Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual

sm02432

Figure 3-33. Checking Shaft to Support Plate Fit

Rocker Arm Shaft to Bushing

Check rocker arm shaft to bushing fit.

See

Figure 3-34

. Measure the inside diameter of the

rocker arm bushing.

See

Figure 3-35

. Measure the outside diameter of

the rocker arm shaft where it rides in the bushing.

Repeat measurement on opposite side of rocker arm and
shaft. Replace shaft or bushings if clearance equals or
exceeds service wear limit of 0.0035 in. (0.089 mm).

sm02433

Figure 3-34. Checking Bushings

sm02434

Figure 3-35. Checking Shaft to Bushing Fit

Replace Rocker Arm Bushings

NOTE

Bushing replacement and reaming must be done one at a time
to achieve proper alignment. Follow all steps for one bushing
and then repeat for the other bushing.

See

Figure 3-36

. Remove bushing from rocker arm:

Turn a 9/16-18 tap (2) into bushing until tight.

Place rocker arm under ram of arbor press with tap
at bottom.

Slide a discarded rocker arm shaft (1) through open
end of rocker arm 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

Figure 3-37

. Using a suitable driver, press

new

bushing into side of rocker arm until flush with casting. Be
sure to orient bushing so that split line faces top of rocker
arm.

NOTE

Never back reamer out of rocker arm or new bushing will be
damaged.

Ream bushing:

See

Figure 3-38

. Lock rocker arm in a vise using

brass jaw inserts or shop towels to prevent casting
damage. Note that old bushing on drive side of reamer
as pilot.

Rotate reamer until the

new

bushing on the far side

is reamed.

Continuing in the same direction, draw drive side of
reamer from

new

bushing.

Repeat steps to remove, install and ream second bushing.

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3-38 2013 Softail Service: Engine

sm02437

1. Discarded shaft used as driver
2. Tap

Figure 3-36. Removing Bushing

sm02438

1. Driver
2. Bushing

Figure 3-37. Installing Bushing

sm02487

Figure 3-38. Ream Bushing

ASSEMBLY

Place the rocker arms into position on the rocker arm
support plate.

Install rocker arm shafts:

Push un-notched ends of rocker arm shafts into right
side of support plate and then into rocker arms.

As they approach their fully installed positions, rotate
shafts until notches are aligned with bolt holes in
support plate.

See

Figure 3-39

. Check for proper end play.

Insert a feeler gauge between the rocker arm and
support plate.

Repeat measurement on other rocker arm.

Replace the rocker arm, rocker arm support plate or
both if end play exceeds 0.025 in. (0.635 mm).

Install the four bolts with flat washers in the rocker arm
support plate. Remember that the two bolts on the pushrod
side (right) must engage the notches in the rocker arm
shafts for proper assembly.

sm02488

Figure 3-39. Check End Play

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2013 Softail Service: Engine 3-39

3.19

PUSHRODS, LIFTERS AND COVERS

DISASSEMBLY

See

Figure 3-40

. With the exception of the lifter covers, all

parts should have been disassembled and marked during the
removal procedure.

Separate upper (2) and lower (8) pushrod covers.

Remove O-ring (9). Discard O-ring.

Remove O-ring (1). Slide O-ring (7), flat washer (6), spring
(5) and spring cap (4) from upper pushrod cover (2). Dis-
card O-rings.

CLEANING AND GENERAL INSPECTION

See

Figure 3-40

. Clean old gasket material from the lifter

cover (11).

With the exception of the hydraulic lifters (14), clean all
parts in a non-volatile cleaning solution or solvent. Verify
that the O-ring seats and contact surfaces of the pushrod
covers (2, 8) are completely clean.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

Dry parts with low pressure compressed air. Verify that all
oil holes are clean and open.

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.

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 lifter
operation.

Examine the pushrods (15). Replace any pushrods that
are bent, dented, damaged, discolored or if the ball ends
show signs of excessive wear or damage.

Cover all parts with a clean plastic sheet to protect them
from dust and dirt.

sm02492

1. Upper O-ring (small)
2. Upper pushrod cover
3. Spring cap retainer
4. Spring cap
5. Spring
6. Flat washer
7. Middle O-ring (intermediate)
8. Lower pushrod cover
9. Lower O-ring (large)
10. Lifter cover screw
11. Lifter cover
12. Anti-rotation pin
13. Lifter cover gasket
14. Hydraulic lifter
15. Pushrod

Figure 3-40. Pushrods, Lifters and Covers

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3-40 2013 Softail Service: Engine

LIFTER INSPECTION

NOTE

Inside and outside micrometers used for measuring lifters and
lifter bores must be calibrated to take accurate readings.

Inspect lifters for excessive clearance in bores. Accurately
measure the lifter outer diameter and record the measure-
ment.

Accurately measure lifter bore inner diameter with a snap
gauge. Subtract this measurement from the lifter measure-
ment to determine clearance.

Clearance should be within 0.0008-0.0020 in. (0.0203-
0.0508 mm).

Install

new

lifters and/or replace crankcases if clear-

ance exceeds SERVICE WEAR LIMIT of 0.0030 in
(0.076 mm).

Check lifter roller radial play.

Roller radial movement should be within 0.0006-
0.0010 in (0.0152-0.0254 mm).

Replace lifters if radial movement exceeds SERVICE
WEAR LIMIT of 0.0015 in. (0.0381 mm).

Check lifter roller end clearance.

End clearance should be within 0.008-0.022 in.
(0.203-0.559 mm).

Replace lifters if end clearance exceeds SERVICE
WEAR LIMIT of 0.022 in. (0.559 mm).

Soak lifters in clean engine oil. Keep covered until
assembly.

ASSEMBLY

With the exception of the pushrod covers, all parts will be
assembled during the installation procedure.

See

Figure 3-41

. Apply a very thin film of clean engine oil

new

O-rings (1, 7 and 9) before installation.

Install small O-ring (1) on seat at the top of the upper
pushrod cover (2).

Slide the spring cap (4), spring (5), flat washer (6) and
intermediate size O-ring (7) onto the body of the upper
pushrod cover. Move parts up body until spring cap con-
tacts upper O-ring seat.

Fit the straight end of the upper pushrod cover into the
flared end of the lower pushrod cover (8).

Install large O-ring (9) on seat at bottom of lower pushrod
cover.

sm02493

Figure 3-41. Assembled Pushrod Cover

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2013 Softail Service: Engine 3-41

3.20

CYLINDER HEAD

DISASSEMBLY

TOOL NAME

PART NUMBER

VALVE SPRING COMPRESSOR

HD-34736-B

CYLINDER HEAD HOLDING FIXTURE

HD-39786

Before proceeding with the disassembly procedure,
determine if valve reconditioning is necessary.

Raise valve ports of cylinder head to strong light
source. If light is visible between valves and seats,
the cylinder head and valves require reconditioning.

Fill ports with solvent. Wait ten full seconds and check
for leakage past valve seats. Recondition cylinder
heads and valves that leak.

See

Figure 3-42

. Secure cylinder head for service.

Thread 12 mm end of CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) (1) into cylinder head
(2) spark plug hole.

Clamp tool in vise at a 45 degree angle or one that
offers a comfortable working position.

sm02494

1. Holding fixture
2. Cylinder head
3. 12 mm end of fixture

Figure 3-42. Cylinder Head Holding Fixture

sm02495

1. Holding fixture
2. Compressor

Figure 3-43. Valve Spring Compressor

See

Figure 3-43

. Release valve spring compression.

Place VALVE SPRING COMPRESSOR (Part No. HD-
34736-B) (2) over cylinder head. Center blunt end on
the valve head. Seat adapter at end of forcing screw
on the valve spring retainer.

Rotate forcing screw to compress valve spring.

See

Figure 3-44

. If spring retainer (2) is not free of

tapered keepers (1), give head of tool a sharp tap
with a soft mallet. Using magnetic rod or small
screwdriver, remove the keepers (1) from the valve
stem (11) groove.

Rotate forcing screw to release the valve spring
compression.

Remove the spring retainer (2) and valve spring (3).

Slide the valve (11) from the valve guide (5).

Remove valve seal assembly.

Mark the valve head F(ront) or R(ear) for identification.
Also, separate and tag tapered keepers, valve spring and
spring retainer so that they are installed on the same valve
at time of assembly.

Remove the remaining valve and components.

Remove fixture tool from spark plug hole.

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3-42 2013 Softail Service: Engine

sm02496

1. Tapered keepers
2. Spring retainer
3. Valve spring
4. Spring seat/valve stem seal
5. Valve guide
6. Lock ring
7. Cylinder headbolt, short
8. Cylinder headbolt, long
9. Cylinder head
10. Valve seat
11. Valve

Figure 3-44. Cylinder Head Assembly

CLEANING

See

Figure 3-44

. Remove old gasket material from cylinder

head (9). Gasket material left on sealing surfaces will
cause leaks. Scraping may result in scratches or nicks.

Do not use glass or sand to bead blast surfaces exposed
to engine oil. Blasting materials can lodge in pores of the
casting. Heat expansion releases this material which can
contaminate oil resulting in engine damage. (00534b)

NOTE

Bead blasting materials could also enter threaded holes. This
would adversely affect fastener engagement and torque indic-
ation. Cover all threaded holes before bead blasting.

Remove all carbon deposits from combustion chamber
and machined surfaces of cylinder head. Do not remove
any metal material.

To soften stubborn deposits, soak the cylinder head in a
chemical solution, such as GUNK HYDRO-SEAL or other
carbon and gum dissolving agent. Repeat previous step
as necessary.

Thoroughly clean the cylinder head, spring retainers,
tapered keepers, valves and valve springs in a non-volatile
cleaning solution or solvent. Follow up with a thorough
wash in hot soapy water.

Dry parts with low pressure compressed air.

INSPECTION

TOOL NAME

PART NUMBER

VALVE GUIDE HONE

B-45525

VALVE GUIDE CLEANING BRUSH

HD-34751

CYLINDER TORQUE PLATES

HD-42324-A

VALVE SPRING TESTER

HD-96796-47

Cylinder Head

Check for scratches and nicks on all gasket sealing sur-
faces.

Check for warpage.

Place a straightedge diagonally across the cylinder
head gasket surface.

Slide a feeler gauge beneath the straightedge to
check the head for warpage.

Repeat the procedure on the opposite diagonal. Dis-
card the head if warpage is 0.006 in. (0.152 mm) or
greater.

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2013 Softail Service: Engine 3-43

Check for warpage (alternate method.)

Use one of the CYLINDER TORQUE PLATES (Part
No. HD-42324-A) in lieu of the straightedge.

Lay the upper plate (without vise grip) flat on the
machined surface of the head.

As a preliminary check, see if the plate rocks from
side to side. A head on which the plate rocks is
immediately suspect.

Insert a feeler gauge between the plate and head at
various locations.

Discard the head if warpage is 0.006 in. (0.152 mm)
or greater.

Verify that oil passageways are open and clean.

Valve Guides

Inspect external surfaces, particularly the combustion
chamber side, for cracks. Replace as necessary.

Prepare valve guides for inspection.

Lightly hone bore using the VALVE GUIDE HONE
(Part No. B-45525).

Scrub with the VALVE GUIDE CLEANING BRUSH
(Part No. HD-34751) to remove any dust or debris.

Polish the valve stem with fine emery cloth or steel
wool to remove carbon buildup.

Check valve stem to guide clearance:

Carefully measure the

inside

diameter of the valve

guide using a ball gauge.

Measure the

outside

diameter of the valve stem with

a micrometer.

Refer to

Table 3-36

. If the clearance between stem

and guide exceeds the limits shown, the valve stem
and/or guide are excessively worn.

Repeat measurements with a

new

valve to determine

if the guide must be replaced.

Table 3-36. Valve Stem to Guide Clearance Service Wear

Limits

VALVE

0.0965

0.0038

Intake

0.0965

0.0038

Exhaust

Valves

Replace the valve if there is evidence of burning or
cracking.

Inspect the end of the valve stem for pitting or uneven
wear. Replace as necessary.

Inspect for burrs around the valve stem keeper groove.
Remove burrs with a fine tooth file.

To determine if the valve stem is excessively worn, see
valve guide inspection.

Valve Springs

Inspect springs for cracked or discolored coils. Replace
as necessary.

Set the valve springs on a level surface and use a
straightedge to check for proper squareness and height.
Too much height corresponds to a reduction in spring
pressure which results in sluggish valve action.

Check free length of springs using a dial vernier caliper
or load test with the VALVE SPRING TESTER (Part
No. HD-96796-47). Replace springs if free length or com-
pression force do not meet specifications. See

3.2 SPE-

CIFICATIONS

Tapered Keepers

Inspect parts for damage or rust pits. Replace as neces-
sary.

Inspect inboard side of tapered keepers for excessive
wear. Upraised center must be pronounced and fit snugly
in valve stem groove. Place keepers into groove and verify
that they grip tightly without sliding.

Valve Seats

Inspect seats for cracking, chipping or burning. Replace
as necessary.

Check seats wear by measuring valve stem protrusion.
See

3.20 CYLINDER HEAD, Valve and Seat Refacing

VALVE GUIDE REPLACEMENT

TOOL NAME

PART NUMBER

VALVE GUIDE REAMER

B-45523

VALVE GUIDE DRIVER

B-45524-1

VALVE GUIDE INSTALLER SLEEVE

B-45524-2A

VALVE GUIDE HONE

B-45525

VALVE GUIDE CLEANING BRUSH

HD-34751

CYLINDER HEAD SUPPORT STAND
KIT

HD-39782-B

CYLINDER HEAD HOLDING FIXTURE

HD-39786

REAMER T-HANDLE

HD-39847

REAMER LUBRICANT

HD-39964

Removal

NOTES

•

If valve guide replacement is necessary, always install
new guide before refacing valve seat.

•

CYLINDER HEAD SUPPORT STAND KIT (Part No. HD-
39782-B) ensures that valve guide and seat are perpen-
dicular. Not keeping cylinder head valve guide bore per-
pendicular will result in damage during the press pro-
cedure.

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3-44 2013 Softail Service: Engine

See

Figure 3-45

. Prepare cylinder head for valve guide

replacement.

Obtain CYLINDER HEAD SUPPORT STAND KIT
(Part No. HD-39782-B).

Insert sleeve of appropriate seat adapter (3 or 4) into
tube at top of support stand (2).

Position cylinder head so that valve seat is centered
on seat adapter.

NOTE

Always press valve guide toward combustion chamber. Carbon
buildup on combustion chamber side of guide can damage
cylinder head bore. As a result, a proper interference fit may
not be possible.

Remove and discard lock ring from valve guide groove.

NOTE

Lock ring is present on OEM intake and exhaust valve guides.

Insert VALVE GUIDE DRIVER (Part No. B-45524-1) (1)
into valve guide bore.

See

Figure 3-46

. Center valve guide driver under ram of

arbor press. Apply pressure until valve guide drops free
of cylinder head. Discard valve guide.

sm02497

1. Valve guide driver
2. Cylinder head support stand
3. Intake seat adapter
4. Exhaust seat adapter
5. Valve guide installer sleeve

Figure 3-45. Valve Guide Replacement Tools

sm02498

1. Valve guide driver
2. Cylinder head stand

Figure 3-46. Remove Valve Guide

Installation

Check valve guide to valve bore interference fit.

Measure the outside diameter of a

new

standard valve

guide.

Measure the cylinder head valve guide bore. The
valve guide should be 0.0020-0.0033 in. (0.051-0.084
mm) larger than the bore.

If interference is not within specification, select one
of the following oversize guides: 0.001 in. (0.025 mm),
0.002 in. (0.05 mm) or 0.003 in. (0.08 mm).

NOTE

Pressing out guide may remove material. Using the next larger
size is not uncommon to guarantee proper interference fit.

Select an oversize guide that will provide the correct
interference fit.

NOTE

The support stand ensures that valve guide and seat are per-
pendicular. Not keeping cylinder head valve guide bore perpen-
dicular will result in damage during the press procedure.

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2013 Softail Service: Engine 3-45

Prepare cylinder head for valve guide replacement.

See

Figure 3-45

. Insert sleeve of the appropriate seat

adapter (3 or 4) into tube at top of support stand (2).
Position cylinder head so that valve seat is centered
on seat adapter.

Apply a thin film of petroleum jelly to lightly lubricate
external surface of valve guide.

Start valve guide into bore.

See

Figure 3-47

. Place VALVE GUIDE INSTALLER

SLEEVE (Part No. B-45524-2A) (2) over valve guide
and then insert valve guide driver (1) into sleeve.

Center valve guide driver under ram of arbor press
and apply pressure only until valve guide is started
in bore and then back off ram slightly to allow guide
to center itself.

NOTE

Always back off ram to allow the valve guide to find center.
Pressing guide into cylinder head in one stroke can bend
driver, break guide, distort cylinder head casting and/or
damage cylinder head valve guide bore.

Verify that support stand (3) and driver (1) are square.
Center driver under ram and press valve guide further
into bore, then back off ram again to allow valve guide
to center itself.

Repeat previous step until installer sleeve contacts
machined area of cylinder head.

Install

new

lock ring into valve guide groove. Verify

that lock ring is square and fully seated in the groove.

sm02299

1. Valve guide driver
2. Valve guide installer sleeve
3. Cylinder head stand

Figure 3-47. Install Valve Guide

Secure cylinder head for service.

Thread 12 mm end of CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) into cylinder head
spark plug hole.

Clamp tool in vise at a 45 degree angle or one that
offers a comfortable working position.

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3-46 2013 Softail Service: Engine

sm02499

1. T-handle
2. Valve guide reamer

Figure 3-48. Reaming Valve Guide Bore

NOTE

Valve guides will be reamed to within 0.0005-0.0001 in. (0.013-
0.0025 mm) under finished size.

See

Figure 3-48

. Ream the guide.

Install REAMER T-HANDLE (Part No. HD-39847) (1)
on VALVE GUIDE REAMER (Part No. B-45523) (2).

Apply a liberal amount of REAMER LUBRICANT (Part
No. HD-39964) to valve guide bore and reamer bit.
Start reamer into bore.

NOTE

Never turn reamer backwards.

Apply slight pressure on reamer while rotating clock-
wise. Squirt additional lubricant onto reamer and into
guide as necessary.

NOTE

For best results, do not push on reamer or apply pressure
to the reamer handle. Excessive pressure results in a
rough cut and the bore will be tapered if pressure is not
centrally applied.

Continue rotating reamer T-handle until entire bit has
passed through valve guide bore.

Remove T-handle from reamer, and carefully draw
reamer out through combustion chamber side of valve
guide.

Remove metal shavings with low pressure compressed
air.

See

Figure 3-49

. Clean valve guide bore with the VALVE

GUIDE CLEANING BRUSH (Part No. HD-34751).

See

Figure 3-50

. Hone bore to finished size.

Install VALVE GUIDE HONE (Part No. B-45525) in a
high speed electric drill.

Apply reamer lubricant to stones of hone and valve
guide bore.

Start stones of hone into bore.

Rotate the hone while moving the stones through the
entire length of the bore for 10 to 12 complete strokes.
Work for a crosshatch pattern of approximately 60
degrees.

Remove debris with low pressure compressed air. Clean
with the VALVE GUIDE CLEANING BRUSH (Part No. HD-
34751).

NOTE

Always check valve stem to valve guide clearance after honing.

10. Check valve stem to valve guide clearance. Refer to

Table 3-37

. If the clearance is not within specification,

repeat the honing process and recheck.

sm02500

Figure 3-49. Scrubbing Valve Guide Bore

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2013 Softail Service: Engine 3-47

sm02501

Figure 3-50. Honing Valve Guide Bore

11. Clean cylinder head assembly.

Using cleaning solvent, thoroughly clean cylinder head
and valve guide bore.

Scrub valve guide bore with the VALVE GUIDE
CLEANING BRUSH (Part No. HD-34751). For best
results, clean the valve guide bore with the type of
swabs or patches found in gun cleaning kits and a
thin engine oil.

Continue to wipe bore until a clean cloth shows no
evidence of dirt or debris. Follow up with a thorough
wash in hot soapy water.

12. Dry parts with low pressure compressed air.

Table 3-37. Valve Stem to Guide Clearance

VALVE

0.0254-0.0762

0.001-0.003

Intake

0.0254-0.0762

0.001-0.003

Exhaust

VALVE AND SEAT REFACING

TOOL NAME

PART NUMBER

VALVE GUIDE CLEANING BRUSH

HD-34751

NEWAY VALVE SEAT CUTTER SET

HD-35758-C

CYLINDER HEAD HOLDING FIXTURE

HD-39786

NOTES

•

Verify correct valve stem to valve guide clearance before
refacing. If new guides must be installed, complete that
task before refacing valve seats. Refer to

Table 3-37

•

This procedure is not based on the lapping of valves. The
end result is an interference fit between the 45 degree
valve face and the valve seat which will be 46 degrees.

Remove carbon deposits from valve head, face and stem
with a wire wheel. Do not remove any metal. Carbon left
on stem may affect alignment during valve refacing.

Polish valve stem with steel wool or crocus cloth to remove
marks left by wire wheel.

Grind valve face to a 45 degree angle using a valve
grinding machine.

NOTES

•

Do not remove any more metal than necessary to clean
up and true the valve face.

•

Replace the valve if margin is less than 0.0313 in (0.795
mm). See

Figure 3-51

sm00148

1. Minimum: 0.040 in. (1.016 mm) / Maximum: 0.062

in. (1.575 mm)

2. 60 degrees
3. 31 degrees
4. 46 degrees
5. Margin

Figure 3-51. Valve and Seat Dimensions

Wipe valve seats and valve faces clean. Install the valve
into the valve guide. Push on head of valve until it contacts
the valve seat.

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3-48 2013 Softail Service: Engine

See

Figure 3-52

. Measure valve stem protrusion.

Use a dial caliper to check the distance from the top
of the valve stem to the machined area on the cylinder
head.

If protrusion exceeds 2.069 in. (52.553 mm), replace
the valve, valve seat or cylinder head as necessary.

NOTE

Do not shorten the valve by grinding the end of the stem.
Grinding removes the hardened case which results in acceler-
ated wear.

Secure cylinder head for servicing.

Thread 12 mm end of CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) into cylinder head
spark plug hole.

Clamp fixture in vise and further tighten cylinder head
onto the fixture to prevent any movement during
operation.

Place cylinder head at a 45 degree angle or one that
offers a comfortable working position.

To determine the correct location of the 46 degree valve
seat in the head, measure the diameter of the valve head
and subtract 0.080 in. (2.032 mm) from that number.

Set the dial caliper to the lesser measurement and lock
down for quick reference. This is the diameter of the valve
seat.

Use a permanent marker to highlight the valve seat area.
Highlight all three angles. Allow marker to dry before pro-
ceeding.

sm02502

Figure 3-52. Checking Valve Stem Protrusion

NOTES

•

Always verify cutter blades and cutter pilot are clean before
beginning the cutting process. The correct cleaning brush
is supplied with the Neway tool set.

•

Always verify the inside of the valve guide is clean by using
VALVE GUIDE CLEANING BRUSH (Part No. HD-34751).

10. See

Figure 3-53

. Obtain the NEWAY VALVE SEAT

CUTTER SET (Part No. HD-35758-C). Choose the cutter
pilot that fits properly into the valve guide hole. Securely
seat the pilot by pushing down and turning using the
installation tool supplied in the tool set.

11. Choose the proper 46 degree cutter (intake or exhaust)

and gently slide the cutter onto the pilot. Do not drop the
cutter onto the seat.

12. While applying a constant and consistent pressure, remove

only enough metal to provide a uniform finish and to
remove pitting.

NOTES

•

If the width of the clean-up cut is greater on one side of
the seat than the other, the guide may need to be replaced
due to improper installation.

•

If a groove cut completely around the seat is apparent,
slightly stagger the blades of the cutter.

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2013 Softail Service: Engine 3-49

13. Measure the 46 degree cut at the outermost edge at the

widest point of the circle to determine what cut will be
made next.

If the outer diameter is too large, use the 31 degree
cutter to lower the valve seat.

If the outer diameter is too small, use the 46 degree
cutter to widen the valve seat or move it away from
the port.

NOTES

•

Because the OD measurement of the valve seat is used
as a reference point it will usually be necessary to use the
31 degree cutter following the initial 46 degree cut.

•

Always highlight the valve seat with the permanent marker
in order to better view the location of the 46 degree valve
seat.

sm02503

Figure 3-53. Neway Valve Seat Cutter Set

14. If the location of the valve seat is not correct, repeat steps

10 through 13.

15. When a complete clean-up of the 46 degree angle is

accomplished and the width is at least 0.062 in. (1.575
mm), proceed to the next step.

16. Select the proper 60 degree cutter and gently slide the

cutter down the cutter pilot to the valve seat.

17. Remove just enough material to provide an even valve

seat width of 0.040-0.062 in. (1.016-1.575 mm).

18. Remove cutter and cutter pilot.

19. Insert valve into the cylinder head. Use thumb pressure

against valve to hold it closed.

20. Completely fill the port with solvent to verify proper seal

between valve and valve seat.

NOTE

Hold pressure against the valve for a minimum of 10 seconds.
If any leakage occurs, examine the valve and valve seat for

irregularities or defects. If necessary repeat the above valve
grinding or valve seat cutting process.

21. Repeat the process on any valve seat that needs service.

22. Clean valves, cylinder head and valve seats in solvent.

Follow up with a thorough wash in hot soapy water.

23. Dry parts with low pressure compressed air.

ASSEMBLY

TOOL NAME

PART NUMBER

VALVE SPRING COMPRESSOR

HD-34736-B

VALVE GUIDE CLEANING BRUSH

HD-34751

CYLINDER HEAD HOLDING FIXTURE

HD-39786

Secure cylinder head for service.

Thread 12 mm end of CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) into cylinder head
spark plug hole.

Clamp tool in vise at a 45 degree angle or one that
offers a comfortable working position.

NOTE

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).

Run the VALVE GUIDE CLEANING BRUSH (Part No. HD-
34751) through the valve guide bore to verify cleanliness.

Apply a liberal amount of SCREAMIN' EAGLE ASSEMBLY
LUBE to valve stem.

Install the valve into the cylinder head.

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.

Remove the valve and apply a second coat of SCREAMIN'
EAGLE ASSEMBLY LUBE to the valve stem. Install the
valve.

Failure to install plastic capsule can cause the valve stem
seal to catch the edge of the valve stem keeper groove.
The resulting damage can cause leakage around the valve
stem, excessive oil consumption and valve sticking.
(00535b)

See

Figure 3-54

. Hold valve against the valve seat. Slide

plastic capsule over valve stem tip and keeper groove.

Apply a very thin film of SCREAMIN' EAGLE ASSEMBLY
LUBE to capsule.

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3-50 2013 Softail Service: Engine

See

Figure 3-55

. Slide

new

valve stem seal/spring seat

over capsule and down valve stem until seated against
cylinder head casting. Remove capsule from valve stem
tip.

sm02504

Figure 3-54. Plastic Capsule

sm02528

Figure 3-55. Valve Stem Seal/Spring Seat Assembly

10. See

Figure 3-56

. Apply a liberal amount of SCREAMIN'

EAGLE ASSEMBLY LUBE to valve stem tip and keeper
groove (1).

11. With the smaller diameter coils topside, install the valve

spring (3). Place the spring retainer (2) on top of the valve
spring.

12. Install keepers:

Place VALVE SPRING COMPRESSOR (Part No. HD-
34736-B) 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.

Rotate forcing screw to compress valve spring.

With the tapered side down, fit the keepers into the
valve stem groove. For best results, apply a dab of
grease to the inboard side of the keepers before
installation and use a magnetic rod for easy place-
ment.

Arrange tapered keepers so that the gaps are evenly
spaced and release valve spring compression.

13. Tap the end of the valve stem once or twice with a soft

mallet to be sure that tapered keepers are tightly seated.

14. Install the other valve and components.

15. Release the cylinder head holding fixture from the vise.

Remove fixture tool from spark plug hole.

16. Cover the cylinder head to protect it from dust and dirt

until time of installation.

sm02505

1. Tapered keepers
2. Spring retainer
3. Valve spring
4. Spring seat/valve stem set seal
5. Valve guide
6. Lock ring

Figure 3-56. Valve Assembly

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2013 Softail Service: Engine 3-51

3.21

CYLINDER

CLEANING

See

Figure 3-57

. Scrape any remaining cylinder head

gasket material from the gasket surface at the top of the
cylinder (3).

Clean cylinder in a non-volatile cleaning solution or solvent.
Blow parts dry with low pressure compressed air. Verify
that oil passageways are clean and open.

Inspect the cylinder bore for obvious defects or damage
in the ring travel area. Replace cylinders that are severely
scored, scuffed, scratched, burnt or gouged.

Use a file to carefully remove any nicks or burrs from the
machined surfaces of the cylinder.

sm02529

1. Cylinder head gasket
2. Dowel pin
3. Cylinder
4. O-ring seal
5. Cylinder stud

Figure 3-57. Cylinder Assembly

INSPECTION

TOOL NAME

PART NUMBER

CYLINDER TORQUE PLATES

HD-42324-A

SNAP-ON TORQUE ANGLE GAUGE

TA360

TORQUE VALUE

FASTENER

13.6-16.3 Nm

120-144

in-lbs

Cylinder torque plate bolts, 1st
torque

20.3-23.0 Nm

15-17 ft-lbs

Cylinder torque plate bolts,
2nd torque

90 degrees

Cylinder torque plate bolts,
final torque

Using Magnaflux Dye Penetrant, inspect the cylinder for
cracks. If no cracks are found, thoroughly wash cylinder
to remove traces of dye.

See

Figure 3-58

. Check the machined surfaces for flatness

using a feeler gauge and CYLINDER TORQUE PLATES
(Part No. HD-42324-A) as follows:

Lay gasket side of the upper torque plate (3) flat
against the head gasket surface of the cylinder.

As a preliminary check, see if the plate rocks from
side to side. A cylinder on which the plate rocks is
immediately suspect.

Insert a feeler gauge between the plate and cylinder
at various locations.

The head gasket surface must be flat within 0.006 in.
(0.15 mm).

Lay the seal side of the lower torque plate (2) flat
against the O-ring seal surface and check flatness
using a feeler gauge.

The O-ring seal surface must be flat within 0.004 in.
(0.102 mm).

Replace the cylinder (and piston) if either surface is
not within specification.

NOTE

Failure to use cylinder torque plates can produce measure-
ments that vary by as much as 0.001 in. (0.025 mm). This may
result in the use of parts that are not suitable for service.

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3-52 2013 Softail Service: Engine

Install CYLINDER TORQUE PLATES (Part No. HD-42324-
A):

Remove O-ring seal from cylinder sleeve, if installed.

See

Figure 3-59

. Clamp the stepped side of the lower

plate in a vise with soft jaws.

Lightly oil threads and shoulders of four bolts (1) with
clean engine oil and slide through holes of lower plate
(2).

Slide cylinder onto bolts with the indent in the cooling
fins facing upward.

Place a used head gasket on cylinder and install
upper plate with blind holes aligned with dowel pins
in cylinder. Secure with bolts (1).

See

Figure 3-60

. Tighten the bolts to 120-144

in-lbs

(13.6-16.3 Nm) in the sequence shown.

Following the same sequence, tighten each bolt to
15-17 ft-lbs (20.3-23.0 Nm).

Final-tighten each bolt an additional 90 degrees (90
degrees) in the same sequence.

NOTE

For best results use SNAP-ON TORQUE ANGLE GAUGE
(Part No. TA360). If the tool is not available, mark a straight
line on each bolt head continuing the line onto the lower plate.

sm02506

1. Bolts
2. Lower plate
3. Upper plate
4. Vise grip step

Figure 3-58. Cylinder Torque Plates

NOTE

Maximum cylinder wear occurs at the top of top ring travel.
Minimum wear occurs below ring travel. Failure to measure
the cylinder at these points may result in a faulty decision
regarding the condition of the cylinder for continued use.

See

Figure 3-61

. Using an inside micrometer or dial bore

gauge, check cylinder bore for out-of round and taper:

At the top of the piston ring travel zone, measure the
cylinder diameter at two locations; parallel and per-
pendicular to the crankshaft. Record the readings.

Repeat the two measurements at the center of the
piston ring travel zone and again at the bottom of the
bore at a point below the piston ring travel zone.

See

3.3 SERVICE WEAR LIMITS

. If the out-of-round

or taper measurements are not within specification,
the cylinder must be rebored and/or honed to accept
the next standard oversize piston. See

3.21 CYL-

INDER, Boring and Honing Cylinder

If cylinders are not scuffed or scored and are not worn
beyond the service limits, see

3.21 CYLINDER,

Deglazing Cylinder

sm02530

1. Bolt (4)
2. Lower plate
3. Vise

Figure 3-59. Attaching Cylinder Torque Plates

sm02531

Figure 3-60. Cylinder Torque Plate Bolt Sequence

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2013 Softail Service: Engine 3-53

Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual - page 20