Harley Davidson Softail 2000-2005. Service manual - page 39

SUPPLEMENT

2004-2005 MODEL SERVICE INFORMATION

This Supplement contains all procedures and specifications

unique

to the 2004-2005 models, including the Screamin’ Eagle

models. If a specific procedure is not included, refer to the procedure
in the appropriate chapter (2-14). Refer to Table 1 in this Supple-
ment to cross-reference 2004-2005 models to the base models.

This Supplement is divided into sections that correspond to those

in the other chapters of this manual. Tables 1-22 are located at the
end of the appropriate sections.

CHAPTER ONE

GENERAL INFORMATION

Table 1 MODEL DESIGNATION

FLSTN/FLSTNI* Softail Deluxe (2005)

Base model FLSTC Heritage Softail Classic

FLSTFI* Fat Boy 15th Anniversary Edition (2005)

Base model FLSTF Fat Boy

FLSTFSE** Screamin’ Eagle Fat Boy (2005)

Base model FLSTF Fat Boy

FLSTSC/FLSTSCI* Softail Springer Classic (2005)

Base model FXSTS Springer Softail

FXSTDES2** Screamin’ Eagle Deuce (2004)

Base model FXSTD Softail Deuce

* The I designation indicates fuel-injected models.
** The FLSTFSE and the FXSTDES2 models are fuel injected but do not have the I designation.

Table 2 GENERAL DIMENSIONS

Wheel base

FLSTN/FLSTNI

64.5 in. (1638.3 mm)

FLSTFI 15th Anniversary Edition

64.5 in. (1638.3 mm)

FLSTFSE

64.5 in. (1638.3 mm)

FLSTSC/FLSTSCI

64.5 in. (1638.3 mm)

FXSTDSE2

66.6 in. (1691.6 mm)

Overall length

FLSTN/FLSTNI

94.7 in. (2405.4 mm)

FLSTFI 15th Anniversary Edition

94.3 in. (2395.2 mm)

FLSTFSE

94.5 in. (2400.3 mm)

FLSTSC/FLSTSCI

94.3 in. (2395.2 mm)

FXSTDSE2

95.4 in. (2423.2 mm)

Overall width

FLSTN/FLSTNI

38.4 in. (975.4 mm)

FLSTFI 15th Anniversary Edition

40.2 in. (1021.1 mm)

FLSTFSE

40.2 in. (1021.1 mm)

FLSTSC/FLSTSCI

32.7 in. (830.6 mm)

FXSTDSE2

35.9 in. (911.9 mm)

Road clearance

FLSTN/FLSTNI

4.8 in. (121.9 mm)

FLSTFI 15th Anniversary Edition

5.1 in. (129.5 mm)

FLSTFSE

FLSTSC/FLSTSCI

4.9 in. (124.5 mm)

FXSTDSE2

Overall height

FLSTN/FLSTNI

43.5 in. (1104.9 mm)

FLSTFI 15th Anniversary Edition

44.5 in. (1130.3 mm)

FLSTFSE

44.5 in. (1130.3 mm)

FLSTSC/FLSTSCI

43.6 in. (1106.7 mm)

FXSTDSE2

49.0 in. (1244.6 mm)

(continued)

534

SUPPLEMENT

Table 2 GENERAL DIMENSIONS (continued)

Saddle height

FLSTN/FLSTNI

24.5 in. (622.3 mm)

FLSTFI 15th Anniversary Edition

25.5 in. (647.7 mm)

FLSTFSE

FLSTSC/FLSTSCI

25.9 in. (657.8 mm)

FXSTDSE2

NA=Information not available.

Table 3 MOTORCYCLE WEIGHT (DRY)

Model

lbs.

FLSTN/FLSTNI

676

307

FLSTFI 15th Anniversary Edition

–

FLSTFSE

689

312

FLSTSC/FLSTSCI

731

332

FXSTDSE2

–

NA=Information not available.

Table 4 GROSS VEHICLE WEIGHT RATINGS

Model

lbs.

FLSTN/FLSTNI

1160

526.1

FLSTFI 15th Anniversary Edition

–

FLSTFSE

1160

526.1

FLSTSC/FLSTSCI

1160

526.1

FXSTDSE2

1125

510.3

NA=Information not available.

Table 5 FUEL TANK CAPACITY

Model

U.S. gal.

Liters

Total

FLSTN/FLSTNI

5.0

18.92

FLSTFI 15th Anniversary Edition

5.0

18.92

FLSTFSE

5.0

18.92

FLSTSC/FLSTSCI

5.0

18.92

FXSTDSE2

4.9

18.55

Reserve

0.5

1.89

2004-2005 MODEL SERVICE INFORMATION

535

CHAPTER THREE

LUBRICATION, MAINTENANCE AND TUNE-UP

ROUTINE SAFETY CHECKS

On FXSTDSE2 and FLSTFSE models, check the

clutch fluid level and condition in the master cylinder. If
necessary, add fluid as described in this section.

PERIODIC LUBRICATION

Engine, Transmission and
Primary Chaincase Oil Recommendations
(FLSTFSE Models)

The motorcycle comes equipped with Harley-Davidson

Screamin’ Eagle SYN3 synthetic motorcycle lubricant. If
additional oil must be added to correct the oil level, and the
SYN3 is not available,

temporarily

add Harley- Davidson

HD360 motor oil. It is suggested that the lubricant be
changed as soon as possible. If the Screamin’ Eagle SYN3
is not going to be used permanently, drain the lubricant
and use the recommended oil listed in Table 3, Chapter
Three.

Engine Oil Level Check (2005 Models)

Check the engine oil level with the dipstick/oil filler cap

(Figure 1) on the right side of the oil tank.
1. Start and run the engine for approximately 10 minutes or
until the engine has reached normal operating temperature.
Then turn the engine off and allow the oil to settle in the oil
tank.
2. Place the motorcycle on a level surface and park it on its
jiffy stand.

CAUTION

Holding the motorcycle straight up will result
in an incorrect oil level reading.

3. Wipe the area around the oil filler cap with a clean rag.
Then pull the oil filler cap (Figure 1) out of the oil tank.
Wipe the dipstick with a clean rag and reinsert the filler cap
all the way into the oil tank until it bottoms. Withdraw the
filler cap and check the oil level on the dipstick. The oil level

should be at the FULL HOT mark on the dipstick (Figure 2).
If the oil level is below the FULL HOT mark, continue with
Step 4. If the oil level is correct, go to Step 5.

4. Add the recommended engine oil.

CAUTION

Do not overfill the oil level in the oil tank or
the oil filler cap will pop out when the oil gets
hot.

5. Check the dipstick O-ring for cracks or other damage.
Replace the O-ring if necessary.

6. Reinstall the oil filler cap and push it down until it bot-
toms.

536

SUPPLEMENT

Upper
groove

Primary Chaincase Oil Level Check
(2005 Models)

The primary chaincase oil level check is identical to prior

years with the exception of the seal on the clutch inspection
cover. The O-ring has been replaced with a large gasket and
must be installed as follows:
1. Position the

new

gasket with the rubber molding and

the words TOWARD ENGINE facing away from the
clutch inspection cover.
2. Align the triangular shaped hole in the

new

gasket with

the top hole in the clutch inspection cover.

CAUTION

Do not push the screw through the triangular
shaped hole in the new gasket as the sealing
qualities of the gasket will be damaged.

3. Insert the screw, with the captive washer, though the
clutch inspection cover and

carefully

thread it it all the way

through the triangular shaped hole in the new gasket.
4. Install the clutch inspection cover and new gasket onto
the chaincase cover and thread the top screw part way in.
5. Make sure the clutch inspection cover is correctly aligned
with the chaincase cover and install the remaining four
screws with captive washers.
6. Use a T27 Torx driver and tighten the screws in a criss-
cross pattern to 84-108 in.-lb. (9.5-12 N•m).

Primary Chaincase Oil Change

The primary chaincase oil change is the same as on previ-

ous models with the exception of the an O-ring seal and a
torque specification for the plug (Figure 3). The drain plug is
now equipped with an O-ring seal that must be replaced every
time the drain plug is removed. Install a

new

O-ring onto the

drain plug, install it and tighten to 33-60 in.-lb (4-7 N•m).

Refer to the preceding procedure regarding the installa-

tion of the new clutch inspection cover gasket.

Clutch Lever Pivot Pin Lubrication
(FXSTDSE2 and FLSTFSE Models)

Inspect the clutch lever pivot pin at the interval in Chap-

ter Three, Table 1. Lubricate the pivot pin with silicone
brake grease. To service the pivot pin, refer to

Clutch

Master Cylinder

in this supplement.

PERIODIC MAINTENANCE

Clutch Hoses and Seals
(FXSTDSE2 and FLSTFSE Models)

Replace the clutch hose every four years and the seals

in the master cylinder and release cylinder every two
years.

Check the clutch hose between the master cylinder and

the release cylinder. If there is any leak, tighten the con-
nections and bleed the clutch as described in this Supple-
ment. If this does not stop the leak or if a line is obviously
damaged, cracked, or chafed, replace the hose and/or the
master cylinder or release cylinder(s), then bleed the
clutch as described in this Supplement.

Clutch Fluid Change
(FXSTDSE2 and FLSTFSE Models)

To change the clutch brake fluid, drain the fluid from

the clutch system as described in this Supplement. Add
new fluid to the master cylinder, and bleed the clutch at
the release cylinder until the fluid leaving the release cyl-
inder is clean and free of contaminants and air bubbles.
Refer to the clutch bleeding procedure in this Supple-
ment.

Clutch Fluid Level Check
(FXSTDSE2 and FLSTFSE Models)

1. Turn the handlebar straight ahead so the clutch master
cylinder is level.
2. Observe the brake fluid level by looking at the sight glass
on the master cylinder reservoir top cover. If the fluid level is
correct, the sight glass will be dark purple. If the level is low,
the sight glass will have a lightened, clear appearance.

CAUTION

Do not use brake fluid labeled

DOT 5.1

This is a glycol-based fluid that is

not com-

patible

with silicone based DOT 5. DOT 5

brake fluid is purple while DOT 5.1 is an
amber/clear color. Do not intermix these

2004-2005 MODEL SERVICE INFORMATION

537

different types of brake fluid, as doing so
will lead to component damage.

CAUTION

Be careful when handling brake fluid. Do
not spill it on painted or plastic surfaces, as
it damages them. Wash the area immedi-
ately with soap and water, and thoroughly
rinse it.

3. If the clutch fluid level is low, perform the following:

a. Clean any dirt from the clutch master cylinder cover

prior to removing it.

b. Remove the top cover and lift the diaphragm out of the

reservoir.

c. Add fresh DOT 5 brake fluid to the FILL LEVEL

mark at the top of the ledge on the rear inside wall of
the reservoir.

d. Reinstall the diaphragm and top cover. Tighten the

screws securely.

NOTE

If the clutch fluid level is low enough to allow
air in the hydraulic system, bleed the clutch
system as described in this Supplement.

538

SUPPLEMENT

AIR FILTER (2005 FLSTFI FAT BOY 15TH ANNIVERSARY MODELS)

1. Screw
2. Air filter
3. Baffle plug
4. Breather screw
5. Moutning stud
6. Backing plate
7. O-ring
8. Gasket
9. Screw

10. Trim ring
11. Cover

TUNE-UP

Air Filter Element Removal/Installation
(FXSTDSE2, FLSTFSE and
FLSTFI-15th Anniversary)

Remove and clean the air filter at the interval in Chapter

Three, Table 1. Replace the element at the interval in Ta-
ble 1 or whenever it is damaged or deteriorated.

Refer to Figures 4-6.

1. Remove the air filter cover screw and remove the cover
and gasket (models so equipped).

2A. On FXSTDSE2 models, remove the screws and bracket
from the air filter element.

2B. On FLSTFSE models, remove the screws and the cover
adapter from the air filter element.

2C. On FLSTFI-15th Anniversary models, remove the
screws from the air filter element.
3. Gently pull the air filter element from the back plate.
4. Gently pull the breather plugs from the breather screws
on the back plate.
5. Clean the air filter and breather plugs as described in the
following procedure.
6. On FXSTDSE2 models, inspect the cover gasket. Re-
place it if necessary.
7. Inspect the breather plugs for deterioration. Replace
them if necessary.
8. Install the breather plugs into the breather screws.
9A. On FLSTFI-15th Anniversary model, move the ele-
ment into position and the screws. Tighten the screws se-
curely.
9B. On models other than FLSTFI-15th Anniversary
models, move the element into position. Install the mount-

2004-2005 MODEL SERVICE INFORMATION

539

AIR FILTER (2004 FXSTDSE2 MODELS)

1. Screw
2. Mounting bracket
3. Air filter
4. Breather screw
5. Mounting stud
6. Backng plate
7. O-ring
8. Gasket
9. Label

10. Screw
11. Trim
12. Cover
13. Seal

ing bracket (FXSTDSE2 models), or cover adapter
(FLSTFSE models), and the screws. Tighten the screws
securely.
10. Apply a drop of low strength threadlocking com-
pound to the cover screw prior to installation.
11. Install the air filter cover and the screw. Tighten the
screw to 36-60 in.-lb. (4-7 N•m).

Air Filter Element Cleaning

1. Remove the air filter element as described in this sec-
tion.
2. Replace the air filter if damaged.

WARNING

Do not clean the air filter in solvent. Never
clean the air filter element in gasoline or
low flash point solvent. The residual solvent

or vapors may cause a fire or explosion af-
ter the filter is reinstalled.

CAUTION

Do not tap or strike the air filter element on
a hard surface to dislodge dirt. Doing so
will damage the element.

3. Place the air filter in a pan filled with lukewarm water
and mild detergent. Move the air filter element back and
forth to help dislodge trapped dirt. Thoroughly rinse it in
clean water to remove all detergent residue.

4. Hold the air filter up to a strong light. Check the filter
pores for dirt and oil. Repeat Step 3 until there is no dirt
and oil in the filter pores. If the air filter cannot be cleaned,
or if the filter is saturated with oil or other chemicals, re-
place it.

540

SUPPLEMENT

AIR FILTER (2005 FLSTFSE MODELS)

1. Screw
2. Cover adapter
3. Air filter
4. Breather plug
5. Breather screw
6. Mounting stud
7. Backing plate
8. O-ring
9. Gasket

10. Label
11. Screw
12. Trim ring
13. Cover

CAUTION

Do not use high air pressure to dry the filter,
as this will damage it.

CAUTION

In the next step, do not blow compressed air
through the outer surface of the air filter el-
ement. Doing so can force dirt trapped on
the outer filter surface deeper into the air
filter element, restricting airflow and dam-
aging the air filter element.

5. Gently apply compressed air through the inside sur-
face of the air filter element to remove loosened dirt and
dust trapped in the filter.

6. Inspect the air filter element. Replace it if it is torn or
damaged. Do not ride the motorcycle with a damaged air
filter element as it will allow dirt to enter the engine.
7. Clean the breather plugs in the same lukewarm water
and mild detergent. Make sure both plugs are clean and
clear. Clean them out with a pipe cleaner if necessary and
dry with compressed air.
8. Wipe the inside of the cover and back plate with a
clean damp shop rag.

CAUTION

Air will not pass through a wet or damp filter.
Make sure the filter is dry before installing it.

9. Allow the filter to dry completely, and reinstall it as de-
scribed in this chapter.

Table 6 TIRE INFLATION PRESSURE (COLD)*

Item

psi

kPa

Front wheel

Solo

248

Rider and passenger

248

Rear wheel

Solo

248

Rider and passenger

276

*Tire inflation pressure is for original equipment tires. Aftermarket tires may require different inflation pressure.

Table 7 FRONT FORK OIL CAPACITY AND OIL LEVEL DIMENSION

Model

Capacity (each fork leg)

Oil level dimension

FLSTF, FLSTC, FXST,

FLSTN, FLSTFSE

12.9 U.S. oz. (382 cc)

4.72 in. (119.9 mm)

FXSTB

12.0 U.S. oz. (356 cc)

7.28 in. (184.9 mm)

FXSTD, FXSTDSE2

11.6 U.S. oz. (343 cc)

7.48 in. (189.9 mm)

Table 8 MAINTENANCE TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Primary chaincase drain plug

(2005 models)

–

36-60

4-7

Air filter cover screw

–

36-60

4-7

Clutch inspection cover

–

84-108

9.5-12

2004-2005 MODEL SERVICE INFORMATION

541

CHAPTER FOUR

ENGINE

Refer to Tables 9-14 for new and revised engine specifi-

cations.

ENGINE

Removal/Installation

Engine removal and installation is the same as on previ-

ous models with the exception of the cylinder head
bracket bolt torque specification. Tighten the bolts to
35-40 ft.-lbs. (47-54 N•m).

ROCKER ARMS AND PUSHRODS

Removal/Installation

The removal procedure is the same as on prior years.

The installation procedure is the same as on prior years

with the exception of the breather assembly components.
The 2000-2001 models are equipped with a breather assem-
bly consisting of four parts. On the 2002-2003 models the
breather assembly parts are combined into a one-piece unit
along with the filter element and gasket. The 2004-2005
models once again use the four parts used on the 2000-2001
models.

542

SUPPLEMENT

Front cylinder head

Rear cylinder head

CYLINDER HEAD

Removal/Installation

On 2004-2005 models, the two O-rings (Figure 10) are no

longer used in junction with the cylinder head dowel pins.

Refer to Figure 7 for the front and rear cylinder head bolt

tightening sequence. Tighten the cylinder head bolts as fol-
lows:
1. Starting with bolt No. 1, tighten each bolt in order to
120-144 in.-lb. (14-16 N•m).
2. Starting with bolt No. 1, tighten each bolt in order to
15-17 ft.-lb. (20-23 N•m).
3. Make a vertical mark with a marker on each bolt head (A,
Figure 8). Make another mark on the cylinder head (B, Fig-
ure 8) at a 90

angle, or 1/4 turn from the mark on the head

bolt.
4. Use the marks as a guide and tighten each bolt 90

, or 1/4

turn, clockwise until the marks are aligned (Figure 9).

Removal/Installation
(FXSTDSE2 and FLSTFSE Models)

The two visible outer cylinder head bolts have a chrome

trim cap.
1. Loosen the set screw and remove the chrome trim cap
from the two bolt heads.
2. Position the chrome trim cap so the set screw is not visi-
ble and install the cap. Tighten the set screw to 60-84 in.-lb.
(7-9 N•m).
3. Test ride the motorcycle to operating temperature and
check tightness of set screws. Tighten if necessary.

VALVE AND VALVE COMPONENTS

(2005 MODELS–EXCEPT FXSTDSE2

AND FLSTFSE MODELS)

Complete valve service requires a number of special

tools, including a valve spring compressor, to remove and
install the valves. The following procedures describe how
to check for valve component wear and to determine what
type of service is required.

Refer to Figure 11.

Valve Removal

1. Remove the cylinder head as described in Chapter
Four.
2. Install the valve spring compressor (Figure 12)
squarely over the valve spring upper retainer (Figure 13)
and against the valve head.

2004-2005 MODEL SERVICE INFORMATION

543

CYLINDER HEAD

(2005 MODELS EXCEPT

FXSTDSE2 AND FLSTFSE)

1. Valve keeper
2. Upper retainer
3. Spring
4. Valve stem seal/spring seat assembly
5. Valve guide
6. Valve guide collar (exhaust valve only)
7. Bolt–short
8. Bolt–long
9. Cylinder head

10. Valve seat
11. Valve
12. Gasket

CAUTION

To avoid loss of spring tension, compress
the spring only enough to remove the valve
keepers.

3. Tighten the valve spring compressor until the valve
keepers separate from the valve stem. Lift the valve keep-
ers out through the valve spring compressor with a mag-
net or needlenose pliers.

4. Gradually loosen the valve spring compressor and re-
move it from the cylinder head.

5. Remove the spring upper retainer and the valve spring.

CAUTION

Remove any burrs from the valve stem
groove before removing the valve (

Figure

); otherwise the valve guide will be dam-

aged as the valve stem passes through it.

6. Remove the valve from the cylinder head while rotat-
ing it slightly.

7. Using needlenose pliers carefully twist and remove
the valve stem seal/spring seat assembly from the valve
guide. Discard the valve stem seal/spring seat assem-
bly.

CAUTION

Keep the components of each valve assem-
bly together by placing each set in a divided
carton, or into separate small boxes or
small plastic bags. Identify the components
as either intake or exhaust. If both cylinders
are disassembled, also label the compo-
nents as front and rear. Do not intermix
components from the valves or wear may
result.

8. Repeat Steps 3-7 to remove the remaining valve.

Valve Inspection

When measuring the valves and valve components in

this section, compare the actual measurements to the new
and service limit specifications in the tables at the end of
the engine section. Replace parts that are out of specifica-
tion or are damaged as described in this section.

1. Clean valves in solvent. Do not gouge or damage the
valve seating surface.

2. Inspect the valve face (Figure 15). Minor roughness
and pitting can be removed by lapping the valve. Exces-
sive unevenness to the contact surface indicates the valve
is not serviceable.

544

SUPPLEMENT

Deburr

Valve stem

3. Inspect the valve stem for wear and roughness. Then
measure the valve stem outside diameter with a microme-
ter (Figure 16).
4. Remove all carbon and varnish from the valve guides
with a stiff spiral wire brush before measuring wear.
5. Measure the valve guide inside diameter with a small
hole gauge (Figure 17) at the top, center and bottom posi-
tions. Then measure the small hole gauge.
6. Determine the valve stem-to-valve guide clearance by
subtracting the valve stem outside diameter from the
valve guide inner diameter.
7. If a small hole gauge is not available, insert each valve
into its guide. Attach a dial indicator to the valve stem
next to the head (Figure 18). Hold the valve slightly off its
seat and rock it sideways in both directions 90

to each

other. If the valve rocks more than slightly, the guide is
probably worn. Take the cylinder head to a Harley-
Davidson dealership or machine shop and have the valve
guides measured.
8. Check the valve spring as follows:

a. Inspect the valve spring for visual damage.
b. Use a square to visually check the spring for distor-

tion or tilt (Figure 19).

c. Measure the valve spring free length with a vernier

caliper (Figure 20) and compare it to the specifica-
tions.

d. Repeat sub-steps a-c for each valve spring.
e. Replace the defective spring(s).

9. Check the valve spring upper retainer seats for cracks
or other damage.
10. Check the valve keepers fit on the valve stem end
(Figure 21). They should index tightly into the valve stem
groove.
11. Inspect the valve seats (Figure 22) in the cylinder
head. If they are worn or burned, they can be recondi-
tioned as described in Chapter Four. Seats and valves in
near-perfect condition can be reconditioned by lapping
with fine Carborundum paste.

2004-2005 MODEL SERVICE INFORMATION

545

Dial indicator

a. Clean the valve seat and corresponding valve mat-

ing areas with contact cleaner.

b. Coat the valve seat with layout fluid.
c. Install the valve into its guide and tap it against its

seat. Do not rotate the valve.

d. Lift the valve out of the guide and measure the seat

width at various points around the seat with a ver-
nier caliper.

e. Compare the seat width with the specifications. If

the seat width is less than specified or uneven, re-
surface the seats as described in Chapter Four.

f. Remove all layout fluid residue from the seats and

valves.

Valve Installation

1. Clean the end of the valve guide.
2. Assemble the valve stem seal/spring seat assembly as
follows:

a. Apply engine oil to the oil seal (A, Figure 23) and

the spring seat (B).

b. Position the oil seal with the spring end going in last

(C, Figure 23) and insert it into the spring seat.

c. Press the oil seal down until it seats completely

within the spring seat (D, Figure 23).

3. Coat a valve stem with Torco MPZ, molybdenum
disulfide paste or equivalent. Install the valve part way
into the guide. Then slowly turn the valve as it enters the
oil seal and continue turning it until the valve is installed
all the way.
4. Work the valve back and forth in the valve guide to en-
sure the lubricant is distributed evenly within the valve
guide.
5. Withdraw the valve and apply an additional coat of the
lubricant.
6. Reinstall the valve into the valve guide but do not push
the valve past the top of the valve guide.
7. Push the valve all the way into the cylinder head until it
bottoms (A, Figure 24).

CAUTION

The oil seal will be torn as it passes the
valve stem keeper groove if the plastic cap-
sule is not installed in Step 8. The capsule is
included in the top end gasket set.

8. Hold the valve in place and install the plastic capsule
(B, Figure 24) onto the end of the valve stem. Apply a
light coat of clean engine oil to the outer surface of the
capsule.
9. With the valve held in place, slowly slide the valve
stem seal/spring seat assembly onto the valve stem. Push

546

SUPPLEMENT

the assembly down until it bottoms on the machined sur-
face of the cylinder head.
10. Remove the plastic capsule from the valve stem.
Keep the capsule as it will be used on the remaining
valves.
11. Position the valve spring with tapered end going on
last and install the valve spring (A, Figure 25). Make sure
it is properly seated on the spring seat.
12. Install the upper spring retainer (B, Figure 25) on top
of the valve spring.

CAUTION

To avoid loss of spring tension, only com-
press the springs enough to install the valve
keepers.

13. Compress the valve spring with a valve spring com-
pressor (Figure 12) and install the valve keepers (Figure
26).
14. Make sure both keepers are seated around the valve
stem prior to releasing the compressor.
15. Slowly release tension from the compressor and re-
move it. After removing the compressor, inspect the valve
keepers to make sure they are properly seated (Figure
27). Tap the end of the valve stem with a

soft-faced

ham-

mer to ensure the keepers are properly seated.
16. Repeat Steps 1-15 for the remaining valves.
17. Install the cylinder head as described in this Supple-
ment.

Valve Guide Replacement

Tools

The following tools or their equivalents are required to

replace the valve guides.
1. Cylinder head stand (HD-39782-A).
2. Intake valve seat adapter (HD-39782A-3).
3. Exhaust valve seat adapter (HD-39782A-4).
4. Valve guide driver (B-45524-1)
5. Valve guide installer sleeve (B-45524-2A).
6. Valve guide brush (HD-34751-A).
7. Valve guide reamer (B-45523) and T-handle (HD-
39847).
8. Valve guide reamer honing lubricant (HD-39964).
9. Valve guide hone (B-45525).
10. Hydraulic press.

Procedure

CAUTION

The valve guides must be removed and in-
stalled using the following special tools to

2004-2005 MODEL SERVICE INFORMATION

547

avoid damage to the cylinder head. Use the
correct size valve guide removal tool to re-
move the valve guides or the tool may expand
the end of the guide. An expanded guide will
widen and damage the guide bore in the cylin-
der head as it passes through it.

1. Remove the old valve guide as follows:

a. Install the intake (A, Figure 28) or exhaust (B) valve

seat adapter into the tube at the top of the support
stand (C).

b. Install the support stand on the hydraulic press table.

c. Install the cylinder head (A, Figure 29) onto the sup-

port stand (B)

centering

the cylinder head valve seat

onto the seat adapter.

d. Insert the valve guide driver (C, Figure 29) into the

valve guide bore until it stops on the valve guide
shoulder.

e. Center the valve guide driver under the press ram and

make sure the driver is perpendicular to the press table.

f. Support the cylinder head, slowly apply pressure and

drive valve guide out through the combustion cham-
ber. Discard the valve guide.

g. Remove the cylinder head and special tools from

the press bed.

h. Repeat sub-steps a-g for the remaining valve

guides.

2. Clean the valve guide bores in the cylinder head.

3. Because the valve guide bores in the cylinder head
may have enlarged during removal of the old guides, mea-
sure each valve guide bore prior to purchasing the new
guides. Then purchase the new valve guides to match their
respective bore diameters. Determine the bore diameter as
follows:

a. Measure the valve guide bore diameter in the cylin-

der head with a bore gauge or snap gauge. Record
the bore diameter.

b. The new valve guide outside diameter must be

0.0020-0.0033 in. (0.050-0.083 mm) larger than the
guide bore in the cylinder head. When purchasing
new valve guides, measure the new guide’s outside
diameter with a micrometer. If the new guide’s out-
side diameter is not within this specification, install
oversize valve guide(s). See a Harley-Davidson
dealership for available sizes and part numbers.

NOTE

The intake valves are not equipped with the
valve guide collar. On exhaust valves, the
collar must be installed onto the valve
guide, see Step 4.

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SUPPLEMENT

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