Top End Overhaul 3.9: Disassembly

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TOP END OVERHAUL 3.9
DISASSEMBLY
1. Use low pressure spray to thoroughly clean exterior sur-

faces of engine prior to disassembly. Dirt caked on cool-
ing fins and other areas can fall into crankcase bore or
stick to subassemblies as parts are removed. Abrasive
particles can damage machined surfaces or plug oil pas-
sageways.
NOTE
Rocker cover and rocker housing bolts have both an internal
and external hex, which allows the bolts to be removed with
either a short 3/16 inch allen wrench (tight spaces), or a 7/16
inch socket or open end/box wrench (open spaces). See Fig-
ure 3-20. The internal hex is necessary if the engine is left in
the chassis for service. In these cases, the short 3/16 inch
allen wrench is indispensable when removing the rocker
f1603x3x
cover and rocker housing bolts on the left side of the engine
(particularly the rear) where there is close proximity to the Figure 3-21. Remove Spring Cap Retainer
frame. A dimple or cavity cast into the left side of the upper
frame crossmember also aides in removing the rocker arm
support plate assembly. 4. Insert the blade of a small screwdriver into cast loop of
spring cap retainer (at top of upper push rod cover), and
2. Alternately loosen the six rocker cover bolts following the while pushing down on spring cap, rotate bottom of
pattern shown in A of Figure 3-22. Remove the rocker screwdriver toward outboard side to remove. See Figure
cover bolts. 3-21. Repeat step on second push rod cover.
5. Collapse upper and lower push rod covers.
NOTE
6. To remove the rocker arm support plate, both lifters of
It is assumed that each step performed on one cylinder is the cylinder being serviced must be on the base circle
automatically repeated on the other. (or lowest position) of the cam.
3. Remove the rocker cover and gasket. Discard the gas-

ket. CAUTION
Removing the rocker arms with the valve train loaded

can result in bent push rods, damaged bushings or
warped support plate.
Internal Hex Lock Patch
3/16 Inch Allen Wrench To find the base circle, it is first necessary to rotate the
engine. Based on the level of disassembly required,
three methods of engine rotation are presented below.
a. With primary cover installed - With vehicle on center
stand, place the transmission in 5th gear and rotate
rear wheel in a clockwise direction (as viewed from
right side) until the base circle is found. See step
6(d) to find the base circle.
b. With primary cover removed - Remove primary
External Hex Captive cover. Place the transmission in neutral. Fit a 1-1/2
7/16 Inch Open End Wrench Washer
f1570x3x inch socket on the compensating sprocket shaft nut.
Rotate nut in a counterclockwise direction until the
base circle is found. See step 6(d) to find the base
Figure 3-20. Rocker Cover Bolt (1-1/4 Inch) circle.
2004 Touring: Engine 3-33

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4 3
f2164x3x 5 1 f2163x3x
Breather
Assembly
2
1
FRONT
6 2
3 4
6 2
3
4
1 2
REAR
3
4 1
5
Remove Two Breather Assembly Bolts.
A Loosen Six Rocker Cover Bolts. B Alternately Loosen Four Rocker Arm Bolts
1/4 Turn in Pattern Shown.
f2165x3x 2 f2166x3x
6 4 4
2
O-Ring
FRONT
1
3
3 3 5 1
5 1 3
1
REAR
4
2 6 4
Alternately Loosen Four Cylinder Head
C Loosen Six Rocker Housing Bolts. D Bolts 1/4 Turn in Pattern Shown.
Figure 3-22. Top End Disassembly
3-34 2004 Touring: Engine

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9. When the rocker arm support plate bolts are free of the
cylinder head, lift the support plate assembly from the
rocker housing. See Section 3.11 SUBASSEMBLY SER-
VICE AND REPAIR, ROCKER ARM ASSEMBLY.
NOTE
Always service each cylinder separately. After the first cylin-
der is serviced the engine must be rotated to find the base
circle on the second cam. Service on the remaining cylinder
can then proceed.
10. Remove the intake and exhaust push rods. Tag the push
f1527x3x
rods as they are removed, so that they can be installed
in their original locations. Also take note of their orienta-
tion to be able to discern top from bottom at time of
Figure 3-23. Sprocket Shaft Engine Rotation Tool
installation.
11. Remove push rod covers from cylinder head and lifter
cover bores. Remove three O-rings from push rod cov-
CAUTION ers and discard. If O-ring is missing from upper push rod
cover, be sure to dislodge it from the cylinder head bore.
Do not attempt to rotate engine by removing cam cover
and placing socket on crank or primary cam sprocket 12. Using a crosswise pattern, remove the four allen head
flange bolt. Head of flange bolt can break off possibly socket screws to release the lifter cover. Remove the
resulting in damage to flywheel or camshaft. lifter cover and gasket. Discard the gasket.
13. Remove the anti-rotation pin. Remove the hydraulic lift-
c. With engine mounted in engine stand - Fashion tool ers. Tag lifters as they are removed, so that they can be
as follows: Obtain used or discarded compensating installed in their original locations. Also take note of their
sprocket shaft extension (HD-40266-85). Weld a 13/ orientation (by observing location of the oil hole) to be
16 inch socket with a 1/2 inch drive to outboard side able to discern front from rear at time of installation.
of extension. See Figure 3-23. Install tool on
sprocket shaft and rotate in a counterclockwise 14. Place the lifters in clean plastic bags to keep out dust,
direction until the base circle is found. See step 6(d) dirt and debris. See Section 3.11 SUBASSEMBLY SER-
to find the base circle. VICE AND REPAIR, PUSH RODS/LIFTERS/COVERS.
15. Remove O-ring from groove around breather baffle hole
d. Finding the base circle: Using one of the methods in rocker housing. Discard the O-ring.
above, rotate engine until piston is at Top Dead
16. Alternately loosen the six rocker housing bolts following
Center (TDC) of compression stroke. To accomplish
the pattern shown in C of Figure 3-22. Remove the
this, first raise lower push rod cover to access intake
rocker housing bolts.
lifter (inside hole of lifter cover). Place index finger
on top of the intake lifter. While rotating engine, feel 17. Remove the rocker housing and gasket. Discard the
lifter rise (valve open) and fall (valve closed). Now gasket.
place finger tightly over spark plug hole and rotate
engine again. In the compression stroke, air will be CAUTION
forced out against your finger until the piston
reaches the TDC position. Stop engine rotation To prevent distortion of the cylinder head, cylinder and
when the flow of air through the spark plug hole cylinder studs, gradually loosen the cylinder head bolts
stops. Direct the beam of a small flashlight into in the specified pattern.
spark plug hole to verify piston is at TDC. Both
18. Alternately loosen each of the four cylinder head bolts
intake and exhaust valves are now closed and the
just 1/4 turn following the pattern shown in D of Figure 3-
push rods are in the unloaded position (and should
22. Continue turning the bolts in these increments until
turn freely).
loose. Remove the cylinder head bolts.
7. Remove two bolts to release breather assembly from the NOTE
rocker arm support plate. See B of Figure 3-22. See
Save the cylinder head gasket if not damaged. The gasket is
Section 3.11 SUBASSEMBLY SERVICE AND REPAIR,
needed to install the CYLINDER TORQUE PLATES (HD-
BREATHER ASSEMBLY.
42324A) when measuring, boring or honing of the cylinder is
8. Alternately loosen each of the four rocker arm support required.
plate bolts just 1/4 turn following the pattern shown in B 19. Remove cylinder head and head gasket. See Section
of Figure 3-22. Continue turning the bolts in these 3.11 SUBASSEMBLY SERVICE AND REPAIR, CYLIN-
increments until loose. DER HEAD.

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23. Remove O-ring seal from the bottom of the cylinder liner.
Discard O-ring seal. See Section 3.11 SUBASSEMBLY
SERVICE AND REPAIR, CYLINDER.
24. Remove O-ring from ring dowel on “downside” of cylin-
der deck. Discard the O-ring.
1CAUTION
Always wear proper eye protection when removing cir-
Claw clips. Slippage may propel the ring with enough force to
cause eye injury.
Figure 3-24. Piston Pin Circlip 25. Verify that clean shop towels are properly positioned
Remover/Installer (Part No. HD-42317A) over the crankcase bore to prevent the piston pin circlip
from falling into the crankcase.
f1635x3x 26. Remove the piston pin circlip as follows:

a. Insert the PISTON PIN CIRCLIP REMOVER/
INSTALLER (HD-42317A) into the piston pin bore
until claw on tool is positioned in slot of piston
(directly under circlip). See Figure 3-25.
b. Squeeze the handles of the tool together and pull
from bore. In the event that the circlip should fly out,
hold a shop towel over the bore during removal.
Remove circlip from claw and discard.
NOTE
It is not necessary to remove both piston pin circlips during
Slot piston removal. Leave the second circlip in the pin bore.
27. Remove the piston pin. If piston pin is difficult to remove,

use PISTON PIN REMOVER (HD-42320A). See Figure
3-26. Proceed as follows:
Figure 3-25. Remove Piston Pin Circlip
a. Remove acorn nut and spacer from rod end of tool.
b. Slide rod end through piston pin. Install spacer and
acorn nut to end of rod.
20. Raise the cylinder just enough to place clean shop tow-
els under the piston. This will prevent any dirt or debris, c. Position rubber-coated tips of tool on flat each side
such as broken ring pieces, from falling into the crank- of pin bore.
case bore. d. Turn handle in a clockwise direction until piston pin
is pulled free of bore. See Figure 3-27.
CAUTION 28. Remove the piston. Be sure to hold the rod shank
upright to prevent it from striking the crankcase. Place a
Exercise caution to avoid bending the cylinder studs. piece of foam-type water pipe insulation around each
Even a slight bend or nick can cause a stress riser lead- rod (about 3 inches long with a 2-1/4 inch O.D. and a 1
ing to stud failure. inch I.D.) to prevent damage if contact should occur.
21. Carefully remove the cylinder to avoid bending the cylin- 29. Turn the piston over and mark the pin boss with the
der studs. As the piston becomes free of the cylinder, letters “F(ront)” or “R(ear)” to identify location. See Sec-
hold it upright to prevent it from striking the studs or tion 3.11 SUBASSEMBLY SERVICE AND REPAIR,
dragging across the stud thread area. Mark the cylinder PISTON and UPPER CONNECTING ROD.
“F(ront)” or “R(ear)” to identify location. 30. If performing a top end overhaul only, see Section 3.11
SUBASSEMBLY SERVICE AND REPAIR, TOP END,
22. Slide plastic tubing, rubber hose or conduit over each before proceeding to Section 3.9 TOP END OVERHAUL,
cylinder stud. Material approximately 6 inches (152 mm) ASSEMBLY, which follows. If performing a complete
long with an I.D. of 1/2 inch (12.70 mm) will protect cylin- engine overhaul, see Section 3.10 BOTTOM END
der studs and piston from damage. OVERHAUL, DISASSEMBLY.

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5. Insert piston pin through pin bore and upper connecting
rod bushing. Push pin until it contacts circlip installed in
opposite pin boss.
CAUTION
Do not reuse piston pin circlips. The circlips may weaken

during removal causing them to break or dislodge dur-
ing engine operation, a condition that will result in
engine damage.
6. Place clean shop towels over the cylinder and lifter

Figure 3-26. Piston Pin Remover (Part No. HD-42320A) bores to prevent the piston pin circlip from falling into the
crankcase. Verify that the circlip groove is clean and free
of dirt and grime.
Spacer and
Acorn Nut Handle
7. Install new piston pin circlip with the PISTON PIN CIR-
CLIP REMOVER/INSTALLER (HD-42317A). Proceed as
follows:
a. Slide circlip down nose of tool until it contacts claw.

Lightly squeeze handles of tool to capture circlip in
claw.
b. Releasing pressure on handles, rotate circlip so that

the end gap is centered at top of tool and then
recapture in claw.
c. Tilt the circlip forward until the end gap contacts

nose of tool. See upper frame of Figure 3-28.
d. Insert the tool into the piston pin bore until claw is
aligned with slot in piston.
f1640x3x
Rubber Coated Tip
e. Firmly push the tool into the piston pin bore until it
bottoms. Release handles and remove tool.
Figure 3-27. Remove Piston Pin
f. Inspect the circlip to verify that it is fully seated in
the groove.
ASSEMBLY
CAUTION
NOTE
O-rings that are missing, distorted, pinched or otherwise
It is assumed that each step performed on one cylinder is damaged will result in either oil leakage or low oil pres-
automatically repeated on the other. sure. Use of the wrong O-ring will have the same results.
Since many O-rings are similar in size and appearance,
1. Slide plastic tubing, rubber hose or conduit over each always use new O-rings keeping them packaged until
cylinder stud, if removed. Material approximately 6 use to avoid confusion.
inches (152 mm) long with an I.D. of 1/2 inch (12.70 mm)
will protect cylinder studs and piston from damage. 8. Install new O-ring over “downside” cylinder deck ring
dowel (that is, rear dowel on rear cylinder, front dowel on
2. Apply clean H-D 20W50 engine oil to piston pin, piston
front cylinder). Apply a very thin film of clean H-D 20W50
bosses and upper connecting rod bushing.
engine oil to O-ring before installation. Verify that O-ring
3. Remove water pipe insulation from rod shank. is properly seated in groove.
4. Place piston over rod end so that the arrow stamped at 9. Install new O-ring seal at the bottom of the cylinder liner.
the top of the piston points toward the front of the Apply a very thin film of clean H-D 20W50 engine oil to
engine. O-ring before installation.

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b. With the forked end of the tool pointing towards the
f1564x3x center of the engine and the adjustable knobs fac-
ing downward, capture shank of connecting rod in
fork. Lay tool on cylinder deck so that adjustable
knobs contact wall of cylinder bore.
Circlip c. Rotate engine until piston skirt is centered and
firmly seated on top of support plate. See Figure 3-
30.
14. Install cylinder as follows:
a. Obtain the PISTON RING COMPRESSOR (HD-
96333-51C).
b. Fit tabs on pliers into slots of ring compressor band
(HD-96333-103). The arrow stamped on the band
indicates the side that faces up, so disregard the
f1636x3x
word “bottom.” Place band around piston. Press the
lever on the right side of the pliers to open the jaws
for band expansion.
c. Orient tool so that the top of the band is positioned
between the top compression ring and the piston
crown. Tightly squeeze handles of tool to compress
piston rings. The racheting action of the tool allows
release of the handles after the rings are com-
pressed.
Figure 3-28. Install Piston Pin Circlip
NOTE
Figure 3-29. Piston Support Plate (Part No. HD-42322)
Excessive lubrication of cylinder sleeve O-ring seal will result
in oil weepage between cylinder and crankcase as engine is
run, a condition that may be incorrectly diagnosed as an oil
Piston
leak. Support Plate
10. Verify that the piston ring end gaps are properly stag-
gered. If necessary, see Section 3.11 SUBASSEMBLY
SERVICE AND REPAIR, PISTON.
11. Apply clean H-D 20W50 engine oil to piston, piston rings
and cylinder bore.
12. Remove plastic tubing or rubber hose from cylinder

studs. Rotate engine until piston is at top dead center. If
necessary, see step 31 for methods of engine rotation.
13. Install the PISTON SUPPORT PLATE (HD-42322). Pro-

ceed as follows:
a. Slide both adjustable knobs on tool down slots away

f1612x3x
from forked end. Tighten knobs when contact is
made with flats at end of slots.
Figure 3-30. Install Piston Support Plate

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h. Carefully set the cylinder over the two ring dowels in
the cylinder deck. Push down on the cylinder until it
is fully seated in the crankcase bore.
NOTE
To hold the first cylinder in position while installing the sec-
ond, install threaded cylinders (HD-95952-1) from CON-
NECTING ROD CLAMPING TOOL (HD-95952-33B) onto
cylinder studs with the knurled side down. This will prevent
the piston rings from raising the cylinder as the engine is
rotated to bring the other piston into position for installation of
the second cylinder. See Figure 3-33.
Figure 3-31. Piston Ring Compressor 15. With the part number topside, place the head gasket
(Part No. HD-96333-51C) over the two ring dowels in the upper flange of the cylin-
der.
f1613x3x Ring Compressor Band 16. Note that the word “Front” or “Rear” is cast into the top of
(3-5/8 - 3-7/8 Inches) the cylinder head to ensure proper installation. With the
Part No. HD-96333-103 indent in the cooling fins facing the right side of the
engine (for accommodation of the push rods and cov-
ers), carefully set the cylinder head over the two cylinder
ring dowels. To avoid damage to machined surfaces or
ring dowels, lower the cylinder head at an angle that
closely approximates the angle of the crankcase.
CAUTION
Thoroughly clean and lubricate the threads of the cylin-

der head bolts before installation. Friction caused by dirt
BO
TTO
M and grime will result in a false torque indication.
Pliers
Threaded
Cylinder
Figure 3-32. Install Cylinder
d. Note that the cylinders should have been marked

with the letters “F(ront)” or “R(ear)” to identify
location. With the indent in the cooling fins facing
the right side of the engine, gently slide cylinder
over the cylinder studs and the piston crown resting
it on the top of the ring compressor band.
e. Place the palms of both hands at the top of the cyl-
inder. Push down on the cylinder with a sharp, quick
motion to pass the piston ring area. See Figure 3-
32.
f. Rotate the engine slightly to raise piston off support
plate. Remove pliers from band and then remove
band from around shank of connecting rod. Remove
piston support plate. f1518b3x
g. Remove shop towels from around the crankcase

bore exercising caution to keep out any dirt or Figure 3-33. Install Threaded Cylinders to Studs
debris. (Part No. HD-95952-1)

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17. Lightly oil threads and shoulders of cylinder head bolts

S = Short Bolt
with clean H-D 20W50 engine oil.
A FRONT
L = Long Bolt
18. Start the cylinder head bolts onto the cylinder studs, two
L short bolts on the left side of the engine, two long bolts
4 on the right.
S
2 19. Tighten the four cylinder head bolts as follows:
CAUTION
Improperly tightened cylinder head bolts may result in

gasket leaks, stud failure and distortion of the cylinder
and/or cylinder head.
a. Alternately turn each cylinder head bolt until finger

tight.
b. Tighten the cylinder head bolts to 120-144 in-lbs
(13.6-16.3 Nm) in the sequence shown in A of Fig-
1 3 ure 3-34.
S L
c. Following the same sequence, tighten each bolt to
L 15-17 ft-lbs (20.3-23.1 Nm).
REAR
3 d. Using a grease pencil, mark a straight line on the
S cylinder head bolt continuing the line over onto the
1 cylinder head. Using the marks as a guide, turn
each bolt 1/4 turn or 90 degrees. See B of Figure 3-
34. Be sure to tighten the cylinder head bolts in the
sequence shown in A of Figure 3-34.
NOTE
For best results, obtain Snap-on® Torque Angle Gauge
TA360.
20. Install a new rocker housing gasket on the cylinder head

flange.
2
S 4 CAUTION
L f2166x3x
Even though all bolt holes (rocker housing, rocker arm
support plate and breather assembly) may appear to be
B in alignment, the rocker housing gasket may be installed
upside down. An upside down gasket will result in an
open breather channel causing an oil leak when the vehi-
cle is started, possibly resulting in engine and/or prop-
erty damage.
21. Verify that the rocker housing gasket is installed cor-

rectly by noting that the breather channel is concealed.
See Figure 3-35.
22. With the indent facing forward, place the rocker housing
into position aligning the holes in the housing with those
in the gasket.
23. Apply a small dab of Loctite Medium Strength Thread-
locker 243 (blue) to threads of six rocker housing bolts.
f1583x3x Start the rocker housing bolts, two long bolts on the left
side of the engine, four intermediate bolts in the interior.
Figure 3-34. Cylinder Head Torque Sequence Alternately tighten the bolts to 120-168 in-lbs (13.6-18.9
and Bolt Size Nm) in the pattern shown in Figure 3-36.

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f1577x3x f1576x3x
Breather Channel Concealed Breather Channel Exposed
CORRECT WRONG
Figure 3-35. Install Rocker Housing Gasket (Rear Cylinder Shown)
L S = Short Bolt, 1 In.

NOTE f2165x3x
I = Intermediate Bolt, 1-1/4 In.
2 I L = Long Bolt, 1-3/4 In.
Rocker housing and rocker cover bolts have both an internal 6
and external hex, which allows the bolts to be installed with 4
either a short 3/16 inch allen wrench (tight spaces), or a 7/16 I
inch socket or open end/box wrench (open spaces). If the O-Ring
engine is left in the chassis for service, the short 3/16 inch
allen wrench is indispensable when installing the rocker
housing and rocker cover bolts on the left side of the engine FRONT
(particularly the rear) where there is close proximity to the
frame.
NOTE
If the engine was left in the chassis for service, final tighten
the rear left rocker housing bolt (rear cylinder) using a torque I
wrench with a 1/4 inch drive. Since this tool may not be avail- 3 1
5 I
able in foot-pounds, tighten the bolt to 120-168 in-lbs. L 3 Torque: 120-168 in-lbs
L 5 I 1
I
CAUTION

damaged will result in either oil leakage or low oil pres-
sure. Use of the wrong O-ring will have the same results.
REAR
always use new O-rings keeping them packaged until
use to avoid confusion.
24. Install new O-ring in groove around breather baffle hole
in rocker housing. Apply a thin film of clean H-D 20W50
engine oil to O-ring before installation. See Figure 3-36. 4
2 6 I I
25. Install the hydraulic lifters in the crankcase bores with L
the flats facing forward and rearward. To preserve exist- Install Six Rocker Housing Bolts.
ing wear patterns, orientation of the oil hole (inboard or
outboard) should have been noted during disassembly. Figure 3-36. Rocker Housing Torque Sequence
To avoid damage, do not drop lifters onto cam lobes. and Bolt Size

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Do not install the spring cap retainers at this time. To
Anti-Rotation ensure proper installation, take note of Table 3-3.
Pin
Lifter Cover 30. Install the push rods in their original positions. Be sure to
remove any tags that may have been used for marking
location and orientation. To ensure proper installation,
take note of Table 3-3. For example, if reassembling the
rear cylinder, slide the intake push rod (silver) through
the front hole in the rocker housing engaging the lifter
socket in the inside hole of the lifter cover. Slide the
exhaust push rod (black) through the rear hole in the
rocker housing engaging the lifter socket in the outside
hole of the lifter cover.
31. To install the rocker arm support plate, both lifters of the
cylinder being serviced must be on the base circle (or
lowest position) of the cam.
CAUTION
Installing the rocker arms and rotating the engine with

the valve train loaded can result in bent push rods and/
Gasket or valve damage.
Ribs f1606x3x
To find the base circle, it is first necessary to rotate the
Figure 3-37. Install Lifters and Lock Position engine. Based on the level of disassembly, three meth-
With Anti-Rotation Pin ods of engine rotation are presented below.
a. With primary cover installed - With vehicle on center

26. Place anti-rotation pin on the machined flat between the stand, place the transmission in 5th gear and rotate
blocks cast into the crankcase. See Figure 3-37. rear wheel in a clockwise direction (as viewed from
27. Install a new lifter cover gasket aligning the holes in the right side) until the base circle is found. See step
gasket with those in the cover. 31(d) to find the base circle.
b. With primary cover removed - Remove primary

CAUTION cover. Place the transmission in neutral. Fit a 1-1/2
inch socket on the compensating sprocket shaft nut.
Movement or loss of the anti-rotation pin can result in Rotate nut in a counterclockwise direction until the
lifter rotation causing catastrophic engine damage. base circle is found. See step 31(d) to find the base
28. Install the lifter cover and start the four allen head socket circle.
screws (1/4 x 1 inch). During installation, verify that the
anti-rotation pin is held in place by the ribs cast into the
inboard side of the lifter cover. See Figure 3-37. Tighten CAUTION
the lifter cover screws to 90-120 in-lbs (10.2-13.6 Nm) in Do not attempt to rotate engine by removing cam cover
a crosswise pattern. and placing socket on crank or primary cam sprocket
29. Hand compress the push rod cover assembly and fit the flange bolt. Head of flange bolt can break off possibly
O-ring end of the lower push rod cover into the lifter resulting in damage to flywheel or camshaft.
cover bore. Expanding the assembly, fit the O-ring end of
the upper push rod cover into the cylinder head bore. c. With engine mounted in engine stand - Fashion tool
as follows: Obtain used or discarded compensating
Table 3-3. Push Rod/Cover Locations sprocket shaft extension (HD-40266-85). Weld a 13/
16 inch socket with a 1/2 inch drive to outboard side
Cylinder Head/ of extension. See Figure 3-23. Install tool on
Cover and Lifter Cover
Cylinder Rocker Housing
Push Rod* Bore sprocket shaft and rotate in a counterclockwise
Bore
direction until the base circle is found. See step
Intake Inside Rear 31(d) to find the base circle.
Front
Exhaust Outside Front
d. Finding the base circle: Using one of the methods
Intake Inside Front above, rotate engine until piston is at Top Dead
Rear
Exhaust Outside Rear Center (TDC) of compression stroke. To accomplish
* Push Rods Are Color Coded - Intake (Silver), Exhaust (Black)

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f2163x3x f2164x3x S = Short Bolt, 1 In.

I = Intermediate Bolt, 1-1/4 In.
Rocker Arm Torque: L = Long Bolt, 1-3/4 In.
18-22 ft-lbs
1 3 5 4
S L
Breather
Assembly Torque: 15-18 ft-lbs
Torque: 90-120 in-lbs 2
1 L
S
FRONT
2 6
4 3 L
S
6 L
2 3
4 S
1 2
S L
REAR
3 4
1 L
5
S
A Alternately Tighten Four Rocker Arm Bolts

1/4 Turn in Pattern Shown.
B Install Six Rocker Cover Bolts.
Figure 3-38. Rocker Arm/Rocker Cover Torque Sequence and Bolt Size
this, first raise lower push rod cover to access intake 34. Alternately tighten each of the four rocker arm support
lifter (inside hole of lifter cover). Place index finger plate bolts just 1/4 turn following the pattern shown in A
on top of the intake lifter. While rotating engine, feel of Figure 3-38. Continue turning the bolts in these
lifter rise (valve open) and fall (valve closed). Now increments until snug. Following the same numerical
place finger tightly over spark plug hole and rotate sequence, tighten the bolts to 18-22 ft-lbs (24.4-29.8
engine again. In the compression stroke, air will be Nm).
forced out against your finger until the piston
35. Alternately tighten the two breather assembly bolts to
reaches the TDC position. Stop engine rotation
90-120 in-lbs (10.2-13.6 Nm).
when the flow of air through the spark plug hole
stops. Direct the beam of a small flashlight into NOTE
spark plug hole to verify piston is at TDC. Both
intake and exhaust valves are now closed and the
the rocker arm support plate bolt on the rear left side of the
push rods are in the unloaded position.
rear cylinder using a 3/8 inch drive torque wrench with a 1/2
32. Place the rocker arm support plate assembly into the inch flank drive “dog bone” torque adapter (Snap-On
rocker housing. Start the four rocker arm support plate FRDH161). Since any extension can act as a torque multi-
bolts into the cylinder head. plier, the torque wrench must be perpendicular to the torque
adapter when the bolt is tightened. The 90 degree orientation
33. Place breather assembly at top of rocker arm support between the tools cancels the multiplier effect and prevents
plate. Apply a small dab of Loctite Medium Strength the bolt from being over-tightened. If the adapter is kept inline
Threadlocker 243 (blue) to threads of two breather with the torque wrench, the multiplier effect is in force and
assembly bolts. Start bolts into cylinder head. distortion of the rocker housing will occur.

HOME
39. Apply a small dab of Loctite Medium Strength Thread-
locker 243 (blue) to threads of six rocker cover bolts.
Start the rocker cover bolts, three short bolts on the left
side of the engine, three long bolts on the right. Tighten
the bolts to 15-18 ft-lbs (20.3-24.4 Nm) in the pattern
shown in B of Figure 3-38.
NOTE
the three rocker cover bolts on the left side of the rear cylin-
der using a 3/8 inch drive torque wrench with a 7/16 inch
flank drive “dog bone” torque adapter (Snap-On FRDH141).
Since any extension can act as a torque multiplier, the torque
wrench must be perpendicular to the torque adapter when
the bolts are tightened. The 90 degree orientation between
the tools cancels the multiplier effect and prevents the bolts
from being over-tightened. If the adapter is kept inline with
the torque wrench, the multiplier effect is in force and distor-
tion of the rocker cover will occur.
f1604x3x
40. If engine was left in the chassis for service, see Section
Figure 3-39. Install Spring Cap Retainer 3.6 ASSEMBLING MOTORCYCLE AFTER STRIPPING.
If engine was removed for service, see Section 3.8
INSTALLING ENGINE IN CHASSIS.
36. Lift up lower push rod covers and verify that both push
rods spin freely.
NOTE
Always service each cylinder separately. After the first cylin-
der is serviced the engine must be rotated to find the base
circle on the second cam. Service on the remaining cylinder
can then proceed.
37. Complete installation of the push rod covers as follows:

a. Verify that the O-ring ends of the upper and lower
push rod covers fit snugly into the cylinder head and
lifter cover bores.
b. Lodge the upper edge of spring cap retainer into the
cylinder head bore leaving the bottom edge free.
c. Insert blade of small screwdriver between bottom
edge of spring cap retainer and top of spring cap.
d. While simultaneously depressing spring cap with tip
of screwdriver, use forefinger to slide bottom edge
of spring cap retainer down shaft towards tip of
screwdriver blade. As spring cap reaches its full
length of travel, spring cap retainer should be in
approximate position against upper push rod cover.
See Figure 3-39.
NOTE
For best results, be sure that screwdriver, spring cap and
spring cap retainer are free of grease and oil.
e. Verify that spring cap retainer is seated tightly

against upper push rod cover.
38. Install a new rocker cover gasket on the rocker housing
flange. Place the rocker cover into position aligning the
holes in the cover with those in the gasket.

HOME
BOTTOM END OVERHAUL 3.10
DISASSEMBLY 3. Using a colored marker, mark the crank sprocket and

one of the links of the primary cam chain. Maintaining
the original direction of rotation during assembly may
1. See Section 3.9 TOP END OVERHAUL, DISASSEM- prolong service life.
BLY. If only servicing cam compartment components,
4. Remove the flange bolt and flat washer from the crank
see steps 1-11. If performing a complete engine over-
sprocket. See Figure 3-40.
haul, reference steps 1-29.
5. Remove the flange bolt and flat washer from the primary
NOTE cam sprocket.
NOTE
The cam support plate, lifter cover and crankshaft position
If too much loctite, or perhaps the wrong loctite, was used to
sensor mount all use the same short allen head socket screw
install the primary cam sprocket flange bolt, it may be very
(1/4 x 1 inch). Only the cam cover uses the longer screw (1/4
difficult to remove. In these cases, break down loctite using
x 1-1/4 inches). For ease of assembly, do not mix short and
heat from a small propane torch. Apply flame evenly around
long screws. Store long screws inside cam cover to avoid
bolt head in a circular motion, but not for so long as to turn
confusion. The short screws are interchangeable.
bolt blue. Do not direct heat at chain tensioner assembly and
other components or damage will result. Other methods of
2. Remove the ten allen head socket screws to release the removal, such as use of a large breaker bar, also may result
cam cover. Remove and discard the cam cover gasket. in damage to chain drive and other components.
Flange Bolt and

Flat Washer Cleaning
Right Plug
Crankcase Half
Front
Camshaft
Primary Cam
Sprocket
Primary Michalski
Cam Chain
Chain Guide
Primary Cam Chain

Tensioner
Crank
Sprocket
Oil Pressure Flange Bolt and
Relief Valve f2141x3x
Flat Washer
Figure 3-40. Cam Support Plate Assembly

HOME
7. Insert small pry bar (seal remover) between inboard side
of primary cam sprocket and cam support plate. Working
Tensioner around its circumference, carefully ease primary cam
Unloader sprocket off splines of rear camshaft until loose.
Slot
8. Ease off crank sprocket with a slightly smaller pry bar
(seal remover). Remove the primary cam sprocket, pri-
mary cam chain and crank sprocket.
9. Remove the primary cam sprocket spacer from the rear
camshaft.
Retention Pins 10. Squeeze tabs to remove chain guide from between
blocks cast into cam support plate.
Figure 3-41. Cam Chain Tensioner Unloader 11. Release the cam support plate from the oil pump flange.
with Retention Pins (Part No. HD-42313) Alternately loosen and then remove the four allen head
socket screws following the pattern shown in B of Figure
3-50.
12. Release the cam support plate from the crankcase
flange. Alternately loosen and then remove the six allen
head socket screws following the pattern shown in A of
Figure 3-50.
13. Two ring dowels in crankcase flange locate cam support
plate (lower rear, upper front). See Figure 3-43. Insert
small pry bar (seal remover) between inboard side of
cam support plate and crankcase flange in area adja-
cent to ring dowels. Alternately work each side free and
then carefully ease cam support plate from end of crank-
shaft. See Section 3.11 SUBASSEMBLY SERVICE AND
REPAIR, CAM SUPPORT PLATE.
f1573b3x O-Ring Right

f2140x3x
Blind Hole
Crankcase Half
Figure 3-42. Retract Primary Cam Chain Tensioner Ring
Dowel
1WARNING
Use extreme caution when operating propane torch.
Read the manufacturers instructions carefully before
use. Do not direct open flame or heat toward any fuel
system component. Extreme heat can cause fuel ignition
and explosion. Inadequate safety precautions could
result in death or serious injury.
6. Using the CAM CHAIN TENSIONER UNLOADER (HD-

42313), retract the primary cam chain tensioner as fol-
lows:
a. With the handle pointing toward the front of the cam
support plate, place cup of tool over spring coil. Cor-
rectly positioned, the slot in the tool should be adja-
cent to the hole in the tensioner. See Figure 3-42.
b. Rotate the handle of the tool in a counterclockwise
direction until the hole in the tensioner is aligned
Ring
O-Ring
with the hole in the boss of the cam support plate. Oil Feed Hole O-Ring
Dowel Oil Pump
c. Insert a retention pin through the hole in the ten-
sioner and into the hole in the cam support plate. Figure 3-43. Oil Pump Assembly

HOME
1CAUTION
Do not pull the retention pin from the primary cam chain
tensioner after removal of the cam support plate. With
35-40 pounds of spring pressure behind the tensioner,
allowing it to accelerate through its full length of travel
will result in spring stretching and/or cracking of the ten-
sioner shoe. Furthermore, if the tensioner should con-
tact fingers or other parts of the hand, minor or
moderate injury may occur.
Figure 3-44. Crankshaft Guide (Part No. HD-42326A)
14. Remove O-ring from groove around oil feed hole in
crankcase flange (directly below rear ring dowel).
Remove O-ring from groove around blind hole in boss Water Pipe f1644x3x
(directly above oil return hole in crankcase flange). Dis- Insulation
card O-rings. See Figure 3-43.
15. Pull oil pump from crankshaft. Remove O-ring from out-
board side of oil pump housing. Remove O-ring from
scavenge port stub. Discard O-rings. See Section 3.11 Crankshaft
SUBASSEMBLY SERVICE AND REPAIR, OIL PUMP. Guide
1WARNING
Be sure that stator mount flange (sprocket shaft side) is
NOT facing up when the case halves are separated or the
flywheel assembly will drop to the floor. Dropping the fly-
wheel assembly may result in parts damage and minor
or moderate injury.
16. Rotate crankcase in the engine stand so that the cam
cover flange is facing upward. Remove the nine crank-
case bolts in the left case half. Follow the sequence
shown in Figure 3-46.
Left
Crankcase Half
1CAUTION
f1645a3x Crankshaft
Never move or lift the crankcase by grasping the cylin- Guide
der studs. The crankcase is too heavy to be carried in
this manner and may be dropped. Dropping the crank-
case may result in parts damage and minor or moderate
injury.
17. Using pry points, loosen case halves. Lift right crank-
case half off end of crankshaft.
18. Remove O-rings from two ring dowels in split line face of
right case half. Discard the O-rings.
19. See Section 3.11 SUBASSEMBLY SERVICE AND
REPAIR, CRANKCASE.
ASSEMBLY
1. If removed, install left crankcase half in engine stand so
Crankshaft Right
that the split line face is vertical.
Bearing Crankcase Half
2. To prevent damage to the sprocket shaft bearing, slide
CRANKSHAFT GUIDE (HD-42326A) over end of Figure 3-45. Install Crankshaft Guide to Protect
sprocket shaft. Install flywheel assembly into left case Crankshaft Bearing
half. Remove tool.

HOME
7. Rotate crankcase in the engine stand so that the stator
mount flange (sprocket shaft side) is facing upward.
1 Install service thrust washer on sprocket shaft with the
ink stamp facing outside (and the chamfer inboard). If
using OE part without markings, orient as required to
preserve existing wear pattern.
5 4 8. To install new oil seal into bearing bore, obtain pilot,
Nice bearing, large flat washer and handle from
SPROCKET SHAFT TIMKEN BEARING CONE
INSTALLER (HD-97225-55B) and proceed as follows:
7 8
a. Verify that seal lip garter spring is in place on both
sides of seal.
b. Thread pilot onto sprocket shaft until contact is
made with shoulder.
c. With the lettering facing outside, slide oil seal over
2 pilot until it contacts bearing bore.
3 d. Slide SPROCKET SHAFT OIL SEAL INSTALLER
(HD-39361A) over pilot until it contacts oil seal. See
Figure 3-47.
9 6
f1585x3x
Figure 3-46. Crankcase Torque Sequence

(Left Side View)
CAUTION

damaged will result in either oil leakage or low oil pres-
Figure 3-47. Sprocket Shaft Oil Seal Installer
(Part No. HD-39361A)
3. Install new O-rings over two ring dowels in split line face
of right case half.
4. Apply a small bead of sealant approximately 0.056 inch f1882x3x
(1.4 mm) wide to the split line face. For best results, use
High-Performance Sealant (gray), Part No. HD-99650-
02.
5. To prevent damage to the crankshaft bearing, place
CRANKSHAFT GUIDE (HD-42326A) over end of crank-
shaft. Mate case halves sliding bearing in right crank-
case half over end of crankshaft. Remove tool. See
Figure 3-45. Sprocket Shaft
Oil Seal Installer
6. Start the nine crankcase bolts and tighten as follows:
a. Alternately turn each crankcase bolt until finger
tight.
b. Tighten the crankcase bolts to 10 ft-lbs (13.6 Nm) in
the sequence shown in Figure 3-46.
c. Following the same sequence, tighten each bolt to
15-19 ft-lbs (20.3-25.8 Nm). Figure 3-48. Install Oil Seal In Bore

HOME
e. Slide Nice bearing and large flat washer over pilot

until contact is made with seal installer. Rear Front
Camshaft Camshaft
f. Thread handle onto pilot shaft.
g. Rotate handle in a clockwise direction until oil seal

installer makes firm contact with crankcase stator
mount. See Figure 3-48.
h. Remove handle, flat washer, Nice bearing, seal

installer and pilot from sprocket shaft.
9. Slide sprocket shaft spacer over end of sprocket shaft.

Push spacer into oil seal until seated against bearing
race.
10. Rotate crankcase in the engine stand so that the cam

cover flange is facing upward.
11. Install oil pump as follows:

Pin Stamped
f2068x3x
Timing Lines
CAUTION
O-rings that are missing, distorted, pinched or otherwise Figure 3-49. Verify Alignment of Timing Lines
damaged will result in either oil leakage or low oil pres- on Front and Rear Camshafts
always use new O-rings keeping them packaged until CAUTION
a. Install new O-ring on scavenge port stub of oil damaged will result in either oil leakage or low oil pres-
pump housing. Apply a very thin film of clean H-D sure. Use of the wrong O-ring will have the same results.
20W50 engine oil to O-ring before installation. Since many O-rings are similar in size and appearance,
b. Slide oil pump housing onto crankshaft fitting O-ring use to avoid confusion.
on scavenge port stub into crankcase bore at back
of cam compartment. Firmly push on scavenge port g. Install new O-ring in groove on outboard side of oil
stub with thumb to be sure that it is snug in bore. pump housing. See Figure 3-43. Apply a very thin
Inspect O-ring on stub to verify that it is not pinched film of clean H-D 20W50 engine oil to O-ring before
or distorted. installation.
c. Separate the gerotor gears into two sets, one wide 12. Install new O-ring in groove around oil feed hole in
(scavenge) and the other narrow (feed). crankcase flange (directly below rear ring dowel). Install
new O-ring around blind hole in boss (directly above oil
NOTE return hole in crankcase flange). Apply a thin film of H-D
Lubricate parts with clean H-D 20W50 engine oil during 20W50 engine oil to O-rings before installation.
assembly.
13. If not retracted, place cup of CAM CHAIN TENSIONER
d. Fit the smaller of the wide gerotor gears into the UNLOADER (HD-42313) over spring coil of secondary
larger. Slide the wide gerotor set down the crank- cam chain tensioner positioning finger on tool between
shaft until it bottoms in the oil pump housing. tensioner and shoe. Rotate tool in a counterclockwise
direction inserting retention pin through hole in boss on
e. Slide the first of two separator plates down the primary cam chain side of cam support plate. Pin
crankshaft until it contacts the wide gerotor set. engages hooks on tensioner to hold it in the retracted
Install wave washer and second separator plate. position. For best results, place cam support plate in a
vise using brass jaw inserts to prevent casting damage.
f. Fit the smaller of the narrow gerotor gears into the
larger. Slide the narrow gerotor set down the crank- 14. Lubricate cam needle bearings with clean H-D 20W50
shaft until it contacts the separator plate. engine oil.

HOME
3 6
2
5
4 2
4
1
1 3
A CAM SUPPORT PLATE

f1581b3x
B OIL PUMP
f1581b3x
Figure 3-50. Cam Support Plate/Oil Pump Torque Sequence
15. Using a straightedge, verify that the pin stamped timing d. Alternately snug and then tighten the screws in
lines on the ends of the front and rear camshafts are in holes 3 and 4 to 40-45 in-lbs (4.5-5.1 Nm).
alignment (although they may be somewhat difficult to
e. Remove the alignment tool from hole 1. Install the
see). See Figure 3-49. If necessary, rotate camshafts in
allen head socket screw and tighten to 40-45 in-lbs
order to make this observation.
(4.5-5.1 Nm).
16. Aligning bushing in cam support plate with end of crank-
f. Repeat step 18(e) to replace alignment tool in hole
shaft, slide cam support plate over crankshaft onto two
2 with allen head socket screw.
ring dowels in crankcase flange. Use a rubber mallet to
fully seat cam support plate on ring dowels. g. Final tighten all four screws to 90-120 in-lbs (10.2-
13.6 Nm). Use the pattern shown in B of Figure 3-
17. Install the six allen head socket screws (1/4 x 1 inch) to
50. Numbers cast adjacent to the bolt holes also
secure the cam support plate to the crankcase flange.
indicate the oil pump torque sequence.
Tighten screws to 90-120 in-lbs (10.2-13.6 Nm) in the
pattern shown in A of Figure 3-50. NOTE
18. Secure the cam support plate to the oil pump flange as If only realigning the oil pump, first loosen all screws following
follows: the pattern shown in B of Figure 3-50. Remove screws from
holes 1 and 2 and then follow the alignment procedure start-
a. Start two allen head socket screws (1/4 x 1 inch)
ing at step 18(b).
into holes 3 and 4. See B of Figure 3-50.
b. Obtain two ALIGNMENT TOOLS used to install lifter 19. Pull retention pin from hole in cam support plate to
guides on Evolution engines (HD-33443). Loosely release secondary cam chain tensioner.
install alignment tools in holes 1 and 2. 20. Squeeze tabs and install chain guide between blocks
c. While rotating the engine, alternately snug and then cast into cam support plate.
tighten the alignment tools to 40-45 in-lbs (4.5-5.1 21. Install primary cam sprocket spacer onto rear camshaft.
Nm).
22. If using the original cam support plate, camshafts, pri-
NOTE mary cam sprocket, crank sprocket and flywheel assem-
For methods of engine rotation, see Section 3.9 TOP END bly, then move to step 23. However, if any of these parts
OVERHAUL, DISASSEMBLY, step 7. have been replaced, then proceed as follows:

HOME
a. Install primary cam sprocket onto splines of rear

camshaft. Install long flange bolt with thicker flat
washer to secure sprocket to end of camshaft.
b. Install crank sprocket onto crankshaft. Install short

flange bolt with smaller diameter flat washer (that is,
washer from bulk inventory) to secure sprocket to
end of crankshaft.
NOTE
Use of smaller diameter flat washer with crank sprocket
flange bolt allows room on sprocket face for placement of
straightedge under step 22(e).
c. To prevent rotation, position the CRANKSHAFT/

CAMSHAFT SPROCKET LOCKING TOOL (HD- f2142x3x
42314) between the crank and primary cam sprock-
ets. See Figure 3-52. The handle of the tool is
stamped “Crank” and “Cam” to ensure proper orien- Figure 3-53. Check Alignment of Crank and
tation. Tighten the crank and primary cam sprocket Primary Cam Sprocket Faces
flange bolts to 15 ft-lbs (20.3 Nm). Remove the
sprocket locking tool. e. Place a straightedge across the crank and primary
cam sprocket faces. Try to insert a 0.010 inch feeler
d. Push on rear camshaft to remove end play.
gauge between the straightedge and each sprocket
face. See Figure 3-53. If the feeler gauge does not
fit at either location, then proceed to step 22(f).
On the other hand, if the crank sprocket is “proud”

(that is, rises above the face of the primary cam
sprocket) more than 0.010 inch, remove the flange
bolt and primary cam sprocket, and noting the part
number stamped on the existing spacer, replace it
with the next larger size. See spacer sizes listed in
Table 3-4. Replace the spacer with the next smaller
size only if the primary cam sprocket is “proud”
(rises above the face of the crank sprocket) more
Figure 3-51. Crankshaft/Camshaft Sprocket Locking Tool than 0.010 inch. Return to step 21 to repeat the
(Part No. HD-42314) check with the new spacer installed.
Table 3-4. Primary Cam Sprocket Spacers

Spacer Size H-D Part Number
0.287 25722-00
0.297 25723-00
0.307 25721-00
0.317 25719-00
0.327 25717-00
0.337 25725-00
Sprocket f. Remove both crank and primary cam sprockets.

Locking Tool
Discard smaller diameter flat washer obtained from
f2139x3x bulk inventory.
Figure 3-52. Lock Crank and Primary Cam Sprockets 23. Install the primary cam chain and sprocket assembly as
Before Tightening Flange Bolts follows:

HOME
NOTE
Crank If the punch marks are not in alignment, then the sprockets
Primary Cam Sprocket must be removed and reinstalled. The vehicle will not run
Sprocket properly if the sprockets are misaligned by even one tooth.
NOTE
Both crank and primary cam sprocket flange bolts are spe-
cially hardened, while the flat washers are of a special diam-
eter and thickness. Therefore, use only genuine Harley-
Davidson parts when replacement is necessary. The crank
and primary cam sprocket flange bolts and flat washers are
NOT interchangeable.
25. Install crank sprocket and primary cam sprocket flange

bolts and flat washers as follows:
NOTE
Exercise caution to avoid mixing oil on washer with thread-
locker on bolt or sealing integrity may be compromised.
a. Apply a thin film of clean H-D 20W50 engine oil to

both sides of flat washers.
b. Install thinner flat washer on short flange bolt.
Punch Marks f2138x3x
c. Install thicker flat washer on long flange bolt.
d. Apply Loctite Primer 7649 (P/N 98968-99) to
Figure 3-54. Verify Alignment of Crank and
threads of flange bolts.
Primary Cam Sprocket Punch Marks
e. Apply one drop of Loctite High Strength Thread-
locker 262 (red) to threads of flange bolts.
a. Place the primary cam sprocket in the cam chain.
Hold the sprocket allowing the chain to hang loose. f. Install short flange bolt with thinner flat washer to
Rotate the sprocket so that the punch mark on the secure crank sprocket to end of crankshaft.
sprocket root faces straight downward. g. Install long flange bolt with thicker flat washer to
NOTE secure primary cam sprocket to end of camshaft.
To maintain the original direction of rotation, verify that the h. Position CRANKSHAFT/CAMSHAFT SPROCKET
colored mark placed on the chain link and crank sprocket is LOCKING TOOL (HD-42314) between the crank
facing away from the cam support plate during installation. and primary cam sprockets to prevent rotation. See
Figure 3-52. The handle of the tool is stamped
b. Place the crank sprocket in the opposite end of the “Crank” and “Cam” to ensure proper orientation.
chain with the punch mark on the sprocket tooth fac-
i. Alternately tighten the crank and primary cam
ing straight upward.
sprocket flange bolts to 15 ft-lbs (20.3 Nm).
c. Maintaining the position of the sprockets on the
j. Loosen each flange bolt one full turn.
chain with the punch marks in alignment, start the
primary cam sprocket onto the splines of the rear k. Tighten the crank sprocket flange bolt to 24 ft-lbs
camshaft. Apply a thin film of clean H-D 20W50 (32.5 Nm).
engine oil to the splines before installation.
l. Tighten the primary cam sprocket flange bolt to 34
d. Maintaining the position of the crank sprocket on the ft-lbs (46.1 Nm).
chain, rotate the primary cam sprocket in a clock- m. Remove the sprocket locking tool.
wise direction until the flat on the crank sprocket is
aligned with the flat on the crankshaft. Install the
crank sprocket. 1CAUTION
24. Rotate the primary cam sprocket in a clockwise direction Ease the primary cam chain tensioner into the unloaded
until the punch mark on the root is aligned with the position using the proper tool. Do not pull the retention
punch mark on the crank sprocket tooth. Lay a straight- pin to unload the tensioner or the pin may be damaged.
edge across the centerline of the crank and primary cam Furthermore, if the tensioner should contact fingers or
sprocket flange bolt holes to verify that the punch marks other parts of the hand, minor or moderate injury may
are in alignment. See Figure 3-54. occur.

HOME
26. Hold the retracted primary cam chain tensioner with the
CAM CHAIN TENSIONER UNLOADER (HD-42313),
Torque: 125-155 in-lbs 7 6 pull retention pin from hole in cam support plate and
4
ease the assembly into the unloaded position.
1
27. Apply clean H-D 20W50 engine oil to crank and primary
cam sprockets.
CAUTION
Before cam cover installation, verify cleanliness of blind

holes in the crankcase flange. Tightening screws with
9 dirt, water or oil in the holes can cause the casting to
crack or break. Damage to the casting requires replace-
10
ment of the right crankcase half.
28. Align holes in new cam cover gasket with those in the
5 crankcase flange.
8 29. Install the cam cover using ten allen head socket screws
(1/4 x 1-1/4 inches). Alternately tighten screws to 125-
155 in-lbs (14.1-17.5 Nm) following the pattern shown in
Figure 3-55.
3 2 f1616b3x 30. If performing a complete engine overhaul, see Section
3.9 TOP END OVERHAUL, ASSEMBLY, steps 1-39. If
Figure 3-55. Cam Cover Torque Sequence only cam compartment components were serviced, just
see steps 28-37.

HOME
Legend:
1. Bolt 24. Upper Push Rod Cover
2. Bolt 25. Spring Cap Retainer
3. Rocker Cover 26. Spring Cap
4. Rocker Cover Gasket
2 27. Spring
5. Breather Bolt 28. Flat Washer
6. Breather Cover 29. O-Ring
7. Breather Cover Gasket 1 30. Lower Push Rod Cover
8. Umbrella Valve 31. O-Ring
9. Breather Baffle 32. Lifter Cover Screw
10. Filter Element 3 33. Lifter Cover
11. Breather Baffle Gasket 34. Anti-Rotation Pin
12. Rocker Arm Bolt 35. Lifter Cover Gasket
13. Rocker Arm Support Plate 5 36. Hydraulic Lifter
14. Rocker Arm Bushing 37. Push Rod
15. Rocker Arm
16. Rocker Arm Shaft
17. Rocker Arm
18. Breather Baffle O-Ring 4
19. Rocker Housing Bolt
20. Rocker Housing Bolt
21. Rocker Housing 7
22. Rocker Housing Gasket
23. O-Ring
6
9
12
8
14 11
15 12
10 13
14
23 19
24
17
16
18
20
16
25 26
21
28
27
29
30 22
31
32 33
37 34
36
35
f2239x3x
Figure 3-56. Rocker Arm/Breather/Lifter Assemblies (Exploded View)

HOME
SUBASSEMBLY SERVICE AND REPAIR 3.11
TOP END
f2176x3x
1
BREATHER ASSEMBLY
Removal 2
1. See Section 3.9 TOP END OVERHAUL, DISASSEM-
BLY, steps 1-8. 3
Disassembly
1. Remove two bolts and lift breather assembly from rocker
arm support plate. See Figure 3-57.
2. Remove the breather cover and gasket. Remove the
breather baffle and gasket. Discard gaskets.
3. Pull filter element from bore on inboard side of breather 4 5
baffle. Pull stem of umbrella valve from hole at top of
breather baffle. Discard both filter element and umbrella
valve.
Cleaning and Inspection

6
1. Clean all parts in a non-volatile cleaning solution or sol-
vent.
7
2. Thoroughly dry all parts with low pressure compressed
air.
1. Bolt
3. Set a straightedge diagonally across the length of the 2. Breather Cover 5. Breather Baffle
breather cover intersecting the opposite corners of the 3. Cover Gasket 6. Filter Element
gasket surface. Slide a feeler gauge beneath the 4. Umbrella Valve 7. Breather Baffle Gasket
straightedge to check the breather cover for warpage.
Repeat the step checking the opposite diagonal. Discard
the breather cover if any low spot exceeds 0.005 inch Figure 3-57. Breather Assembly
(0.13 mm).
4. Repeat step 3 to inspect the gasket surface of the
breather baffle for flatness. Discard the breather baffle if
any low spot exceeds 0.005 inch (0.13 mm).
3. Place breather baffle gasket on a clean flat surface.
Aligning holes, place breather baffle, cover gasket and
Assembly breather cover on top. Slide two screws through stackup
to keep assembly together until time of installation.
1. Insert stem of new umbrella valve through center hole at
top of breather baffle. Carefully pull rubber bead on stem
through hole in baffle. Use denatured alcohol or glass
cleaner to lubricate stem, if necessary. Verify that rubber Installation
bead is pulled completely through hole and resides on
bottom side of baffle. 1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
steps 31-39.
2. Press new filter element into bore at bottom of baffle.
Hole in filter element accommodates umbrella valve
stem.

HOME
ROCKER ARM ASSEMBLY 3. Remove the rocker arms from the rocker arm support
plate. Mark the rocker arms to indicate location.
Removal
BLY, steps 1-9. 1. Clean all parts in a non-volatile cleaning solution or sol-
vent. Thoroughly dry with low pressure compressed air.
Disassembly 2. Check rocker arms for uneven wear or pitting where con-
tact is made with the valve stem tips. Check for concave
1. Remove the four bolts from the rocker arm support plate. wear where rocker arms contact the push rod ends.
If necessary, slightly wiggle the two bolts on the push rod Replace rocker arm if excessive wear is found at either
side (right) to disengage them from the notches in the location.
rocker arm shafts.
3. Verify that oil holes in rocker arms and rocker arm sup-
2. Using a hammer and brass drift, tap left side of rocker port plate are clean and open.
arm shafts so that the notched ends exit the rocker arm
support plate first. Mark the shafts so that they are 4. Inspect rocker arm shafts for scratches, burrs, scoring or
installed in their original locations at time of assembly. excessive wear. Replace as necessary.
A B
C D
Figure 3-58. Measure Rocker Arm Assembly for Wear

HOME
5. Measure the inside diameter of the rocker arm support

plate bore. See A of Figure 3-58. Measure the outside
Remove Bushings.
diameter of the rocker arm shaft where it fits in the bore.
See B of Figure 3-58. Repeat the measurement on
opposite side of support plate and shaft. Replace the
shaft or support plate if any measurement equals or
exceeds 0.0035 inch (0.089 mm). Driver
Discarded Shaft
6. Measure the inside diameter of the rocker arm bushing.
See C of Figure 3-58. Measure the outside diameter of
the rocker arm shaft where it rides in the bushing. See D
of Figure 3-58. Repeat the measurement on opposite
side of rocker arm and shaft. Replace the shaft or bush-
ings if any measurement equals or exceeds 0.0035 inch
(0.089 mm).
7. To replace rocker arm bushings, proceed as follows:
NOTE
Remove, install and ream one bushing at a time. 9/16”-18 Tap
6916
a. Obtain a 9/16”-18 (14.29 mm) tap. Turn tap into
bushing until tight. Place rocker arm under ram of
arbor press with tap at bottom. Slide a discarded
rocker arm shaft through open end of rocker arm Install Bushings.
until contact is made with tap. Using shaft as driver
(and untapped bushing as pilot), press against shaft
until both tap and bushing are free. See upper Driver
frame of Figure 3-59.
b. Using a suitable driver, press new bushing into side
of rocker arm until flush with casting. See center
frame of Figure 3-59. Be sure to orient bushing so
that split line faces top of rocker arm.
CAUTION
Never back reamer out of rocker arm or new bushing will

be damaged.
c. Lock rocker arm in a vise using brass jaw inserts or
shop towels to prevent casting damage. Insert
6922
tapered end of ROCKER ARM BUSHING REAMER
(HD-94804-57) into old bushing in rocker arm. Note
that old bushing on drive side of reamer serves as
pilot. See lower frame of Figure 3-59. Rotate reamer
until new bushing on far side is reamed, and then Ream Bushings.
continuing in the same direction, draw drive side of
reamer from new bushing.
Bushing Reamer
d. Repeat steps 7(a) thru 7(c) to remove, install and Part No. HD-94804-57
ream second bushing.
Assembly
1. Place the rocker arms into position on the rocker arm
support plate.
2. Push the un-notched ends of the rocker arm shafts into
the right side of the support plate and then into the
rocker arms. As they approach their fully installed posi-
tions, rotate the shafts so that the notches are aligned
with the bolt holes in the support plate.
6923
Figure 3-59. Replace Rocker Arm Bushings

HOME
3. To check for proper end play, insert a feeler gauge

between the rocker arm and support plate. See Figure 3-
60. Repeat measurement on other rocker arm. Replace
the rocker arm, rocker arm support plate, or both if end
play exceeds 0.025 inch (0.635 mm).
4. Install the four bolts in the rocker arm support plate. For
proper assembly, remember that the two bolts on the
push rod side (right) must engage the notches in the
rocker arm shafts.
Installation
1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
steps 31-39.
6917
Figure 3-60. Check End Play

HOME
PUSH RODS/LIFTERS/COVERS
Spring Cap
Retainer
O-Ring
Removal Small

BLY, steps 1-14.
Disassembly
1. With the exception of the lifter covers, all parts should
have been disassembled and marked during the Spring Cap
removal procedure. Disassemble the lifter covers as fol-
lows:
Spring
a. Separate upper and lower push rod covers.
b. Remove O-ring from seat at bottom of lower push Flat

rod cover. Discard O-ring. O-Ring Washer
Intermediate
c. Remove O-ring from seat at top of upper push rod
cover. Slide O-ring, flat washer, spring and spring
cap from body of upper push rod cover. Discard O-
rings. Upper
Push Rod
Cover
Flared End
1. Scrape old gasket material from the lifter cover flange.
Old gasket material left on mating surfaces will cause
leaks.
2. With the exception of the hydraulic lifters, clean all parts

in a non-volatile cleaning solution or solvent. Verify that
the O-ring seats and contact surfaces of the push rod
covers are completely clean.
Lower
3. Thoroughly dry all parts with low pressure compressed
Push Rod
air. Verify that all oil holes are clean and open. Cover
4. Verify that the hydraulic lifter rollers turn freely and are
free of flat spots, scuff marks and pitting. If flat spots
exist, examine the cam lobe on which the lifter operates.
5. Inspect the lifter socket for signs of wear. Verify that the
plunger of the hydraulic lifter is fully extended up against
the C-clip. Use index finger to pump plunger to verify O-Ring
lifter operation. Large f1584x3x
6. Examine the push rods. Replace any push rods that are
bent, dented, broken or discolored. Replace the rod if Figure 3-61. Push Rod Cover Assembly
the ball ends show signs of excessive wear or damage.
7. Cover all parts with a clean plastic sheet to protect them

from dust and dirt. CAUTION

Assembly damaged will result in either oil leakage or low oil pres-
1. With the exception of the lifter covers, all parts will be Since many O-rings are similar in size and appearance,
assembled during the installation procedure. Assemble always use new O-rings keeping them packaged until
the lifter covers as follows: use to avoid confusion.

HOME
a. Obtain three new o-rings- small, intermediate and d. Fit the straight end of the upper push rod cover into
large. the flared end of the lower push rod cover.
b. Install small O-ring on seat at the top of the upper e. Install large O-ring on seat at bottom of lower push
push rod cover. rod cover.
NOTE
Apply a very thin film of clean H-D 20W50 engine oil to O-
Installation
rings before installation.
c. Slide the spring cap, spring, flat washer and inter- 1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
mediate size O-ring onto the body of the upper push steps 25-39.
rod cover. Move parts up body until spring cap con-
tacts upper O-ring seat.

HOME
NOTES

HOME
Legend:
1
1. Tapered Keepers 2
2. Spring Retainer
3. Inner Spring 3
4. Outer Spring
5. Valve Stem Seal
6. Spring Seat
7. Valve Guide 8
8. Cylinder Head Bolt 4
9. Cylinder Head Bolt
10. Cylinder Head
11. Valve Seat
12. Valve 5
13. Cylinder Head Gasket
14. Cylinder 9
15. Ring Dowel
16. O-Ring Seal 6
17. Cylinder Stud 7
18. Piston
19. Piston Pin
20. Circlip
21. Top Compression Ring
22. Second Compression Ring
23. Oil Rail
24. Oil Rail Spacer
10
11
13
12
15
21
23
22 14
23
20
24
19
18
20
16
17
f21332x3x
Figure 3-62. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)

HOME
CYLINDER HEAD
Removal
BLY, steps 1-11 and 15-19.
Disassembly
1. Before proceeding with the disassembly procedure,
determine if cylinder head reconditioning is necessary.
Proceed as follows: Figure 3-65. Valve Spring Compressor
a. Raise valve ports of cylinder head to strong light (Part No. HD-34736B)
source. If light is visible around edges of seats, then
move to step 2 to recondition cylinder head.
f1648x3x
b. Fill ports at top of cylinder head with solvent. Wait
ten full seconds and then check for leakage into
combustion chamber. If solvent leakage into com-
bustion chamber is evident, then move to step 2 to
recondition cylinder head.
14mm End
12mm End
Figure 3-63. Cylinder Head Holding Fixture

(Part No. HD-39786) Figure 3-66. Compress Valve Springs
f1658x3x 2. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

39786) and proceed as follows:
a. Note that both ends of the fixture are threaded, one
end at 14mm and the other at 12mm. Thread the
12mm end of the tool into the spark plug hole of the
cylinder head.
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position). See Figure
3-64.
3. Obtain the VALVE SPRING COMPRESSOR (HD-
34736B) and proceed as follows:
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.
Cylinder Head See Figure 3-66.
Holding Fixture
b. Rotate forcing screw to compress valve springs.
c. If spring retainer has not broken free of tapered
keepers, give head of tool a sharp tap with a soft
mallet. Using magnetic rod or small screwdriver,
Figure 3-64. Install Cylinder Head Holding Fixture in Vise remove the keepers from the valve stem groove.

HOME
d. Rotate forcing screw to release the valve spring 4. Thoroughly clean the cylinder head, spring retainers,
compression. tapered keepers, valves, inner and outer valve springs
and spring seats in a non-volatile cleaning solution or
4. Remove the spring retainer and inner and outer valve solvent. Follow up with a thorough wash in hot soapy
springs. water. Blow dry with compressed air.
5. Slide the valve from the valve guide.
Inspection
6. Using pliers, twist and remove the valve stem seal from
the top of the valve guide. Discard the valve stem seal. Cylinder Head
7. Remove the spring seat from the cylinder head. 1. Check for scratches and nicks on all gasket sealing sur-
faces.
8. Mark the bottom of the valve “F(ront)” or “R(ear)” to indi-
cate the cylinder head from which it was removed. Also, 2. With the combustion chamber side facing upward, set a
separate and tag tapered keepers, valve springs, spring straightedge diagonally across the length of the cylinder
retainers and spring seats so that they are installed on head intersecting the upper and lower corners of the
the same valve at time of assembly. gasket surface. Slide a feeler gauge beneath the
straightedge to check the head for warpage. Checking
9. Repeat steps 3-8 to remove the other valve components. the opposite diagonal, repeat the procedure to verify that
10. Release the cylinder head holding fixture from the vise the gasket surface is flat (especially if a head gasket was
and then remove the tool from the spark plug hole. blown). Discard the head if any low spot is 0.005 inch
(0.13 mm) or greater.
NOTE
Cleaning and Inspection For good results, use one of the CYLINDER TORQUE
PLATES (HD-42324A) in lieu of the straightedge. Lay the
Cleaning upper plate flat on the machined surface of the head. As a
preliminary check, see if the plate rocks from side to side. A
1. Remove old gasket material from cylinder head. Gasket
head on which the plate rocks is immediately suspect. Insert
material left on sealing surfaces will cause leaks.
a feeler gauge between the plate and head at various loca-
2. Remove all carbon deposits from combustion chamber tions to see if warpage exceeds above specification.
and machined surfaces of cylinder head. Exercise cau-
3. Verify that oil passageways are open and clean.
tion 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. Valve Guides
3. To soften stubborn deposits, soak the cylinder head in a 1. Inspect external surfaces for cracks (particularly the
chemical solution, such as GUNK HYDRO-SEAL or combustion chamber side). Replace the guide if any
other carbon and gum dissolving agent. Repeat step 2 cracks are found.
as necessary. 2. To verify cleanliness of valve guides, lightly hone bore
using the VALVE GUIDE HONE (HD-34723) and then
scrub with the VALVE GUIDE CLEANING BRUSH (HD-
CAUTION 34751) to remove any dust or debris. Polish the valve
Do not use glass or sand to bead blast surfaces exposed stem with fine emery cloth or steel wool to remove car-
to the engine oil. Bead blasting materials become lodged bon buildup, and then check valve stem to guide clear-
in the pores of the casting where they cannot be ance as follows:
removed through ordinary cleaning methods. Only after Carefully measure the inside diameter of the valve guide
the engine is put into use will heat expansion cause this using an inside ball micrometer. Measure the outside
material to be released, and the resulting oil contamina- diameter of the valve stem with an outside micrometer.
tion will accelerate wear and lead to engine failure. If The valve stem and/or guide are excessively worn if the
bead blasting must be employed, use wallnut shells or clearance exceeds the limits shown in Table 3-5. Repeat
other soft non-damaging abrasive that can be digested measurements with a new valve to determine if the
in the engine oil. guide must be replaced.
Table 3-5. Service Wear Limits

CAUTION
Valve Valve Stem to Guide Clearance
Be aware that bead blasting materials may also enter
threaded holes adversely affecting fastener engagement Intake 0.0035 inch (0.089 mm)
and torque indication. Carefully cover all threaded holes
if bead blasting is employed. Exhaust 0.0040 inch (0.102 mm)

HOME
Tapered Keepers
1. Inspect parts for damage or rust pits. Replace as neces-
Intake Seat sary.
Adapter 2. Inspect inboard side of tapered keepers for excessive
Part No. HD-39782A-3
Cylinder Head wear. Upraised center must be pronounced and fit
Support Stand snugly in valve stem groove. Place keepers into groove
and verify that they grip tightly without sliding.
Valve Seats
1. Inspect seats for cracking, chipping or burning. Replace
seats if any evidence of these conditions are found.
Exhaust Seat 2. Check seats for recession by measuring valve stem pro-
Adapter trusion. See VALVE AND SEAT REFACING in this sec-
Part No. HD-39782A-4 tion, steps 5-6.
Figure 3-67. Cylinder Head Support Stand VALVE GUIDE REPLACEMENT

Removal
NOTE
If valve guide replacement is necessary, always install new
guide before refacing valve seat.
1. Obtain the CYLINDER HEAD SUPPORT STAND (HD-
39782A) and proceed as follows:
a. Insert sleeve of intake or exhaust seat adapter into
tube at top of support stand. See Figure 3-67.
Figure 3-68. Valve Guide Driver (Part No. HD-34740) b. Position cylinder head so that valve seat is centered
on seat adapter. Support stand ensures that valve
guide and seat are perpendicular. If perpendicular-
Valves ity is not achieved, the cylinder head valve guide
bore will be damaged during the press procedure.
1. Replace the valve if there is evidence of burning or
cracking.
2. Inspect the end of the valve stem for pitting or uneven f1681x3x
wear. Replace the valve if either of these conditions are Ram

found. Valve Guide
Driver
3. Inspect for burrs around the valve stem keeper groove.
Remove burrs with a fine tooth file if found.
4. To determine if the valve stem is excessively worn, see
INSPECTION, VALVE GUIDES, step 2.
Valve Springs
1. Inspect springs for broken or discolored coils. Replace
springs if either of these conditions are found.
2. Set the intake and exhaust valve springs on a level sur-
face and use a straightedge to check for proper square-
ness and height.
3. Check free length of inner and outer springs using a dial Cylinder Head
vernier caliper or load test with the VALVE SPRING Support Stand
TESTER (HD-96796-47). Replace springs if free length
or compression force do not meet specifications. See
Section 3.1 SPECIFICATIONS. Figure 3-69. Remove Valve Guide

HOME
Installation
1. Measure the outside diameter of a new standard valve
Valve Guide
guide, and then measure the cylinder head valve guide
Driver
bore. The valve guide should be 0.0020-0.0033 inch
(0.051-0.084 mm) larger than the bore.
If clearance is not within specification, then select one of
the following oversize guides - 0.001 inch (0.025 mm),
0.002 inch (0.05 mm) or 0.003 inch (0.08 mm).
Valve Guide
Installer Sleeve NOTE
Since some material is typically removed when the guide is
pressed out, it is normal to go to the next larger size for the
Figure 3-70. Valve Guide Driver (Part No. HD-34740) and proper interference fit.
Valve Guide Installer Sleeve (Part No. HD-34731)
2. Measure cylinder head bore and outside diameter of
selected oversize guide to verify correct interference fit.
f1680x3x
3. Obtain the CYLINDER HEAD SUPPORT STAND (HD-
Valve Guide 39782A), VALVE GUIDE DRIVER (HD-34740) and
Driver VALVE GUIDE INSTALLER SLEEVE (HD-34731). Pro-
ceed as follows:
Valve Guide
Installer Sleeve a. 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 adapter. Sup-
port stand ensures that valve guide and seat are
perpendicular. If perpendicularity is not achieved,
cylinder head valve guide bore will be damaged dur-
ing the press procedure.
b. Apply Vaseline to lightly lubricate external surfaces
of valve guide. Spread lubricant so that thin film cov-
ers entire surface area.
c. At top of cylinder head, start valve guide into bore.
d. Place installer sleeve over valve guide, and then
Cylinder Head insert tapered end of valve guide driver into installer
Support Stand sleeve.
e. Center valve guide driver under ram of arbor press
and apply pressure only until valve guide is started
Figure 3-71. Install Valve Guide
in bore and then back off ram slightly to allow guide
to center itself. See Figure 3-71.
CAUTION CAUTION
Do not press out the valve guide from the bottom of the Always back off ram to allow the valve guide to find cen-
cylinder head. Carbon buildup on the combustion cham- ter. Pressing guide into cylinder head in one stroke can
ber side of the guide can deeply gouge the cylinder head bend driver, break guide, distort cylinder head casting
bore diminishing the likelihood of achieving the proper and/or damage cylinder head valve guide bore.
interference fit and possibly requiring replacement of
f. Verify that support stand and driver are square.
the cylinder head casting.
Center driver under ram and press valve guide fur-
ther into bore, but then back off ram again to allow
2. At the top of the cylinder head, insert VALVE GUIDE
valve guide to find center.
DRIVER (HD-34740) into valve guide bore until stopped
by shoulder. g. Repeat step 3f and then apply pressure to driver
until installer sleeve contacts machined area of cyl-
3. Center valve guide driver under ram of arbor press. inder head.
Apply pressure until valve guide drops free of cylinder
4. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
head. Discard the valve guide. See Figure 3-69. 39786) and proceed as follows:

HOME
c. Placing thumb on drive socket of reamer T-handle,
apply slight pressure on reamer while rotating in a
clockwise direction. See Figure 3-73. Squirt addi-
Valve Guide tional lubricant onto reamer and into guide as nec-
Reamer essary.
CAUTION
For best results, do not push on reamer or apply pres-

sure to the reamer handle. While excessive pressure
Reamer results in a rough cut, bore will be tapered if pressure is
T-Handle not centrally applied.
d. Continue rotating reamer T-handle until entire bit
Figure 3-72. Valve Guide Reamer (Part No. HD-39932) and has passed through valve guide bore and shank of
Reamer T-Handle (Part No. HD-39847) reamer rotates freely.
f1659x3x CAUTION
Never back reamer out of valve guide or bore will be

damaged.
Valve Guide e. Remove T-handle from reamer, and carefully pulling
Reamer on bit, draw shaft of reamer out combustion cham-
ber side of valve guide.
Reamer CAUTION
T-Handle
Abrasive particles can damage machined surfaces and
plug oil passageways possibly resulting in engine fail-
ure.
6. Direct compressed air into the valve guide bore to
remove any metal shavings or debris.
7. Clean valve guide bore with the VALVE GUIDE CLEAN-
ING BRUSH (HD-34751).
8. Obtain the VALVE GUIDE HONE (HD-34723) and
Figure 3-73. Ream Valve Guide Bore
REAMER LUBRICANT (HD-39964). Proceed as follows:
a. Install hone in a high speed electric drill.
a. Thread the 12mm end of the tool into the spark plug b. Apply reamer lubricant to finishing stones of hone
hole of the cylinder head. and valve guide bore.
c. Start finishing stones of hone into bore.
offers a comfortable working position). d. Activating the drill, move the entire length of the fin-
ishing stone arrangement forward and backward
NOTE through the bore for 10 to 12 complete strokes. See
Figure 3-75. Work for a crosshatch pattern of
Valve guides must be reamed to within 0.0005 - 0.0001 inch approximately 60˚.
(0.013 - 0.0025 mm) of finished size.
5. Obtain the VALVE GUIDE REAMER (HD-39932), CAUTION

REAMER T-HANDLE (HD-39847) and REAMER LUBRI- Abrasive particles can damage machined surfaces and
CANT (HD-39964). Proceed as follows: plug oil passageways possibly resulting in engine fail-
a. Install T-handle on reamer. ure.
9. Direct compressed air into the valve guide bore to
b. Apply a liberal amount of reamer lubricant to valve remove any debris and then clean with the VALVE
guide bore and bit of reamer. Start bit of reamer into GUIDE CLEANING BRUSH (HD-34751). See Figure 3-
bore at top of cylinder head. 77.

HOME
bore with the type of swabs or patches found in gun
cleaning kits. Continue to wipe bore until clean cloth
shows no evidence of dirt or debris. Follow up with a
thorough wash in hot soapy water. Blow dry with com-
pressed air.
VALVE AND SEAT REFACING

NOTE
Figure 3-74. Valve Guide Hone (Part No. HD-34723) Verify correct valve stem to valve guide clearance before
refacing. See Table 3-6. If new guides must be installed,
complete that task before refacing valves and seats.
f1661x3x 1. Hold the valve firmly against a wire wheel in a bench

grinder. Remove all carbon deposits from the valve
head, face and stem, but exercise caution to avoid
removing any metal. Carbon left on the stem may affect
alignment in the valve refacer. Polish the valve stem with
steel wool or crocus cloth to remove any marks that
might be left by the wire wheel.
Figure 3-75. Hone Valve Guide Bore
Figure 3-76. Valve Guide Brush (Part No. HD-34751)

NOTE
Always verify valve stem to valve guide clearance after hon-
f1660x3x
ing, since a worn reamer may cut the bore undersize.
10. Measure the inside diameter of the valve guide with an

inside ball micrometer. Measure the outside diameter of
the valve stem with an outside micrometer. The valve
stem may be excessively worn or the valve guide bore
undercut if the clearance is not within the limits (low end
preferable) shown in Table 3-6.
Table 3-6. New Parts Limits

Valve Valve Stem to Guide Clearance
Intake 0.0008 - 0.0026 inch (0.020-0.066 mm)

Exhaust 0.0015 - 0.0033 inch (0.038-0.084 mm)
11. Using cleaning solvent, thoroughly clean cylinder head

and valve guide bore. Scrub valve guide bore with the
VALVE GUIDE CLEANING BRUSH (HD-34751). For
best results, use a thin engine oil and clean valve guide Figure 3-77. Scrub Valve Guide Bore

HOME
a. Thread the 12mm end of the tool into the spark plug
f1662x3x
hole of the cylinder head.
offers a comfortable working position).
Dial Vernier 4. Obtain the NEWAY VALVE SEAT CUTTER SET (HD-
Caliper 35758A) and cut valve seat angle to 46°.
NOTE
Do not remove any more metal than is necessary to clean up
the seat (that is, to provide a uniform finish and remove pit-
ting).
5. From the bottom of the cylinder head, insert the valve

stem into the valve guide. Push on bottom of valve until it
contacts the valve seat.
6. Placing finger at bottom of valve to keep valve seated,
use a dial vernier caliper to check the distance from the
top of the valve stem to the machined area on the cylin-
der head. See Figure 3-78.
Seat wear and valve refacing causes the valve stem pro-
trusion to change. If valve stem protrusion exceeds
2.034 inches (51.66 mm), but is less than 2.064 inches
(52.43 mm), obtain the short service replacement valve.
Service replacement valves are 0.030 inch (0.76 mm)
shorter than the standard valve.
If protrusion exceeds 2.064 inches (52.43 mm), then use
the existing valve, but replace the valve seat.
CAUTION
Do not shorten the valve by grinding on the end of the

f1663x3x stem. Grinding replaces the hardened case with mild
steel which results in accelerated wear.
Figure 3-78. Measure Valve Stem Protrusion 7. Remove valve from cylinder head. Apply magic marker
or similar product to valve seat and allow to thoroughly
dry.
2. Install valve (both intake and exhaust) in a valve refacer 8. Insert the valve stem into the valve guide. Push on bot-
set to a 45 degree angle. The valve refacer is required tom of valve until it contacts the valve seat.
equipment, since accuracy in matching the angle of the
valve face with the angle of the valve seat is critical. 9. Obtain the VALVE LAPPING TOOL (HD-96550-36A) and
proceed as follows:
Do not remove any more metal than is necessary to
clean up and true the valve face. Removing metal a. Attach suction cup at end of tool to valve head.
reduces the service life of the valve. The amount of b. Holding shank of tool between the palms of both
grinding needed to retrue the valve is a clear indication hands, oscillate the tool back and forth a few times.
of its condition. Discard the valve if it cannot be quickly See Figure 3-80.
refaced while maintaining a good margin. Valves that do
not clean up quickly are either warped, excessively worn 10. Remove the valve from the cylinder head and carefully
or too deeply pitted to be used. inspect the mating surfaces under a good light.
Obtain a new valve if grinding leaves the margin less Inspection of the valve seat should show an unbroken
than 0.0313 inch (0.795 mm). A valve in this condition contact area of uniform width. If the seat is not concen-
does not seat normally, burns easily and may crack or tric with the valve guide, then the cutter will remove more
cause pre-ignition. material in one spot than another. Carbon deposits may
have caused the guide to be pressed in crooked, the
3. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD- guide may be cracked, or the cutter blade or cutter pilot
39786) and proceed as follows: have not have been properly cleaned.

HOME
f1655x3x
Head
Seat 60˚
0.040-0.062 in.
(1.02-1.57 mm)
Valve
Figure 3-79. Valve Lapping Tool (Part No. HD-96550-36A) 31˚ 46˚ Cutting Margin
45˚ Grinding 0.0313 in.
(0.795 mm)
6873
Figure 3-81. Valve Seat Angles
14. Remove the valve and perform a final inspection of the

contact pattern. If necessary, return to step 11.
15. Remove the valve from the cylinder head. Use contact
Valve Lapping cleaner to thoroughly clean magic marker and/or dye
Tool from valve face and seat, if present.
16. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
17. To confirm quality of valve and seat refacing work, pro-
ceed as follows:
a. Insert valve in guide, and holding valve to seat,
raise port to strong light source. If light is visible
around edge of seat, then valves and seats must be
Figure 3-80. Oscillate Tool to Create Contact Area reconditioned.
b. Holding valve to seat, fill port at top of cylinder head
NOTE with solvent. Wait ten full seconds and then check
If the results are not acceptable, then recut the valve seat or for leakage into combustion chamber. If solvent
replace the valve guide. leakage into combustion chamber is evident, then
11. Inspect the contact pattern on the valve seat to be sure valves and seats must be reconditioned.
area is 0.040-0.062 inch (1.02-1.57 mm) wide and con- 18. Clean valves, cylinder head and valve seats in solvent.
tacts the valve two-thirds of the way towards the outer Follow up with a thorough wash in hot soapy water. Blow
edge of the valve face. See Figure 3-81. If necessary, dry with compressed air.
modify the seat pattern as follows:
a. Use the 31° angle cutter to lower the valve seat sur-
face and reduce its width.
Assembly
b. Use the 60° angle cutter to raise the valve seat sur-
face and reduce its width. 1. Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-
c. Use the 46° angle cutter to widen the valve seat sur- 39786) and proceed as follows:
face. a. Thread the 12mm end of the tool into the spark plug
12. Using a magic marker, mark three equally spaced verti- hole of the cylinder head.
cal lines across the valve face and then insert the valve
back into the cylinder head.
offers a comfortable working position).
13. Attach suction cup of VALVE LAPPING TOOL (HD-
96550-36A) to valve head, and holding shank of tool 2. Slide spring seat over valve guide until it contacts the
between the palms of both hands, oscillate the tool back machined area on the cylinder head casting. Use a little
and forth a few times. grease to hold the spring seat in position, if necessary.

HOME
f1664x3x
Plastic
Capsule
Figure 3-82. Valve Stem Seal Installer

Spring
NOTE Seat
At the time of disassembly, all parts should have been
marked or tagged so that they are installed on the same
valve (and in the same head). Install plastic capsule.
3. Run the VALVE GUIDE CLEANING BRUSH (HD-34751) f1665x3x

through the valve guide bore to verify cleanliness.
4. Using TORCO MPZ or another suitable product, apply a Plastic
liberal amount of engine assembly lube to valve stem. Capsule
5. From the bottom of the cylinder head, insert the valve
stem into the valve guide.
6. To distribute the assembly lube evenly around the valve
stem and guide, hand spin the valve as it is installed.
Work the valve back and forth in the bore to verify that it
slides smoothly and seats properly.
7. Remove the valve and apply a second coat of assembly
lube to the valve stem. Install the valve in the valve
guide.
Valve Stem Seal
8. Retract the valve so that the stem is not visible above the
top of the valve guide.
9. Using isopropyl alcohol or other suitable degreaser, thor- Install valve stem seal.
oughly clean external surface of valve guide until com-
pletely free of grease and oil.
Valve Stem
CAUTION Seal Installer
Do not apply Loctite to inside of valve stem seal or top of
valve guide or valve may stick to seal resulting in loss of
compression and valve sticking.
10. Obtain tube of Loctite RC/620 (green) High Temperature
Retaining Compound. Carefully apply Loctite to valve
stem seal seating surface on outside diameter of valve
guide. Exercise caution to keep compound out of valve
guide bore.
CAUTION
Failure to install plastic capsule will cause the valve Tap installer to seat valve stem seal. f1666x3x
stem seal to catch the edge of the valve stem keeper
groove. The resulting damage will lead to leakage around
the valve stem, excessive oil consumption and valve Figure 3-83. Install Valve Stem Seal
sticking.

HOME
11. Push on bottom of valve until it contacts the valve seat.

Placing finger at bottom of valve to keep valve seated,
f1654x3x
slide plastic capsule over valve stem tip and keeper Valve Guide
groove. See upper frame of Figure 3-83. Driver
12. Apply a very thin film of clean H-D 20W50 engine oil to
capsule. Slide new valve stem seal over capsule and
down valve stem until contact is made with top of valve
guide. See center frame of Figure 3-83. Remove cap-
sule from valve stem tip.
Valve Stem
Seal Installer
CAUTION
To avoid damaging the valve stem seal and/or cracking

the valve guide, always use the proper valve stem seal
installer tool. Use of an ordinary socket will damage the Valve Stem
seal or guide, resulting in leakage around the valve Seal
stem, excessive oil consumption and valve sticking.
13. Obtain the VALVE STEM SEAL INSTALLER (HD-
Valve
34643A) and proceed as follows:
Valve Guide
a. Slide the installer tool over the valve stem seal
using valve stem as pilot. The tool bore allows inser-
tion of the valve stem, while the counterbore fits
over the valve stem seal.
CAUTION
Repeated blows on installer after seal is in place will

cause seal distortion resulting in leakage around the
valve stem, excessive oil consumption and valve stick-
ing. Valve
Seat
b. Using a small hammer, gently tap the end of the tool
until it lightly bottoms on the installed spring seat.
See lower frame of Figure 3-83. For best results,
brace the cylinder head with chest area to prevent
movement during seal installation.
Figure 3-84. Using Arbor Press to Install Valve Stem Seal
NOTE
If an arbor press is the preferred method of valve stem seal
installation, use the VALVE STEM SEAL INSTALLER (HD- 16. Obtain the VALVE SPRING COMPRESSOR (HD-
34643A) with the VALVE GUIDE DRIVER (HD-34740). See 34736B) and proceed as follows:
Figure 3-84.
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
CAUTION forcing screw is seated on the valve spring retainer.
Removing the valve after seal installation will cause the
valve stem seal to catch the edge of the valve stem CAUTION
keeper groove. The resulting damage will lead to leakage
around the valve stem, excessive oil consumption and Over-compressing the valve spring can damage the
valve sticking. valve stem seal resulting in leakage around the valve
stem, excessive oil consumption and valve sticking.
14. Apply a liberal amount of assembly lube to valve stem tip
and keeper groove. b. Rotate forcing screw to compress valve springs.
15. Install the inner and outer valve springs over the valve
guide. Fit the spring retainer on top of the inner and c. With the tapered side down, fit the keepers into the
outer valves springs. Like the spring seat, the smaller valve stem groove. For best results, apply a dab of
diameter flange fits inside the inner valve spring. The grease to the inboard side of the keepers before
larger diameter flange separates the inner and outer installation and use a magnetic rod for easy place-
springs. ment.

HOME
d. Arranging tapered keepers so that the gaps are Installation

evenly spaced, turn forcing screw to release valve
spring compression. See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps
14-24 and 29-39.
17. Tap the end of the valve stem once or twice with a soft
mallet to ensure that tapered keepers are tightly seated
in the valve stem groove.
18. Repeat steps 1-17 to install the other valve components.
19. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
20. Cover the cylinder head to protect it from dust and dirt
until time of installation.

HOME
CYLINDER
Removal
BLY, steps 1-11 and 15-24.

CLEANING
1. Scrape old gasket material from the machined surface at
the top of the cylinder. Old gasket material left on the Figure 3-85. Cylinder Torque Plates
mating surface will cause leaks. (Part No. HD-42324A)
2. Clean cylinder in a non-volatile cleaning solution or sol-
vent. Thoroughly dry with low pressure compressed air.
Verify that oil passageways are clean and open. A Lower Plate
Bolts
(with Flat Washers)
3. Inspect the cylinder bore for defects or damage in the
ring travel area. Replace cylinders that are severely
scored, scuffed, scratched, burnt or gouged.
4. Using Magnaflux Dye Penetrant, inspect the cylinder for
cracks. If no cracks are found, thoroughly wash cylinder
to remove traces of dye.
5. Use a file to carefully remove any nicks or burrs from the
machined surfaces of the cylinder.
6. Using a feeler gauge and the CYLINDER TORQUE
PLATES (HD-42324A), check the machined surfaces for
flatness. Proceed as follows:
a. Lay gasket side of the upper plate (without vise grip) Vise
flat against the head gasket surface.
b. As a preliminary check, see if the plate rocks from f2075x3x
side to side. A cylinder on which the plate rocks is
immediately suspect.
c. Insert a feeler gauge between the plate and cylinder
at various locations.
B 3 Upper Plate
d. The head gasket surface must be flat within 0.006 4

inch (0.15 mm).
e. Now turn the cylinder upside down and lay the seal
side of the lower plate (with vise grip) flat against
the O-ring seal surface. Repeat steps 6(b) and 6(c).
f. The O-ring seal surface must be flat within 0.004
inch (0.102 mm).
g. Replace the cylinder (and piston) if either surface is
not within specification.
INSPECTION
CAUTION 2
Failure to use the cylinder torque plates can produce
measurements that vary by as much as 0.001 inch (0.025
1 f2074x3x
mm), possibly resulting in the use of parts that are not

suitable for service. Figure 3-86. Install Cylinder to Torque Plates

HOME
1. To simulate an assembled cylinder for accurately mea-

suring cylinder taper and out-of-round conditions, as well f1686x3x
as for boring, honing or deglazing, obtain the CYLIN-
DER TORQUE PLATES (HD-42324A). Install the torque
plates as follows:
a. Remove O-ring seal from cylinder sleeve, if

installed.
b. Place used head gasket over two ring dowels at top

of cylinder.
c. Install brass jaws or shop towels around teeth of

vise to prevent damage to tool. Clamp stepped side
of lower plate in vise with the simulated split line
(machined strip) facing away.
d. Slide four bolts (with flat washers) all the way

through holes of lower plate until washers contact
outboard side. See A of Figure 3-86.
e. Slide cylinder down bolts with the indent in the cool-

ing fins facing upward.
f. With the head gasket in place, align holes in upper

plate with ends of bolts. Blind holes in upper plate
accommodate ring dowels in cylinder. Alternately
tighten four bolts into upper plate in a crosswise pat-
tern until snug. Figure 3-87. Measure for Out-of-Round and Taper
g. Tighten the bolts to 84-108 in-lbs (9.5-12.2 Nm) in

the sequence shown in B of Figure 3-86. c. Repeat the measurements again at the bottom of
h. Following the same sequence, tighten each bolt to the bore at a point below the piston ring travel zone.
12-14 ft-lbs (16.3-18.9 Nm).
d. Rebore the cylinder if the parallel and perpen-
i. Using a grease pencil, mark a straight line on one of dicular measurements at either the top, middle or
the bolts continuing the line over onto the lower bottom of the bore vary by more than 0.002 inch
plate. Repeat step for remaining three bolts. Using (0.051 mm), which indicates an out-of-round condi-
the marks as a guide, turn each bolt 1/4 turn or 90 tion.
degrees. Be sure to tighten the bolts in the
Rebore the cylinder if the top, middle and bottom
sequence shown in B of Figure 3-86.
bore diameters either parallel or perpendicular to
the crankshaft vary by more than 0.002 inch (0.051
NOTE
mm), which indicates excessive taper.
For best results, obtain Snap-on® Torque Angle Gauge
TA360.
CAUTION
j. For purposes of inspection, remove the assembly
from the vise and place on bench top. Maximum cylinder wear occurs at the very top of top ring
travel. Minimum wear occurs below ring travel. Failure to
2. See Figure 3-87. Using an inside micrometer or dial bore measure the cylinder at these points may result in a
gauge, check cylinder bore for out-of round and taper. faulty decision regarding the suitability of the cylinder
Proceed as follows: for continued use.
a. At the top of the piston ring travel zone (starting 3. If cylinders are not scuffed or scored, and are not worn
about 0.50 inch or 12.70 mm from the top of the cyl- beyond the service limits described under step 2(d), see
inder), measure the cylinder diameter at two loca- DEGLAZING CYLINDER on the next page.
tions- parallel and perpendicular to the crankshaft.
Write the readings down. On the other hand, if cylinders are worn beyond the ser-
vice limits, then they must be rebored and/or honed to
b. Repeat the two measurements at the center of the accept the next standard oversize piston. See BORING
piston ring travel zone. AND HONING CYLINDER on the next page.

HOME
DEGLAZING CYLINDER 2. Hone the cylinder to its finished size using a 280 grit
rigid hone.
NOTE
Deglazing removes wear patterns, minor scuff marks and 3. Stop frequently to examine the cylinder bore and/or take
scratches without enlarging the bore diameter. measurements. Remember, a precise 60˚ cross hatch
pattern in the piston travel area is important.
1. Lightly swab the cylinder bore with a cloth dipped in
clean engine oil. 4. Thoroughly wash the cylinder bore with liquid dishwash-
ing soap and warm water to remove all abrasive parti-
2. Obtain a 240 grit flexible ball-type deglazing tool with a
cles and residual grit. Continue cleaning until a clean
bristle tip or finishing stone arrangement able to produce
cloth shows no evidence or dirt or debris.
a 60˚ cross hatch pattern.
3. Install the deglazing tool in a slow-speed drill. The speed Table 3-7. Oversize Pistons
at which the tool rotates determines the speed at which
it must be stroked up and down the bore to produce the Cylinder Bore
desired cross hatch pattern. Piston
Finished Size
4. Starting at the bottom of the cylinder, move the deglaz-
3.7500 - 3.7505 in.
ing tool up and down the entire length of the cylinder Standard
(95.250 - 95.263 mm)
bore for 10 to 12 complete strokes.
0.005 In. (0.13 mm) 3.7550 - 3.7555 in.
5. Stop to examine the cylinder bore and/or take measure-
Oversize (95.377 - 95.390 mm)
ments. A precise 60˚ cross hatch pattern in the piston
travel area is the most important. 0.010 In. (0.25 mm) 3.7600 - 3.7605 in.
Oversize (95.504 - 95.517 mm)
CAUTION Example: A 0.005 in. (0.13 mm) oversize piston will have
the proper running clearance with a cylinder bore size of
The angular cross hatch pattern ensures an even flow of 3.7550 - 3.7555 in. (95.377 - 95.390 mm).
oil onto the cylinder walls and promotes longer cylinder,
piston and ring life. An Improper crosshatch pattern will
result in insufficient oil retention and possible piston
5. Hot rinse the cylinder and dry with moisture free com-
seizure and/or high oil consumption.
pressed air. Immediately apply a thin film of clean engine
oil to prevent rusting.
CAUTION
6. With the cylinder at room temperature, check the piston
Failure to remove all abrasive particles may result in pre- clearance in the cylinder in which the piston will run. See
mature cylinder, piston and ring wear and possible PISTON, INSPECTION, step 5.
engine failure.
6. Thoroughly wash the cylinder bore with liquid dishwash-
ing soap and warm water to remove all abrasive parti-
cles and residual grit. Continue cleaning until a clean
Installation
cloth shows no evidence or dirt or debris.
1. See Section 3.9 TOP END OVERHAUL, ASSEMBLY,
7. Hot rinse the cylinder and dry with moisture free com- steps 8-24 and 29-39.
pressed air. Immediately apply a thin film of clean engine
oil to prevent rusting.
8. With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See
PISTON, INSPECTION, step 5.
BORING AND HONING CYLINDER

1. Bore the cylinder to 0.003 inch (0.08 mm) under the
desired finished size. See Table 3-7.
CAUTION
An improper crosshatch pattern or too fine a hone will

result in insufficient oil retention and possible piston
seizure and/or high oil consumption.

Top End Overhaul 3.9: Disassembly

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HOME

TOP END OVERHAUL 3.9

1. Use low pressure spray to thoroughly clean exterior sur-

3. Remove the rocker cover and gasket. Discard the gas-

Removing the rocker arms with the valve train loaded

2004 Touring: Engine 3-33

Figure 3-22. Top End Disassembly

3-34 2004 Touring: Engine

2004 Touring: Engine 3-35

f1635x3x 26. Remove the piston pin circlip as follows:

27. Remove the piston pin. If piston pin is difficult to remove,

3-36 2004 Touring: Engine

Do not reuse piston pin circlips. The circlips may weaken

6. Place clean shop towels over the cylinder and lifter

a. Slide circlip down nose of tool until it contacts claw.

b. Releasing pressure on handles, rotate circlip so that

c. Tilt the circlip forward until the end gap contacts

2004 Touring: Engine 3-37

Figure 3-28. Install Piston Pin Circlip

12. Remove plastic tubing or rubber hose from cylinder

13. Install the PISTON SUPPORT PLATE (HD-42322). Pro-

a. Slide both adjustable knobs on tool down slots away

3-38 2004 Touring: Engine

Thoroughly clean and lubricate the threads of the cylin-

Figure 3-32. Install Cylinder

d. Note that the cylinders should have been marked

g. Remove shop towels from around the crankcase

2004 Touring: Engine 3-39

17. Lightly oil threads and shoulders of cylinder head bolts

Improperly tightened cylinder head bolts may result in

a. Alternately turn each cylinder head bolt until finger

20. Install a new rocker housing gasket on the cylinder head

21. Verify that the rocker housing gasket is installed cor-

3-40 2004 Touring: Engine

L S = Short Bolt, 1 In.

O-rings that are missing, distorted, pinched or otherwise

2004 Touring: Engine 3-41

Installing the rocker arms and rotating the engine with

a. With primary cover installed - With vehicle on center

b. With primary cover removed - Remove primary

3-42 2004 Touring: Engine

f2163x3x f2164x3x S = Short Bolt, 1 In.

A Alternately Tighten Four Rocker Arm Bolts

2004 Touring: Engine 3-43

37. Complete installation of the push rod covers as follows:

e. Verify that spring cap retainer is seated tightly

3-44 2004 Touring: Engine

BOTTOM END OVERHAUL 3.10

DISASSEMBLY 3. Using a colored marker, mark the crank sprocket and

Flange Bolt and

Primary Cam Chain

Figure 3-40. Cam Support Plate Assembly

2004 Touring: Engine 3-45

f1573b3x O-Ring Right

6. Using the CAM CHAIN TENSIONER UNLOADER (HD-

3-46 2004 Touring: Engine

2004 Touring: Engine 3-47