Harley Davidson 2018 softail models. Service manual — page 14
Inspect for more detail.
Special Tool: BORESCOPE (HD-50549)
6. Remove dowel from induction module.
7. Connect TCA connector.
8. Assemble the air cleaner. See Remove.
9. Install the spark plugs. Connect spark plug wires.
Torque: 10-15 N·m (89-133 in-lbs) Spark plug
Table 1. Compression Specifications
ACR STATUS
PSI
KPA
ACR connected
90 (min)
621 (min)
ACR disconnected
175 (min)
1207 (min)
Table 2. Compression Test Results
TEST RESULTS
DIAGNOSIS
Compression low on first stroke.
- Ring trouble
Compression builds on the following strokes, but does not reach normal.
Improves considerably when oil is added to cylinder.
Compression low on first stroke.
- Head gasket leak
Compression does not build much on following strokes.
- Incorrect valve lash
Does not improve considerably with the addition of oil.
- Valve trouble
Special Tools
Description
Part Number
Qty.
CYLINDER LEAKDOWN TESTER
HD-35667-A
1
BORESCOPE
HD-50549
1
CRANKSHAFT LOCKING TOOL
HD-52252
1
1.
Verify that the leakdown tester is free from leakage.
Special Tool: CYLINDER LEAKDOWN TESTER
(HD-35667-A)
a. Apply a soap/water solution around all tester fittings.
b. Connect cylinder leakdown tester to compressed air
source.
c. Bubbles indicate leakage.
2.
NOTE
Perform the test with the ignition switch turned OFF.
Remove one spark plug per cylinder.
3.
Set piston in the cylinder being tested at top dead center
(TDC) of compression stroke (both valves closed).
4.
NOTE
Never use CRANKSHAFT LOCKING TOOL (Part
Number:HD-52252) for procedures such as servicing
the compensator, servicing the clutch or servicing the
camshaft. Crankcase damage will result.
Lock the crankshaft.
a. Remove CKP. See Prepare.
b. Install crankshaft locking tool.
Special Tool: CRANKSHAFT LOCKING TOOL
(HD-52252)
5.
Follow the manufacturer's instructions to perform the
leakdown test.
a. Record the percent of leakage.
b. Listen for air leaks at throttle body, exhaust pipe, oil
fill spout and head gasket.
6.
Verify that the piston is still at TDC. Repeat the test if it
moved.
7.
Results:
a. Leakage greater than 25 percent indicates that further
diagnosis is warranted.
b. Air escaping through the throttle body indicates
leaking past intake valves.
c. Air escaping through the exhaust pipe indicates
leaking past exhaust valves.
d. Air sound from the oil fill spout indicates leaking past
piston rings.
e. Inspect cylinder using borescope. Refer to Clean and
Inspect for more detail.
Special Tool: BORESCOPE (HD-50549)
8. Remove crankshaft locking tool.
Crankshaft Installed
NOTE
Perform the following checks during engine disassembly as a method to determine condition of crankshaft
and whether crankshaft is suitable for reuse. The checks can be done with the engine either installed in the
frame or removed.
Dial indicators must be set up and zeroed perpendicular to the shaft in both directions. The indicator must
be 90 degrees when viewed from the end and from the side.
For a reliable reading, only measure on the cam support plate bushing machined surface of the crankshaft,
never on a shaft adapter or the bolt holes.
Never secure the dial indicator base to the vehicle frame. Movement within the engine mounts will result in a
false reading.
While rotating the crankshaft, the indicator needle may move to both the minus and plus sides of zero. The
total indicator reading is the value to record.
1.
Right Side
a. Remove spark plugs.
b. Remove the cam support plate. See Prepare.
c. Secure a dial indicator base to a stable location (crankcase, engine stand, etc.).
NOTE
To obtain an accurate measurement, the dial indicator must be set up perpendicular in both directions to
the shaft being measured.
d. Attach a dial indicator and set it up to measure runout at the cam plate bearing contact area of the
crankshaft. Adjust the indicator to zero.
e. Slowly rotate the crankshaft one complete revolution and record the total needle movement.
f. Compare results of measurements. If the total indicator reading exceeds service wear limit, the
crankshaft/flywheel assembly should be removed and checked on a truing stand. Refer to Table 1.
2.
Left Side
a. Remove spark plugs.
b. Remove the primary cover and compensating sprocket. See Prepare.
c. Secure a dial indicator base to a stable location (crankcase, engine stand, etc.).
NOTE
To obtain an accurate measurement, the dial indicator must be set up perpendicular in both directions to
the shaft being measured.
d. Attach a dial indicator set up to measure runout near the end of the splined area of the crankshaft.
Adjust the indicator to zero on the "high" part of one spline.
e. Mark the crankshaft and crankcase to use as reference for the amount of rotation.
NOTE
Pay attention to only the values from the "high" part of the splines.
f. Slowly rotate the crankshaft one complete revolution and record the total needle movement.
g. Compare results to Table 1. If the total indicator reading exceeds service wear limit, remove the
crankshaft/flywheel assembly and check on a truing stand.
Crankshaft Removed
NOTE
The following procedure should be performed if the crankshaft/flywheel assembly is suspected of being
out-of-true.
The crankshaft must be supported by the bearing races during inspection. Never use centers as the holes
may not be perfectly centered.
Verify that the bearing races are in good condition and suitable for performing this inspection.
1. See Figure 1. Mount crankshaft in truing stand so it is supported on the bearing races (1) by the roller supports
(2).
2. Secure a dial indicator mount near each end of the crankshaft.
NOTE
Dial indicators must be perpendicular to the shaft in both directions.
3. Set up each indicator (3) to measure the machined surface (4) on one end and splines (5) on the other.
4. Adjust both indicators to zero.
5. Slowly rotate the crankshaft assembly while observing the total indicator reading.
NOTE
Twin Cam crankshaft/flywheel assemblies are not serviceable. Replace parts not within specifications.
6. Compare results of measurements. If the total indicator reading exceeds service wear limit, replace the
crankshaft/flywheel assembly. Refer to Table 1.
1
Bearing race
2
Roller support
3
Dial indicator
4
Machined surface
5
Spline
Figure 1. Checking Crankshaft Runout
Table 1. Flywheel
FLYWHEEL
REPLACE IF WEAR EXCEEDS
IN
MM
Runout (shaft measured in case)
0.012
0.305
Runout (measured in truing stand)
0.005
0.127
End play
0.013
0.330
NOTE
Some valve train noise at start-up is normal until lifters fill with oil. Continuous noise requires diagnosis.
1. With engine and oil at normal operating temperature, check oil pressure at 2000 rpm.
2. If oil pressure is above 345 kPa (50 psi) or below 34 kPa (5 psi), inspect the following:
a. Oil pump wear
b. Crankcase passages for blockages
c. Oil hoses for blockages
3. If oil-starved hydraulic lifters are suspected, remove lifters and inspect. See Inspect Lifters.
a. Clean lifter bore of all foreign material.
4. Inspect pushrod, lifter and lifter bore for proper fit and unusual wear.
5. Visually inspect camshaft lobes for abnormal wear.
6. Check top end components.
a. Check for excess rocker arm end play or binding.
b. Inspect valve stems for scuffing. Check stem to guide clearance.
c. Check for loose valve seats or signs of shifting.
7. Grind valves and valve seats. See Valve and Seat Repair.
Perform both a compression test and a cylinder leakage test. See Compression Test and Cylinder Leakdown Test. If
further testing is needed, inspect for the following:
Check Before Cylinder Head Removal:
1. Oil level too high
2. Oil carryover
3. Restricted breather hose
4. Restricted oil filter
Check After Cylinder Head Removal:
1. Clogged oil return passages
2. Valve guide seals
3. Valve guide to valve stem clearance
4. Gasket surfaces of head and cylinder
5. Cylinder head casting porosity allowing oil to drain into combustion chamber
6. O-ring damaged or missing from oil pump/crankcase junction
7. If the above checks do not reveal the cause:
a. Remove the cylinder.
b. Verify that the piston ring gaps are properly staggered.
c. Inspect for excess piston ring wear.
Removal
NOTE
Pry overlap to release crimp clamps. If clamps must be cut, use a sharp high-quality wire cutter. To prevent
breaking plastic fittings, do not twist clamp while cutting.
1. See Figure 1. Push the tip of a small screwdriver under
end of tang (2).
2.
NOTE
Plastic fittings are fragile. Use care when removing
clamp.
Pry until tang is free of tab (1).
3. Remove clamp.
1
Tab
2
Tang
Figure 1. Removing Crimp Clamp
Special Tools
Description
Part Number
Qty.
HOSE CLAMP PLIERS
HD-41137
1
Installation
1. Install new clamp.
2. Tighten clamp using:
Special Tool: HOSE CLAMP PLIERS (HD-41137)
1. Remove main fuse. See Main Fuse.
2. See null. Remove oil cooler cover.
a.
Remove screw (6).
b.
Remove cover (5).
Oil Cooler
1. See Figure 1. Disconnect hoses (9, 10) from the oil
cooler (1).
a. Remove clamps (2, 8). See Remove.
b. Remove hoses.
NOTE
If any damage is caused to the hoses during
removal of the crimp clamps, replace the
hoses.
2. Remove screw (4) and washer (3).
3. Slide oil cooler assembly up to disengage from isolators
(7). Remove oil cooler assembly.
1
Oil cooler
2
Hose clamp (upper hose)
3
Washer
4
Screw
5
Oil cooler cover
6
Screw
7
Isolator (2)
8
Hose clamp (lower hose)
9
Lower hose
10
Upper hose
Figure 1.
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
Oil Cooler
NOTE
See null. If removed, install hose (9) with paint stripe facing out and at check valve end.
1.
See null. Inspect condition of isolators (7).
2.
Install oil cooler assembly.
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
a. Engage pins on bottom of oil cooler into isolators
(7).
NOTE
Lubricate pins with 50/50 mix of isopropyl
alcohol and water.
b. Install washer (3) and screw (4). Apply thread locker
and tighten.
Torque: 9.5-11.3 N·m (84-100 in-lbs) Oil cooler
screw
3.
Install new clamps (2, 8) onto hose (9, 10) ends.
4.
NOTE
Clamps should be tightened close to the end of the
hose, NOT right behind the barb bead.
Connect hoses (9, 10) to the oil cooler (1).
a. Tighten clamps (2, 8). See Remove.
Remove
1. Remove oil cooler cover. SeePrepare.
2. Remove oil cooler screw (4) and washer (5).
3. See Figure 1. Disconnect hose from oil check valve
(2).
4. Remove oil check valve.
5. Discard O-ring (3).
Install
1. Lubricate O-ring (3) with fresh oil.
2. See Figure 1. Install oil check valve (2) with new O-
ring. Tighten.
Torque: 24.4-29.8 N·m (18-22 ft-lbs) Crankcase oil
check valve or plug with O-ring
3. Install lower hose.
a. Place new clamp on lower hose.
b. Connect hose to check valve (2).
c. Install clamp.
4. Install oil cooler. See Prepare.
1
Oil pressure switch
2
Oil check valve
3
O-ring
Figure 1. Oil Check Valve
1. Install oil cooler cover.
a. Install cover (5).
b. Install screw (6). Tighten.
Torque: 9.5-11.3 N·m (84-100 in-lbs) Oil cooler
cover screw
2. Check engine oil level. See Check Engine Oil Level.
1. Remove left and right side covers. See Remove and
Remove.
2. Remove main fuse. See Main Fuse.
3. Remove seat. See Remove.
4. Remove fuel tank. See Prepare.
5. Remove upper engine mount. See Prepare.
6. Remove oil cooler cover and upper screw. See Prepare.
1. Disconnect right side spark plug cables.
2. See null. Disconnect upper hose (3) from oil cooler.
3. Use low-pressure compressed air to clear residual oil out of line assembly.
a. Remove engine oil filler cap.
b. Blow into the hose (3) where disconnected from oil cooler.
4. Disconnect hose (2) from transmission fitting.
a. Remove hose clamp from hose.
5. Remove screws (1) from each manifold (4).
6. Remove line assembly from the right side.
7. If necessary, remove rear oil hose (2) from line assembly.
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
NOTE
Verify that all components and mating surfaces are free of all debris before assembling.
1.
Clean components.
a. Remove all residual thread locking material from
screws and manifolds.
b. Clean all debris from mating surfaces and threaded
holes.
c. Clean all debris from coolant ports in heads and
manifolds.
d. Thoroughly clean interior of all lines, especially if an
engine failure occurred.
2.
See Figure 1. If removed, install hose (2) to line
assembly. Secure clamp. See Remove.
3.
NOTE
Make sure o-rings are not rolled after assembly.
Install new O-rings (5) on the ports of each manifold (4).
4.
Install line assembly with screws (1).
a. Apply threadlocker to threads of screws.
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
(99642-97)
b. Tighten to 10.2-13.6 N·m (90-120 in-lbs).
5.
Install hose (2) to transmission fitting with spring clamp.
6.
Connect right spark plug cables.
1
Screw (4)
2
Rear oil hose
3
Front oil hose
4
Manifold
5
O-ring (4)
6
Bracket (2)
Figure 1.
1. Install upper front engine mount. See Prepare.
2. Install oil cooler upper screw and cover. See Prepare.
3. Install fuel tank. See Prepare.
4. Install seat. See Remove.
5. Install main fuse. See Main Fuse.
6. Install side covers. See Removeand Remove.
7. Check engine oil level. See Check Engine Oil Level.
Special Tools
Description
Part Number
Qty.
FAT JACK
HD-45968
1
1. Remove main fuse. See Main Fuse.
2. Lower Front Engine Mount:
a. Support engine using the following jack or equivalent.
Special Tool: FAT JACK (HD-45968)
b. Detach right foot control bracket. See Remove and
Install: Forward Foot Controls.
c. Detach rear brake master cylinder bracket. See
Prepare.
Remove
1. See Figure 1. Loosen pinch bolt (3).
2. Remove and discard locknut (4).
3. Remove mounting bolt (1).
4. Remove spacer (2).
Install
1. See Figure 1. Install mounting bolt (1) through spacer
(2).
2. Install new locknut (4). Tighten.
Torque: 67.8-74.5 N·m (50-55 ft-lbs) Engine mount
bolt, front, lower
3. See Figure 2.Verify spacer is installed properly.
4. See Figure 1.Tighten pinch bolt (3).
Torque: 10.2-12.2 N·m (8-9 ft-lbs) Engine mount pinch
bolt, front, lower
1
Mounting bolt
2
Spacer
3
Pinch bolt
4
Locknut
Figure 1. Lower Front engine Mount
Figure 2. Spacer Installed Properly
Remove
1. See Figure 1. Remove frame-to-engine bracket screws
(4).
2. Remove frame bracket (2).
a. Remove frame bracket screws (3).
b. Remove frame bracket (2).
3. Remove engine bracket (1).
a. Loosen engine bracket screws (5).
b. Remove engine bracket (1) by lifting left side up
then pulling to the left.
Install
1. See Figure 1. Install engine bracket.
a. Install engine bracket (1).
b. Hand tighten engine bracket screws (5).
2. Install frame bracket.
a. Install frame bracket (2).
b. Install frame bracket screws (3). Hand tighten.
3. Install frame bracket-to-engine bracket screws (4). Hand
tighten.
4. Tighten fasteners in the following order.
a. Tighten engine bracket screws (5).
Torque: 61-67.8 N·m (45-50 ft-lbs) Engine mount
screw, front, upper engine bracket
b. If left side engine mount removed: Tighten
bracket-to-head screws. See Prepare.
c. Tighten frame bracket screws (3).
Torque: 61-67.8 N·m (45-50 ft-lbs) Engine mount
screw, front, upper frame bracket
d. If left side engine mount removed: Tighten
bracket-to-frame screws. See Prepare.
e. Tighten frame bracket-to-engine bracket screws (4).
Torque: 61-67.8 N·m (45-50 ft-lbs) Engine mount
screw, front, upper frame bracket-to-engine bracket
1
Engine bracket
2
Frame bracket
3
Frame bracket screw (2)
4
Frame-to-engine bracket screw (2)
5
Engine bracket screw (2)
Figure 1. Upper Front Engine Mount
1. Lower Front Engine Mount:
a. Attach rear brake master cylinder bracket. See
Prepare.
b. Attach right foot control bracket. See Remove and
Install: Forward Foot Controls.
c. Remove jack.
2. Install main fuse. See Main Fuse.
1. Remove main fuse. See Main Fuse.
2. Remove ignition coil. See Prepare.
3. Lift rear of fuel tank. See Lift Rear Of Fuel Tank.
1. See Left Side Engine Mount. Remove bracket (1).
a. Remove screws (3).
b. Remove screws and washers (2).
c.
Remove bracket (1).
1. See Figure 1. Install bracket (1).
a. Install bracket (1).
b. Install screws and washers (2). Hand tighten.
c. Install screws (3). Hand tighten.
2.
NOTE
If upper front engine mount was also removed, see
the combined tightening sequence in Remove and
Install: Upper Front Engine Mount.
Tighten fasteners in the following order.
a. Tighten screws and washers (2).
Torque: 38-44.7 N·m (28-33 ft-lbs) Engine mount
screw, left side, bracket-to-head
b. Tighten screws (3).
Torque: 61-67.8 N·m (45-50 ft-lbs) Engine mount
screw, left side, bracket-to-frame
1
Bracket
2
Screw and washer (2)
3
Screw (2)
Figure 1. Left Side Engine Mount
1. Install main fuse. See Main Fuse.
2. Install ignition coil. See Prepare.
3. Secure fuel tank. See Secure Fuel Tank.
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 upper cooling lines. See Prepare.
8. See Engine Wire Harness. Reposition engine harness
caddy.
a. Disconnect rear knock sensor (8).
b. Separate rear knock sensor connector from electrical
caddy.
c. Disconnect rear ACR (9).
d. Disconnect front ACR (10).
e. Remove push/lock pin securing electrical caddy to
right side of backbone.
f. Gently bend tabs outward at rear of electrical caddy to
separate from backbone.
g. Move rear electrical caddy and engine wire harness to
gain access as needed.
1. See Rocker Cover Screws. Remove the rocker cover
screws.
a.
Hold hex on stud (4).
b.
Remove center screw (3).
c.
Remove remaining screws.
2. Remove the rocker cover (2) and gasket (1) from right
side of vehicle. Discard gasket.
3. Clean threadlocker from all screws and threaded holes.
See Cleaning Threads and Threaded Holes in
Cleaning.
a. Cover exposed internal engine area to prevent
contamination from loosened threadlocker.
b. Verify that no foreign material in the threaded hole.
1. Verify that all threaded holes are free from oil and
threadlocking residue.
2. Install rocker cover and new gasket.
a. Verify torque of stud (4).
Torque: 10.2-13.6 N·m (90-120 in-lbs) Lower rocker
cover stud
b. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to 5-7
screw threads.
c. Start all screws.
d. Hold hex on stud (4) when tightening center screw
(3).
e. See Rocker Cover Tightening Sequence. Tighten in
sequence shown.
Torque: 13.6-15.8 N·m (120-140 in-lbs) Upper
rocker cover screws
1. See Engine Wire Harness. Attach engine harness and
caddy.
a. Gently bend tabs outward at rear of electrical caddy to
allow rear mounting pins to engage holes in
backbone.
b. Install push/lock pin through electrical caddy mounting
hole on right side of backbone.
c. Connect front ACR (10).
d. Connect rear ACR (9).
e. Attach rear knock sensor (8) to electrical caddy.
f. Connect rear knock sensor.
2. Install upper cooling lines. See Prepare.
3. Install upper front engine mount. See Prepare.
4. Install spark plug cables. See Remove.
5. Install fuel tank. See Prepare.
6. Install seat. See Remove.
7. Connect negative battery cable. See Main Fuse.
1
Gasket
2
Rocker cover
3
Center screw
4
Stud
Figure 1. Rocker Cover Screws
Figure 2. Rocker Cover Tightening Sequence
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. See Breather. Remove screw (1).
2. Remove breather assembly (2).
NOTE
Breather assembly contains no service parts. Replace as an assembly.
1. See Figure 1. Lubricate O-ring (3).
2. Install breather with screw (1). Tighten to 10.2-13.6 N·m
(90-120 in-lbs).
1
Screw
2
Breather assembly
3
O-ring
Figure 1. Breather
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.
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