Harley Davidson 1940-58 45" SV & SERI-CAR. Service manual — page 2

If seat is refaced with a cutter it will not be as smooth as when refaced with a grinder and a greater amount of lapping will be necessary to attain a perfect seat.

When a new valve guide is installed, it is not likely to have exactly the same relation that the old guide had to valve seat. Therefore, it is especially important, after fitting new guides, that seats be carefully refaced to make them concentric with guides and assure perfect alignment and matching of valve face and valve seat.

Testing Valve Seating

If valve seats and valve faces have been smoothly and accurately refaced with grinders available for this purpose, very little grinding or lapping will be required to complete seating operation. Apply a light coat of fine compound to valve face, insert it in cylinder and give it a few oscillations with a screwdriver—just enough to give face and seat a lapped finish. Remove valve, wash valve face and seat thoroughly with clean gasoline and allow to dry, or dry with compressed air. If inspection shows an unbroken lapped finish around both valve face and seat, valve is well seated. If lapped finish is not complete around either valve or seat, further seating is required.

Valve Springs

Inspect each spring in comparison with a new one; if a spring is shrunken more than Vt". replace with a new one.

Re-installing Valve Assemblies

To re-install valve assembly in cylinder, reverse removal procedure. Be sure all parts are clean. Valve sects and stems should be lightly oiled. Install new seals between upper valve covers and guides; also, if needed, new packing between valve covers.

Caution: Intake and exhaust valves are of different materials and must not be interchanged. Intake valves are marked (IN) on head; exhaust valves are marked (EX).

Timing Gear Shaft Bushings

Check timing gear shaft bushings in right side crankcase and timing gear case cover for extent of wear. These bushings normally do not require renewal until an engine has run extremely high mileage. However, if engine has been run under dusty conditions and, as a result of lack of attention to air cleaner, considerable road dust has been taken into engine through carburetor, abnormal wear may be found at any mileage.

Specified clearance for camshaft bearings is .0005” to .001". When bushings are worn to the extent of increasing clearance to .002" or more, they should be renewed, as the cam gears are likely to become very noisy with excessive clearance in these bearings. Worn bushings in case and cover, with both
ends open, can be pushed out with an arbor press, supporting case or cover on a suitable collar or sleeve at the flanged end of bushing. Bushings in cover, with o.ie end blind, must be pulled with manufacturer's special tool number 11952-36.

Before removing old bushings, note location of oil transfer hole in pinion shaft bushing in timing gear case cover. New bushing must be installed with oil transfer hole in same location (30° ahead of vertical center line), as normal function of oiling system depends upon correct location of this hole.

After new bushings have been pressed in they must be dowel pinned to prevent them from turning, by drilling a hole with a number 31 drill through bushing flange and into aluminum. The hole should be of a depth so when dowel pin (part number 661-31) is driven in and bottomed, its end will be slightly below face of bushing flange. Peen bushing around dowel pin hole to prevent pin from coming out. Oil holes for lubrication of cover bushings will have to be drilled in three of the bushings, according to holes already in bushing bosses.

Attach cover to right case and line-ream with special reamers, manufacturer's numbers 12135-37, 12133-37 and 12132-36.

Valve Tappets and Valve Tappet Guides

Inspect valve tappets for excessive clearance in guides. Also check tappet rollers for excessive bearing looseness and damaged roller faces.

Tappets and tappet guides are normally long-life parts that seldom require replacement. Tappets are originally fitted with .0005" to .001" clearance in guides. Guides ате a light press fit in crankcase and are secured with screws. To remove a lappet, it is first necessary to pull tappet guide out of crankcase. After removing screws, heat case around guide, and pull with manufacturer's tool number 11960-38. Cam gear must be assembled in case for tappet to butt against when using puller.

Excessive tappet-guide clearance is serviced by fitting new tappet, and new guide if needed. It is also recommended practice to renew tappet complete