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

HOME

3-28 2011 Touring Service: Engine

3.15

ASSEMBLING MOTORCYCLE AFTER SERVICE

PROCEDURE

After Top End Service

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

NOTE

Check each end of the stabilizer link for excessive wear prior
to installation. The spherical ball end may rotate freely, but
should not have any lateral movement. Replace the link if lateral
movement exists.

Secure stabilizer link to frame weldment. Tighten bolt to
18-22 ft-lbs (24.4-29.8 Nm).

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

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

Install induction module. See

4.13 INDUCTION MODULE

Continue with steps under After Cam Compartment Ser-
vice.

After Cam Compartment Service

Install purge solenoid hose, if equipped, to induction
module. See

4.22 EVAPORATIVE EMISSIONS CONTROL

SYSTEM

Install spark plugs and connect spark plug cables.

Install backplate and air cleaner. See

4.4 AIR CLEANER

ASSEMBLY

Install fuel tank. See

4.5 FUEL TANK

Install exhaust system. See

4.19 EXHAUST SYSTEM

HOME

2011 Touring Service: Engine 3-29

3.16

REMOVING ENGINE FROM CHASSIS

PROCEDURE

TOOL NAME

PART NUMBER

BENCH STAND

HD-42310

TWIN CAM 88 CRADLE

HD-42310-2

ROLLING STAND

HD-43646A

Remove exhaust system. See

4.19 EXHAUST SYSTEM

Remove fuel tank. See

4.5 FUEL TANK

Remove air cleaner and backplate. See

4.4 AIR CLEANER

ASSEMBLY

Remove spark plug cables. Remove spark plugs. See

1.17 SPARK PLUGS

Remove induction module. See

4.13 INDUCTION

MODULE

Gather disconnected branches of main harness and tape
to top of wire trough.

Remove voltage regulator. See

7.3 VOLTAGE REGU-

LATOR

Remove CKP sensor. See

7.20 CRANKSHAFT POSITION

SENSOR (CKP)

Remove oil filter. See

1.6 ENGINE OIL AND FILTER

10. Remove oil pressure switch/sender. See

7.25 OIL PRES-

SURE SWITCH AND SENDER

11. Coil main harness and allow to hang below lower frame

tube at front of motorcycle.

12. Remove primary chaincase. See

5.5 PRIMARY CHAIN-

CASE HOUSING

13. Remove rotor and stator. See

7.22 ALTERNATOR

14. Wrap rear master cylinder reservoir with foam padding or

bubble pack.

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

foam padding or bubble pack to prevent paint damage to
left frame tube, brake line and main harness. A split loom
conduit or a half shell of PVC tubing will also produce good
results.

16. Cover rocker covers with foam padding or bubble pack.

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

between the jack and oil pan to distribute pressure across
the length of the casting. Raise the jack until firm contact
is made with the bottom of the oil pan.

18. Remove top engine mounting bracket from front cylinder

head. Remove stabilizer link from frame weldment.

19. Remove four bolts (with flat washers) in a crosswise pat-

tern to free transmission from crankcase.

20. Remove front engine mount. See

2.51 FRONT ENGINE

MOUNT

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

at bottom of transmission flange. Raise engine and remove
from right side of motorcycle. Exercise caution to avoid
contact with rear brake line, rear brake master cylinder
reservoir, and main harness.

22. See

Figure 3-15

. Using the TWIN CAM 88 CRADLE (Part

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

23. Thoroughly wipe all engine oil from pockets in crankcase

flange. Remove gasket and two index pins from transmis-
sion flange. Discard gasket.

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

conditions. See

3.31 OIL PAN

Metal debris is found in the engine or crankcase.

Oil contamination is suspected.

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

The engine is being replaced with a

new

one.

sm03672

Figure 3-15. Engine/Transmission Bench Stand (HD-42310)

HOME

3-30 2011 Touring Service: Engine

3.17

INSTALLING ENGINE IN CHASSIS

PROCEDURE

TOOL NAME

PART NUMBER

OPEN END CROWFOOT

SNAP-ON FC018

Install oil pan, if removed. See

3.31 OIL PAN

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

Cover lower frame tubes (both left and right side) with
foam padding or bubble pack to prevent paint damage to
left frame tube, brake line and main harness. A split loom
conduit or a half shell of PVC tubing will also produce good
results.

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

Install engine in chassis from right side of motorcycle set-
ting front of crankcase onto front engine mount cross-
member. Engine must be forward far enough to clear two
ring dowels in lower flange of transmission. Exercise
caution to avoid contact with rear brake master cylinder
reservoir, brake line and main harness at top of lower right
frame tube.

Install

new

gasket and engage two index pins in holes at

center of transmission flange. Mate engine to transmission
and fully engage two ring dowels at bottom of transmission
flange.

Install front engine mount assembly. Install but do not
fasten crankcase to front engine mount bracket at this
time. See

2.51 FRONT ENGINE MOUNT

Secure the engine as follows:

Hand tighten four bolts (with flat washers) to secure
transmission to crankcase. Install the shorter 1/2 inch
bolts at the top, the longer 9/16 inch bolts at the
bottom.

Tighten the four transmission to crankcase bolts to
15 ft-lbs (20.3 Nm) in a crosswise pattern.

NOTE

For best results, use OPEN END CROWFOOT (Part
No. Snap-On FC018) on upper left and upper right trans-
mission to crankcase bolts.

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

Secure

engine

front

engine

mount.

See

2.51 FRONT ENGINE MOUNT

NOTE

Check each end of the stabilizer link for excessive wear
prior to installation. The spherical ball end may rotate
freely, but should not have any lateral movement. Replace
the link if lateral movement exists.

Secure front stabilizer link bracket to front cylinder
head. Tighten bolts to 30-35 ft-lbs (41-48 Nm).

Secure stabilizer link to frame weldment. Tighten bolt
to 18-22 ft-lbs (24.4-29.8 Nm).

Remove jack and wooden block from under oil pan.

10. Install oil filter. See

1.6 ENGINE OIL AND FILTER

11. Install stator and rotor. See

7.22 ALTERNATOR

12. Install primary chaincase. See

5.5 PRIMARY CHAINCASE

HOUSING

13. Uncoil main harness conduit and allow to hang below

lower frame tube at front of motorcycle.

14. Install oil pressure switch/sender. See

7.25 OIL PRES-

SURE SWITCH AND SENDER

15. Install CKP sensor. See

7.20 CRANKSHAFT POSITION

SENSOR (CKP)

16. Install voltage regulator. See

7.3 VOLTAGE REGULATOR

17. Release disconnected branches of main harness from top

of wire trough.

18. Install induction module. See

4.13 INDUCTION MODULE

19. Install purge solenoid hose, if equipped, to induction

module. See

4.22 EVAPORATIVE EMISSIONS CONTROL

SYSTEM

20. Install spark plugs. See

1.17 SPARK PLUGS

21. Install spark plug cables.

22. Install backplate and air cleaner. See

4.4 AIR CLEANER

ASSEMBLY

23. Install fuel tank. See

4.5 FUEL TANK

24. Install exhaust system. See

4.19 EXHAUST SYSTEM

25. Verify proper oil level. See

1.6 ENGINE OIL AND FILTER

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

If oil pan was

not

drained, perform

COLD CHECK

and

HOT CHECK

only.

HOME

2011 Touring Service: Engine 3-31

3.18

TOP END OVERHAUL: DISASSEMBLY

GENERAL

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

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

ROCKER COVERS

NOTE

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

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

See

Figure 3-17

. Following the sequence shown, altern-

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

Remove the rocker cover and gasket. Discard gasket.

sm02324

1. Internal hex
2. External hex
3. Lock patch

Figure 3-16. Rocker Cover Bolt (Rocker Housing Bolt

Similar)

sm02326

Figure 3-17. Rocker Cover Bolt Removal Sequence

ROCKER ARM SUPPORT PLATE

TOOL NAME

PART NUMBER

CRANKSHAFT ROTATING WRENCH

HD-48283

See

Figure 3-18

. Insert the blade of a small screwdriver

into cast loop (1) of spring cap retainer (at top of upper
push rod cover). While pushing down on spring cap (2),
rotate bottom of screwdriver toward outboard side to
remove. Repeat step on second push rod cover.

HOME

3-32 2011 Touring Service: Engine

sm02329

1. Cast loop
2. Spring cap

Figure 3-18. Removing Spring Cap Retainer

Collapse upper and lower push rod covers.

NOTE

Do not attempt to rotate the crankshaft by removing the cam
cover and placing a socket on the crankshaft or primary cam
sprocket flange bolt.

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

With primary cover installed:

Remove spark plugs.

With the rear wheel raised, place the transmission in
6th gear and rotate rear wheel backward until the
base circle is found.

With primary cover removed:

Remove spark plugs.

Place the transmission in neutral. Fit a socket on the
compensating sprocket shaft nut. Rotate nut counter-
clockwise until the base circle is found.

See

Figure 3-19

With engine mounted in engine

stand:

Install

CRANKSHAFT

ROTATING

WRENCH (Part No. HD-48283) on sprocket shaft and
rotate counterclockwise until the base circle is found.

sm02377

Figure 3-19. Crankshaft Rotating Wrench

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

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

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

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

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

See

Figure 3-20

. Remove two bolts to release breather

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

3.19 BREATHER ASSEMBLY

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

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

3.20 ROCKER ARM SUPPORT PLATE

NOTE

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

HOME

2011 Touring Service: Engine 3-33

sm02386a

Figure 3-20. Rocker Arm Bolt Sequence (late production

shown)

PUSH RODS, LIFTERS AND COVERS

See

Figure 3-21

. Remove the intake and exhaust push

rods and push rod covers.

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

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

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

See

Figure 3-22

. Remove lifter covers.

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

Remove the lifter cover and gasket. Discard gasket.

Remove lifters.

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

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

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

See

Figure 3-23

. Remove and discard O-ring from groove

around breather baffle hole in rocker housing.

For inspection and repair information, see

3.21 PUSH

RODS, LIFTERS AND COVERS

sm02181

1. Front cylinder exhaust push rod
2. Front cylinder intake push rod
3. Rear cylinder intake push rod
4. Rear cylinder exhaust push rod

Figure 3-21. Push Rod Locations

sm02378

1. Screw with captive washer (4)
2. Lifter cover

Figure 3-22. Lifter Cover

HOME

3-34 2011 Touring Service: Engine

sm02680

Figure 3-23. Breather Baffle Hole O-Ring

CYLINDER HEAD

TOOL NAME

PART NUMBER

CYLINDER TORQUE PLATES

HD-42324-A

See

Figure 3-24

. Following the sequence shown, altern-

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

Remove rocker housing and gasket. Discard gasket.

NOTE

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

See

Figure 3-25

. Remove cylinder head bolts.

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

Continue turning the bolts in these increments until
loose.

Remove the cylinder head bolts.

Remove cylinder head and head gasket.

NOTE

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

For inspection and repair information, see

3.22 CYLINDER

HEAD

sm02389

Figure 3-24. Rocker Housing Bolts Removal Sequence

HOME

2011 Touring Service: Engine 3-35

sm02392

Figure 3-25. 1/4 Turn Head Bolts in Sequence

CYLINDER

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

NOTE

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

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

Mark cylinder FRONT or REAR as appropriate.

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

See

Figure 3-26

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

of the cylinder liner. Discard O-ring seal.

See

Figure 3-27

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

base of cylinder deck. Discard O-ring.

For inspection and repair information, see

3.23 CYL-

INDER

sm02294

1. Dowel pin
2. Head gasket
3. Cylinder
4. O-ring seal

Figure 3-26. Cylinder Assembly

PISTON

TOOL NAME

PART NUMBER

PISTON PIN CIRCLIP
REMOVER/INSTALLER

HD-42317-A

PISTON PIN REMOVER

HD-42320-B

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

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

HOME

3-36 2011 Touring Service: Engine

See

Figure 3-27

. Remove the piston pin circlip.

I n s e r t

t h e

P I S TO N

P I N

C I R C L I P

REMOVER/INSTALLER (Part No. HD-42317-A) (1)
into the piston pin bore. Position claw on tool in slot
of piston (2) (directly under circlip).

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

sm02336

1. Piston pin circlip remover/installer
2. Piston
3. Protective material over cylinder studs
4. Cylinder deck dowel (O-ring not shown)

Figure 3-27. Piston Pin Circlip Removal (Part No. HD-42317)

NOTE

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

See

Figure 3-28

. Remove the piston pin. If piston pin is

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

Remove acorn nut and spacer from rod end of tool.

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

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

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

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

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

Service as needed. For inspection and repair information,
see

3.24 PISTON

Complete engine work.

If performing a top end overhaul only, see

3.25 TOP

END OVERHAUL: ASSEMBLY

If performing a complete engine overhaul, see

3.26 CAM COMPARTMENT AND COMPONENTS

and

sm02334

1. Spacer and acorn nut
2. Rubber coated tip
3. Handle

Figure 3-28. Piston Pin Remover (Part No. HD-42320-B)

HOME

2011 Touring Service: Engine 3-37

3.19

BREATHER ASSEMBLY

DISASSEMBLY

Early Production

Remove rocker cover. See

3.18 TOP END OVERHAUL:

DISASSEMBLY, Rocker Covers

See

Figure 3-29

. Remove two fasteners (1) from the

breather assembly cover (2) and remove breather
assembly from rocker arm support plate (8).

Remove the breather cover and cover gasket (3). Discard
gasket. Remove breather baffle (5) and breather baffle
gasket (7). Discard gasket. Pull filter element (6) from bore
on underside of breather baffle. Pull umbrella valve (4)
from hole at top of breather baffle. Discard both filter ele-
ment and umbrella valve.

Late Production

NOTE

See

Figure 3-30

. Breather baffle assembly is manufactured

with gaskets attached and is supplied with the filter element
(5) and umbrella valve (3). Any time the breather is disas-
sembled, the baffle assembly must be replaced with a new
assembly.

Remove rocker cover. See

3.18 TOP END OVERHAUL:

DISASSEMBLY, Rocker Covers

Remove two fasteners (1) and remove breather cover (2)
from rocker arm support plate (6).

Remove breather baffle (4). Discard breather baffle, filter
element (5) and umbrella valve (3).

CLEANING AND INSPECTION

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)

Clean cover and screws in a non-volatile cleaning solution
or solvent. Dry parts with low pressure compressed air.

Set a straightedge diagonally across the length of the
breather cover intersecting the opposite corners of the
gasket surface. Slide a feeler gauge beneath the
straightedge to check the breather cover flatness. Repeat
the step checking the opposite diagonal. Discard the
breather cover if any low spot exceeds 0.005 in. (0.13
mm).

Early Production:

Check the breather baffle gasket sur-

face flatness. Discard the breather baffle if any low spot
exceeds 0.005 in. (0.13 mm).

ASSEMBLY

Early Production

See

Figure 3-29

. Insert stem of

new

umbrella valve (4)

through center hole at top of breather baffle (5). Carefully

pull rubber bead on stem through hole in baffle. Use
denatured alcohol or glass cleaner to lubricate stem if
necessary. Verify that rubber bead is pulled completely
through hole.

Press

new

filter element (6) into bore at bottom of baffle.

Hole in filter element accommodates umbrella valve stem.

Place breather baffle gasket (7) on a clean flat surface.
Stack breather baffle (5), cover gasket (3) and breather
cover (2) on top of breather baffle gasket. Slide two
fasteners (1) through stack-up to keep assembly together
until time of installation.

Install breather assembly and rocker cover. See

3.25 TOP

END OVERHAUL: ASSEMBLY, Breather and Rocker
Cover

Late Production

See

Figure 3-29

. Install breather assembly using

new

baffle

assembly and rocker cover. See

3.25 TOP END OVERHAUL:

ASSEMBLY, Breather and Rocker Cover

sm02429

1. Fasteners (2)
2. Breather cover
3. Cover gasket
4. Umbrella valve
5. Breather baffle
6. Filter element
7. Breather baffle gasket
8. Rocker arm support plate

Figure 3-29. Breather Assembly, Early Production

HOME

3-38 2011 Touring Service: Engine

sm02429a

1. Fasteners (2)
2. Breather cover
3. Umbrella valve
4. Breather baffle
5. Filter element
6. Rocker arm support plate

Figure 3-30. Breather Assembly, Late Production

HOME

2011 Touring Service: Engine 3-39

Content .. 18 19 20 21 ..