gasket.
6. Remove lifters.
a. Remove screw (4) securing anti-rotation device (5).
b. Remove anti-rotation device.
c. Remove the lifters (6) and place in clean plastic bags to prevent contamination.
1
Tab
2
Spring cap
Figure 1. Removing Spring Cap Retainer
1
Screw (4)
2
Lifter cover
3
Gasket
4
Screw
5
Anti-rotation device
6
Lifter (2)
Figure 2. Lifter Cover
1. Except for the hydraulic lifters, clean all parts in a non-
volatile cleaning solution or solvent.
WARNING
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)
2. Dry parts with low-pressure, compressed air.
3. Verify that the O-ring seats and contact surfaces of the
pushrod covers are completely clean.
4. Verify that all oil holes are clean and open.
5. Examine the pushrods. Replace any pushrods that are
bent, dented, damaged, discolored or if the ball ends
show signs of excessive wear or damage.
6. Cover all parts to protect them from dust and dirt.
1.
Measure the lifter outer diameter. Record the
measurement.
2.
Measure lifter bore. Subtract this measurement from the
lifter measurement to determine clearance.
a. Clearance when new is 0.023-0.066 mm (0.0009-
0.0026 in)
b. Install new lifters and/or replace crankcases if
clearance exceeds service wear limit of 0.152 mm
(0.006 in)
3.
Check lifter roller end clearance.
a. Allowable end clearance is within. 0.203-0.559 mm
(0.008-0.022 in)
b. Replace lifters if end clearance exceeds service wear
limit of. 0.559 mm (0.022 in)
4.
Soak lifters in clean engine oil. Keep covered until
assembly.
5.
Examine lifter rollers. If damaged, examine the associated
cam lobe.
a. Verify that the hydraulic lifter rollers turn freely.
b. Check for flat spots, scuff marks and pitting.
c. See Roller Inspection. A dull lifter roller surface is
called frosting (2). Frosting is a cosmetic condition
and does not affect function.
6.
Inspect the lifter for signs of wear.
a. Verify that the plunger is fully extended against the C-
clip.
b. Pump plunger to verify operation.
1
Normal roller
2
Frosted roller
Figure 1. Roller Inspection
1. See Assembled Pushrod Cover. Apply a film of clean engine oil to new O-rings (1, 6 and 8).
2. Install upper O-ring (1) on the upper pushrod cover (2).
3. Slide the spring cap (4) and spring (5) onto the body of the upper pushrod cover. Move parts up until spring cap
contacts upper O-ring seat.
4. Install middle O-ring (6) into groove on top of lower pushrod cover (7).
5. Apply a light film of clean engine oil on the upper pushrod cover.
6. Slide the straight end of the upper pushrod cover into the end of the lower pushrod cover.
7. Wipe pushrod covers clean.
8. Install lower O-ring (8) on lower pushrod cover.
1
Upper O-ring (small)
2
Upper pushrod cover
3
Spring cap retainer
4
Spring cap
5
Spring
6
Middle O-ring (intermediate)
7
Lower pushrod cover
8
Lower O-ring (large)
Figure 1. Assembled Pushrod Cover
NOTE
Anti-rotation devices are marked "F" (front) and "R" (rear).
1.
Install lifters.
a. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to outer
surface of each lifter. Pour a small amount onto each
cam lobe.
b. Rotate crankshaft until both cam lobes are visible in
lifter bores.
c. Carefully install lifters in lifter bores. Do not drop lifters
onto cam lobes.
d. See Lifter Cover. Install anti-rotation device.
e. Install screw (4). Tighten.
Torque: 10.2-13.6 N·m (90-120 in-lbs) Lifter anti-
rotation device screw
2.
Install lifter cover (2), new gasket (3) and screws (1).
Tighten in a cross-wise pattern.
Torque: 14.9-17.6 N·m (132-156 in-lbs) Lifter cover
screws
3.
Install pushrod covers.
a. Assemble pushrod covers with new O-rings.
b. Install new O-rings on each end of the pushrod cover.
c. Compress pushrod cover assembly and fit into lifter
cover bore.
d. Extend assembly into cylinder head bore.
e. Verify that the ends of the pushrod cover fit snugly into
cylinder head and lifter cover bores.
4.
Install spring cap retainers using 94086-09 (PUSHROD
COVER RETAINER INSTALLATION AND REMOVAL
TOOL).
a. Insert upper edge of spring cap retainer into cylinder
head bore.
b. See Figure 1. Alternately, insert blade of small
screwdriver between bottom edge of spring cap
retainer and top of spring cap.
c. Press spring cap down and slide bottom edge of
retainer toward tip of screwdriver.
d. Verify that spring cap retainer seats tightly against
upper pushrod cover.
5.
Apply a small amount of SCREAMIN' EAGLE ASSEMBLY
LUBE to ends of each pushrod.
6.
NOTE
If installing original parts, install them in their original
location and orientation. Use 10.301 inch long (light
blue stripes) as intake and 10.531 inch long (yellow
stripes) as exhaust.
Install pushrods.
Figure 1. Install Spring Cap Retainers
1. Install rocker arms. See Prepare.
2. Install upper rocker covers. See Prepare.
3. Install spark plugs. See Prepare.
4. Connect electrical connectors.
a. Rear cylinder: Knock sensor and ACR.
b. Front cylinder: ACR
5. Install upper cooling lines. See Prepare.
6. Install oil cooler upper screw and cover. See Prepare.
7. Install upper front engine mount. See Prepare.
8. Install air cleaner backplate assembly. See Prepare.
9. Install air cleaner. See Remove.
10. Install spark plug cables. See Remove.
11. Install fuel tank. See Prepare.
12. Install seat. See Remove.
13. Connect negative battery cable. See Main Fuse.
NOTE
Abrasive particles can damage machined surfaces or plug oil passageways. Clean parts before disassembly to prevent
component damage.
1. Use low-pressure compressed air to clean exterior
surfaces of engine.
2. Disconnect negative battery cable. See Main Fuse.
3. Remove seat. See Remove.
4. Remove fuel tank. See Prepare.
5. Remove spark plug cables. See Remove.
6. Remove coil. See Prepare.
7. Remove left side engine mount. See Prepare.
8. Remove air cleaner. See Remove.
9. Remove air cleaner backplate assembly. See Prepare.
10. Remove upper front engine mount. See Prepare.
11. Remove oil cooler cover and upper screw. See Prepare.
12. Remove upper cooling lines. See Prepare.
13. Remove induction module. See Prepare.
14. Disconnect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor, and ACR.
b. Front cylinder: Knock sensor and ACR.
15. Remove spark plugs. See Prepare.
16. Remove upper rocker covers. See Prepare.
17. Remove breathers. See Prepare.
18. Remove lower rocker covers. See Prepare.
19. Remove rocker arms. See Prepare.
20. Remove pushrods, lifters and covers. See Prepare.
1. Disconnect knock sensor connector.
2. See Figure 1. Remove cylinder head bolts.
a. Loosen each cylinder head bolt in sequence shown.
b. Remove head bolts.
3. Remove cylinder head.
a. Lift cylinder head from dowel pins.
b. Discard gasket.
Figure 1. Head Bolt Tightening Sequence
NOTE
Avoid getting debris in coolant and oil passages during gasket removal and cleaning.
1. Remove old gasket material from cylinder head. Do not
cause scratches or nicks.
NOTE
Bead blasting materials could enter threaded holes.
This would adversely affect fastener engagement and
torque indication. Cover all threaded holes before
bead blasting.
NOTICE
Do not use glass or sand to bead blast surfaces
exposed to engine oil. Blasting materials can lodge
in pores of the casting. Heat expansion releases
this material which can contaminate oil resulting in
engine damage. (00534b)
2.
Remove all carbon deposits from combustion chamber
and machined surfaces of cylinder head. Do not remove
any metal material.
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 previous step
as necessary.
NOTE
Keep all parts grouped by location so they can be
installed in the original location.
4.
Thoroughly clean the cylinder head, spring retainers,
tapered keepers, valves and valve springs in a non-
volatile cleaning solution or solvent. Follow up with a
thorough wash in hot soapy water.
5.
Thoroughly flush all coolant and oil passages to remove
loose debris.
WARNING
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)
6. Dry parts with low-pressure, compressed air.
7. Clean threadlocker from all screws and threaded holes.
See Cleaning Fastener Threads in Cleaning.
a. Cover exposed internal engine area to prevent
contamination from loosened threadlocker.
1.
Clean all gasket surfaces.
2.
Thoroughly flush all coolant and oil passages to remove
loose debris.
3.
See Figure 1. Install cylinder head.
a. Install new gasket with the part number facing up.
b. Install cylinder head on dowel pins.
4.
Install cylinder head flange nuts.
a. Apply new engine oil to flanges and threaded portion
of the cylinder head nuts.
b. Install cylinder head nuts.
5.
See Head Bolt Tightening Sequence.Tighten head nuts
in five stages following sequence shown.
a. Tighten.
Torque: 27.1-40.7 N·m (20-30 ft-lbs) Cylinder head
nut torque step 1.
b. Loosen one full turn.
Torque: -360° (-360°) Cylinder head nut torque step 2.
Loosen one turn.
c. Tighten.
Torque: 12.2-14.9 N·m (9-11 ft-lbs) Cylinder head nut
torque step 3.
d. Tighten.
Torque: 33.9-36.6 N·m (25-27 ft-lbs) Cylinder head
nut torque step 4.
e. Tighten to final torque.
Torque: 90° (90°) Cylinder head nut torque step 5.
Tighten additional degree value.
6.
Connect knock sensor, engine temperature sensor, and
ACR.
1
Head flange nut (4)
2
Cylinder head
3
Head gasket
Figure 1. Cylinder Head
Special Tools
Description
Part Number
Qty.
CYLINDER HEAD HOLDING
B-49312
1
FIXTURE
VALVE SPRING COMPRESSOR
HD-34736-B
1
1. Secure cylinder head for service.
a. Remove spark plugs.
b. Turn 12 mm end of CYLINDER HEAD HOLDING FIXTURE (Part Number:B-49312) (1) into cylinder head
(2) spark plug hole.
c. Clamp tool in vise at a comfortable working position.
2. Remove ACR. See Prepare.
3. See Figure 1. Remove screw (2) and knock sensor (1).
4. Remove cylinder head temperature sensor (3).
5. See Figure 3. Remove valves.
a. See Figure 2. Use VALVE SPRING COMPRESSOR (Part Number:HD-34736-B) to compress valve
spring.
b. Remove tapered keepers (1).
c. Slowly release valve spring compression.
d. Remove the spring retainer (2) and valve spring (3).
e. Remove the valve (11).
6. Remove and discard valve stem seal assembly (4).
7. Identify components.
a. Mark the valve head for identification.
b. Place tapered keepers, valve spring and spring retainer in a plastic bag with identification.
8. Remove the remaining valves and components.
1
Knock sensor
2
Screw
3
ET (Engine temperature) sensor (rear head only)
Figure 1. Cylinder Head Sensors
1
Holding fixture
2
Compressor
Figure 2. Valve Spring Compressor
1
Keepers (2)
2
Retainer
3
Spring
4
Stem seal assembly
5
Valve
Figure 3. Valve Components
Special Tools
Description
Part Number
Qty.
VALVE GUIDE HONE
B-45525
1
CLEANING BRUSH
HD-34751
1
See Engine for specifications not shown here.
Cylinder Head
1. Check all gasket sealing surfaces for scratches and
nicks.
2. Check head flatness with feeler gauge.
a. Using a straightedge, check gasket surface for
warpage.
b. Replace the head if warpage is beyond
specification.
Length/Dimension/Distance: 0.152 mm (0.006 in)
3. Verify that all oil holes are clean and open.
Valve Guides
1. Inspect external surfaces for cracks.
2. Prepare valve guides for inspection.
a. Lightly hone bore.
Special Tool: VALVE GUIDE HONE (B-45525)
b. Scrub bore.
Special Tool: CLEANING BRUSH (HD-34751)
c. Polish valve stem with fine emery cloth or steel wool
to remove carbon buildup.
3. Check valve stem to guide clearance.
a. Measure the inside diameter of the valve guide.
b. Measure the outside diameter of the valve stem.
c. If stem to guide clearance exceeds service limits,
repeat measurements with a new valve to determine
worn components.
d. If stem to guide clearance exceeds service limits
with a new valve, replace cylinder head.
Valves and Valve Seats
1. With valves removed, inspect the sealing surface of the
valve face and valve seat.
2. a. The sealing surfaces must be smooth and even
around entire contact area.
b. If the sealing contact area is uneven or shows
evidence of pitting, carbon tracking, or other
indications of combustion gas leakage, recondition
the valve and seat, or replace cylinder head
assembly. See Valve and Seat Repair
3. Inspect the valve for burning, cracking, carbon tracking,
or other indications of combustion gas leakage.
4. Inspect the end of the valve stem for pitting or uneven
wear.
5. Remove burrs around the valve stem keeper groove
with a fine tooth file.
6. To determine if the valve stem is excessively worn, see
valve guide inspection.
Valve Springs
1. Inspect springs for cracked or discolored coils.
2. Check for squareness.
3. Check free length.
4. Load test using a commercially available valve spring tester.
Tapered Keepers
Install new keepers any time valves are installed.
Valve Seats
1. Inspect seats for cracking, chipping or burning, carbon tracking, or other indications of combustion gas leakage.
2. Check seat wear by measuring valve stem protrusion. See Valve and Seat Repair.
3. Replace cylinder head if seats are damaged or worn excessively.
NOTE
Verify correct valve stem to valve guide clearance before refacing. Refer to Table 1.
The correct finished angles are 45 degree valve face and 46 degree valve seat eliminating the need to lap.
Finish valve seat to an even width of 1.016-1.575 mm (0.040-0.062 in).
See Figure 1. Replace the valve if margin (5) is less than 0.795 mm (0.0313 in).
Refurbish valves and seats in pairs. Valve stem protrusion of a pair operated by the same rocker arm must be
equal. Verify that valve lash is within specification. See Install.
If valve stem protrusion exceeds 44.5 mm (1.752 in), replace the valve or cylinder head as necessary.
1
0.040-0.080 in (1.02-2.03 mm)
2
60 degrees
3
31 degrees
4
46 degrees
5
Margin: 0.031 in (0.79 mm) minimum
Figure 1. Valve and Seat Dimensions
Table 1. Valve Stem to Guide Clearance
VALVE
IN
MM
Intake
0.001-0.003
0.0254-0.0762
Exhaust
0.001-0.003
0.0254-0.0762
Special Tools
Description
Part Number
Qty.
CYLINDER HEAD HOLDING
B-49312
1
FIXTURE
VALVE SPRING COMPRESSOR
HD-34736-B
1
CLEANING BRUSH
HD-34751
1
VALVE GUIDE SEAL INSTALLER
HD-45322
1
1.
Secure cylinder head for service.
a. Turn 10 mm end of CYLINDER HEAD HOLDING
FIXTURE (Part Number:B-49312) into spark plug
hole.
b. Clamp tool in vise at a comfortable working position.
NOTE
Install all parts in their original location and
position.
2.
Install valve.
a. Clean valve guide with CLEANING BRUSH (Part
Number:HD-34751).
b. Apply a liberal amount of SCREAMIN' EAGLE
ASSEMBLY LUBE to valve stem.
c. Install the valve into the cylinder head.
d. Spin the valve as it is installed to distribute the
lubricant evenly.
e. Remove the valve and apply a second coat of
SCREAMIN' EAGLE ASSEMBLY LUBE to the valve
stem. Install the valve.
NOTICE
Failure to install plastic capsule can cause the valve
stem seal to catch the edge of the valve stem
keeper groove. The resulting damage can cause
leakage around the valve stem, excessive oil
consumption and valve sticking. (00535b)
3.
Install valve stem seal.
a. Slide VALVE GUIDE SEAL INSTALLER (Part
Number:HD-45322) over valve stem tip.
b. Apply SCREAMIN' EAGLE ASSEMBLY LUBE
to installer.
c. See Figure 1. Slide new valve stem seal assembly
over installer and down valve stem until seated
against cylinder head casting.
d. Remove installer from valve stem tip.
Figure 1. Valve Stem Seal Assembly
4.
See Valve Components. Install valve spring.
a. Apply a liberal amount of SCREAMIN' EAGLE
ASSEMBLY LUBE to valve stem tip and keeper
groove.
b. Install the valve spring (3) with the smaller diameter
coils topside.
c. Place the spring retainer (2) on top of the valve
spring.
5.
Install new keepers.
a. compress valve spring with VALVE SPRING
COMPRESSOR (Part Number:HD-34736-B).
b. Install the keepers.
c. Slowly release valve spring compression.
d. Tap the end of the valve stem once or twice with a
soft mallet to make sure that tapered keepers are
tightly seated.
6.
Install remaining valves.
7.
Install ACR. See Prepare.
8.
See Cylinder Head Sensors. Install knock sensor with
screw (2).
a. Rotate sensor housing up against head casting.
b. Tighten to 17.6-23 N·m (13-17 ft-lbs).
9.
Install temperature sensor (3). Tighten to 13.6-20.3 N·m
(120-180 in-lbs).
1. Install pushrods, lifters and covers. See Prepare.
2. Install rocker arms. See Prepare.
3. Install lower rocker covers. See Prepare.
4. Install breathers. See Prepare.
5. Install upper rocker covers. See Prepare.
6. Install spark plugs. See Prepare.
7. Connect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR.
8. Install induction module. See Prepare.
9. Install upper cooling lines. See Prepare.
10. Install oil cooler upper screw and cover. See Prepare.
11.
NOTE
See Remove and Install: Upper Front Engine
Mount for proper tightening sequence.
Install left side engine mount. See Prepare.
12. Install upper front engine mount. See Prepare.
13. Install air cleaner backplate assembly. See Prepare.
14. Install air cleaner. See Remove.
15. Install coil. See Prepare.
16. Install spark plug cables. See Remove.
17. Install fuel tank. See Prepare.
18. Install seat. See Remove.
19. Connect negative battery cable. See Main Fuse.
NOTE
Abrasive particles can damage machined surfaces or plug oil passageways. Clean parts before disassembly to prevent
component damage.
1. Use low-pressure compressed air to clean exterior
surfaces of engine.
2. Disconnect negative battery cable. See Main Fuse.
3. Remove seat. See Remove.
4. Remove fuel tank. See Prepare.
5. Remove spark plug cables. See Remove.
6. Remove coil. See Prepare.
7. Remove left side engine mount. See Prepare.
8. Remove air cleaner. See Remove.
9. Remove air cleaner backplate assembly. See Prepare.
10. Remove upper front engine mount. See Prepare.
11. Remove oil cooler cover and upper screw. See Prepare.
12. Remove upper cooling lines. See Prepare.
13. Remove induction module. See Prepare.
14. Disconnect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR.
15. Remove spark plugs. See Prepare.
16. Remove upper rocker covers. See Prepare.
17. Remove breathers. See Prepare.
18. Remove lower rocker covers. See Prepare.
19. Remove rocker arms. See Prepare.
20. Remove pushrods, lifters and covers. See Prepare.
21. Remove cylinder heads. See Prepare.
NOTE
Do not bend the cylinder studs.
1. Remove the cylinder.
a. Raise the cylinder and place clean shop towels under the piston.
b. Hold the piston to prevent touching the studs as it exits the cylinder.
c. Lift cylinder clear of piston.
2. Slide plastic tubing, rubber hose or conduit over each cylinder stud to protect cylinder studs and piston from
damage.
3. See Figure 1. Discard gasket (4).
1
Head gasket
2
Dowel pin
3
Cylinder
4
Gasket
Figure 1. Cylinder Assembly
Special Tools
Description
Part Number
Qty.
PISTON RING COMPRESSOR
HD-96333-51F
1
NOTE
Front and rear cylinders are unique. Install them in the correct locations.
1. Prepare for cylinder installation.
a. Install new base gasket to the crankcase.
b. See Piston Ring Order of Assembly and Gap Alignment. Verify piston ring alignment.
c. Apply clean engine oil to piston, piston rings and cylinder bore.
d. Rotate crankshaft until piston is at top dead center.
2. Remove protective covers from cylinder studs.
3. See Figure 1. Install the HD-52185 (PISTON SUPPORT PLATE) under piston.
4. Rotate crankshaft until piston skirt is centered and firmly seated on top of support plate.
1
Support plate
2
Knobs
3
Screw
Figure 1. Piston Support Plate
5. See Figure 2. Install cylinder using PISTON RING COMPRESSOR (Part Number:HD-96333-51F).
a. Align tool with the top of the band positioned between the top compression ring and the piston crown.
b. Compress piston rings.
c. Align the indent in the cooling fins to the right side of the engine. Slide cylinder over the cylinder studs and
piston until it rests on the top of the ring compressor.
d. Push down on the cylinder with a sharp, quick motion using the palms of both hands.
e. Remove pliers and piston support plate.
f. Remove shop towels from around the crankcase bore.
g. Push down on the cylinder until it is fully seated in the crankcase bore.
h. See Figure 3. Install HD-52020 (CYLINDER HOLD-DOWN NUTS) onto cylinder studs.
1
Pliers
2
Compressor band
Figure 2. Piston Ring Compressor
Figure 3. Install Threaded Cylinders to Studs
1. Clean all gasket material from the cylinder.
2. Clean parts in a non-volatile cleaning solution. Dry parts with low-pressure, compressed air.
3. Inspect the cylinder bore for defects or damage in the ring travel area.
a. Light scratches that are not the length of the piston travel are considered normal. Hone pattern should travel
through the scratches. This cylinder is fit for operation.
b. Run a fingernail across the scratches. If a scratch catches a fingernail, the cylinder must be replaced.
c. Scoring or broad bands that are the length of piston travel, or evidence that material transferred between
the piston and cylinder, replace the cylinder.
4. Deglaze cylinders. See Deglaze Cylinder.
5. Verify that all oil holes are clean and open.
6. Carefully remove any nicks or burrs from the machined gasket surfaces.
7. Check the gasket surfaces for flatness. Measure with a straightedge and feeler gauge.
a. Check head gasket surface of the cylinder. Record measurements.
b. Check lower gasket surface of the cylinder. Record measurements.
c. Discard cylinder if either gasket surface flatness is not within wear limits. See Engine
8. Measure cylinder bore for out-of round and taper. Measure parallel to and perpendicular to the crankshaft
centerline.
a. Measure the cylinder diameter at the top of the piston ring travel zone, below the combustion zone. Record
the measurements.
b. Repeat the measurements at the center of the piston ring travel zone.
c. If the measurements are not within wear limits, replace the cylinder. See Engine.
1. Lightly swab the cylinder bore with a cloth dipped in clean
engine oil.
NOTE
A precise 60 degree crosshatch pattern in the piston
travel area is important.
NOTICE
The angular crosshatch pattern ensures an even
flow of oil onto the cylinder walls and promotes
longer cylinder, piston and ring life. An incorrect
cross hatch pattern will result in insufficient oil
retention and possible piston seizure and/or high oil
consumption. (00536c)
2.
Deglaze cylinder with a 240 grit flexible ball-type deglazing
tool. Create a 60 degree crosshatch.
NOTICE
Failure to remove all abrasive particles may result in
premature cylinder, piston and ring wear and
engine failure. (00537c)
3.
Thoroughly wash the cylinder bore with liquid dishwashing
soap and hot water. Continue cleaning until a clean cloth
shows no evidence of dirt or debris.
a. Hot rinse the cylinder and dry with moisture free
compressed air.
b. Immediately apply a thin film of clean engine oil to a
clean white paper towel and thoroughly wipe the
inside of the cylinder.
c. Repeat wiping process until a new towel remains
white.
1. Install cylinder heads. See Prepare.
2. Install pushrods, lifters and covers. See Prepare.
3. Install rocker arms. See Prepare.
4. Install lower rocker covers. See Prepare.
5. Install breathers. See Prepare.
6. Install upper rocker covers. See Prepare.
7. Install spark plugs. See Prepare.
8. Connect electrical connectors.
a. Rear cylinder: Engine temperature sensor, knock
sensor and ACR.
b. Front cylinder: Knock sensor and ACR
9. Install induction module. See Prepare.
10. Install upper cooling lines. See Prepare.
11. Install oil cooler upper screw and cover. See Prepare.
12.
NOTE
See Remove and Install: Upper Front Engine
Mount for proper tightening sequence.
Install left side engine mount. See Prepare.
13. Install upper front engine mount. See Prepare.
14. Install air cleaner backplate assembly. See Prepare.
15. Install air cleaner. See Remove.
16. Install coil. See Prepare.
17. Install spark plug cables. See Remove.
18. Install fuel tank. See Prepare.
19. Install seat. See Remove.
20. Connect negative battery cable. See Main Fuse.
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