Harley Davidson 2011 Touring Models. Service Manual - page 21

3.20

ROCKER ARM SUPPORT PLATE

DISASSEMBLY

See

. Remove four bolts with flat washers (1)

from the rocker arm support plate (5). The rocker arm
shafts (4) on the push rod side (right) are notched to lock
them in position.

Using a hammer and brass drift, tap left side of rocker arm
shafts (4) so that the notched ends exit the rocker arm
support plate (5) first. Mark the shafts so that they are
installed in their original locations at time of assembly.

Remove the rocker arms from the rocker arm support
plate. Mark the rocker arms to indicate location.

CLEANING AND INSPECTION

TOOL NAME

PART NUMBER

ROCKER ARM BUSHING REAMER

HD-94804-57

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 all parts in a non-volatile cleaning solution or
solvent. Blow parts dry with low pressure compressed air.

See

Figure 3-31

. Check rocker arms (3) for uneven wear

or pitting where contact is made with the valve stem tips.
Check for concave wear where rocker arms contact the
push rod ends. Replace rocker arm if excessive wear is
found at either location.

Verify that oil holes in rocker arms and rocker arm support
plate (5) are clean and open.

Inspect rocker arm shafts (4) for scratches, burrs, scoring
or excessive wear. Replace as necessary.

sm02298

1. Bolt with flat washer
2. Rocker arm bushings
3. Rocker arm
4. Rocker arm shaft
5. Rocker arm support plate
6. Notch

Figure 3-31. Rocker Arm Assembly

Rocker Shaft Fit

See

Figure 3-32

. Measure the inside diameter of the rocker

arm support plate bore.

See

Figure 3-33

. Measure the outside diameter of the

rocker arm shaft where it fits in the bore.

Repeat the measurement on opposite side of support plate
and shaft. Replace shaft or support plate if clearance
equals or exceeds 0.0035 in. (0.089 mm).

sm02431

Figure 3-32. Checking Support Plate Bore

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3-40 2011 Touring Service: Engine

sm02432

Figure 3-33. Checking Shaft to Support Plate Fit

Rocker Arm Shaft to Bushing

Check rocker arm shaft to bushing fit.

See

Figure 3-34

. Measure the inside diameter of the

rocker arm bushing.

See

Figure 3-35

. Measure the outside diameter of

the rocker arm shaft where it rides in the bushing.

Repeat measurement on opposite side of rocker arm and
shaft. Replace shaft or bushings if clearance equals or
exceeds service wear limit of 0.0035 in. (0.089 mm).

sm02433

Figure 3-34. Checking Bushings

sm02434

Figure 3-35. Checking Shaft to Bushing Fit

Replace Rocker Arm Bushings

NOTE

Bushing replacement and reaming must be done one at a time
to achieve proper alignment. Follow all steps for one bushing
and then repeat for the other bushing.

See

Figure 3-36

. Turn a 9/16"-18 tap (2) into bushing until

tight. Place rocker arm under ram of arbor press with tap
at bottom. Slide a discarded rocker arm shaft (1) through
open end of rocker arm until contact is made with tap.
Using shaft as driver (and untapped bushing as pilot),
press against shaft until both tap and bushing are free.

See

Figure 3-37

. Using a suitable driver, press

new

bushing into side of rocker arm until flush with casting. Be
sure to orient bushing so that split line faces top of rocker
arm.

NOTE

Never back reamer out of rocker arm or new bushing will be
damaged.

See

Figure 3-38

. Lock rocker arm in a vise using brass

jaw inserts or shop towels to prevent casting damage.
Insert tapered end of ROCKER ARM BUSHING
REAMER (Part No. HD-94804-57) into old bushing in
rocker arm. Note that old bushing on drive side of reamer
as pilot. Rotate reamer until the

new

bushing on the far

side is reamed, and then continuing in the same direction,
draw drive side of reamer from

new

bushing.

Repeat steps to remove, install and ream second bushing.

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2011 Touring Service: Engine 3-41

sm02437

1. Discarded shaft used as driver
2. Tap

Figure 3-36. Removing Bushing

sm02438

1. Driver
2. Bushing

Figure 3-37. Installing Bushing

sm02487

Figure 3-38. Ream Bushing

ASSEMBLY

Place the rocker arms into position on the rocker arm
support plate.

Push the un-notched ends of the rocker arm shafts into
the right side of the support plate and then into the rocker
arms. As they approach their fully installed positions, rotate
the shafts so that the notches are aligned with the bolt
holes in the support plate.

See

Figure 3-39

. Check for proper end play.

Insert a feeler gauge between the rocker arm and
support plate.

Repeat measurement on other rocker arm.

Replace the rocker arm, rocker arm support plate or
both if end play exceeds 0.025 in. (0.635 mm).

Install the four bolts with flat washers in the rocker arm
support plate. Remember that the two bolts on the push
rod side (right) must engage the notches in the rocker arm
shafts for proper assembly.

sm02488

Figure 3-39. Check End Play

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3-42 2011 Touring Service: Engine

3.21

PUSH RODS, LIFTERS AND COVERS

DISASSEMBLY

See

Figure 3-40

. With the exception of the lifter covers, all

parts should have been disassembled and marked during the
removal procedure. Disassemble the lifter covers as follows:

Separate upper (2) and lower push rod covers (8).

Remove O-ring (9) from seat at bottom of lower push rod
cover. Discard O-ring.

Remove O-ring (1) from seat at top of upper push rod
cover. Slide O-ring (7), flat washer (6), spring (5) and
spring cap (4) from body of upper push rod cover (2).
Discard O-rings.

CLEANING AND INSPECTION

See

Figure 3-40

. Scrape old gasket material from the lifter

cover (11) flange. Old gasket material left on mating sur-
faces will cause leaks.

With the exception of the hydraulic lifters (14), clean all
parts in a non-volatile cleaning solution or solvent. Verify
that the O-ring seats and contact surfaces of the push rod
covers (2, 8) are completely clean.

Blow parts dry with low pressure compressed air. Verify
that all oil holes are clean and open.

Verify that the hydraulic lifter rollers turn freely and are
free of flat spots, scuff marks and pitting. If flat spots exist,
examine the cam lobe on which the lifter operates.

Inspect the lifter socket for signs of wear. Verify that the
plunger of the hydraulic lifter is fully extended up against
the C-clip. Use index finger to pump plunger to verify lifter
operation.

Examine the push rods (15). Replace any push rods that
are bent, dented, damaged or discolored. Replace the rod
if the ball ends show signs of excessive wear or damage.

Cover all parts with a clean plastic sheet to protect them
from dust and dirt.

sm02492

1. Upper O-ring (small)
2. Upper push rod cover
3. Spring cap retainer
4. Spring cap
5. Spring
6. Flat washer
7. Middle O-ring (intermediate)
8. Lower push rod cover
9. Lower O-ring (large)
10. Lifter cover screw
11. Lifter cover
12. Anti-rotational pin
13. Lifter cover gasket
14. Hydraulic lifter
15. Push rod

Figure 3-40. Push Rods, Lifters and Covers

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2011 Touring Service: Engine 3-43

LIFTER INSPECTION

NOTE

Inside and outside micrometers used for measuring lifters and
lifter bores must be calibrated to take accurate readings.

Inspect lifters for excessive clearance in bores. Accurately
measure the lifter outer diameter and record the measure-
ment.

Accurately measure lifter bore inner diameter with a snap
gauge. Subtract this measurement from the lifter measure-
ment to determine clearance.

Clearance should be within 0.0008-0.0020 in. (0.0203-
0.0508 mm).

Install

new

lifters and/or replace crankcases if clear-

ance exceeds SERVICE WEAR LIMIT of 0.0030 in
(0.076 mm).

Check lifter roller radial play.

Roller radial movement should be within 0.0006-
0.0010 in (0.0152-0.0254 mm).

Replace lifters if radial movement exceeds SERVICE
WEAR LIMIT of 0.0015 in. (0.0381 mm).

Check lifter roller end clearance.

End clearance should be within 0.008-0.022 in.
(0.203-0.559 mm).

Replace lifters if end clearance exceeds SERVICE
WEAR LIMIT of 0.022 in. (0.559 mm).

Soak lifters in clean engine oil. Keep covered until
assembly.

ASSEMBLY

With the exception of the push rod covers, all parts will be
assembled during the installation procedure. Assemble the
push rod covers as follows:

NOTE

O-rings that are missing, distorted, pinched or otherwise dam-
aged will result in either oil leakage or low oil pressure. Use of
the wrong O-ring will have the same results. Since many O-
rings are similar in size and appearance, always use new O-
rings keeping them packaged until use to avoid confusion.

See

Figure 3-41

. Obtain three

new

O-rings (1, 7 and 9).

Apply a very thin film of clean H-D 20W50 engine oil to O-
rings before installation.

Install

new

small O-ring (1) on seat at the top of the upper

push rod cover (2).

Slide the spring cap (4), spring (5), flat washer (6) and

new

intermediate size O-ring (7) onto the body of the

upper push rod cover. Move parts up body until spring cap
(4) contacts upper O-ring seat.

Fit the straight end of the upper push rod cover into the
flared end of the lower push rod cover (8).

Install

new

large O-ring (9) on seat at bottom of lower

push rod cover.

sm02493

Figure 3-41. Assembled Push Rod Cover

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3-44 2011 Touring Service: Engine

3.22

CYLINDER HEAD

DISASSEMBLY

TOOL NAME

PART NUMBER

VALVE SPRING COMPRESSOR

HD-34736-B

CYLINDER HEAD HOLDING FIXTURE

HD-39786

Before proceeding with the disassembly procedure,
determine if valve reconditioning is necessary.

Raise valve ports of cylinder head to strong light
source. If light is visible around edges of seats, the
cylinder head and valves require reconditioning.

Fill ports at top of cylinder head with solvent. Wait ten
full seconds and and check for leakage into combus-
tion chamber. If solvent leakage into combustion
chamber is evident, the cylinder head and valves
require reconditioning.

See

Figure 3-42

. Secure cylinder head for service.

Thread 12 mm end of CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) (1) into cylinder head
(2) spark plug hole.

Clamp tool in vise at a 45 degree angle or one that
offers a comfortable working position.

sm02494

1. Holding fixture
2. Cylinder head
3. 12 mm end of fixture

Figure 3-42. Cylinder Head Holding Fixture

See

Figure 3-43

. Release valve spring compression.

Place VALVE SPRING COMPRESSOR (Part No. HD-
34736-B) (2) over cylinder head. Center blunt end on
the valve head. Seat adapter at end of forcing screw
on the valve spring retainer.

Rotate forcing screw to compress valve spring.

See

Figure 3-44

. If spring retainer (2) is not free of

tapered keepers (1), give head of tool a sharp tap
with a soft mallet. Using magnetic rod or small
screwdriver, remove the keepers (1) from the valve
stem (11) groove.

Rotate forcing screw to release the valve spring
compression.

Remove the spring retainer (2) and valve spring (3).

Slide the valve (11) from the valve guide (5).

Remove valve seal assembly.

Mark the bottom of the valve F(ront) or R(ear) for identific-
ation. Also, separate and tag tapered keepers, valve spring
and spring retainer so that they are installed on the same
valve at time of assembly.

Repeat previous steps to remove the other valve compon-
ents.

Release the cylinder head holding fixture from the vise.
Remove fixture tool from spark plug hole.

sm02495

1. Holding fixture
2. Compressor

Figure 3-43. Valve Spring Compressor (Part No.

HD-34736-B)

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2011 Touring Service: Engine 3-45

sm02496

1. Tapered keepers
2. Spring retainer
3. Valve spring
4. Spring seat/valve stem seal
5. Valve guide
6. Lock ring
7. Cylinder head bolt, short
8. Cylinder head bolt, long
9. Cylinder head
10. Valve seat
11. Valve

Figure 3-44. Cylinder Head Assembly

CLEANING

See

Figure 3-44

. Remove old gasket material from cylinder

head (9). Gasket material left on sealing surfaces will
cause leaks.

Do not use glass or sand to bead blast surfaces exposed
to engine oil. Blasting materials can lodge in pores of the
casting. Heat expansion releases this material which can
contaminate oil resulting in engine damage. (00534b)

NOTE

Bead blasting materials could also enter threaded holes
adversely affecting fastener engagement and torque indication.
Cover all threaded holes before bead blasting.

Remove all carbon deposits from combustion chamber
and machined surfaces of cylinder head. Exercise caution
to avoid removing any metal material. For best results,
use an air tool with a

worn

wire brush. Scraping may result

in scratches or nicks.

To soften stubborn deposits, soak the cylinder head in a
chemical solution, such as GUNK HYDRO-SEAL or other
carbon and gum dissolving agent. Repeat previous step
as necessary.

Thoroughly clean the cylinder head, spring retainers,
tapered keepers, valves and valve springs in a non-volatile
cleaning solution or solvent. Follow up with a thorough
wash in hot soapy water.

Blow parts dry with low pressure compressed air.

INSPECTION

TOOL NAME

PART NUMBER

VALVE GUIDE HONE

B-45525

VALVE GUIDE CLEANING BRUSH

HD-34751

CYLINDER TORQUE PLATES

HD-42324-A

VALVE SPRING TESTER

HD-96796-47

Cylinder Head

Check for scratches and nicks on all gasket sealing sur-
faces.

Check for warpage.

With the combustion chamber side facing upward,
set a straightedge diagonally across the length of the
cylinder head intersecting the upper and lower corners
of the gasket surface.

Slide a feeler gauge beneath the straightedge to
check the head for warpage.

Checking the opposite diagonal, repeat the procedure
to verify that the gasket surface is flat (especially if a
head gasket was blown). Discard the head if any low
spot is 0.006 in. (0.152 mm) or greater.

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3-46 2011 Touring Service: Engine

NOTE

For best results, use one of the CYLINDER TORQUE
PLATES (Part No. HD-42324-A) in lieu of the straightedge.
Lay the upper plate (without vise grip) flat on the machined
surface of the head. As a preliminary check, see if the plate
rocks from side to side. A head on which the plate rocks is
immediately suspect. Insert a feeler gauge between the plate
and head at various locations to see if warpage exceeds above
specification.

Verify that oil passageways are open and clean.

Valve Guides

Inspect external surfaces, particularly the combustion
chamber side, for cracks. Replace the guide if any cracks
are found.

Prepare valve guides for inspection.

Lightly

hone

bore

using

the

VALVE

GUIDE

HONE (Part No. B-45525).

Scrub

with

the

VALVE

GUIDE

CLEANING

BRUSH (Part No. HD-34751) to remove any dust or
debris.

Polish the valve stem with fine emery cloth or steel
wool to remove carbon buildup.

Check valve stem to guide clearance:

Carefully measure the

inside

diameter of the valve

guide using an inside ball gauge.

Measure the

outside

diameter of the valve stem with

an outside micrometer.

Refer to

Table 3-40

. If the clearance between stem

and guide exceeds the limits shown, the valve stem
and/or guide are excessively worn.

Repeat measurements with a

new

valve to determine

if the guide must be replaced.

Table 3-40. Valve Stem to Guide Clearance Service Wear

Limits

IN.

VALVE

0.0965

0.0038

Intake

0.0965

0.0038

Exhaust

Valves

Replace the valve if there is evidence of burning or
cracking.

Inspect the end of the valve stem for pitting or uneven
wear. Replace the valve if either of these conditions are
found.

Inspect for burrs around the valve stem keeper groove.
Remove burrs with a fine tooth file if found.

To determine if the valve stem is excessively worn, see
valve guide inspection.

Valve Springs

Inspect springs for cracked or discolored coils. Replace
springs if either of these conditions are found.

Set the intake and exhaust valve springs on a level surface
and use a straightedge to check for proper squareness
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

3.22 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.

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2011 Touring Service: Engine 3-47

See

Figure 3-45

. 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)

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 3-46

. Center valve guide driver under ram of

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

sm02497

1. Valve guide driver
2. Cylinder head support stand
3. Intake seat adapter
4. Exhaust seat adapter
5. Valve guide installer sleeve

Figure 3-45. Valve Guide Replacement Tools

sm02498

1. Valve guide driver
2. Cylinder head stand

Figure 3-46. 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.

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3-48 2011 Touring Service: Engine

Prepare cylinder head for valve guide replacement.

See

Figure 3-45

. 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 3-47

. 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.

sm02299

1. Valve guide driver
2. Valve guide installer sleeve
3. Cylinder head stand

Figure 3-47. 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.

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2011 Touring Service: Engine 3-49

sm02499

1. T-handle
2. Valve guide reamer

Figure 3-48. Reaming Valve Guide Bore

See

Figure 3-48

. 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.

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

See

Figure 3-49

. Clean valve guide bore with the VALVE

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

See

Figure 3-50

. 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 degrees.

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 3-41

. 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 3-49. Scrubbing Valve Guide Bore

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3-50 2011 Touring Service: Engine

sm02501

Figure 3-50. 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 3-41. 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

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 3-41

. 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 degree
valve face and the valve seat which will be 46 degrees.

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 degree 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 3-53

. 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 3-51

. 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.

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2011 Touring Service: Engine 3-51

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 degree angle or one that
offers a comfortable working position.

In order to determine the correct location of the 46 degree
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 3-51. Checking Valve Stem Protrusion

NOTES

•

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

•

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

See

Figure 3-52

. 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 degree 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 degree angle. Do not remove any more metal than is
necessary 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 degree 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 degrees will help in determ-
ining where new angles are.

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

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

If the 46 degree cut is too high (towards the combus-
tion chamber), use the 31 degree cutter to lower the
valve seat closer to the port.

If the 46 degree cut is too low, use the 60 degree
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 degree cutter following the initial 46 degree
cut.

•

Always highlight the valve seat with the permanent magic
marker in order to better view the location of the 46 degree
valve seat.

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3-52 2011 Touring Service: Engine

sm02503

Figure 3-52. 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

degree angle and the width is at least 0.062 in. (1.575
mm), proceed to the next step.

15. Select the proper 60 degree 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.

sm00148

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

in. (1.575 mm)

2. 60 degrees
3. 31 degrees
4. 46 degrees
5. Margin

Figure 3-53. 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.

Apply a liberal amount of Screamin' Eagle Assembly Lube
(Part No. 94971-09) 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.

HOME

2011 Touring Service: Engine 3-53

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 3-54

. 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 Screamin' Eagle Assembly Lube
(Part No. 94971-09) to capsule.

See

Figure 3-55

. 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 3-54. Plastic Capsule

sm02528

Figure 3-55. Valve Stem Seal/Spring Seat Assembly

11. See

Figure 3-56

. 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.

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 be sure 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.

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3-54 2011 Touring Service: Engine

sm02505

1. Tapered keepers
2. Spring retainer
3. Valve spring
4. Spring seat/valve stem set seal
5. Valve guide
6. Lock ring

Figure 3-56. Valve Assembly

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2011 Touring Service: Engine 3-55

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