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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 15

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7.

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

Placing finger at bottom of valve to keep valve seated,

8702

A

slide plastic capsule over valve stem tip and keeper

groove. See Figure 3-81.

8.

Apply a very thin film of clean H-D 20W50 engine oil to

capsule.

9.

Obtain new valve stem seal and spring seat. Assemble

parts as shown in Figure 3-82.

10. Slide valve stem seal/spring seat over capsule and down

valve stem until contact is made with top of valve guide

8703

8704

B

C

and machined area of cylinder head casting. Remove

capsule from valve stem tip.

CAUTION

Removing the valve after seal installation will cause the

valve 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 sticking.

Figure 3-82. Valve Stem Seal/Spring Seat Assembly

11. Apply a liberal amount of assembly lube to valve stem tip

and keeper groove.

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

b. Rotate forcing screw to compress valve spring.

spring over the valve guide. Place the spring retainer on

top of the valve spring.

c. With the tapered side down, fit the keepers into the

13. Obtain the VALVE SPRING COMPRESSOR

(HD-

valve stem groove. For best results, apply a dab of

34736B) and proceed as follows:

grease to the inboard side of the keepers before

installation and use a magnetic rod for easy place-

a. Place tool over cylinder head so that the blunt end is

ment.

centered on the valve head and adapter at end of

forcing screw is seated on the spring retainer.

d. Arranging tapered keepers so that the gaps are

evenly spaced, turn forcing screw to release valve

spring compression.

CAUTION

Over-compressing the valve spring can damage the

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

valve stem seal resulting in leakage around the valve

mallet to ensure that tapered keepers are tightly seated

stem, excessive oil consumption and valve sticking.

in the valve stem groove.

15. Repeat steps 1-14 to install the other valve components.

16. Release the cylinder head holding fixture from the vise

f2411x3x

and then remove the tool from the spark plug hole.

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

Plastic

Capsule

until time of installation.

Installation

See Section 3.9 TOP END OVERHAUL, ASSEMBLY, steps

15-24 and 29-39.

Figure 3-81. Lubricate Plastic Capsule

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CYLINDER

Removal

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11 and 15-24.

Cleaning and Inspection

CLEANING

1.

Scrape old gasket material from the machined surface at

the top of the cylinder. Old gasket material left on the

Figure 3-83. 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.

Lower Plate

A

Bolts

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

3

B

Upper Plate

at various locations.

4

d. The head gasket surface must be flat within 0.006

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

1

measurements that vary by as much as 0.001 inch (0.025

f2074x3x

mm), possibly resulting in the use of parts that are not

suitable for service.

Figure 3-84. Install Cylinder to Torque Plates

3-68

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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.

Lightly oil threads and shoulders of four bolts with

clean H-D 20W50 engine oil. Slide bolts all the way

through holes of lower plate. See A of Figure 3-84.

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 until finger tight.

Figure 3-85. Measure for Out-of-Round and Taper

g.

Tighten the bolts to 120-144 in-lbs (13.6-16.3 Nm)

in the sequence shown in B of Figure 3-84.

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.

15-17 ft-lbs (20.3-23.1 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

sequence shown in B of Figure 3-84.

Rebore the cylinder if the top, middle and bottom

bore diameters either parallel or perpendicular to

NOTE

the crankshaft vary by more than 0.002 inch (0.051

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 3-85. 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.

On the other hand, if cylinders are worn beyond the ser-

Write the readings down.

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.

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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

Piston

desired cross hatch pattern.

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-

Installation

cles and residual grit. Continue cleaning until a clean

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.

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6.

Using Magnaflux Dye Penetrant, inspect the piston for

PISTON

surface cracks. Pay special attention to the area around

the pin bores, ring lands and oil drain holes beneath the

piston crown. If no cracks are found, thoroughly wash

Removal

piston to remove traces of dye.

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11 and 15-29.

Inspection

1.

Lightly oil a good piston pin and insert it into the piston

pin bore to feel for the proper interference fit. The pin

Disassembly

should slide in and out without binding, but also without

pivoting or rocking. Replace piston and/or pin if clear-

Piston Rings, Removal

ance exceeds 0.0008 in. (0.020 mm).

2.

Carefully inspect the pistons for damage or excessive

1WARNING

wear. Discard pistons with cracked, broken or bent ring

lands. Check the piston skirt for cracks, gouges, deep

Always wear proper eye protection when removing the

scratches or heavy scoring. Check the piston heads for

compression rings. Slippage may propel the ring with

evidence of burning, etching or melting. Look for marks

enough force to cause eye injury.

or imprints caused by contact with valves. Pistons with

superficial wear marks, minor scratching or mild scoring

1.

Carefully remove first and second compression rings

may continue to be used.

using the proper piston ring expander (Snap-On PRS8).

3.

Run your index finger around the edge of the piston

2.

Using your fingers, remove the top and bottom oil rails

crown to feel for dings, nicks or burrs. Lightly file the

from the third ring groove. Remove the expander spring.

edge of the crown to remove any defects.

3.

Discard the piston rings.

CAUTION

Cleaning and Inspection

Worn ring grooves result in high oil consumption and

blow-by of exhaust gases. Blow-by of exhaust gases

Cleaning

contaminates the engine oil supply with acids and

leaves sludge in the crankcase. It also reduces engine

CAUTION

efficiency by weakening the combustion seal necessary

for efficient transfer of energy to the piston.

Do not sand blast or glass bead blast pistons. Bead

blasting rounds off ring lands and will result in oil con-

4.

Measure the piston ring side clearance as follows:

tamination leading to accelerated wear.

a. Insert the edge of a new ring into the piston ring

groove. Insert a feeler gauge between the upper

1.

To remove all carbon and combustion deposits, soak the

surface of the ring and the ring land. See Figure 3-

pistons in a special detergent that will not corrode alumi-

86.

num. Maintain the temperature of the cleaning solution

well below 212^o F. (100^o C.).

2.

Thoroughly rinse the pistons and dry with moisture free

6906

compressed air.

3.

Clean the oil drain holes leading from the oil control ring

groove to the underside of the piston crown. Run a small

bristle brush through the passageways to ensure their

cleanliness, but be careful not to damage or enlarge the

holes. Do not use a wire brush.

4.

Verify that all other oil holes are clean and open.

CAUTION

Exercise care to avoid scratching the sides of the piston

ring grooves.

5.

Thoroughly clean the three piston ring grooves of all car-

bon deposits. A broken compression ring properly

ground to a sharp chisel-like edge may be used for this

purpose.

Figure 3-86. Measure Piston Ring Side Clearance

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NOTE

On late style pistons, the measurement is taken on the bare

aluminum to avoid measuring errors. An oval-shaped open-

EARLY STYLE

ing is present on each side of the piston for proper placement

of the micrometer. See upper frame of Figure 3-88. Since the

FULLY COATED

oval openings are too small for a standard flat anvil microme-

No Bare

ter, which would result in measuring errors, use a 3-4 inch

Aluminum

blade or ball anvil style micrometer, or a 4-5 inch micrometer

with spherical ball anvil adapters. See lower frame of Figure

3-88.

f2114x3x

c. Using a grease pencil, mark the top, middle and

bottom of the piston ring travel zone in the cylinder

bore. Measure at markings in cylinder parallel and

perpendicular to crankshaft.

CAUTION

Do not check piston running clearance immediately after

honing or deglazing cylinder. Since heat will cause mea-

surements to vary by as much as 0.0002 inch (0.005 mm),

both piston and cylinder must be at room temperatures.

d. Replace piston and/or cylinder if running clearance

exceeds 0.003 in. (0.076 mm).

LATE STYLE

f1685x3x

Figure 3-87. Measure Early Style Piston for

Running Clearance

b. Since the grooves wear unevenly, repeat this check

at several locations around the piston groove cir-

cumference.

Bare

Aluminum

c. Discard the piston if the side clearance of either

compression ring exceeds 0.0045 in. (0.11 mm).

Discard the piston if the oil control ring side clear-

ance exceeds 0.010 in. (0.25 mm).

f2113x3x

5.

Measure the running clearance on fully coated early

style pistons as follows:

NOTE

Check the piston clearance in the cylinder in which the piston

4-5 Inch

will run. The torque plates must be installed on the cylinder

Micrometer

and it must be deglazed and suitable for continued service.

a. Holding outside micrometer, measure piston skirt

diameter across the thrust faces (perpendicular to

pin bore). Start below the bottom ring land and

move micrometer towards bottom of skirt. Microme-

ter will be loose, then tight (about 1/2 inch from bot-

tom), and then loose again. See lower frame of

Figure 3-87.

Spherical Ball

b. Measure the piston skirt at the tightest spot and

Anvil Adapters

f2109x3x

then transfer that measurement to the dial bore

gauge.

Figure 3-88. Measure Late Style Piston for

Running Clearance

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NOTE

Ring end gap dimensions also apply to oversize rings.

Replace ring if end gap exceeds specification. If end gap is

under specification, filing is permissible.

3.

Use compressed air to remove any dirt or dust that may

have settled in the oil drain holes and piston ring

grooves.

4.

Install piston rings as follows:

a.

Apply clean H-D 20W50 engine oil to three piston

ring grooves.

b.

Install expander spring into third ring groove. Spiral

bottom oil rail into space below expander spring

positioning the gap 90 degrees from the gap in the

6905

expander spring. Spiral top oil rail into space above

expander spring positioning gap 180 degrees from

the gap in the bottom oil rail.

Figure 3-89. Measure Ring End Gap

Assembly

Piston Rings, Installation

4

3

NOTE

Always use new piston rings. Piston rings take a definite set

and must not be reused if the engine has been operated.

FRONT

Always deglaze (or hone) the cylinder before installing new

rings. Ring sets are available to fit oversize pistons.

1.

Before placing each ring on the piston, perform the fol-

lowing check.

CAUTION

2

1

5

Insufficient ring end gap may cause the ends to abut at

engine operating temperatures, resulting in ring break-

2

1

5

age, cylinder scuffing and/or piston seizure.

CAUTION

REAR

Excessive ring end gap results in high oil consumption

and blow-by of exhaust gases. While blow-by contami-

nates the oil supply and leaves sludge in the crankcase,

it also reduces engine efficiency by weakening the com-

bustion seal necessary for efficient transfer of energy to

the piston.

4

3

2.

Insert the new ring into the cylinder, square it in the bore

using the top of the piston and measure the ring end gap

with a feeler gauge. See Figure 3-89. Do not use the ring

1.

Expander spring

if the end gap does not fall within the following specifica-

2.

Bottom oil rail

tions.

3.

Top oil rail

f2066x3x

Table 3-8. Ring End Gap

4.

Second compression ring

5.

Top compression ring

Ring Type

Ring End Gap

Top compression ring

0.010 in. (0.25 mm) - 0.020 in. (0.51 mm)

Figure 3-90. Piston Ring Gap Alignment

2nd compression ring

0.014 in. (0.36 mm) - 0.024 in. (0.61 mm)

Oil control ring rails

0.010 in. (0.25 mm) - 0.050 in. (1.27 mm)

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UPPER CONNECTING ROD

Removal

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11 and 15-29.

Disassembly/Assembly

Threaded

NOTE

Cylinders

Service of connecting rods is limited to replacement of the

Part No. HD-95952-1

upper bushing. Damage to connecting rods or lower bushing

service requires replacement of the flywheel assembly.

Figure 3-91. Connecting Rod Clamping Tool

(Part No. HD-95952-33B)

Upper Connecting Rod Bushing

f1597x3x

Removal

Threaded

NOTE

Cylinder

Replace the upper rod bushing if the piston pin to rod bush-

ing clearance exceeds 0.002 inch (0.051 mm).

CAUTION

Place clean shop towels in and around the crankcase

bore to prevent chips and shavings from falling into the

crankcase.

1.

Obtain the CONNECTING ROD CLAMPING TOOL (HD-

95952-33B) and proceed as follows:

a. Slide clamp over connecting rod so that slots

engage cylinder head studs. See Figure 3-92. Exer-

cise caution to avoid scratching or bending studs.

b. With the knurled side up, install threaded cylinders

(HD-95952-1) onto studs to secure position of

Clamp

Thumbscrew

clamp.

c. Alternately turn each clamp thumbscrew a few turns

to gradually fix position of connecting rod. Turning

Figure 3-92. Install Connecting Rod Clamping Tool

only one thumbscrew will move rod off-center, while

tightening second thumbscrew can cause rod to flex

f.

Thread the hex cylinder onto rod until assembly is

or bend.

snug. See upper frame of Figure 3-94.

2.

Obtain the CONNECTING ROD BUSHING REMOVER/

INSTALLER (HD-95970-32D) and proceed as follows:

g. Holding nut at end of threaded rod with a 5/8 inch

box wrench, turn hex cylinder with a 5/8 inch socket

a. Sparingly apply graphite lubricant to threads of rod

until bushing is free.

to prolong service life and ensure smooth operation.

h. Unthread hex cylinder from rod. Remove flat

b. Slide receiver cup (HD-95984-99) onto threaded rod

washer, Nice bearing and driver. Remove threaded

with the closed side facing hex nut.

rod from bushing bore.

c. Insert threaded rod through upper rod bushing.

i.

Remove bushing from receiver cup and discard.

d. Slide remover side of driver (HD-95986-99) down

threaded rod. The driver is stamped to ensure

Installation

proper orientation.

e. Slide Nice bearing and flat washer down threaded

1.

Obtain the CONNECTING ROD BUSHING REMOVER/

rod until it contacts driver.

INSTALLER (HD-95970-32D) and proceed as follows:

3-76

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Receiver

Driver

Driver

Cup

Remover Side

Part No. HD-95986-99

Nice

Bearing

Hex

Cylinder

Receiver Cup

Part No. HD-95984-99

Figure 3-93. Connecting Rod Bushing Remover/Installer

Flat

(Part No. HD-95970-32D)

Washer

a. Slide receiver cup (HD-95984-99) onto threaded rod

Connecting

Threaded

with the closed side facing hex nut.

Rod

Rod

b. Insert threaded rod through upper rod bushing bore.

Remover Stackup

c. Slide new bushing down threaded rod. Start bush-

f1601x3x

ing into bore. Verify that center of slot in bushing is

aligned with oil hole at top of rod. Also, be sure that

f1602x3x

Upper Rod

bushing is square in bore and not cocked. See cen-

Bushing

ter frame of Figure 3-94.

Oil Hole

Driver

d. Slide installer side of driver (HD-95986-99) down

Installer Side

threaded rod until shoulder contacts bushing. The

driver is stamped to ensure proper orientation.

e. Slide Nice bearing and flat washer down threaded

rod until it contacts driver.

f.

Thread the hex cylinder onto rod until assembly is

snug.

g. Holding nut at end of threaded rod with a 5/8 inch

box wrench, turn hex cylinder with a 5/8 inch socket

until collar on driver bottoms against connecting

rod. See lower frame of Figure 3-94.

Slot

h. Unthread hex cylinder from rod and remove flat

Installer Stackup

washer, Nice bearing and driver. Remove threaded

rod from bushing bore, but exercise caution to avoid

scratching or gouging bushing.

f1598x3x

Reaming Upper Rod Bushing

1.

Obtain the CONNECTING ROD BUSHING REAMER

(HD-42318) and REAMER HANDLE/DRIVE SOCKET

(HD-43645). Proceed as follows:

a. Carefully insert bit of reamer into upper connecting

rod bushing. Do not apply lubricant to reamer or

bushing. Ream the bushing dry or cut will not be

accurate.

b. Install handle/drive socket on reamer lug. See Fig-

ure 3-96.

c. Placing thumb on drive socket, apply slight pressure

on reamer while rotating handle/drive socket in a

clockwise direction.

Hold hex nut on threaded rod with 5/8 inch box.

Turn cylinder hex with 5/8 inch socket.

Figure 3-94. Remove/Install Connecting Rod Bushing

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2.

Using contact cleaner or cleaning solvent, thoroughly

wipe upper connecting rod and bushing of any metal

Handle/Drive Socket

shavings or debris.

Honing Upper Rod Bushing

Reamer

1.

Obtain the CONNECTING ROD BUSHING HONE (HD-

42569) and REAMER LUBRICANT (HD-39964). Pro-

ceed as follows:

a. Install hone in a high speed electric drill.

b. Apply reamer lubricant to finishing stones of hone

Figure 3-95. Connecting Rod Bushing Reamer (Part No.

and inside of upper connecting rod bushing.

HD-42318) and Handle/Drive Socket (Part No. HD-43645)

c. Start finishing stones of hone into bushing.

d. Activating the drill, move the entire length of the fin-

f1642x3x

ishing stone arrangement forward and backward

through the bushing bore for 10 to 12 complete

strokes. See Figure 3-98. Work for a crosshatch

pattern of approximately 60˚.

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

Figure 3-96. Ream Connecting Rod Bushing

CAUTION

For best results, do not push on reamer or apply pres-

Figure 3-97. Connecting Rod Bushing Hone

sure to the reamer handle. While excessive pressure

(Part No. HD-42569)

results in a rough cut, bushing bore will be tapered if

pressure is not centrally applied.

f1643x3x

d. Continue rotating handle/drive socket until entire bit

has passed through bushing and shank of reamer

rotates freely in the bore.

CAUTION

Never back reamer out of connecting rod or bushing will

be damaged.

e. Remove handle/drive socket, and carefully pulling

on bit, draw shaft of reamer out of connecting rod

bushing.

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

Figure 3-98. Hone Connecting Rod Bushing

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Legend:

1.

T20 TORX Screw

17. Roll Pin

2.

Cam Position Sensor Cover

18. Oil Pressure Relief Valve Piston

3.

Screw

19. Valve Spring

4.

Cam Cover

20. Chain Guide

5.

Cam Cover Gasket

21. Screw

6.

Primary Cam Chain

22. Cam Support Plate

45

7.

Flange Bolt

23. Secondary Cam Chain Tensioner

8.

Flat Washer

24. Retaining Ring

9.

Primary Cam Sprocket

25. Retaining Ring

10.

Spacer

26. Rear Cam (Roller) Bearing

11.

Retaining Ring

27. Front Cam (Ball) Bearing

12.

Primary Cam Chain Tensioner

44

13.

Flange Bolt

14.

Flat Washer

15.

Crank Sprocket

16.

Crankshaft Bushing

33

43

31

41

34

39

32

42

28

30

38

36

40

26

37

37

25

29

35

27

28.

Bearing Retainer Plate

29.

T20 TORX Screw

30.

Secondary Cam Chain

31.

Roller Bearing Inner Race

32.

Thrust Washer

33.

O-Ring

34.

Rear Camshaft

23

35.

Front Camshaft

24

36.

Feed Gerotor Set

37.

Separator Plate

38.

Wave Washer

39.

Scavenge Gerotor Set

40.

O-Ring

20

41.

Oil Pump Housing

42.

O-Ring (Scavenge Port Stub)

43.

O-Ring (Oil Feed Hole)

44.

O-Ring (Blind Hole)

19

45.

Right Crankcase Half

22

18

4

5

8

7

10

21

17

12

11

9

13

16

2

15

14

6

1

3

f2413x3x

Figure 3-99. Cam Support Plate/Oil Pump Assemblies (Exploded View)

3-80

2006 Touring: Engine

HOME

2.

Center support tube under ram of arbor press.

BOTTOM END

3.

Center crankshaft bushing in cam support plate over

support tube. Be sure that the primary cam chain side of

the cam support plate is facing upward.

CAM SUPPORT PLATE

CAUTION

Removal

If the crankshaft bushing is pressed out the primary cam

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

chain side, the bore will be damaged by the knurled edge

BLY, steps 1-11.

of the bushing. Damage to the bore requires replace-

ment of the cam support plate.

NOTE

When removing the cam support plate, it is not necessary to

4.

Insert remover side of driver into crankshaft bore so that

disturb the lifter assemblies if a method is devised to prevent

shoulder on tool is seated on edge of bushing. See

the hydraulic lifters from dropping into the cam compartment.

upper frame of Figure 3-102.

One such method is provided in the following step. Leaving

5.

Press on driver until collar of tool contacts cam support

the lifter assemblies intact simplifies the procedure, since the

plate. Remove bushing from support tube and discard.

lifter cover, gasket, anti-rotation pin and hydraulic lifters can

be left in place.

Installation

2.

Fashion lifter holding tool as follows:

1.

Obtain the CRANKSHAFT BUSHING REMOVER/

a. Obtain a large binder clip (available at any office

INSTALLER (HD-42315).

supply store). Squeeze wireforms to remove from

2.

Center support tube under ram of arbor press.

binder clip. See upper frame of Figure 3-100.

b. Compress wireform slightly and insert free ends into

outer and inner lifter cover bores so that legs

engage walls of both hydraulic lifter sockets. See

f1596x3x

lower frame of Figure 3-100.

Binder Clip

3.

See Section 3.10 BOTTOM END OVERHAUL, DISAS-

SEMBLY, steps 1-14.

Wireform

Disassembly/Assembly

1CAUTION

Do not pull the retention pins from the primary or sec-

ondary cam chain tensioners with the chains and

sprockets removed. With 35-40 pounds of spring pres-

sure behind the tensioner, allowing it to accelerate

through its full length of travel will cause spring stretch-

f1595x3x

ing and/or cracking of the tensioner shoe, damage which

requires replacement of the assembly. Furthermore, if

the tensioner should contact fingers or other parts of the

Wireform

hand, minor or moderate injury may occur.

NOTE

If the retention pins interfere with cleaning or service proce-

dures, hold the retracted cam chain tensioner with the CAM

CHAIN TENSIONER UNLOADER (HD-42313), pull the

retention pin and ease the assembly into the unloaded posi-

tion.

Crankshaft Bushing

Removal

1.

Obtain the CRANKSHAFT BUSHING REMOVER/

INSTALLER (HD-42315).

Figure 3-100. Fashion Tool to Hold Hydraulic Lifters

2006 Touring: Engine

3-81

HOME

f1599x3x

Ram

Driver

Remover

Installer

Remover Side

Side

Side

Down

Support

Tube

Driver

Figure 3-101. Crankshaft Bushing Remover/Installer

(Part No. HD-42315)

Support

Tube

REMOVE

3.

Turn cam support plate over so that secondary cam

CRANKSHAFT

chain side is facing upward.

BUSHING

4.

Start new bushing into bore with the knurled edge top-

side. Be sure that hole in bushing is aligned with oil hole

in bushing bore.

Crankshaft

f1600x3x

Driver

Bushing

Installer Side

Knurled Side Up

Down

CAUTION

If the crankshaft bushing is pressed in from the primary

cam chain side, or from the secondary cam chain side

with the knurled edge of the bushing down, the bushing

bore will be damaged. Damage to the bore requires

replacement of the cam support plate.

5.

Center crankshaft bushing bore over support tube.

6.

Insert installer side of driver into bushing. See lower

frame of Figure 3-102.

Ensure Oil

Hole Alignment

7.

Press on driver until collar of tool makes firm contact

with cam support plate.

INSTALL

8.

Ream the crankshaft bushing following the directions

CRANKSHAFT

below.

BUSHING

Figure 3-102. Remove/Install Crankshaft Bushing

Reaming Crankshaft Bushing

in Cam Support Plate

NOTE

A new crankshaft bushing must be reamed for proper size

a. From flywheel compartment side, carefully insert

and alignment. If crankcase halves are not split, ream the

tapered end of reamer pilot into crankshaft bearing

bushing using a spare right case half to avoid further engine

until it stops. See left frame of Figure 3-104.

disassembly.

b. Slide reamer through pilot starting bit into crank-

1.

Slide cam support plate onto two ring dowels in crank-

shaft bushing in cam support plate. Do not apply

case flange.

lubricant to reamer or bushing. Ream the bushing

dry or cut will not be accurate.

2.

Install six allen head socket screws (1/4 x 1 inch) to

secure cam support plate to crankcase flange. Alter-

c. Install handle/drive socket on reamer lug. See right

nately tighten screws until snug.

frame of Figure 3-104.

3.

Obtain the CRANKSHAFT BUSHING REAMER (HD-

d. Placing thumb on drive socket, apply slight pressure

42316) and REAMER HANDLE/DRIVE SOCKET (HD-

on reamer while rotating handle/drive socket in a

43645). Proceed as follows:

clockwise direction.

3-82

2006 Touring: Engine

HOME

f.

Remove handle/drive socket, and carefully pulling

Handle/Drive Socket

on bit, draw shaft of reamer out of bushing on cam

side of crankcase.

g. Remove pilot from crankshaft bearing. Tap on pilot

Pilot

using a soft rubber mallet, if necessary.

4.

Remove the allen head socket screws to release the

cam support plate from the crankcase flange.

CAUTION

Abrasive particles can damage machined surfaces and

Reamer

plug oil passages possibly resulting in engine failure.

Figure 3-103. Crankshaft Bushing Reamer (Part No. HD-

5.

Thoroughly flush right crankcase half and cam support

42316) and Handle/Drive Socket (Part No. HD-43645)

plate in cleaning solvent to remove any metal shavings

or debris. Blow dry with compressed air.

CAUTION

Camshafts/Camshaft Bearings

For best results, do not push on reamer or apply pres-

sure to the reamer handle. While excessive pressure

Removal

results in a rough cut, bushing bore will be tapered if

1.

Place cup of CAM CHAIN TENSIONER UNLOADER

pressure is not centrally applied.

(HD-42313) over spring coil of secondary cam chain ten-

e. Continue rotating handle/drive socket until entire bit

sioner positioning finger on tool between tensioner and

has passed through bushing and shank of reamer

shoe. See Figure 3-105. Rotate tool in a counterclock-

rotates freely in the bore.

wise direction inserting retention pin through hole in

boss on primary cam chain side of cam support plate.

Pin engages hooks on tensioner to hold it in the

CAUTION

retracted position. For best results, place cam support

Never back reamer out flywheel side of crankcase or

plate in a vise using brass jaw inserts to prevent casting

crankshaft bushing will be damaged.

damage.

Install pilot and reamer from flywheel side of case.

Install handle/drive socket on reamer.

Right Crankcase

Handle/

Reamer

Half

Drive Socket

Crankshaft

Bearing

Pilot

f1619x3x

f1611x3x

Figure 3-104. Ream Crankshaft Bushing

2006 Touring: Engine

3-83

HOME

Press out camshafts (with bearings).

Finger

Ram

Camshaft

Driver

Tensioner

Shoe

Retention

Pin

f1637b3x

Parallel

Figure 3-105. Retract Secondary Cam Chain Tensioner

Blocks

f1623x3x

1WARNING

Remove bearing from front camshaft.

Always wear proper eye protection when removing re-

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

Forcing

worn. Slippage may propel the ring with enough force to

Screw

cause eye injury.

3/8-16 Inch

2.

Remove retaining ring from groove at end of front cam-

Bolt

shaft. Discard retaining ring.

with Flat Washer

3.

Remove four T20 TORX screws to free bearing retainer

plate from inboard side of cam support plate.

Bridge

4.

Using a colored marker, mark one of the links of the sec-

ondary cam chain. Maintaining the original direction of

rotation during assembly may prolong service life of

Hardened

chain.

Plug

Bearing

5.

With the primary cam chain side facing upward, place

cam support plate on parallel blocks under ram of arbor

press.

6.

Obtain the CAMSHAFT/CAMSHAFT BEARING RE-

MOVER/INSTALLER (HD-43644). See Figure 3-106.

Wedge

Attachment

Support Block

Front

Camshaft

f1611x3x

Figure 3-107. Remove Camshafts/Front Cam Bearing

CAUTION

Camshaft Driver

Bearing Pilot/Driver

Since the bearing fit to the camshafts is tighter than its

fit in the support plate, any attempt to remove the cam-

Figure 3-106. Camshaft/Camshaft Bearing

shafts without the bearings will result in damage to the

Remover/Installer (Part No. HD-43644)

cam support plate and bearing retainer plate, if installed.

3-84

2006 Touring: Engine

HOME

f1806x3x

Pull Bearing Inner Race and Thrust Washer

A

From Rear Cam. Remove O-Ring if Present.

Thrust

Washer

Inner

Shop

Race

Rag

Box Wrench

5/8 Inch

NOTE

Although the vane has been eliminated

from the cam sprocket on production

motorcycles, the service part retains the

vane to retrofit earlier models having a

camshaft position sensor.

Box Wrench

Inner

9/16 Inch

Race

Shop

Thrust

Rag

Washer

Install O-Ring and Thrust Washer.

B

Press Bearing Inner Race Onto Rear Cam.

f1807x3x

Figure 3-108. Remove/Install Bearing Inner Race (With O-Ring and Thrust Washer) Onto Rear Camshaft

CAUTION

camshafts (with attached bearings) from the cam sup-

port plate. See upper frame of Figure 3-107.

Cam bearings may be a loose fit in the cam support

plate. To avoid possible damage, be aware that camshaft

8.

Remove secondary cam chain from cam sprockets.

and bearing assemblies may drop out at start of press

9.

If reusing front camshaft, remove bearing as follows:

procedure.

7.

Fit cups of camshaft driver over ends of front and rear

a. Position WEDGE ATTACHMENT (HD-95637-46B)

camshafts, so that contact is made with the bearing

on inboard side of front camshaft bearing and turn

inner races. Centering driver under ram at a point mid-

hex nuts an equal number of turns to draw halves of

way between the camshafts, simultaneously press both

wedge together.

2006 Touring: Engine

3-85

HOME

b. Obtain two 3/8-16 inch bolts 3-1/2 inches long (with

flat washers). Install flat washers on bolts. Obtain

O-Ring

Thrust Washer

bridge, forcing screw and hardened plug from

MAINSHAFT BEARING INNER RACE PULLER/

INSTALLER (HD-34902B).

c. Slide one bolt into channel on each side of bridge

so that flat washer is between bridge and bolt head.

Thread bolts into wedge attachment an equal num-

ber of turns.

d. Sparingly apply graphite lubricant to threads of forc-

ing screw to prolong service life and ensure smooth

operation. Start forcing screw into center hole of

Bearing Inner Race

bridge.

Roller Bearing

f1805x3x

CAUTION

Figure 3-109. Rear Cam Roller Bearing Kit (P/N 8983)

Failure to use hardened plug may result in damage to

forcing screw and/or camshaft.

2.

Install O-ring, thrust washer and bearing inner race onto

e. Place cupped side of hardened plug against end of

rear camshaft as follows:

camshaft. Thread forcing screw into bridge until the

steel ball at the end of the screw makes firm contact

a. To properly locate thrust washer, first install O-ring

with hardened plug.

in grinding relief groove. Groove is on the splined

end between the machined area and the secondary

f.

Verify that the tool assembly is square so that the

cam sprocket. Exercise caution to avoid stretching

bearing is not cocked during removal. See lower

or breaking the O-ring. Since the O-ring is not sold

frame of Figure 3-107. Turn forcing screw until bear-

separately, damage will require purchase of a new

ing is pulled free of camshaft. Discard bearing.

roller bearing kit.

10.

If reusing rear camshaft, remove roller bearing assembly

as follows:

CAUTION

a. Slide roller bearing from end of rear camshaft.

Since bearing is a loose fit on cam, no pressing

The thrust washer will be offset to one side if the O-ring

tools are required.

is not installed in the grinding relief groove. Damage to

the bearing cage can occur if the thrust washer is not

b. Install tools as you would to remove the bearing

properly centered.

from the front camshaft, but position cup of wedge

inboard of the thrust washer.

b. Slide thrust washer down rear camshaft until cen-

c. Wrap a shop rag around camshaft to get a firm grip

tered over O-ring in grinding relief groove.

and also to protect hand from sharp edges of

c. Slide bearing inner race down rear camshaft until

sprocket.

contact is made with shoulder of machined area.

d. Using a 5/8 inch box wrench, turn forcing screw until

d. Install primary cam sprocket spacer and sprocket

bearing inner race and thrust washer are pulled free

on camshaft and secure using thicker flat washer

of camshaft. See A of Figure 3-108. A light interfer-

and long flange bolt.

ence fit allows the parts to be removed with little

effort. Discard inner race and thrust washer.

NOTE

e. If present, remove O-ring from grinding relief groove

If not enough of the splined shaft is exposed to install the

in camshaft. Groove is on the splined end between

sprocket, leave out the spacer and proceed to step 2(e).

the machined area and the secondary cam

Once the bearing inner race has been started onto the

sprocket. Discard O-ring.

machined area, remove the flange bolt, washer and sprocket,

and then reassemble using the spacer. Repeat step 2(e) to

NOTE

fully install bearing inner race.

Since the O-ring is not used in production, it will only be

found if the cams were serviced at the dealer level.

e. Wrap a shop rag around camshaft to get a firm grip

and also to protect hand from sharp edges of

sprocket. Using a 9/16 inch box wrench, turn flange

Installation

bolt in a clockwise direction. Bearing inner race is

1.

Obtain new rear cam roller bearing kit (Part No. 8983).

fully installed when it makes firm contact with the

See Figure 3-109.

thrust washer. See B of Figure 3-108.

3-86

2006 Touring: Engine

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