Harley Davidson 2009 Dyna Models. Service manual

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
seats if any evidence of these conditions are found.

Check seats for recession by measuring valve stem pro-
trusion. See

3.23 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

HD-39782-1

INTAKE SEAT ADAPTER

HD-39782-3

EXHAUST SEAT ADAPTER

HD-39782-4

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. If perpendicularity is not achieved, the cylinder
head valve guide bore will be damaged during the press
procedure.

See

Figure 3-83

. Prepare cylinder head for valve guide

replacement.

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

Insert sleeve of INTAKE SEAT ADAPTER (Part
No. HD-39782-3) (3) or EXHAUST SEAT
ADAPTER (Part No. HD-39782-4) (4) seat adapter
into tube at top CYLINDER HEAD SUPPORT
STAND (Part No. HD-39782-1) (2).

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

NOTE

Do not press out the valve guide from the bottom of the cylinder
head. Carbon buildup on the combustion chamber side of the
guide can deeply gouge the cylinder head bore diminishing
the likelihood of achieving the proper interference fit and pos-
sibly requiring replacement of the cylinder head casting.

Remove and discard lock ring from valve guide groove.

NOTE

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

At top of the cylinder head, insert VALVE GUIDE
DRIVER (Part No. B-45524-1) (1) into valve guide bore
until stopped by shoulder.

See

Figure 3-84

. Center valve guide driver under ram of

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

sm02497

Valve guide driver

Cylinder head support stand

Intake seat adapter

Exhaust seat adapter

Valve guide installer sleeve

Figure 3-83. Valve Guide Replacement Tools

HOME

3-68 2009 Dyna Service: Engine

sm02498

Valve guide driver

Cylinder head stand

Figure 3-84. Remove Valve Guide

Installation

Check valve guide to valve bore clearance.

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 clearance is not within specification, then 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

Since some material is typically removed when the guide is
pressed out, it is normal to go to the next larger size for the
proper interference fit.

Measure cylinder head bore and outside diameter of
selected oversize guide to verify correct interference fit.

NOTE

Support stand ensures that valve guide and seat are perpen-
dicular. If perpendicularity is not achieved, cylinder head valve
guide bore will be damaged during the press procedure.

Prepare cylinder head for valve guide replacement.

See

Figure 3-83

. Insert sleeve of INTAKE SEAT

ADAPTER (Part No. HD-39782-3) (3) or EXHAUST
SEAT ADAPTER (Part No. HD-39782-4) (4) into tube
at top of support stand (2). Position cylinder head so
that valve seat is centered on seat adapter.

Apply Vaseline to lightly lubricate external surfaces
of valve guide. Spread lubricant so that thin film
covers entire surface area.

At top of cylinder head, start valve guide into bore.

See

Figure 3-85

. Place VALVE GUIDE INSTALLER

SLEEVE (Part No. B-45524-2A) (2) over valve guide
and then insert tapered end of 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, but then back off ram again to allow valve
guide to find center.

Repeat previous step and then apply pressure to
driver 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.

HOME

2009 Dyna Service: Engine 3-69

sm02299

Valve guide driver

Valve guide installer sleeve

Cylinder head stand

Figure 3-85. 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.

NOTE

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

sm02499

T-handle

Valve guide reamer

Figure 3-86. Reaming Valve Guide Bore

See

Figure 3-86

. Obtain the VALVE GUIDE

REAMER (Part No. B-45523), REAMER T-HANDLE (Part
No. HD-39847) and REAMER LUBRICANT (Part No. HD-
39964).

Install T-handle (1) on reamer (2).

Apply a liberal amount of reamer lubricant to valve
guide bore and bit of reamer. Start bit of reamer into
bore at top of cylinder head.

Placing thumb on drive socket of reamer T-handle,
apply slight pressure on reamer while rotating in a
clockwise direction. 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. While excessive pressure results in
a rough cut, bore will be tapered if pressure is not centrally
applied.

Continue rotating reamer T-handle until entire bit has
passed through valve guide bore and shank of reamer
rotates freely.

Remove T-handle from reamer, and carefully pulling
on bit, draw shaft of reamer out combustion chamber
side of valve guide.

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)

Direct compressed air into the valve guide bore to remove
any metal shavings or debris.

See

Figure 3-87

. Clean valve guide bore with the VALVE

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

HOME

3-70 2009 Dyna Service: Engine

See

Figure 3-88

. Obtain the VALVE GUIDE HONE (Part

No. B-45525) and REAMER LUBRICANT (Part No.HD-
39964).

Install hone in a high speed electric drill.

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

Start finishing stones of hone into bore.

Activating the drill, move the entire length of the fin-
ishing stone arrangement forward and backward
through the bore for 10 to 12 complete strokes. Work
for a crosshatch pattern of approximately 60°.

Direct compressed air into the valve guide bore to remove
any debris. Clean with the VALVE GUIDE CLEANING
BRUSH (Part No. HD-34751).

NOTE

Always verify valve stem to valve guide clearance after honing,
since a worn reamer may cut the bore undersize.

10. Check valve stem to valve guide clearance.

Measure the inside diameter of the valve guide with
an inside ball micrometer.

Measure the outside diameter of the valve stem with
an outside micrometer.

Refer to

Table 3-33

. If the clearance between stem

and guide is not within the limits shown, the low end
being preferable, then the valve stem may be
excessively worn or the valve guide bore undercut.

sm02500

Figure 3-87. Scrubbing Valve Guide Bore

sm02501

Figure 3-88. Honing Valve Guide Bore

11. Clean cylinder head assembly again.

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, use a thin engine oil and clean valve guide
bore with the type of swabs or patches found in gun
cleaning kits.

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

12. Blow parts dry with low pressure compressed air.

Table 3-33. Valve Stem to Guide Clearance

IN.

VALVE

0.0254-0.0762

0.001-0.003

Intake

0.0254-0.0762

0.001-0.003

Exhaust

HOME

2009 Dyna Service: Engine 3-71

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. Refer to

Table 3-33

. If new guides must be

installed, complete that task before refacing valve seats.

•

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

Hold the valve firmly against a wire wheel in a bench
grinder. Remove all carbon deposits from the valve head,
face and stem, but exercise caution to avoid removing any
metal. Carbon left on the stem may affect alignment in the
valve refacer. Polish the valve stem with steel wool or
crocus cloth to remove any marks that might be left by the
wire wheel.

Install valve (both intake and exhaust) in a valve refacer
set to a 45° angle. The valve refacer is required equipment,
since accuracy in matching the angle of the valve face
with the angle of the valve seat is critical.

NOTES

•

Do not remove any more metal than is necessary to clean
up and true the valve face. Removing metal reduces the
service life of the valve. The amount of grinding needed
to retrue the valve is a clear indication of its condition.
Discard the valve if it cannot be quickly refaced while
maintaining a good margin. See

Figure 3-91

. Valves that

do not clean up quickly are either warped, excessively
worn or too deeply pitted to be used.

•

Obtain a new valve if grinding leaves the margin less than
0.0313 in (0.795 mm). A valve in this condition does not
seat normally, burns easily and may crack or cause pre-
ignition.

Wipe valve seats and valve faces clean. From the bottom
of the cylinder head, insert the valve stem into the valve
guide. Push on head of valve until it contacts the valve
seat.

See

Figure 3-89

. Measure valve stem protrusion. Seat

wear causes the valve stem protrusion to change.

Placing finger at bottom of valve to keep valve seated,
use a dial vernier caliper to check the distance from
the top of the valve stem to the machined area on the
cylinder head.

Seat wear and valve refacing causes the valve stem
protrusion to change. If protrusion exceeds 2.069 in.
(52.553 mm), then replace the valve, valve seat or
cylinder head as necessary.

NOTE

Do not shorten the valve by grinding on the end of the stem.
Grinding replaces the hardened case with mild steel which
results in accelerated 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° angle or one that offers
a comfortable working position.

In order to determine the correct location of the 46° valve
seat in the head, measure the width of the valve to be
used and subtract 0.080 in. (2.032 mm) from that number.

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

Use a permanent magic marker to highlight the valve seat
area that is going to be cut. Be sure to highlight all three
angles. Allow marker to dry before proceeding.

sm02502

Figure 3-89. Checking Valve Stem Protrusion

NOTES

•

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

•

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

HOME

3-72 2009 Dyna Service: Engine

See

Figure 3-90

. 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.

10. Choose the proper 46° cutter (intake or exhaust) and

gently slide the cutter onto the pilot. Be careful not to drop
the cutter onto the seat.

11. While applying a constant and consistent pressure, remove

just enough material to show a complete clean-up on the
46° angle. Do not remove any more metal than is neces-
sary to clean up the seat (that is, to provide a uniform finish
and remove pitting).

NOTES

•

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

•

After making the 46° cut, if you discover a groove cut
completely around the seat, this means the blades of the
cutter are in alignment and need to be staggered. This is
accomplished by loosening all of the blades from the cutter
body and moving each blade slightly in its cradle in
opposite directions on the cutter. The tool needed to
loosen the blades is supplied in the tool set. A permanent
magic marker mark every 90° will help in determining
where new angles are.

12. Next, with your dial caliper locked to the predetermined

setting, measure the 46° cut at the outermost edge at the
widest point of the circle to determine what cut needs to
be made next.

If the 46° cut is too high (towards the combustion
chamber), use the 31° cutter to lower the valve seat
closer to the port.

If the 46° cut is too low, use the 60° cutter to raise the
valve seat or move it away from the port.

NOTES

•

Because you are using the top measurement of the valve
seat as a reference point it will usually be necessary to
use the 31° cutter following the initial 46° cut.

•

Always highlight the valve seat with the permanent magic
marker in order to ensure the location of the 46° valve
seat.

sm02503

Figure 3-90. Neway Valve Seat Cutter Set

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

10 and 11.

14. When you accomplish a complete clean-up of the 46°

angle and the width is at least 0.062 in. (1.575 mm), pro-
ceed to the next step.

15. Select the proper 60° cutter and gently slide the cutter

down the cutter pilot to the valve seat.

16. Remove just enough material to provide an even valve

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

17. Remove cutter and cutter pilot.

18. Insert valve to be used in the valve guide and bottom on

the valve seat. Positioning the cylinder head port upwards
and with slight thumb pressure against the valve, com-
pletely fill the port with solvent to verify proper seal
between the valve and the 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 and if necessary repeat the above valve
grinding or valve seat cutting process.

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

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

Follow up with a thorough wash in hot soapy water.

21. Blow parts dry with low pressure compressed air.

HOME

2009 Dyna Service: Engine 3-73

sm00148

Minimum: 0.040 in. (1.016 mm) / Maximum: 0.062
in. (1.575 mm)

60 degrees

31 degrees

46 degrees

Margin

Figure 3-91. Valve and Seat Dimensions

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.

Using TORCO MPZ or another suitable product, apply a
liberal amount of engine assembly lube to valve stem.

From the bottom of the cylinder head, insert the valve stem
into the valve guide.

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 assembly
lube to the valve stem. Install the valve in the valve guide.

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 3-92

. Push on bottom of valve until it contacts

the valve seat. Placing finger at bottom of valve to keep
valve seated, slide plastic capsule over valve stem tip and
keeper groove.

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

See

Figure 3-93

. Obtain new valve stem seal.

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

down valve stem until contact is made with top of valve
guide and machined area of cylinder head casting.
Remove capsule from valve stem tip.

sm02504

Figure 3-92. Plastic Capsule

sm02528

Figure 3-93. Valve Stem Seal/Spring Seat Assembly

11. See

Figure 3-94

. Apply a liberal amount of assembly lube

to valve stem tip and keeper groove (1).

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

spring (3) over the valve guide (5). Place the spring
retainer (2) on top of the valve spring.

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3-74 2009 Dyna Service: Engine

13. Obtain the VALVE SPRING COMPRESSOR (Part No. HD-

34736-B) and proceed as follows:

Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.

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.

Arranging tapered keepers so that the gaps are evenly
spaced, turn forcing screw to release valve spring
compression.

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

mallet to ensure that tapered keepers are tightly seated
in the valve stem groove.

15. Repeat previous steps to install the other valve compon-

ents.

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

Remove fixture tool from spark plug hole.

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

until time of installation.

sm02505

Tapered keepers

Spring retainer

Valve spring

Spring seat/valve stem set seal

Valve guide

Lock ring

Figure 3-94. Valve Assembly

INSTALLATION OVERVIEW

See

3.17 TOP END OVERHAUL: ASSEMBLY

Install cylinder head.

Install push rod covers and push rods.

Install rocker arm support plate.

Install breather assembly.

Continue with vehicle assembly as directed.

HOME

2009 Dyna Service: Engine 3-75

3.24

CYLINDER

REMOVAL OVERVIEW

See

3.16 TOP END OVERHAUL: DISASSEMBLY

Remove breather assembly.

Remove rocker arm support plate.

Remove push rods and push rod covers. Do not remove
lifters or lifter covers.

Remove cylinder head.

Remove cylinder.

CLEANING

TOOL NAME

PART NUMBER

CYLINDER TORQUE PLATES

HD-42324-A

See

Figure 3-95

. Scrape old gasket material from the

machined surface at the top of the cylinder (3). Old gasket
(1) material left on the mating surface will cause leaks.

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

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

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

See

Figure 3-96

. 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) (without
vise grip step) 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).

Now turn the cylinder upside down and lay the seal
side of the lower torque plate (2) (with vise grip step)
flat against the o-ring seal surface. Repeat steps 6b
and 6c above.

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.

sm02529

Cylinder head gasket

Dowel pin

Cylinder

O-ring seal

Cylinder stud

Figure 3-95. Cylinder Assembly

HOME

3-76 2009 Dyna Service: Engine

INSPECTION

TOOL NAME

PART NUMBER

CYLINDER TORQUE PLATES

HD-42324-A

NOTE

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

See

Figure 3-97

. To simulate an assembled cylinder for

accurately measuring cylinder taper and out-of-round
conditions, as well as for boring, honing or deglazing,
obtain the CYLINDER TORQUE PLATES (Part No. HD-
42324-A). Install the torque plates as follows:

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

Place used head gasket over two dowel pins at top
of cylinder.

See

Figure 3-97

. 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.

Lightly oil threads and shoulders of four bolts (1) with
clean H-D 20W50 engine oil. Slide four bolts all the
way through holes of lower plate (2).

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

With the two dowel pins and head gasket in place,
align holes in upper plate with ends of bolts. Blind
holes in upper plate accommodate dowel pins in cyl-
inder. Tighten four bolts into upper plate until finger
tight.

See

Figure 3-98

. 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 (20.3-23.1 Nm).

Using a grease pencil, mark a straight line on one of
the bolts continuing the line over onto the lower plate.
Repeat step for remaining three bolts.

Using the marks as a guide, turn each bolt 1/4 turn
or 90°. Be sure to tighten the bolts in the sequence
shown in

Figure 3-98

NOTE

For best results, obtain SNAP-ON TORQUE ANGLE
GAUGE TA360.

For purposes of inspection, remove the assembly
from the vise and place on bench top.

sm02506

Bolts

Lower plate

Upper plate

Vise grip step

Figure 3-96. Cylinder Torque Plates (Part No. HD-42324-A)

NOTE

Maximum cylinder wear occurs at the very 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 suitability of the cylinder for continued use.

See

Figure 3-99

. Using an inside micrometer or dial bore

gauge, check cylinder bore for out-of round and taper.
Proceed as follows:

At the top of the piston ring travel zone, starting about
0.50 in. (12.70 mm) or from the top of the cylinder,
measure the cylinder diameter at two locations; par-
allel and perpendicular to the crankshaft. Record the
readings.

Repeat the two measurements at the center of the
piston ring travel zone.

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

Rebore the cylinder if the parallel and perpendicular
measurements at either the top, middle or bottom of
the bore vary by more than 0.002 in. (0.051 mm).
This indicates an out-of-round condition.

Rebore the cylinder if the top, middle and bottom bore
diameters either parallel or perpendicular to the
crankshaft vary by more than 0.002 in. (0.051 mm).
This indicates excessive taper.

Continue with cylinder service.

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

3.24 CYLINDER,

Deglazing Cylinder

If cylinders are worn beyond the service limits, then
they must be rebored and/or honed to accept the next
standard oversize piston. See

3.24 CYLINDER,

Boring and Honing Cylinder

HOME

2009 Dyna Service: Engine 3-77

sm02530

Bolt (4)

Lower plate

Vise

Figure 3-97. Attaching Cylinder Torque Plates

sm02531

Figure 3-98. Cylinder Torque Plate Bolt Sequence

sm02532

Figure 3-99. Measure for Out-of-Round and Taper

DEGLAZING CYLINDER

NOTE

Deglazing removes wear patterns, minor scuff marks and
scratches without enlarging the bore diameter.

Lightly swab the cylinder bore with a cloth dipped in clean
engine oil.

Obtain a 240 grit flexible ball-type deglazing tool with a
bristle tip or finishing stone arrangement able to produce
a 60° cross hatch pattern.

Install the deglazing tool in a slow-speed drill. The speed
at which the tool rotates determines the speed at which it
must be stroked up and down the bore to produce the
desired cross hatch pattern.

Starting at the bottom of the cylinder, move the deglazing
tool up and down the entire length of the cylinder bore for
10 to 12 complete strokes.

Stop to examine the cylinder bore and/or take measure-
ments. A precise 60° cross hatch pattern in the piston
travel area is the most important.

The angular cross hatch pattern ensures an even flow of
oil onto the cylinder walls and promotes longer cylinder,
piston and ring life. An incorrect cross hatch pattern will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00536b)

Failure to remove all abrasive particles may result in pre-
mature cylinder, piston and ring wear and engine failure.
(00537b) .

HOME

3-78 2009 Dyna Service: Engine

Thoroughly wash the cylinder bore with liquid dishwashing
soap and warm water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth shows
no evidence of dirt or debris.

Hot rinse the cylinder and dry with moisture free com-
pressed air. Immediately apply a thin film of clean engine
oil to a clean white paper towel and thoroughly wipe the
inside of the cylinder to prevent the cylinder bore from
rusting.

NOTE

After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.

With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See

3.24 CYLINDER, Inspection

BORING AND HONING CYLINDER

Bore cylinder with gaskets and torque plates attached.
Refer to

Table 3-34

. Bore the cylinder to 0.003 in. (0.08

mm) under the desired finished size.

An incorrect cross hatch pattern or too fine a hone will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00538b)

Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing must
be done with the torque plates attached. All honing must
be done from the bottom (crankcase) end of the cylinder.
Work for a 60° crosshatch pattern.

Stop frequently to examine the cylinder bore and/or take
measurements. Remember, a precise 60° crosshatch
pattern in the piston travel area is important.

Failure to remove all abrasive particles may result in pre-
mature cylinder, piston and ring wear and engine failure.
(00537b) .

NOTE

Example: A 0.005 in. (0.13 mm) oversize piston will have the
proper running clearance with a cylinder bore size of 3.7550-
3.7555 in. (95.377-95.390 mm).

Hot rinse the cylinder and dry with moisture free com-
pressed air.

Immediately apply a thin film of clean engine oil to a clean
white paper towel and thoroughly wipe the inside of the
cylinder. This prevents the cylinder bore from rusting.

NOTE

With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See

3.25 PISTON, Inspection

Table 3-34. Oversize Pistons/Cylinder Bores

CYLINDER BORE FINISHED SIZE

PISTON

IN.

SIZE

95.250-95.263

3.7500-3.7505

N/A

Standard

95.377-95.390

3.7550-3.7555

0.13

0.005

Oversize

95.504-95.517

3.7600-3.7605

0.25

0.010

INSTALLATION OVERVIEW

See

3.17 TOP END OVERHAUL: ASSEMBLY

Install cylinder.

Install cylinder head.

Install push rod covers and push rods.

Install rocker arm support plate.

Install breather assembly.

Continue with vehicle assembly as directed.

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2009 Dyna Service: Engine 3-79

3.25

PISTON

REMOVAL OVERVIEW

NOTE

Do not use 2006 and earlier connecting rods with 2007 and
later pistons. 2007 and later pistons have a tapered wrist pin
boss. The wrist pin portion of the 2007 and later connecting
rod is tapered to match the boss on the piston.

See

3.16 TOP END OVERHAUL: DISASSEMBLY

Remove breather assembly.

Remove rocker arm support plate.

Remove push rods and push rod covers. Do not remove
lifters or lifter covers.

Remove cylinder head.

Remove cylinder.

Remove piston.

DISASSEMBLY

Piston Rings

Wear safety glasses or goggles when removing or
installing compression rings. Compression rings can slip
from the pliers and could be propelled with enough force
to cause serious eye injury. (00469c)

See

Figure 3-100

. Carefully remove top (7) and second

(6) compression rings using the proper piston ring
expander (Snap-on PRS8).

Using your fingers, remove top and bottom oil rails (4)
from the third ring groove. Remove the oil rail expansion
ring (5).

Discard the piston rings.

sm02508

Circlip

Piston pin

Piston

Oil rail

Expansion ring

Second compression ring

Top compression ring

Figure 3-100. Piston Assembly

CLEANING

To remove all carbon and combustion deposits, soak the
pistons in a special detergent that will not corrode alu-
minum. Maintain the temperature of the cleaning solution
well below 212° F (100° C).

NOTE

Do not sand blast or glass bead blast pistons. Bead blasting
rounds off ring lands and will result in oil contamination leading
to accelerated wear.

Thoroughly rinse the pistons. Blow parts dry with moisture
free compressed air.

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

HOME

3-80 2009 Dyna Service: Engine

cleanliness, but be careful not to damage or enlarge the
holes. Do not use a wire brush.

Verify that all other oil holes are clean and open.

NOTE

Exercise care to avoid scratching the sides of the piston ring
grooves.

Thoroughly clean the three piston ring grooves of all
carbon deposits. A broken compression ring properly
ground to a sharp chisel-like edge may be used for this
purpose.

Using Magnaflux Dye Penetrant, inspect the piston for
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
piston to remove traces of dye.

INSPECTION

See

Figure 3-101

. Check piston pin.

Lightly oil a good piston pin and insert it into the piston
pin bore to feel for the proper interference fit. The pin
should slide in and out without binding, but also
without pivoting or rocking.

Replace piston and/or pin if clearance exceeds 0.0008
in. (0.02 mm).

NOTE

Pistons with superficial wear marks, minor scratching or mild
scoring may continue to be used.

Carefully inspect the pistons for damage or excessive
wear.

Discard pistons with cracked, broken or bent ring
lands.

Check the piston skirt for cracks, gouges, deep
scratches or heavy scoring.

Check the piston heads for evidence of burning,
etching or melting.

Look for marks or imprints caused by contact with
valves.

Run your index finger around the edge of the piston crown
to feel for dings, nicks or burrs. Lightly file the edge of the
crown to remove any defects.

NOTE

Worn ring grooves result in high oil consumption and blow-by
of exhaust gases. Blow-by of exhaust gases contaminates the
engine oil supply with acids and leaves sludge in the crankcase.
It also reduces engine efficiency by weakening the combustion
seal necessary for efficient transfer of energy to the piston.

See

Figure 3-102

. Measure piston ring side clearance.

Insert the edge of a new ring into the piston ring
groove. Insert a feeler gauge between the upper sur-
face of the ring and the ring land.

Since the grooves wear unevenly, repeat this check
at several locations around the piston groove circum-
ference.

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 clearance
exceeds 0.010 in. (0.25 mm).

NOTES

•

Check the piston clearance in the cylinder in which the
piston will run. The torque plates must be installed on the
cylinder and it must be deglazed and suitable for continued
service.

•

This inspection is very heat sensitive. Do not check piston
running clearance immediately after honing or deglazing
cylinder. Even holding the piston in your hand for too long
can cause measurements to vary by as much as 0.0002
in. (0.0051 mm). Both piston and cylinder must be at room
temperatures before proceeding.

•

Piston measurement is taken on the bare aluminum to
avoid measuring errors. An oval-shaped opening is present
on each side of the piston for proper placement of the
micrometer. See upper frame of

Figure 3-103

. The oval

openings are too small for a standard flat anvil micrometer
which would result in measuring errors. Use a 3-4 inch
blade or ball anvil style micrometer, or a 4-5 inch micro-
meter with spherical ball anvil adapters. See lower frame
of

Figure 3-103

See

Figure 3-103

. Measure running clearance of pistons

as follows:

Holding outside micrometer, measure piston skirt
diameter across the thrust faces (perpendicular to
piston pin bore). Start below the bottom ring land and
move micrometer towards bottom of skirt. Micrometer
will be loose, then tight, about 0.5 in. (12.7 mm), from
bottom and then loose again.

Measure the piston skirt at the tightest spot and then
transfer that measurement to dial bore gauge.

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.

Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).

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2009 Dyna Service: Engine 3-81

sm02534

Pin must slide without binding or pivoting

Figure 3-101. Piston Pin Clearance

sm02535

Figure 3-102. Measure Piston Ring Side Clearance

sm02509

Bare aluminum

4-5 inch micrometer

Spherical ball anvil adapters

Figure 3-103. Measuring Running Clearance of Piston

ASSEMBLY

Checking Piston Ring Gap

NOTES

•

Always use new piston rings. Piston rings take a definite
set and must not be reused if the engine has been oper-
ated. Always deglaze (or hone) the cylinder before
installing new rings. Ring sets are available to fit oversize
pistons.

•

Insufficient ring gap may cause the ends to abut at engine
operating temperatures, resulting in ring breakage, cylinder
scuffing and/or piston seizure.

•

Excessive ring gap results in high oil consumption and
blow-by of exhaust gases. While blow-by contaminates
the oil supply and leaves sludge in the crankcase, it also
reduces engine efficiency by weakening the combustion
seal necessary for efficient transfer of energy to the piston.

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3-82 2009 Dyna Service: Engine

See

Figure 3-104

. Check ring gap before placing each

ring on the piston.

Insert the new ring into the cylinder and square it in
the bore using the top of the piston. Measure the ring
gap with a feeler gauge.

Top compression ring gap must be 0.010-0.020 in.
(0.25-0.51 mm).

Second compression ring gap must be 0.014-0.024
in. (0.36-0.61 mm).

Oil control rail gap must be 0.010-0.050 in. (0.25-1.27
mm).

NOTE

Ring end gap dimensions also apply to oversize rings. Replace
ring if end gap exceeds specification. If end gap is under spe-
cification, filing is permissible.

Use compressed air to remove any dirt or dust that may
have settled in the oil drain holes and piston ring grooves.

sm02536

Figure 3-104. Measuring Ring Gap

Installing Piston Rings

See

Figure 3-105

. Apply clean H-D 20W50 engine oil to

three piston ring grooves.

Install expansion ring (4) into third ring groove.

Spiral bottom oil rail (5) into space below expansion ring
(4). Position gap 90° from the gap in the expansion ring.

Spiral top oil rail (3) into space above expansion ring (4).
Position gap 180° from the gap in the bottom oil rail.

Wear safety glasses or goggles when removing or
installing compression rings. Compression rings can slip
from the pliers and could be propelled with enough force
to cause serious eye injury. (00469c)

NOTES

•

Use the proper piston ring spreader to prevent excessive
ring twist and expansion. Over expansion may cause the
ring to crack opposite the ring gap. Damaged or distorted
rings result in blow-by of exhaust gases, increased oil
consumption and lower service life on valves and other
components.

•

Installing the second compression ring upside down will
cause oil to be scraped up into the combustion chamber
resulting in excessive oil consumption and low service life
on valves and other components.

Using the proper piston ring expander (Snap-on PRS8),
carefully install the second compression ring. Make sure
the dot (punch mark) near the ring gap faces the piston
crown. Rotate the ring so the gap is 180° from the gap in
the expansion ring.

Using the proper piston ring expander (Snap-on PRS8),
carefully install the top compression ring. Make sure the
dot (punch mark) near the ring gap faces the piston crown.
Rotate the ring so the gap is 180° from the gap in the
second compression ring.

Rotate the three piston rings using the palms of both
hands. The rings must rotate freely without sticking.

See

Figure 3-106

. Verify the ring gaps are still properly

staggered.

sm02537

Top compression ring

Second compression ring

Top oil rail

Expansion ring

Bottom oil rail

Figure 3-105. Piston Rings

HOME

2009 Dyna Service: Engine 3-83

Harley Davidson 2009 Dyna Models. Service manual - page 18