Harley Davidson 2008 Touring Models. Service Manual - page 20

3.13 REMOVING ENGINE FROM CHASSIS

. During top end

disassembly, the engine may be left in the chassis for service.

NOTE

If the engine is to be removed from the chassis, see

in lieu of

3.11 STRIPPING MOTORCYCLE FOR SERVICE

In the top end disassembly instructions, references are made
to

through

for

service of all top end subassemblies: breathers, rocker arms,
pushrods, cylinder heads, cylinders, pistons and upper con-
necting rods.

To rebuild the engine after a top end overhaul is complete,
perform the steps under

3.16 TOP END OVERHAUL:

3.12 ASSEMBLING MOTORCYCLE

, immediately following the disassembly instruc-

tions. Then, refer to

AFTER SERVICE

to complete the project.

NOTE

For clarity, all artwork in this section shows the engine removed
from the chassis for service.

Table 3-26. Top End Service

TOP END SERVICE

Engine Removed

Engine in Chassis

Removing Engine From Chassis.

Stripping Motorcycle For Service.

Top End Overhaul, Disassembly.

Subassembly Service and Repair, Top End.

Top End Overhaul, Assembly.

Installing Engine In Chassis.

Assembling Motorcycle After Service.

BOTTOM END OVERHAUL

Bottom end service may require either partial or complete dis-
assembly of the engine. Servicing components in the cam
compartment requires only partial disassembly, while servicing
those in the flywheel compartment requires complete disas-
sembly. An easy rule to remember is that any time the crank-
case halves must be split, complete disassembly needs to
occur.The cam compartment can be accessed through removal
of the cam cover making complete engine disassembly unne-
cessary.

During bottom end service that requires complete disassembly,
the engine must be removed from the chassis and placed in
an engine stand. To begin, see

3.13 REMOVING ENGINE

FROM CHASSIS

After the motorcycle has been stripped and the engine
removed, follow all of the steps under

3.15 TOP END OVER-

HAUL: DISASSEMBLY

. When finished, continue with disas-

sembly of the bottom half by performing those steps listed
under

3.17 BOTTOM END OVERHAUL: DISASSEMBLY

As with the top end disassembly instructions, references are
made to

3.25 COVER AND CAM SUPPORT PLATE

through

3.28 FLYWHEEL AND CONNECTING RODS

for service of

bottom end subassemblies- cam support plate, oil pump,
crankcase and flywheel.

Since it is standard practice to inspect and clean all oil pas-
sages when the engine is completely disassembled, a detailed
explanation of the engine oil circuit is presented under

3.3 ENGINE OIL FLOW

To rebuild the engine after a bottom end overhaul is complete,
perform the steps under

3.18 BOTTOM END OVERHAUL:

, and then proceed to

3.16 TOP END OVERHAUL:

3.25 COVER AND CAM SUPPORT PLATE

, to rebuild the upper end.

Once the engine is assembled, refer to

3.14 INSTALLING

ENGINE IN CHASSIS

to complete the project.

The flow charts in this section show how the same subsections
are used for various levels of service.

Table 3-27. Bottom End Service

BOTTOM END SERVICE

Engine Removed

(Flywheel Compartment or Complete Engine Overhaul)

Engine in Chassis

(Cam Compartment)

Removing Engine From Chassis.

Stripping Motorcycle For Service.

Top End Overhaul, Disassembly.

2008 Touring Service: Engine 3-17

Table 3-27. Bottom End Service

BOTTOM END SERVICE

Engine Removed

(Flywheel Compartment or Complete Engine Overhaul)

Engine in Chassis

(Cam Compartment)

Bottom End Overhaul, Disassembly.

Subassembly Service and Repair, Top End.

Subassembly Service and Repair, Bottom End.

Bottom End Overhaul, Assembly.

Top End Overhaul, Assembly.

Assembling Motorcycle After Service.

Installing Engine In Chassis.

SUBASSEMBLY SERVICE AND REPAIR

Finally, if the task entails servicing of only one particular sub-
assembly, then move directly to the appropriate section for all
service instructions.

For example, if just installing new cams, then refer to

The specific steps under

3.16 TOP END OVERHAUL:

and

3.11 STRIPPING MOTORCYCLE FOR SERVICE

that need to be followed for the removal and installation of the
cam support plate are given.

Furthermore, detailed instructions for disassembling, cleaning,
inspecting, replacing and assembling cam support plate com-
ponents are provided.

3-18 2008 Touring Service: Engine

3.9

TOP END SERVICE

ENGINE IN CHASSIS

Table 3-28. Engine In Chassis

COMPONENT REPAIR
PROCEDURE

SERVICE PROCEDURE

Remove parts to gain access to all components above cylinder deck. See

Disassemble top end. See

Inspect and repair.

BREATHER ASSEMBLY

See

Inspect and repair.

ROCKER ARM SUPPORT

See

Inspect and repair.

PUSH RODS, LIFTERS AND COVERS

See

Inspect and repair.

CYLINDER HEAD

See

3.22 CYLINDER HEAD

Inspect and repair.

CYLINDER

See

3.23 CYLINDER

Inspect and repair.

PISTON

See

Assemble top end. See

3.12 ASSEMBLING MOTORCYCLE AFTER SER-

Assemble motorcycle. See

VICE

Note: * If no other work is to be done, you may advance to

3.13 REMOVING ENGINE FROM

when this step is completed

during top end service.

2008 Touring Service: Engine 3-19

ENGINE REMOVED FROM CHASSIS

Table 3-29. Engine Removed From Chassis

COMPONENT REPAIR
PROCEDURE

SERVICE PROCEDURE

Remove engine from motorcycle. See

CHASSIS

Disassemble top end. See

Inspect and repair.

BREATHER ASSEMBLY

See

Inspect and repair.

ROCKER ARM SUPPORT

See

Inspect and repair.

PUSH RODS, LIFTERS AND COVERS

See

Inspect and repair.

CYLINDER HEAD

See

3.22 CYLINDER HEAD

Inspect and repair.

CYLINDER

See

3.23 CYLINDER

Inspect and repair.

PISTON

See

Assemble top end. See

3.14 INSTALLING ENGINE IN CHASSIS

Install engine in motorcycle. See

Note: * If no other work is to be done, you may advance to

3.11 STRIPPING MOTORCYCLE FOR SERVICE

when this step is completed

during top end service.

3-20 2008 Touring Service: Engine

3.10

BOTTOM END SERVICE

ENGINE IN CHASSIS

Table 3-30. Engine In Chassis: Cam Compartment Service

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove parts to gain access to all components above cylinder deck. See

Dissassemble top end. See

Inspect and repair.

BREATHER ASSEMBLY.

See

Inspect and repair.

ROCKER ARM SUPPORT PLATE.

See

Inspect and repair.

PUSH RODS, LIFTERS AND COVERS.

See

3.17 BOTTOM END OVERHAUL: DISASSEMBLY

Disassemble bottom end. See

Inspect and repair.

COVER AND CAM SUPPORT PLATE

See

3.25 COVER AND CAM SUPPORT

PLATE

Inspect and repair.

OIL PUMP

See

3.26 OIL PUMP

Assemble bottom end. See

3.12 ASSEMBLING MOTORCYCLE AFTER SER-

Assemble motorcycle. See

VICE

Note: * If no other work is to be done, you may advance to

3.13 REMOVING ENGINE FROM CHASSIS

when this step is

completed during bottom end service.

2008 Touring Service: Engine 3-21

ENGINE REMOVED FROM CHASSIS

Table 3-31. Engine Removed: Flywheel Compartment Service or Complete Engine Overhaul

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove engine from motorcycle. See

Dissassemble top end. See

Inspect and repair.

BREATHER ASSEMBLY.

See

Inspect and repair.

ROCKER ARM SUPPORT PLATE.

See

Inspect and repair.

PUSH RODS, LIFTERS AND COVERS.

See

Inspect and repair.

CYLINDER HEAD

See

3.22 CYLINDER HEAD

Inspect and repair.

CYLINDER

See

3.23 CYLINDER

Inspect and repair.

PISTON

See

Disassemble bottom end. See

3.25 COVER AND CAM SUPPORT

Inspect and repair.

COVER AND CAM SUPPORT PLATE

See

PLATE

Inspect crankcase and repair.

CRANKCASE

See

3.27 CRANKCASE

Inspect and repair flywheel/connecting rod
assembly.
See

3.28 FLYWHEEL AND CONNECTING

RODS

Assemble bottom end. See

Assemble top end. See

3.14 INSTALLING ENGINE IN CHASSIS

Install engine in motorcycle. See

3-22 2008 Touring Service: Engine

3.11

STRIPPING MOTORCYCLE FOR SERVICE

PROCEDURE

Cam Compartment Service Only

Remove exhaust system. See

Remove fuel tank. See

Remove air cleaner and backplate. See

Remove spark plug cables. Remove spark plugs. See

1.18 SPARK PLUGS

Remove ignition coil. See

Remove purge solenoid if equipped. See

Top End Service

Complete all steps under Cam Compartment Service Only.

Remove induction module. See

4.12 INDUCTION

MODULE

Gather disconnected branches of main harness and tape
to top of wire trough to keep out of the way.

Remove two hex head bolts (with flat washers) to release
top engine mounting bracket from front cylinder head.
Remove hex head bolt to release stabilizer link from frame
weldment.

2008 Touring Service: Engine 3-23

3.12

ASSEMBLING MOTORCYCLE AFTER SERVICE

PROCEDURE

After Top End Service

Start two hex head bolts (with flat washers) to fasten top
engine mounting bracket to front cylinder head. Alternately
tighten bolts to 30-35 ft-lbs (41-48 Nm).

Start hex head bolt to fasten stabilizer link to frame weld-
ment. Tighten bolt to 18-22 ft-lbs (24-30 Nm).

Start bolt (with flat washer) to fasten horn bracket to front
cylinder head.

Remove tape to release disconnected branches of main
harness from top of wire trough.

Install induction module. See

4.12 INDUCTION MODULE

Continue with steps under After Cam Compartment Ser-
vice.

After Cam Compartment Service

Install purge solenoid if equipped. See

Install ignition coil. See

Install spark plugs and connect spark plug cables.

Install backplate and air cleaner. See

Install fuel tank. See

Install exhaust system. See

3-24 2008 Touring Service: Engine

3.13

REMOVING ENGINE FROM CHASSIS

PROCEDURE

TOOL NAME

PART NUMBER

BENCH STAND

HD-42310

TWIN CAM 88 CRADLE

HD-42310-2

ROLLING STAND

HD-43646A

Remove exhaust system. See

Remove fuel tank. See

Remove air cleaner and backplate. See

Remove spark plug cables. Remove spark plugs. See

1.18 SPARK PLUGS

Remove ignition coil. See

Remove purge solenoid if equipped. See

1.5 ENGINE OIL AND FILTER

Remove induction module. See

4.12 INDUCTION

MODULE

Gather disconnected branches of main harness and tape
to top of wire trough. If wiring is not moved out of the way,
it may be damaged during engine removal.

Remove voltage regulator. See

8.2 VOLTAGE REGU-

LATOR

10. Remove CKP sensor. See

8.20 CRANKSHAFT POSITION

SENSOR (CKP)

11. Remove oil filter. See

12. Remove oil pressure switch/sender. See

8.24 OIL PRES-

SURE SWITCH AND SENDER

13. Coil main harness conduit and allow to hang below lower

frame tube at front of motorcycle. If wiring is not moved
out of the way, it may be damaged during engine removal.

14. Remove primary chaincase. See

6.4 PRIMARY CHAIN-

CASE HOUSING

15. Remove rotor and stator. See

8.21 ALTERNATOR

16. Wrap rear master cylinder reservoir with foam padding or

bubble pack.

17. Cover lower frame tubes (both left and right side) with

foam padding or bubble pack. Split loom conduit or a half
shell of PVC tubing will also produce good results. Protec-
tion is necessary to prevent nicks or paint damage to left
frame tube and chafing, cutting or kinking of the brake line
and main harness conduit at the top of the right frame
tube.

18. Cover rocker covers of front and rear cylinders with foam

padding or bubble pack.

19. Place a jack under the oil pan and use a block of wood

between the jack and oil pan to distribute pressure across

the length of the casting. Raise the jack until firm contact
is made with the bottom of the oil pan.

20. Remove two hex head bolts (with flat washers) to release

top engine mounting bracket from front cylinder head.
Remove hex head bolt to release stabilizer link from frame
weldment.

21. Remove four bolts (with flat washers) to free transmission

from crankcase. Loosen and remove bolts in a crosswise
pattern.

22. Remove two hex head bolts (with flat washers) to free

front of crankcase from front engine mounting bracket.

23. Move engine forward far enough to clear two ring dowels

at bottom of transmission flange. Raise engine and remove
from right side of motorcycle. Exercise caution to avoid
contact with rear brake line and main harness conduit at
top of lower frame tube. Also be sure to avoid the rear
brake master cylinder reservoir.

24. Using the TWIN CAM 88 CRADLE (Part No. HD-42310-

2), install engine in BENCH STAND (Part No. HD-42310)
or ROLLING STAND (Part No. HD-43646A). See

Figure 3-11

25. Thoroughly wipe all engine oil from pockets in crankcase

flange. Remove gasket pulling two index pins from holes
in transmission flange. Discard gasket.

26. Remove and clean the oil pan under any of the following

conditions. See

3.29 OIL PAN

Metal debris is found in the engine or crankcase.

Oil contamination is suspected.

A complete engine overhaul is being performed as a
result of a major engine failure.

The engine is being replaced with a new one.

sm03672

Figure 3-11. Engine/Transmission Bench Stand (HD-42310)

2008 Touring Service: Engine 3-25

3.14

INSTALLING ENGINE IN CHASSIS

PROCEDURE

TOOL NAME

PART NUMBER

BENCH STAND

HD-42310

ROLLING STAND

HD-43646A

Install oil pan, if removed. See

3.29 OIL PAN

Cover rocker covers of front and rear cylinders with foam
padding or bubble pack.

Cover lower frame tubes (both left and right side) with
foam padding or bubble pack. Split loom conduit or a half
shell of PVC tubing will also produce good results. Protec-
tion is necessary to prevent nicks or paint damage to left
frame tube and chafing, cutting or kinking of the brake line
and main harness conduit at the top of the right frame
tube.

Wrap rear master cylinder reservoir with foam padding or
bubble pack.

Remove engine from BENCH STAND (Part No. HD-42310)
or ROLLING STAND (Part No. HD-43646A) and set on
floor on right side of chassis.

Raise engine and install in chassis from right side of
motorcycle setting front of crankcase onto front engine
mounting bracket. Engine must be set forward far enough
to clear two ring dowels in lower flange of transmission.
Exercise caution to avoid contact with rear brake master
cylinder reservoir. Also be sure to avoid brake line and
main harness conduit at top of lower right frame tube.

Install new gasket engaging two index pins in holes at
center of transmission flange. Move engine rearward to
fully engage two ring dowels at bottom of transmission
flange.

Secure the engine as follows:

Using a crosswise pattern, hand tighten four bolts
(with flat washers) to secure transmission to crank-
case. Install the shorter 1/2 inch bolts at the top, the
longer 9/16 inch bolts at the bottom.

Hand tighten two bolts (with flat washers) to secure
front of crankcase to front engine mounting bracket.

Alternately tighten the four transmission to crankcase
bolts to 15 ft-lbs (20.3 Nm) in the crosswise pattern
previously used.

NOTE

For best results, use Open End Crowfoot (Snap-On
FC018) on upper left and upper right transmission to
crankcase bolts.

Repeating the crosswise pattern again, final tighten
the four transmission to crankcase bolts to 34-39 ft-
lbs (46.1-52.9 Nm).

Install two hex head bolts (with flat washers) to fasten
crankcase to front engine mounting bracket. Altern-
ately tighten bolts to 36-40 ft-lbs (48.8-54.2 Nm).

Install two hex head bolts (with flat washers) to secure
top engine mounting bracket to front cylinder head.
Alternately tighten bolts to 30-35 ft-lbs (41-48 Nm).

Install hex head bolt to secure stabilizer link to frame
weldment. Tighten bolt to 18-22 ft-lbs (24-30 Nm).

Remove jack and wooden block from under oil pan.

10. Install oil filter. See

1.5 ENGINE OIL AND FILTER

11. Install stator and rotor. See

8.21 ALTERNATOR

12. Install primary chaincase. See

6.4 PRIMARY CHAINCASE

HOUSING

13. Uncoil main harness conduit and allow to hang below

lower frame tube at front of motorcycle.

14. Install oil pressure switch/sender. See

8.24 OIL PRES-

SURE SWITCH AND SENDER

15. Install CKP sensor. See

8.20 CRANKSHAFT POSITION

SENSOR (CKP)

16. Install voltage regulator. See

8.2 VOLTAGE REGULATOR

17. Remove tape to release disconnected branches of main

harness from top of wire trough.

18. Install induction module. See

4.12 INDUCTION MODULE

19. Install purge solenoid if equipped. See

20. Install spark plugs. See

1.18 SPARK PLUGS

21. Install ignition coil and spark plug cables. See

22. Install backplate and air cleaner. See

23. Install fuel tank. See

24. Install exhaust system. See

1.5 ENGINE OIL AND FILTER

25. Verify proper oil level. See

If oil pan was drained, add appropriate amount and
type of engine oil before checking oil level.

If oil pan was not drained, perform COLD CHECK
and HOT CHECK only.

3-26 2008 Touring Service: Engine

3.15

TOP END OVERHAUL: DISASSEMBLY

GENERAL

It is assumed that each step performed on one cylinder is
automatically repeated on the other.

To perform a complete top end overhaul, follow all steps listed
in this section including inspection and repair procedures.

ROCKER COVERS

TOOL NAME

PART NUMBER

LOWER ROCKER BOX WRENCH

HD-47248

UPPER ROCKER BOX WRENCH

HD-47258

NOTE

Dirt caked on cooling fins and other areas can fall into crank-
case bore or stick to subassemblies as parts are removed.
Abrasive particles can damage machined surfaces or plug oil
passageways. Remove all dirt and particles before disassembly
to prevent component damage.

Use low pressure spray to thoroughly clean exterior sur-
faces of engine prior to disassembly.

NOTE

See

Figure 3-12

. If the engine is left in the chassis for service,

use the UPPER ROCKER BOX WRENCH (Part No. HD-47258)
and LOWER ROCKER BOX WRENCH (Part No. HD-47248)
to remove the rocker cover and rocker housing bolts, respect-
ively. These tools are especially useful when removing the
bolts on the left side of the engine (particularly the rear) where
there is close proximity to the frame. With both an external and
internal hex, the bolts also can be removed with either a 7/16
inch socket or open end/box wrench (open spaces), or a short
3/16 inch allen wrench (tight spaces).

See

Figure 3-13

. Following the sequence shown, altern-

ately loosen the six rocker cover bolts. Remove the rocker
cover bolts and their captive washers.

Remove the rocker cover and gasket. Discard gasket.

sm02324

Internal hex

External hex

Lock patch

Figure 3-12. Rocker Cover Bolt (Rocker Housing Bolt

Similar)

sm02326

Figure 3-13. Rocker Cover Bolt Removal Sequence

ROCKER ARM SUPPORT PLATE

TOOL NAME

PART NUMBER

CRANKSHAFT ROTATING WRENCH

HD-48283

Figure 3-14

. Insert the blade of a small screwdriver

into cast loop of spring cap retainer (at top of upper push
rod cover). While pushing down on spring cap, rotate
bottom of screwdriver toward outboard side to remove.
Repeat step on second push rod cover.

2008 Touring Service: Engine 3-27

sm02329

Figure 3-14. Removing Spring Cap Retainer

Collapse upper and lower push rod covers.

To remove the rocker arm support plate, both lifters of the
cylinder being serviced must be on the base circle (lowest
position) of the cam. To find the base circle, it is first
necessary to rotate the engine. Based on the level of dis-
assembly required, three methods of engine rotation are
presented below.

With primary cover installed - Remove spark plugs.
With the rear wheel raised, place the transmission in
6th gear and rotate rear wheel in a clockwise direction
(as viewed from right side) until the base circle is
found. Continue with next numbered step.

With primary cover removed - Remove spark plugs.
Place the transmission in neutral. Fit a socket on the
compensating sprocket shaft nut. Rotate nut in a
counterclockwise direction until the base circle is
found. Continue with step 4.

NOTE

Do not attempt to rotate engine by removing cam cover
and placing socket on crank or primary cam sprocket
flange bolt. Head of flange bolt can break off possibly
resulting in damage to flywheel or camshaft.

Figure 3-15

. With engine mounted in engine

stand - Install CRANKSHAFT ROTATING
WRENCH (Part No. HD-48283) on sprocket shaft and
rotate in a counterclockwise direction until the base
circle is found.

sm02377

Figure 3-15. Crankshaft Rotating Wrench

Using one of the methods above, rotate engine until piston
is at top dead center (TDC) of compression stroke.

To accomplish this, first raise lower push rod cover
to access intake lifter (inside hole of lifter cover).

Place index finger on top of the intake lifter. While
rotating engine, feel lifter rise (valve open) and fall
(valve closed).

Now place finger tightly over spark plug hole and
rotate engine again. In the compression stroke, air
will be forced out against your finger until the piston
reaches the TDC position. Stop engine rotation when
the flow of air through the spark plug hole stops.

Direct the beam of a small flashlight into spark plug
hole to verify piston is at TDC. Both intake and
exhaust valves are now closed and the push rods are
in the unloaded (loose) position.

See

Figure 3-16

. Remove two bolts to release breather

assembly (arrow) and filter element from the rocker arm
support plate. For inspection and repair information, see

Alternately loosen each of the four rocker arm support
plate bolts 1/4 turn in the pattern shown the figure. Con-
tinue turning the bolts in these increments until loose.
Remove the rocker arm support plate bolts with flat
washers.

Remove the rocker arm support plate assembly from the
rocker housing. For inspection and repair information, see

NOTE

Always service each cylinder separately. After the first cylinder
is serviced the engine must be rotated to find the base circle
on the second cam. Service on the remaining cylinder can then
proceed.

3-28 2008 Touring Service: Engine

sm02386

Figure 3-16. 1/4 Turn Rocker Arm Bolts in Sequence

PUSH RODS, LIFTERS AND COVERS

See

Figure 3-17

. Remove the intake and exhaust push

rods and push rod covers.

Tag the push rods for location (front/rear cylinder),
and orientation (top/bottom) as they are removed.
This will simplify installation.

Remove push rod covers from cylinder head and lifter
cover bores.

Remove three o-rings from push rod covers and dis-
card. If o-ring is missing from upper push rod cover,
be sure to dislodge it from the cylinder head bore.

Figure 3-18

. Remove lifter covers.

Using a crosswise pattern, remove four screws with
captive washers (1) to release the lifter cover (2).

Remove the lifter cover and gasket. Discard gasket.

Remove lifters.

Remove the anti-rotational pin to free the hydraulic
lifters.

Tag the lifters for location (front/rear cylinder) and
function (intake/exhaust) as they are removed. This
will simplify installation.

Place the lifters in clean plastic bags to keep out dust,
dirt and debris.

Figure 3-19

. Remove and discard o-ring from groove

around breather baffle hole in rocker housing.

For inspection and repair information, see

3.21 PUSH

RODS, LIFTERS AND COVERS

sm02181

Front cylinder exhaust push rod

Front cylinder intake push rod

Rear cylinder intake push rod

Rear cylinder exhaust push rod

Figure 3-17. Push Rod Locations

sm02378

Screw with captive washer (4)

Lifter cover

Figure 3-18. Lifter Cover

2008 Touring Service: Engine 3-29

sm02680

Figure 3-19. Breather Baffle Hole O-Ring

CYLINDER HEAD

TOOL NAME

PART NUMBER

CYLINDER TORQUE PLATES

HD-42324-A

See

Figure 3-20

. Following the sequence shown, altern-

ately loosen the six rocker housing bolts. Remove rocker
housing bolts and their captive washers.

Remove rocker housing and gasket. Discard gasket.

NOTE

To prevent distortion of the cylinder head, cylinder and cylinder
studs, gradually loosen the cylinder head bolts in the specified
sequence.

Figure 3-21

. Remove cylinder head bolts.

Following the sequence shown, alternately loosen
each of the four cylinder head bolts just 1/4 turn.

Continue turning the bolts in these increments until
loose.

Remove the cylinder head bolts.

Remove cylinder head and head gasket.

NOTE

Save the cylinder head gasket (if salvageable) for use with the
CYLINDER TORQUE PLATES (Part No. HD-42324-A) when
measuring, boring or honing of the cylinder is required.

For inspection and repair information, see

3.22 CYLINDER

HEAD

sm02389

Figure 3-20. Rocker Housing Bolts Removal Sequence

3-30 2008 Touring Service: Engine

sm02392

Figure 3-21. 1/4 Turn Head Bolts in Sequence

CYLINDER

Raise the cylinder just enough to place clean shop towels
under the piston. This will prevent any dirt or debris, such
as broken ring pieces, from falling into the crankcase bore.

NOTE

Exercise caution to avoid bending the cylinder studs. Even a
slight bend or nick can cause a stress riser leading to stud
failure.

Carefully remove the cylinder. Exercise caution to avoid
bending the cylinder studs. As the piston becomes free of
the cylinder, hold it upright to prevent it from striking the
studs or dragging across the stud thread area.

Mark cylinder FRONT or REAR as appropriate.

Slide approximately 6.0 in. (152 mm) of plastic tubing,
rubber hose or conduit over each cylinder stud. Use
material with I.D. of 0.5 in. (12.7 mm) to protect cylinder
studs and piston from damage.

Figure 3-22

. Remove o-ring seal (4) from the bottom

of the cylinder liner. Discard o-ring seal.

Figure 3-23

. Remove o-ring from dowel pin (4) on

base of cylinder deck. Discard o-ring.

For inspection and repair information, see

3.23 CYL-

INDER

sm02294

Dowel pin

Head gasket

Cylinder

O-ring seal

Figure 3-22. Cylinder Assembly

PISTON

TOOL NAME

PART NUMBER

PISTON PIN CIRCLIP
REMOVER/INSTALLER

HD-42317-A

PISTON PIN REMOVER

HD-42320-A

Verify that clean shop towels are properly positioned over
the crankcase bore to prevent the piston pin circlip from
falling into the crankcase.

Wear safety glasses or goggles when removing or
installing piston pin retaining rings. Piston pin retaining
rings are compressed in the ring groove and can fly out
when removed from the groove, which could result in
serious eye injury. (00293a)

See

Figure 3-23

. Remove the piston pin circlip.

I n s e r t t h e P I S TO N P I N C I R C L I P
REMOVER/INSTALLER (Part No. HD-42317-A) (1)
into the piston pin bore. Position claw on tool in slot
of piston (2) (directly under circlip).

Hold a shop towel over the piston pin bore in case a
circlip should fly out during removal. Squeeze the
handles of the tool together and pull from bore.
Remove circlip from claw and discard.

2008 Touring Service: Engine 3-31

sm02336

Piston pin circlip remover/installer

Piston

Protective material over cylinder studs

Cylinder deck dowel (O-ring not shown)

Figure 3-23. Piston Pin Circlip Removal (Part No. HD-42317)

NOTE

It is not necessary to remove both piston pin circlips during
piston removal. Leave the second circlip in the pin bore.

Figure 3-24

. Remove the piston pin. If piston pin is

difficult to remove, use PISTON PIN REMOVER (Part
No. HD-42320-A).

Remove acorn nut and spacer from rod end of tool.

Slide rod end through piston pin. Install spacer and
acorn nut (1) on end of rod.

Position rubber-coated tips (2) of tool on flat each
side of pin bore.

Turn handle (3) in a clockwise direction until piston
pin is pulled free of bore.

Remove the piston. Be sure to hold the connecting rod
shank upright to prevent it from striking the crankcase.
Place a 3.0 in. (76.2 mm) long piece of foam-type water
pipe insulation around each connecting rod. Use material
with an O.D. of 2.25 in. (57.1 mm) and an I.D. of 1.0
in. (25.4 mm) to prevent damage.

Turn the piston over. Mark the pin boss with the letters
F(ront) or R(ear) to identify location.

Service as needed. For inspection and repair information,
see