Harley Davidson 2011 Touring Models. Service Manual

2011 Harley-Davidson Touring Models Service Manual

NOTES

TORQUE VALUE

FASTENER

2.45 FRONT FENDER, Installation

22-27 Nm

16-20 ft-lbs

Front fender mount screws

7.15 FENDER TIP LAMPS, Front Fender Tip Lamp

2.3-2.8 Nm

20-25

in-lbs

Front fender tip lamp bracket screws

7.15 FENDER TIP LAMPS, Front Fender Tip Lamp
Jumper Harness

2.3-2.8 Nm

20-25

in-lbs

Front fender tip lamp bracket screws

7.15 FENDER TIP LAMPS, Front Fender Tip Lamp
Jumper Harness

1.1-1.7 Nm

10-15

in-lbs

Front fender tip lamp trim strip tee bolt
nuts

1.5 MAINTENANCE SCHEDULE, General

1.1-1.4 Nm

10-12

in-lbs

Front master cylinder reservoir cover
screws

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement

1.1-1.4 Nm

10-12

in-lbs

Front master cylinder reservoir cover
screws

2.16 BLEEDING BRAKES, Procedure

1.1-1.4 Nm

10-12

in-lbs

Front master cylinder reservoir cover
screws

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

6.8-9.5 Nm

60-84

in-lbs

Front turn signal lamp acorn nuts, frame
mounted fairing

7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp

20-27 Nm

15-20 ft-lbs

Front turn signal lamp mounting bracket
screws (Bullet Style; fork mounted)

7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp

4.1-6.8 Nm

30-60

in-lbs

Front turn signal lamp mounting bracket
screws (FLHR/C, FLHT/C/U)

7.16 TURN SIGNAL LAMPS, Front Turn Signal
Lamp

20-27 Nm

15-20 ft-lbs

Front turn signal lamp-to-bracket
fastener: Bullet Style; fork mounted

4.5 FUEL TANK, Fuel Supply Check
Valve/Tube/metric

29.8-35.3 Nm

22-26 ft-lbs

Fuel supply line quick-connect fitting

4.16 FUEL INJECTORS, Installation/metric

7.5-9.3 Nm

66-82

in-lbs

Fuel supply tube clamp screw

7.33 ADVANCED AUDIO SYSTEM, Front Headset
Receptacle

4.1-6.8 Nm

36-60

in-lbs

Fuel tank console screws

4.5 FUEL TANK, Installation

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank front screws

4.5 FUEL TANK, Installation

20.3-27.1 Nm

15-20 ft-lbs

Fuel tank rear bracket screws

7.6 IGNITION COIL, Installation

5.7-10.2 Nm

50-90

in-lbs

Ground terminal nut

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

43.4-48.8 Nm

32-36 ft-lbs

Guard to frame screws

2.22 CLUTCH CABLE, Installation

8.1-12.0 Nm

72-108

in-lbs

Handlebar clamp to clutch lever bracket
screws

2.23 HANDLEBARS, Adjustment

8.1-12.0 Nm

72-108

in-lbs

Handlebar clamp to clutch lever bracket
screws

7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Left Side Handlebar Switches

8.1-12.2 Nm

72-108

in-lbs

Handlebar clamp to clutch lever bracket
screws

7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation

8.1-12.2 Nm

72-108

in-lbs

Handlebar clamp to clutch lever bracket
screws

2.12 FRONT BRAKE MASTER CYL-
INDER, Assembly and Installation

8.1-12.2 Nm

72-108

in-lbs

Handlebar clamp to master cylinder
screws

7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Right Side Handlebar Switches

8.1-12.2 Nm

72-108

in-lbs

Handlebar clamp to master cylinder
screws

2.23 HANDLEBARS, Rubber Mounts

40.7-54.2 Nm

30-40 ft-lbs

Handlebar lower clamp bolts (risers)

1.5 MAINTENANCE SCHEDULE, General

4.0-5.1 Nm

35-45

in-lbs

Handlebar switch housing screw

7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Right Side Handlebar Switches

4.0-5.0 Nm

35-45

in-lbs

Handlebar switch housing screws

7.40 HANDLEBAR SWITCH ASSEM-
BLIES, Assembly: Left Side Handlebar Switches

4.0-5.0 Nm

35-45

in-lbs

Handlebar switch housing screws

XII TORQUE VALUES

2011 Harley-Davidson Touring Models Service Manual

NOTES

TORQUE VALUE

FASTENER

7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation

4.0-5.0 Nm

35-45

in-lbs

Handlebar switch housing screws

7.40 HANDLEBAR SWITCH ASSEMBLIES, Install-
ation

4.0-5.0 Nm

35-45

in-lbs

Handlebar switch housing screws

2.23 HANDLEBARS, Adjustment

21.7-27.1 Nm

16-20 ft-lbs

Handlebar upper clamp screws

2.23 HANDLEBARS, Installation

21.7-27.1 Nm

16-20 ft-lbs

Handlebar upper clamp screws

2.23 HANDLEBARS, Installation

21.7-27.1 Nm

16-20 ft-lbs

Handlebar upper clamp screws

7.35 MAIN WIRING HARNESS, Installation: All
Models (Part 1)/(10 mm)

5.7-10.2 Nm

50-90

in-lbs

Harness ground stud flange nuts

7.35 MAIN WIRING HARNESS, Installation: All
Models (Part 1)/(10 mm)

5.7-10.2 Nm

50-90

in-lbs

Harness ground stud flange nuts

7.12 HEADLAMP: ROAD GLIDE, Headlamp
Adjuster Assembly

4.0-5.1 Nm

35-45

in-lbs

Headlamp adjuster mounting screw (dual
headlamp models)

7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models

1.0-2.0 Nm

9-18

in-lbs

Headlamp door screw

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.0-2.0 Nm

9-18

in-lbs

Headlamp housing screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.0-2.0 Nm

9-18

in-lbs

Headlamp housing screws

7.12 HEADLAMP: ROAD GLIDE, Headlamp
Adjuster Assembly

1.7-2.8 Nm

15-25

in-lbs

Headlamp mounting screw (dual head-
lamp models)

7.12 HEADLAMP: ROAD GLIDE, Headlamp Bulb
Replacement: Dual Headlamp Models

1.7-2.8 Nm

15-25

in-lbs

Headlamp mounting screw (dual head-
lamp models)

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.7-2.3 Nm

15-20

in-lbs

Headlamp nacelle handlebar chrome
strip flange nut

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.1-2.3 Nm

10-20

in-lbs

Headlamp nacelle handlebar clamp
shroud screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

1.1-2.3 Nm

10-20

in-lbs

Headlamp nacelle handlebar clamp
shroud screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

8.1-12.2 Nm

72-108

in-lbs

Headlamp nacelle to fork bracket stud
acorn nuts

7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models

2.5-3.6 Nm

22-32

in-lbs

Headlamp retaining screws (Fairing
equipped)

7.11 HEADLAMP: ALL EXCEPT ROAD
GLIDE, Headlamp: Single Headlamp Models

1.0-2.0 Nm

9-18

in-lbs

Headlamp retaining screws (Non-fairing
equipped)

7.27 HORN, Installation

9.0-13.6 Nm

80-120

in-lbs

Horn bracket acorn nut

7.27 HORN, Installation

9.0-11.3 Nm

80-100

in-lbs

Horn stud flange nut

7.6 IGNITION COIL, Installation

3.6-4.5 Nm

32-40

in-lbs

Ignition coil screws

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Fairing Models

9.6-13.0 Nm

85-115

in-lbs

Ignition switch housing nut

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Fairing Models

4.1-6.8 Nm

36-60

in-lbs

Ignition switch housing screws

7.17 IGNITION/LIGHT KEY SWITCH AND FORK
LOCK, Road King Models

2.3-3.4 Nm

20-30

in-lbs

Ignition switch screws (Road King)

4.13 INDUCTION MODULE, Installation/metric

10.9-16.3 Nm

96-144

in-lbs

Induction module flange adapter screws

4.13 INDUCTION MODULE, Installation/metric

10.9-16.3 Nm

96-144

in-lbs

Induction module flange adapter screws

7.19 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS, Installation

2.8-4.0 Nm

25-35

in-lbs

Instrument bezel screws

TORQUE VALUES XIII

Remove retaining ring securing front camshaft. Discard
retaining ring.

Remove spacer from front camshaft. Do not mix front and
rear camshaft spacers. Front spacer is 0.100 in. (2.54 mm)
thick.

Using a colored marker, mark one of the links of the sec-
ondary cam chain. Maintaining the original direction of
rotation during assembly may prolong service life.

Slide camshafts and secondary cam chain out of cam
support plate.

Remove secondary cam chain from cam sprockets.

sm02512

1. Cam support plate
2. Front cam
3. Secondary cam chain tensioner
4. Secondary cam chain tensioner fasteners
5. Rear cam

Figure 3-96. Camshafts

Installation

See

Figure 3-97

. Align timing marks on teeth of secondary

cam sprockets.

NOTE

Do not mix camshafts during installation. The rear camshaft,
which can be identified by the splined shaft, must go into the
hole at the rear of the cam support plate.

Place the secondary cam chain around the sprockets of
both the front and rear camshafts while keeping the timing
marks (3) in alignment. To maintain the original direction
of rotation, be sure that the mark placed on the chain link
during disassembly is visible during installation.

sm02513

1. Rear camshaft
2. Front camshaft
3. Timing marks

Figure 3-97. Camshaft Timing Marks

sm02514

1. Rear camshaft
2. Small guide
3. Front camshaft
4. Large guide
5. Cam chain
6. Timing marks
7. Assembly tool base

Figure 3-98. Camshaft Assembly Tool

See

Figure 3-98

. Obtain CAMSHAFT ASSEMBLY

TOOL (Part No. HD-47956). Place crankcase side of
camshaft/cam chain assembly into assembly tool base (7)
while maintaining cam timing mark (6) alignment.

Place small guide (2) on rear camshaft (1). Place large
guide (4) on front camshaft (3).

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3-78 2011 Touring Service: Engine

Lubricate support plate camshaft cavities with Screamin'
Eagle Assembly Lube (Part No. 94971-09).

Install cam support plate over guides.

Remove guides and base.

See

Figure 3-99

. Using a straightedge, verify that the

timing marks are in alignment. If they are not, then the
camshafts must be removed, realigned and reinstalled.

Install 0.100 in. (2.54 mm) thick front camshaft spacer
over end of front camshaft.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

10. With the sharp edge out, install

new

retaining ring in

groove at end of front camshaft.

11. Inspect primary and secondary cam chain tensioners.

Inspect tensioners for wear. Replace tensioners if
damaged or if chain contact portion of shoe material
is less than 0.060 in. (1.52 mm) thick.

See

Figure 3-100

. Be sure primary and secondary

cam chain tensioners are assembled as shown. If
assembled incorrectly, tensioners will not function
properly.

12. Install secondary cam chain tensioner. Tighten fasteners

to 90-120

in-lbs

(10.2-13.6 Nm).

sm02300

1. Rear camshaft
2. Front camshaft
3. Timing marks

Figure 3-99. Verify Alignment of Timing Marks

sm02515

1. Secondary cam chain tensioner
2. Primary cam chain tensioner
3. Piston
4. Spring
5. Shoe

Figure 3-100. Cam Chain Tensioner Assemblies

OIL PRESSURE RELIEF VALVE

Removal

See

Figure 3-101

. Secure the cam support plate in a vise

with soft jaws.

With piston in place, insert straight stiff wire into bore until
it bottoms in the piston. Mark wire at edge of bore in cam
support plate. Remove wire and measure distance from
the end to the mark. With piston fully seated in the bore,
depth should be approximately 2.25 in. (57.15 mm). If it
is less than specified, the piston is not fully seated and a
low oil pressure condition will likely be the result.

Use a 1/8 in. punch to remove roll pin (1). Discard roll pin.

Remove spring (2) and piston (3) from bypass port.

Inspection

NOTE

A stretched spring or sticking piston can result in high oil
pressure.

Inspect spring for stretching, kinks, or distortion.

Inspect piston and bore for burrs, scoring or other damage.
Look for steel particles or aluminum chips. Replace cam
support plate and piston if any of these conditions are
found.

Measure running clearance of piston in bore. If running
clearance exceeds 0.003 in. (0.076 mm), install

new

piston

and measure again. Replace cam support plate if running
clearance still exceeds specification.

Installation

Secure the cam support plate in a vise with soft jaws.

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2011 Touring Service: Engine 3-79

See

Figure 3-101

. Lubricate piston (3) with Screamin'

Eagle Assembly Lube (Part No. 94971-09). Slide piston
into bypass port of cam support plate with the open side
facing outward.

Slide spring (2) into bypass port until seated in piston.

Start

new

roll pin (1) into hole in cam support plate.

Compress spring using the blade of a small screwdriver.

Hold spring compressed and tap roll pin into cam support
plate until it approaches pin hole on opposite side.

Remove screwdriver to release spring. Verify that spring
is straight and square in bore.

Use a 1/8 in. punch to install roll pin until flush with casting.

sm02516

1. Roll pin
2. Spring
3. Piston
4. Bypass port

Figure 3-101. Oil Pressure Relief Valve Assembly

CAM NEEDLE BEARINGS

TOOL NAME

PART NUMBER

CAMSHAFT NEEDLE BEARING
REMOVER/INSTALLER

HD-42325-A

Removal

Obtain

the

CAMSHAFT

NEEDLE

BEARING

REMOVER/INSTALLER (Part No. HD-42325-A).

See

Figure 3-103

. Remove four thumb screws (1) from

threaded holes in support plate (2), if installed.

Sparingly apply clean engine oil (9) to threads of collet (3)
to prolong service life and verify smooth operation.

Slide collet through support plate so that threaded end
exits stamped side of plate.

Aligning two large holes in support plate with needle
bearing bores, hang right side of plate on ring dowel in
crankcase flange.

Install thumb screws to secure support plate to crankcase.

Center expandable end of collet in bearing bore and slide
bearing (7) and flat washer (5) on threaded end. Start hex
nut (8) on threaded end.

Push expandable end of collet through bearing bore into
flywheel compartment. Feel for inside edge of needle
bearing using end of collet and then back off slightly.

sm02517

1. Flat
2. Hex

Figure 3-102. Expanding Collet by Turning Hex Clockwise

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3-80 2011 Touring Service: Engine

sm02533

Installer (1 in., 25.4 mm)

Thumb screw

Support plate

Bearing

Hex nut

Removal collet (Threaded end: left, Expandable
end: right)

9. Graphite lubricant

4. Installer forcing screw
5. Flat washer

Figure 3-103. Camshaft Needle Bearing Remover/Installer (Part No. HD-42325-A)

Holding collet to prevent lateral movement, finger tighten
hex nut until bearing contacts support plate.

10. See

Figure 3-107

. Hold flat on collet to prevent rotation

and expand collet by turning hex at end of shaft clockwise.
Expandable end of collet makes contact with needle
bearing ID.

11. See

Figure 3-102

. Turn hex nut clockwise until bearing is

free. If necessary, hold flat on collet to prevent rotation.

12. Remove four thumb screws and pull support plate from

crankcase.

13. Holding flat on collet, turn hex at end of shaft counterclock-

wise to close collet. Remove and discard needle bearing.

14. Repeat procedure to remove second needle bearing.

sm02518

Figure 3-104. Bearing Removal

Installation

Obtain

the

CAMSHAFT

NEEDLE

BEARING

REMOVER/INSTALLER (Part No. HD-42325-A).

NOTE

To avoid engine damage, care must be taken to install needle
bearings to the correct depth. The correct depth is achieved
only when the edge of the needle bearing is 3.10 in. (78.7 mm)
from the cam cover flange.

HOME

2011 Touring Service: Engine 3-81

See

Figure 3-105

. Using a dial caliper, measure thickness

of support plate.

Determine the required distance from the top of the support
plate to the edge of the installed needle bearing by adding
support place thickness to 3.10 in. (78.7 mm).

NOTE

For example, if the support plate is 0.50 in. (12.7 mm) thick,
then the measurement from the top of the support plate to the
edge of the needle bearing should be 3.60 in. (91.4 mm).

See

Figure 3-103

. Sparingly apply clean engine oil to

threads of installer forcing screw (4) to prolong service life
and verify smooth operation.

Thread installer forcing screw into stamped side of support
plate (2) until threads begin to emerge from opposite side.

Place installer (6) at end of installer forcing screw.

Place

new

needle bearing on installer with lettered side

facing shoulder of installer.

See

Figure 3-106

. Aligning two large holes in support plate

with needle bearing bores, hang right side of plate on ring
dowel in crankcase flange.

Install thumb screws to secure support plate to crankcase.

sm03818

Figure 3-105. Measure Thickness of Support Plate

sm02519

Figure 3-106. Installer Forcing Screw Installation

10. Install first needle bearing as follows:

See

Figure 3-107

. Turn forcing screw clockwise to

press needle bearing into bore.

Back out forcing screw and remove installer. Remove
forcing screw from support plate.

See

Figure 3-108

. Insert dial caliper through forcing

screw bore and measure distance from top of support
plate to edge of needle bearing.

Repeat steps until bearing is at correct installed depth.
Temporarily leave tool in this position.

11. See

Figure 3-109

. Once the bearing is at correct depth,

measure from head (top) of installer forcing screw to sup-
port plate. Record this measurement.

12. Remove forcing screw from support plate and install over

second needle bearing bore. Place installer at end of for-
cing screw. Place

new

needle bearing on installer with

lettered side facing shoulder of installer.

13. Turn forcing screw until distance from head (top) of forcing

screw to support plate equals measurement obtained
previously.

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3-82 2011 Touring Service: Engine

sm02520

Figure 3-107. Bearing Installation

sm03843

Figure 3-108. Measure from Top of Support Plate to Edge

of Needle Bearing

sm03844

Figure 3-109. Measure from Top of Forcing Screw to

Support Plate

CAM SUPPORT PLATE AND COVER
INSTALLATION

TOOL NAME

PART NUMBER

CRANKSHAFT/CAMSHAFT
SPROCKET LOCKING TOOL

HD-47941

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 3-110

. Apply a very thin film of Screamin' Eagle

Assembly Lube (Part No. 94971-09) to

new

O-ring (1) and

install in groove around oil feed hole.

Lubricate cam needle bearings with Screamin' Eagle
Assembly Lube (Part No. 94971-09).

See

Figure 3-111

. Verify that the timing marks on the ends

of the front and rear camshafts are in alignment.

sm02414

1. Oil feed hole O-ring
2. Rear ring dowel
3. O-ring on crankcase post

Figure 3-110. Oil Feed Hole

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2011 Touring Service: Engine 3-83

sm02300

1. Rear camshaft
2. Front camshaft
3. Timing marks

Figure 3-111. Verify Alignment of Timing Marks

Slide cam support plate over crankshaft and onto two ring
dowels in crankcase flange. Use a rubber mallet to fully
seat cam support plate on ring dowels.

NOTE

Cam cover screws are 1/4 x 1-1/4 in. while the cam support
plate, lifter cover and crankshaft position sensor screws are
1/4 x 1 in. The shorter screws are interchangeable. Use care
to keep the two lengths separate to be sure of using the correct
length during assembly.

See

Figure 3-112

. Install cam support plate screws and

tighten to 90-120

in-lbs

(10.2-13.6 Nm) in the sequence

shown.

See

Figure 3-113

. Secure oil pump.

Start four screws to secure oil pump.

NOTE

Rotating the crankshaft while tightening screws will allow
the oil pump to find its natural center. For methods of
crankshaft rotation, see

3.18 TOP END OVERHAUL:

DISASSEMBLY, Rocker Arm Support Plate

While rotating the crankshaft, tighten screws (1 and
2) until snug.

Tighten the screws (3 and 4) until snug.

NOTE

Numbers cast adjacent to the bolt holes indicate the oil
pump torque sequence.

Tighten all four screws to 40-45

in-lbs

(4.5-5.1 Nm)

in sequence shown.

Final tighten all four screws to 90-120

in-lbs

(10.2-

13.6 Nm) in the sequence shown.

With the lettering facing inboard, install rear cam sprocket
spacer onto the rear camshaft.

sm02404

Figure 3-112. Cam Support Plate Torque Sequence

sm02185

Figure 3-113. Oil Pump Torque Sequence

If using the original cam support plate, camshafts, primary
cam sprocket, crank sprocket and flywheel assembly,

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3-84 2011 Touring Service: Engine

move to next step. However, if any of these parts have
been replaced, then proceed as follows:

Install primary cam sprocket without chain using the
long flange bolt with thicker flat washer.

Install crank sprocket without chain using the short
flange bolt and a smaller diameter flat washer from
bulk inventory.

Position the CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL (Part No. HD-47941) between the
crank and primary cam sprockets. Tighten the crank
and primary cam sprocket flange bolts to 15 ft-lbs
(20.3 Nm). Remove the sprocket locking tool.

Rotate engine stand so cam compartment is pointing
upward. Push on crankshaft and rear camshaft to
eliminate endplay.

If engine was not removed from motorcycle, install
compensating sprocket assembly to pull the crank-
shaft to the left side of the engine. Push on crankshaft
and rear camshaft to eliminate endplay.

See

Figure 3-114

. Place a straightedge across the

sprocket faces. Attempt to insert a 0.010 in. (0.254
mm) feeler gauge between the straightedge and the
each sprocket face. If the feeler gauge will not fit at
either location, sprocket offset is within specification.
Remove both sprockets and discard temporary small
washer.

If measurement is not within specification, replace
the rear cam sprocket spacer using

Table 3-45

as a

guide.

Repeat height inspection with the

new

spacer

installed. Remove both sprockets when measurement
is within specification and discard temporary small
washer.

sm02418

Figure 3-114. Check Alignment of Crank and Rear Cam

Sprocket Faces

Table 3-45. Rear Cam Sprocket Spacers

MM.

IN.

PART NO.

2.54

0.100

25729-06

2.79

0.110

25731-06

3.05

0.120

25734-06

3.30

0.130

25736-06

3.56

0.140

25737-06

3.81

0.150

25738-06

See

Figure 3-115

. Apply a light film of Screamin' Eagle

Assembly Lube (Part No. 94971-09) to splines on rear
cam. Install the primary cam chain and sprocket assembly.

Place both cam sprockets (2, 4) in the primary chain
with the timing marks aligned. Verify that the colored
mark placed on the chain link (7) is on the same side
as the timing marks and is visible during installation.

With the timing marks in alignment, start the rear cam
sprocket onto the end of the rear camshaft. Note that
the sprocket has an integral key that must be aligned
with the keyway in the camshaft.

Maintaining the position of the crank sprocket on the
chain, rotate the rear cam sprocket in a clockwise
direction until the flat on the crank sprocket is aligned
with the flat on the crankshaft. Install the crank
sprocket.

10. Rotate the crankshaft clockwise until the timing marks on

the sprockets are aligned and also aligned with alignment
mark (5) on cam support plate.

NOTES

•

If the timing marks are not in alignment, then the sprockets
must be removed and realigned. Misaligned sprockets will
make the engine run erratically.

•

Both crank and rear cam sprocket flange bolts are specially
hardened and the flat washers are of a special diameter.
Use only genuine Harley-Davidson parts when replace-
ment is necessary. If new flange bolts are not available,
thoroughly clean both internal and external threads and
apply a small amount LOCTITE THREADLOCKER 262
(red) before installation. Both sprocket bolts must install
freely by hand. The crankshaft and rear cam sprocket
flange bolts and flat washers are not interchangeable.

11. Apply a film of oil to bottom of both sprocket bolt heads

and washers. Loosely install to secure sprockets.

12. Position the CRANKSHAFT/CAMSHAFT SPROCKET

LOCKING TOOL (Part No. HD-47941) between the crank
and rear cam sprockets to prevent rotation. The handle

HOME

2011 Touring Service: Engine 3-85

of the tool is stamped "Crank" and "Cam" to verify proper
orientation.

Tighten both sprocket bolts (1, 3) to 15 ft-lbs (20.3
Nm).

Loosen both bolts one revolution (360 degrees).

Final tighten the rear cam sprocket bolt (1) to 34 ft-
lbs (46.1 Nm).

Final tighten the crankshaft sprocket bolt (3) to 24 ft-
lbs (32.5 Nm).

Remove the sprocket locking tool.

13. Install primary cam chain tensioner. Tighten fasteners to

90-120

in-lbs

(10.2-13.6 Nm).

14. Apply Screamin' Eagle Assembly Lube (Part No. 94971-

09) to both sprockets.

NOTE

Before installing cam cover, verify cleanliness of blind holes in
the crankcase flange. Tightening a screw with dirt, water or oil
in the hole can cause the casting to crack or break. Damage
to the casting requires replacement of the right crankcase half.

15. See

Figure 3-116

. Install cam cover and

new

cam cover

gasket.

sm02423

1. Rear cam sprocket bolt (large) and flat washer
2. Rear cam sprocket
3. Crank sprocket bolt (small) and flat washer
4. Crank sprocket
5. Alignment mark on support plate
6. Primary chain tensioner
7. Marked link

Figure 3-115. Primary Chain and Sprockets

sm02425

Figure 3-116. Cam Cover Gasket

16. See

Figure 3-117

. Secure cover with socket head screws.

Following the sequence shown, tighten the screws to 90-
120

in-lbs

(10.2-13.6 Nm).

17. Complete motorcycle assembly.

If engine was completely overhauled, see

3.25 TOP

END OVERHAUL: ASSEMBLY

. Perform all steps.

If only cam compartment components were serviced,
install push rod covers, push rods, rocker arm support
plate and breather assembly. See appropriate topics
under

3.25 TOP END OVERHAUL: ASSEMBLY

sm02183

Figure 3-117. Cam Cover Screws

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3-86 2011 Touring Service: Engine

3.27

OIL PUMP

REMOVAL

See

3.18 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.

Support hydraulic lifters from dropping into the cam
compartment using fabricated tool. See

3.26 CAM

COMPARTMENT AND COMPONENTS

Remove cover and cam support plate. See

3.26 CAM

COMPARTMENT AND COMPONENTS

Carefully remove oil pump assembly from crankshaft.

See

Figure 3-118

. Remove and discard O-rings (1, 2).

See

Figure 3-119

. Disassemble and inspect oil pump

components.

sm02408

1. Oil feed hole O-ring
2. O-ring on crankcase post

Figure 3-118. Oil Pump O-rings

sm02187

1. Narrow gerotor set (feed)
2. Separator plate
3. Wave washer
4. Wide gerotor set (scavenge)
5. Oil pump housing
6. Scavenge port O-ring

Figure 3-119. Assembling Oil Pump

CLEANING AND INSPECTION

Clean all parts in a non-volatile cleaning solution or
solvent.

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)

Dry parts using low pressure compressed air. Verify that
all oil passages are clean and open.

Inspect for scoring, gouging or cracking caused by foreign
material.

Inspect for grooves or scratches on the cam support plate.

Check for excessive wear or damage on lobes of outer
and inner gerotor gears.

See

Figure 3-120

. Check gerotor wear.

Mesh pieces of one gerotor set together.

Use a feeler gauge to determine clearance between
tips of lobes on inner and outer gerotors.

Replace gerotors as a set if clearance exceeds 0.004
in. (0.10 mm). Inspect second gerotor set in the same
manner.

HOME

2011 Touring Service: Engine 3-87

Measure and compare thickness of each rotor in both
gerotor sets. Replace the gerotor set if the difference
exceeds 0.001 in. (0.025 mm).

See

Figure 3-121

. Assemble the oil pump. Verify that feed

gerotors stand proud of the oil pump surface 0.015-0.025
in. (0.38-0.64 mm). If measurement is less than 0.015 in.
(0.38 mm), remove feed gerotor set and reassemble using

new

wave washer. Repeat measurement and replace oil

pump body if still not within specification.

sm02521

1. Outer gerotor
2. Inner gerotor
3. Wear limit

Figure 3-120. Measure Gerotor Sets for Wear

INSTALLATION

NOTES

•

O-rings that are missing, distorted, pinched or otherwise
damaged 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.

•

Lubricate parts with Screamin' Eagle Assembly Lube (Part
No. 94971-09) during assembly.

See

Figure 3-121

. Apply a very thin film of Screamin' Eagle

Assembly Lube (Part No. 94971-09) to

new

scavenge port

stub O-ring (6) and install on scavenge port stub of oil
pump housing.

Slide oil pump housing (5) onto crankshaft while fitting O-
ring on scavenge port stub into crankcase bore. Firmly
push on scavenge port stub with thumb to be sure that it
is snug in bore. Inspect O-ring to verify that it is not
pinched or distorted.

Assemble the wide gerotor set (4) and install on the
crankshaft until it bottoms in the oil pump housing.

Install inside separator plate (2) on the crankshaft until it
contacts the wide gerotor set (4). Install wave washer (3)
and outside separator plate (2).

Assemble the narrow gerotor set (1) and install on the
crankshaft until it contacts the outside separator plate (2).

See

Figure 3-122

. Apply a very thin film of Screamin' Eagle

Assembly Lube (Part No. 94971-09) to

new

O-ring (3) for

crankcase post. Install

new

O-ring in groove on crankcase

post.

Complete engine assembly. See

and

sm02187

1. Narrow gerotor set (feed)
2. Separator plate
3. Wave washer
4. Wide gerotor set (scavenge)
5. Oil pump housing
6. Scavenge port O-ring

Figure 3-121. Assembling Oil Pump

HOME

3-88 2011 Touring Service: Engine

3.28

CRANKCASE DISASSEMBLY AND REPAIR

CRANKCASE DISASSEMBLY

Remove oil pump from crankshaft.

NOTE

Do NOT rotate left crankcase half in the engine stand so the
flywheel sprocket shaft is facing up. The flywheel assembly
will fall out of the case.

Rotate crankcase in the engine stand so that the cam
cover flange is facing straight upward.

See

Figure 3-123

. Remove the nine crankcase bolts in

the sequence shown.

NOTE

Never move or lift the crankcase by grasping the cylinder studs.
The crankcase is too heavy to be carried in this manner and
may be dropped.

Separate case halves. Lift right crankcase half off end of
crankshaft.

See

Figure 3-124

. Remove two dowel pins in split line face

of right case half.

Remove flywheel assembly from the crankcase. Inspect
crankshaft/flywheel assembly. See

3.29 FLYWHEEL AND

CONNECTING RODS

sm02186

Figure 3-123. Crankcase Bolt Sequence

sm02296

Figure 3-124. Right Crankcase Forward Dowel Pin (Rear

Dowel Pin Not Shown)

CLEANING AND INSPECTION

Scrape old gasket material from the crankcase flanges.
Old gasket material left on mating surfaces will cause
leaks.

Clean all parts in a non-volatile cleaning solution or
solvent.

Dry parts with moisture free compressed air..

Verify that all oil holes and passageways are clean and
open.

Check ring dowels for looseness, wear or damage.
Replace as necessary.

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

Clean out tapped holes and clean up damaged threads.

Check the top of the crankcase for flatness with a
straightedge and feeler gauge. Replace if warped.

Spray all machined surfaces with clean engine oil.

10. Inspect crankshaft/flywheel assembly. See

3.29 FLY-

WHEEL AND CONNECTING RODS

HOME

3-90 2011 Touring Service: Engine

RIGHT CRANKCASE HALF

TOOL NAME

PART NUMBER

CRANKCASE BEARING
REMOVER/INSTALLER

B-45655

CRANKSHAFT BEARING DRIVER
SHIM

HD-42720-4

REMOVER/INSTALLER SUPPORT
TUBE

HD-42720-5

Main Bearing Removal

NOTE

Do not move or lift the crankcase by grasping the cylinder
studs. The crankcase is too heavy to be carried in this manner
and could be dropped.

See

Figure 3-127

. Remove two main bearing retaining

screws (5) from the cam compartment side.

See

Figure 3-125

. Obtain CRANKCASE BEARING

REMOVER/INSTALLER

(Part

No.

B-45655)

and

REMOVER/INSTALLER SUPPORT TUBE (Part No. HD-
42720-5).

Place support tube (4) on hydraulic press table with the
"A" end up. Note that the sides of the support tube are
stamped to verify proper orientation.

With the cam compartment side facing downward, position
main bearing bore over support tube.

Slide remover/installer (1) through bearing into support
tube.

Center remover/installer under ram (3) of press. Apply
pressure until bearing is free.

Remove crankcase, remover/installer and bearing from
support tube. Discard bearing.

sm02301a

1. Crankcase bearing remover/installer
2. Support tube
3. Ram
4. Support tube "A" end up

Figure 3-125. Right Main Bearing Removal

Main Bearing Installation

See

Figure 3-126

. Obtain CRANKCASE BEARING

REMOVER/INSTALLER (Part No. B-45655), CRANK-
SHAFT BEARING DRIVER SHIM (Part No. HD-42720-4)
and REMOVER/INSTALLER SUPPORT TUBE (Part
No. HD-42720-5).

Spread a thin film of clean engine oil on O.D. of

new

bearing (4).

Place support tube (2) on press table so that the "B" end
is up. The ends of the support tube are stamped "A" and
"B" to verify proper orientation.

Place CRANKSHAFT BEARING DRIVER SHIM (Part
No. HD-42720-4) on support tube (2).

With the cam compartment side facing upward, position
main bearing bore over support tube.

Start the

new

bearing in bearing bore with the lettering

facing into the cam compartment (up).

Slide remover/installer (1) through bearing into support
tube.

Center remover/installer under ram (3) of press. Apply
pressure until resistance is felt and bearing is bottomed
on the support tube.

HOME

2011 Touring Service: Engine 3-91

Harley Davidson 2011 Touring Models. Service Manual - page 34