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Harley Davidson 2005 touring models. Service repair manual - page 15

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6.

Using Magnaflux Dye Penetrant, inspect the piston for

PISTON

surface cracks. Pay special attention to the area around

the pin bores, ring lands and oil drain holes beneath the

piston crown. If no cracks are found, thoroughly wash

Removal

piston to remove traces of dye.

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11 and 15-29.

Inspection

1.

Lightly oil a good piston pin and insert it into the piston

pin bore to feel for the proper interference fit. The pin

Disassembly

should slide in and out without binding, but also without

pivoting or rocking. Replace piston and/or pin if clear-

Piston Rings, Removal

ance exceeds 0.0008 in. (0.020 mm).

2.

Carefully inspect the pistons for damage or excessive

1WARNING

wear. Discard pistons with cracked, broken or bent ring

lands. Check the piston skirt for cracks, gouges, deep

Always wear proper eye protection when removing the

scratches or heavy scoring. Check the piston heads for

compression rings. Slippage may propel the ring with

evidence of burning, etching or melting. Look for marks

enough force to cause eye injury.

or imprints caused by contact with valves. Pistons with

superficial wear marks, minor scratching or mild scoring

1. Carefully remove first and second compression rings

may continue to be used.

using the proper piston ring expander (Snap-On PRS8).

3.

Run your index finger around the edge of the piston

2. Using your fingers, remove the top and bottom oil rails

crown to feel for dings, nicks or burrs. Lightly file the

from the third ring groove. Remove the expander spring.

edge of the crown to remove any defects.

3. Discard the piston rings.

CAUTION

Cleaning and Inspection

Worn ring grooves result in high oil consumption and

blow-by of exhaust gases. Blow-by of exhaust gases

Cleaning

contaminates the engine oil supply with acids and

leaves sludge in the crankcase. It also reduces engine

CAUTION

efficiency by weakening the combustion seal necessary

for efficient transfer of energy to the piston.

Do not sand blast or glass bead blast pistons. Bead

blasting rounds off ring lands and will result in oil con-

4.

Measure the piston ring side clearance as follows:

tamination leading to accelerated wear.

a. Insert the edge of a new ring into the piston ring

groove. Insert a feeler gauge between the upper

1. To remove all carbon and combustion deposits, soak the

surface of the ring and the ring land. See Figure 3-

pistons in a special detergent that will not corrode alumi-

87.

num. Maintain the temperature of the cleaning solution

well below 212^o F. (100^o C.).

2. Thoroughly rinse the pistons and dry with moisture free

6906

compressed air.

3. Clean the oil drain holes leading from the oil control ring

groove to the underside of the piston crown. Run a small

bristle brush through the passageways to ensure their

cleanliness, but be careful not to damage or enlarge the

holes. Do not use a wire brush.

4. Verify that all other oil holes are clean and open.

CAUTION

Exercise care to avoid scratching the sides of the piston

ring grooves.

5. Thoroughly clean the three piston ring grooves of all car-

bon deposits. A broken compression ring properly

ground to a sharp chisel-like edge may be used for this

purpose.

Figure 3-87. Measure Piston Ring Side Clearance

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NOTE

On late style pistons, the measurement is taken on the bare

aluminum to avoid measuring errors. An oval-shaped open-

EARLY STYLE

ing is present on each side of the piston for proper placement

of the micrometer. See upper frame of Figure 3-89. Since the

FULLY COATED

oval openings are too small for a standard flat anvil microme-

No Bare

ter, which would result in measuring errors, use a 3-4 inch

Aluminum

blade or ball anvil style micrometer, or a 4-5 inch micrometer

with spherical ball anvil adapters. See lower frame of Figure

3-89.

f2114x3x

c. Using a grease pencil, mark the top, middle and

bottom of the piston ring travel zone in the cylinder

bore. Measure at markings in cylinder parallel and

perpendicular to crankshaft.

CAUTION

Do not check piston running clearance immediately after

honing or deglazing cylinder. Since heat will cause mea-

surements to vary by as much as 0.0002 inch (0.005 mm),

both piston and cylinder must be at room temperatures.

d. Replace piston and/or cylinder if running clearance

exceeds 0.003 in. (0.076 mm).

LATE STYLE

f1685x3x

Figure 3-88. Measure Early Style Piston for

Running Clearance

b. Since the grooves wear unevenly, repeat this check

at several locations around the piston groove cir-

cumference.

Bare

Aluminum

c. Discard the piston if the side clearance of either

compression ring exceeds 0.0045 in. (0.11 mm).

Discard the piston if the oil control ring side clear-

ance exceeds 0.010 in. (0.25 mm).

f2113x3x

5.

Measure the running clearance on fully coated early

style pistons as follows:

NOTE

Check the piston clearance in the cylinder in which the piston

4-5 Inch

will run. The torque plates must be installed on the cylinder

Micrometer

and it must be deglazed and suitable for continued service.

a. Holding outside micrometer, measure piston skirt

diameter across the thrust faces (perpendicular to

pin bore). Start below the bottom ring land and

move micrometer towards bottom of skirt. Microme-

ter will be loose, then tight (about 1/2 inch from bot-

tom), and then loose again. See lower frame of

Figure 3-88.

Spherical Ball

b. Measure the piston skirt at the tightest spot and

Anvil Adapters

f2109x3x

then transfer that measurement to the dial bore

gauge.

Figure 3-89. Measure Late Style Piston for

Running Clearance

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NOTE

Ring end gap dimensions also apply to oversize rings.

Replace ring if end gap exceeds specification. If end gap is

under specification, filing is permissible.

3.

Use compressed air to remove any dirt or dust that may

have settled in the oil drain holes and piston ring

grooves.

4.

Install piston rings as follows:

a.

Apply clean H-D 20W50 engine oil to three piston

ring grooves.

b.

Install expander spring into third ring groove. Spiral

bottom oil rail into space below expander spring

positioning the gap 90 degrees from the gap in the

6905

expander spring. Spiral top oil rail into space above

expander spring positioning gap 180 degrees from

the gap in the bottom oil rail.

Figure 3-90. Measure Ring End Gap

Assembly

Piston Rings, Installation

4

3

NOTE

Always use new piston rings. Piston rings take a definite set

and must not be reused if the engine has been operated.

FRONT

Always deglaze (or hone) the cylinder before installing new

rings. Ring sets are available to fit oversize pistons.

1. Before placing each ring on the piston, perform the fol-

lowing check.

CAUTION

2

1

5

Insufficient ring end gap may cause the ends to abut at

engine operating temperatures, resulting in ring break-

2

1

5

age, cylinder scuffing and/or piston seizure.

CAUTION

REAR

Excessive ring end gap results in high oil consumption

and blow-by of exhaust gases. While blow-by contami-

nates the oil supply and leaves sludge in the crankcase,

it also reduces engine efficiency by weakening the com-

bustion seal necessary for efficient transfer of energy to

the piston.

4

3

2. Insert the new ring into the cylinder, square it in the bore

using the top of the piston and measure the ring end gap

with a feeler gauge. See Figure 3-90. Do not use the ring

1.

Expander spring

if the end gap does not fall within the following specifica-

2.

Bottom oil rail

tions.

3.

Top oil rail

f2066x3x

Table 3-8. Ring End Gap

4.

Second compression ring

5.

Top compression ring

Ring Type

Ring End Gap

Top compression ring

0.010 in. (0.25 mm) - 0.020 in. (0.51 mm)

Figure 3-91. Piston Ring Gap Alignment

2nd compression ring

0.014 in. (0.36 mm) - 0.024 in. (0.61 mm)

Oil control ring rails

0.010 in. (0.25 mm) - 0.050 in. (1.27 mm)

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UPPER CONNECTING ROD

Removal

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11 and 15-29.

Disassembly/Assembly

Threaded

NOTE

Cylinders

Service of connecting rods is limited to replacement of the

Part No. HD-95952-1

upper bushing. Damage to connecting rods or lower bushing

service requires replacement of the flywheel assembly.

Figure 3-92. Connecting Rod Clamping Tool

(Part No. HD-95952-33B)

Upper Connecting Rod Bushing

f1597x3x

Removal

Threaded

NOTE

Cylinder

Replace the upper rod bushing if the piston pin to rod bush-

ing clearance exceeds 0.002 inch (0.051 mm).

CAUTION

Place clean shop towels in and around the crankcase

bore to prevent chips and shavings from falling into the

crankcase.

1.

Obtain the CONNECTING ROD CLAMPING TOOL (HD-

95952-33B) and proceed as follows:

a. Slide clamp over connecting rod so that slots

engage cylinder head studs. See Figure 3-93. Exer-

cise caution to avoid scratching or bending studs.

b. With the knurled side up, install threaded cylinders

(HD-95952-1) onto studs to secure position of

Clamp

Thumbscrew

clamp.

c. Alternately turn each clamp thumbscrew a few turns

to gradually fix position of connecting rod. Turning

Figure 3-93. Install Connecting Rod Clamping Tool

only one thumbscrew will move rod off-center, while

tightening second thumbscrew can cause rod to flex

f.

Thread the hex cylinder onto rod until assembly is

or bend.

snug. See upper frame of Figure 3-95.

2.

Obtain the CONNECTING ROD BUSHING REMOVER/

INSTALLER (HD-95970-32D) and proceed as follows:

g. Holding nut at end of threaded rod with a 5/8 inch

box wrench, turn hex cylinder with a 5/8 inch socket

a. Sparingly apply graphite lubricant to threads of rod

until bushing is free.

to prolong service life and ensure smooth operation.

h. Unthread hex cylinder from rod. Remove flat

b. Slide receiver cup (HD-95984-99) onto threaded rod

washer, Nice bearing and driver. Remove threaded

with the closed side facing hex nut.

rod from bushing bore.

c. Insert threaded rod through upper rod bushing.

i.

Remove bushing from receiver cup and discard.

d. Slide remover side of driver (HD-95986-99) down

threaded rod. The driver is stamped to ensure

Installation

proper orientation.

e. Slide Nice bearing and flat washer down threaded

1.

Obtain the CONNECTING ROD BUSHING REMOVER/

rod until it contacts driver.

INSTALLER (HD-95970-32D) and proceed as follows:

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Receiver

Driver

Driver

Cup

Part No. HD-95986-99

Nice

Remover Side

Bearing

Hex

Cylinder

Receiver Cup

Part No. HD-95984-99

Figure 3-94. Connecting Rod Bushing Remover/Installer

Flat

(Part No. HD-95970-32D)

Washer

a.

Slide receiver cup (HD-95984-99) onto threaded rod

Connecting

Rod

Threaded

with the closed side facing hex nut.

Rod

b.

Insert threaded rod through upper rod bushing bore.

Remover Stackup

c.

Slide new bushing down threaded rod. Start bush-

f1601x3x

ing into bore. Verify that center of slot in bushing is

f1602x3x

aligned with oil hole at top of rod. Also, be sure that

Upper Rod

bushing is square in bore and not cocked. See cen-

Bushing

ter frame of Figure 3-95.

Oil Hole

Driver

d.

Slide installer side of driver (HD-95986-99) down

Installer Side

threaded rod until shoulder contacts bushing. The

driver is stamped to ensure proper orientation.

e.

Slide Nice bearing and flat washer down threaded

rod until it contacts driver.

f.

Thread the hex cylinder onto rod until assembly is

snug.

g.

Holding nut at end of threaded rod with a 5/8 inch

box wrench, turn hex cylinder with a 5/8 inch socket

until collar on driver bottoms against connecting

rod. See lower frame of Figure 3-95.

Slot

h.

Unthread hex cylinder from rod and remove flat

Installer Stackup

washer, Nice bearing and driver. Remove threaded

rod from bushing bore, but exercise caution to avoid

scratching or gouging bushing.

f1598x3x

Reaming Upper Rod Bushing

1. Obtain the CONNECTING ROD BUSHING REAMER

(HD-42318) and REAMER HANDLE/DRIVE SOCKET

(HD-43645). Proceed as follows:

a. Carefully insert bit of reamer into upper connecting

rod bushing. Do not apply lubricant to reamer or

bushing. Ream the bushing dry or cut will not be

accurate.

b. Install handle/drive socket on reamer lug. See Fig-

ure 3-97.

c. Placing thumb on drive socket, apply slight pressure

on reamer while rotating handle/drive socket in a

clockwise direction.

Hold hex nut on threaded rod with 5/8 inch box.

Turn cylinder hex with 5/8 inch socket.

Figure 3-95. Remove/Install Connecting Rod Bushing

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2.

Using contact cleaner or cleaning solvent, thoroughly

wipe upper connecting rod and bushing of any metal

Handle/Drive Socket

shavings or debris.

Honing Upper Rod Bushing

Reamer

1. Obtain the CONNECTING ROD BUSHING HONE (HD-

42569) and REAMER LUBRICANT (HD-39964). Pro-

ceed as follows:

a. Install hone in a high speed electric drill.

b. Apply reamer lubricant to finishing stones of hone

Figure 3-96. Connecting Rod Bushing Reamer (Part No.

and inside of upper connecting rod bushing.

HD-42318) and Handle/Drive Socket (Part No. HD-43645)

c. Start finishing stones of hone into bushing.

d. Activating the drill, move the entire length of the fin-

f1642x3x

ishing stone arrangement forward and backward

through the bushing bore for 10 to 12 complete

strokes. See Figure 3-99. Work for a crosshatch

pattern of approximately 60˚.

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

Figure 3-97. Ream Connecting Rod Bushing

CAUTION

For best results, do not push on reamer or apply pres-

Figure 3-98. Connecting Rod Bushing Hone

sure to the reamer handle. While excessive pressure

(Part No. HD-42569)

results in a rough cut, bushing bore will be tapered if

pressure is not centrally applied.

f1643x3x

d. Continue rotating handle/drive socket until entire bit

has passed through bushing and shank of reamer

rotates freely in the bore.

CAUTION

Never back reamer out of connecting rod or bushing will

be damaged.

e. Remove handle/drive socket, and carefully pulling

on bit, draw shaft of reamer out of connecting rod

bushing.

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

Figure 3-99. Hone Connecting Rod Bushing

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Legend:

1.

T20 TORX Screw

17.

Roll Pin

2.

Cam Position Sensor Cover

18.

Oil Pressure Relief Valve Piston

3.

Screw

19.

Valve Spring

4.

Cam Cover

20.

Chain Guide

5.

Cam Cover Gasket

21.

Screw

6.

Primary Cam Chain

22.

Cam Support Plate

47

7.

Flange Bolt

23.

Secondary Cam Chain Tensioner

8.

Flat Washer

24.

Retaining Ring

9.

Primary Cam Sprocket

25.

O-Ring

10.

Spacer

26.

Cleaning Plug

11.

Retaining Ring

27.

Retaining Ring

12.

Primary Cam Chain Tensioner

46

13.

Flange Bolt

14.

Flat Washer

15.

Crank Sprocket

16.

Crankshaft Bushing

35

45

33

43

36

41

34

44

30

32

40

38

42

28

39

39

27

31

37

29

28.

Rear Cam (Roller) Bearing

29.

Front Cam (Ball) Bearing

30.

Bearing Retainer Plate

26

31.

T20 TORX Screw

32.

Secondary Cam Chain

33.

Roller Bearing Inner Race

34.

Thrust Washer

25

23

35.

O-Ring

24

36.

Rear Camshaft

37.

Front Camshaft

38.

Feed Gerotor Set

39.

Separator Plate

40.

Wave Washer

20

41.

Scavenge Gerotor Set

42.

O-Ring

43.

Oil Pump Housing

44.

O-Ring (Scavenge Port Stub)

19

45.

O-Ring (Oil Feed Hole)

18

22

46.

O-Ring (Blind Hole)

47.

Right Crankcase Half

4

5

8

7

10

21

17

11

12

9

13

16

2

15

14

6

1

3

f2143x3x

Figure 3-100. Cam Support Plate/Oil Pump Assemblies (Exploded View)

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2. Center support tube under ram of arbor press.

BOTTOM END

3. Center crankshaft bushing in cam support plate over

support tube. Be sure that the primary cam chain side of

the cam support plate is facing upward.

CAM SUPPORT PLATE

CAUTION

Removal

If the crankshaft bushing is pressed out the primary cam

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

chain side, the bore will be damaged by the knurled edge

BLY, steps 1-11.

of the bushing. Damage to the bore requires replace-

ment of the cam support plate.

NOTE

When removing the cam support plate, it is not necessary to

4. Insert remover side of driver into crankshaft bore so that

disturb the lifter assemblies if a method is devised to prevent

shoulder on tool is seated on edge of bushing. See

the hydraulic lifters from dropping into the cam compartment.

upper frame of Figure 3-103.

One such method is provided in the following step. Leaving

5. Press on driver until collar of tool contacts cam support

the lifter assemblies intact simplifies the procedure, since the

plate. Remove bushing from support tube and discard.

lifter cover, gasket, anti-rotation pin and hydraulic lifters can

be left in place.

Installation

2. Fashion lifter holding tool as follows:

1.

Obtain the CRANKSHAFT BUSHING REMOVER/

a. Obtain a large binder clip (available at any office

INSTALLER (HD-42315).

supply store). Squeeze wireforms to remove from

2.

Center support tube under ram of arbor press.

binder clip. See upper frame of Figure 3-101.

b. Compress wireform slightly and insert free ends into

outer and inner lifter cover bores so that legs

engage walls of both hydraulic lifter sockets. See

f1596x3x

lower frame of Figure 3-101.

Binder Clip

3. See Section 3.10 BOTTOM END OVERHAUL, DISAS-

SEMBLY, steps 1-14.

Wireform

Disassembly/Assembly

1CAUTION

Do not pull the retention pins from the primary or sec-

ondary cam chain tensioners with the chains and

sprockets removed. With 35-40 pounds of spring pres-

sure behind the tensioner, allowing it to accelerate

through its full length of travel will cause spring stretch-

f1595x3x

ing and/or cracking of the tensioner shoe, damage which

requires replacement of the assembly. Furthermore, if

the tensioner should contact fingers or other parts of the

Wireform

hand, minor or moderate injury may occur.

NOTE

If the retention pins interfere with cleaning or service proce-

dures, hold the retracted cam chain tensioner with the CAM

CHAIN TENSIONER UNLOADER (HD-42313), pull the

retention pin and ease the assembly into the unloaded posi-

tion.

Crankshaft Bushing

Removal

1. Obtain the CRANKSHAFT BUSHING REMOVER/

INSTALLER (HD-42315).

Figure 3-101. Fashion Tool to Hold Hydraulic Lifters

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f1599x3x

Ram

Driver

Remover

Installer

Remover Side

Side

Side

Down

Support

Tube

Driver

Figure 3-102. Crankshaft Bushing Remover/Installer

(Part No. HD-42315)

Support

Tube

REMOVE

3.

Turn cam support plate over so that secondary cam

CRANKSHAFT

chain side is facing upward.

BUSHING

4.

Start new bushing into bore with the knurled edge top-

side. Be sure that hole in bushing is aligned with oil hole

in bushing bore.

Crankshaft

f1600x3x

Driver

Bushing

Installer Side

Knurled Side Up

Down

CAUTION

If the crankshaft bushing is pressed in from the primary

cam chain side, or from the secondary cam chain side

with the knurled edge of the bushing down, the bushing

bore will be damaged. Damage to the bore requires

replacement of the cam support plate.

5.

Center crankshaft bushing bore over support tube.

6.

Insert installer side of driver into bushing. See lower

frame of Figure 3-103.

Ensure Oil

Hole Alignment

7. Press on driver until collar of tool makes firm contact

with cam support plate.

INSTALL

8. Ream the crankshaft bushing following the directions

CRANKSHAFT

below.

BUSHING

Figure 3-103. Remove/Install Crankshaft Bushing

Reaming Crankshaft Bushing

in Cam Support Plate

NOTE

A new crankshaft bushing must be reamed for proper size

a. From flywheel compartment side, carefully insert

and alignment. If crankcase halves are not split, ream the

tapered end of reamer pilot into crankshaft bearing

bushing using a spare right case half to avoid further engine

until it stops. See left frame of Figure 3-105.

disassembly.

b. Slide reamer through pilot starting bit into crank-

1. Slide cam support plate onto two ring dowels in crank-

shaft bushing in cam support plate. Do not apply

case flange.

lubricant to reamer or bushing. Ream the bushing

dry or cut will not be accurate.

2. Install six allen head socket screws (1/4 x 1 inch) to

secure cam support plate to crankcase flange. Alter-

c. Install handle/drive socket on reamer lug. See right

nately tighten screws until snug.

frame of Figure 3-105.

3. Obtain the CRANKSHAFT BUSHING REAMER (HD-

d. Placing thumb on drive socket, apply slight pressure

42316) and REAMER HANDLE/DRIVE SOCKET (HD-

on reamer while rotating handle/drive socket in a

43645). Proceed as follows:

clockwise direction.

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f.

Remove handle/drive socket, and carefully pulling

on bit, draw shaft of reamer out of bushing on cam

Handle/Drive Socket

side of crankcase.

g. Remove pilot from crankshaft bearing. Tap on pilot

using a soft rubber mallet, if necessary.

Pilot

4.

Remove the allen head socket screws to release the

cam support plate from the crankcase flange.

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passages possibly resulting in engine failure.

Reamer

5. Using a small screwdriver, carefully pry cleaning plug

from top of cam support plate. Thoroughly flush right

Figure 3-104. Crankshaft Bushing Reamer (Part No. HD-

crankcase half and cam support plate in cleaning sol-

42316) and Handle/Drive Socket (Part No. HD-43645)

vent to remove any metal shavings or debris. Blow dry

with compressed air. Install cleaning plug in cam support

plate replacing O-ring if torn or damaged.

CAUTION

For best results, do not push on reamer or apply pres-

Camshafts/Camshaft Bearings

sure to the reamer handle. While excessive pressure

Removal

results in a rough cut, bushing bore will be tapered if

pressure is not centrally applied.

1.

Place cup of CAM CHAIN TENSIONER UNLOADER

(HD-42313) over spring coil of secondary cam chain ten-

e. Continue rotating handle/drive socket until entire bit

sioner positioning finger on tool between tensioner and

has passed through bushing and shank of reamer

shoe. See Figure 3-106. Rotate tool in a counterclock-

rotates freely in the bore.

wise direction inserting retention pin through hole in

boss on primary cam chain side of cam support plate.

Pin engages hooks on tensioner to hold it in the

CAUTION

retracted position. For best results, place cam support

Never back reamer out flywheel side of crankcase or

plate in a vise using brass jaw inserts to prevent casting

crankshaft bushing will be damaged.

damage.

Install pilot and reamer from flywheel side of case.

Install handle/drive socket on reamer.

Right Crankcase

Handle/

Reamer

Half

Drive Socket

Crankshaft

Bearing

Pilot

f1619x3x

f1611x3x

Figure 3-105. Ream Crankshaft Bushing

2005 Touring: Engine

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Press out camshafts (with bearings).

Finger

Ram

Camshaft

Driver

Tensioner

Unloader

Shoe

Retention

Pin

f1637x3x

Parallel

Figure 3-106. Retract Secondary Cam Chain Tensioner

Blocks

f1623x3x

1WARNING

Remove bearing from front camshaft.

Always wear proper eye protection when removing re-

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

Forcing

worn. Slippage may propel the ring with enough force to

Screw

cause eye injury.

3/8-16 Inch

2. Remove retaining ring from groove at end of front cam-

Bolt

shaft. Discard retaining ring.

with Flat Washer

3. Remove four T20 TORX screws to free bearing retainer

plate from inboard side of cam support plate.

Bridge

4. 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 of

Hardened

chain.

Plug

Bearing

5. With the primary cam chain side facing upward, place

cam support plate on parallel blocks under ram of arbor

press.

6. Obtain the CAMSHAFT/CAMSHAFT BEARING RE-

MOVER/INSTALLER (HD-43644). See Figure 3-107.

Wedge

Attachment

Support Block

Front

Camshaft

f1611x3x

Figure 3-108. Remove Camshafts/Front Cam Bearing

CAUTION

Camshaft Driver

Bearing Pilot/Driver

Since the bearing fit to the camshafts is tighter than its

fit in the support plate, any attempt to remove the cam-

Figure 3-107. Camshaft/Camshaft Bearing

shafts without the bearings will result in damage to the

Remover/Installer (Part No. HD-43644)

cam support plate and bearing retainer plate, if installed.

3-90

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f1806x3x

Pull Bearing Inner Race and Thrust Washer

A

From Rear Cam. Remove O-Ring if Present.

Thrust

Washer

Inner

Shop

Race

Rag

Box Wrench

5/8 Inch

NOTE

Although the vane has been eliminated

from the cam sprocket on production

motorcycles, the service part retains the

vane to retrofit earlier models having a

camshaft position sensor.

Box Wrench

Inner

9/16 Inch

Race

Shop

Thrust

Rag

Washer

Install O-Ring and Thrust Washer.

B

Press Bearing Inner Race Onto Rear Cam.

f1807x3x

Figure 3-109. Remove/Install Bearing Inner Race (With O-Ring and Thrust Washer) Onto Rear Camshaft

CAUTION

camshafts (with attached bearings) from the cam sup-

port plate. See upper frame of Figure 3-108.

Cam bearings may be a loose fit in the cam support

plate. To avoid possible damage, be aware that camshaft

8.

Remove secondary cam chain from cam sprockets.

and bearing assemblies may drop out at start of press

9.

If reusing front camshaft, remove bearing as follows:

procedure.

7. Fit cups of camshaft driver over ends of front and rear

a. Position WEDGE ATTACHMENT (HD-95637-46A)

camshafts, so that contact is made with the bearing

on inboard side of front camshaft bearing and turn

inner races. Centering driver under ram at a point mid-

hex nuts an equal number of turns to draw halves of

way between the camshafts, simultaneously press both

wedge together.

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b. Obtain two 3/8-16 inch bolts 3-1/2 inches long (with

flat washers). Install flat washers on bolts. Obtain

O-Ring

Thrust Washer

bridge, forcing screw and hardened plug from

MAINSHAFT BEARING INNER RACE PULLER/

INSTALLER (HD-34902B).

c. Slide one bolt into channel on each side of bridge

so that flat washer is between bridge and bolt head.

Thread bolts into wedge attachment an equal num-

ber of turns.

d. Sparingly apply graphite lubricant to threads of forc-

ing screw to prolong service life and ensure smooth

operation. Start forcing screw into center hole of

Bearing Inner Race

bridge.

Roller Bearing

f1805x3x

CAUTION

Figure 3-110. Rear Cam Roller Bearing Kit (P/N 8983)

Failure to use hardened plug may result in damage to

forcing screw and/or camshaft.

2.

Install O-ring, thrust washer and bearing inner race onto

e. Place cupped side of hardened plug against end of

rear camshaft as follows:

camshaft. Thread forcing screw into bridge until the

steel ball at the end of the screw makes firm contact

a. To properly locate thrust washer, first install O-ring

with hardened plug.

in grinding relief groove. Groove is on the splined

end between the machined area and the secondary

f.

Verify that the tool assembly is square so that the

cam sprocket. Exercise caution to avoid stretching

bearing is not cocked during removal. See lower

or breaking the O-ring. Since the O-ring is not sold

frame of Figure 3-108. Turn forcing screw until bear-

separately, damage will require purchase of a new

ing is pulled free of camshaft. Discard bearing.

roller bearing kit.

10.

If reusing rear camshaft, remove roller bearing assembly

as follows:

CAUTION

a. Slide roller bearing from end of rear camshaft.

Since bearing is a loose fit on cam, no pressing

The thrust washer will be offset to one side if the O-ring

tools are required.

is not installed in the grinding relief groove. Damage to

the bearing cage can occur if the thrust washer is not

b. Install tools as you would to remove the bearing

properly centered.

from the front camshaft, but position cup of wedge

inboard of the thrust washer.

b. Slide thrust washer down rear camshaft until cen-

c. Wrap a shop rag around camshaft to get a firm grip

tered over O-ring in grinding relief groove.

and also to protect hand from sharp edges of

c. Slide bearing inner race down rear camshaft until

sprocket.

contact is made with shoulder of machined area.

d. Using a 5/8 inch box wrench, turn forcing screw until

d. Install primary cam sprocket spacer and sprocket

bearing inner race and thrust washer are pulled free

on camshaft and secure using thicker flat washer

of camshaft. See A of Figure 3-109. A light interfer-

and long flange bolt.

ence fit allows the parts to be removed with little

effort. Discard inner race and thrust washer.

NOTE

e. If present, remove O-ring from grinding relief groove

If not enough of the splined shaft is exposed to install the

in camshaft. Groove is on the splined end between

sprocket, leave out the spacer and proceed to step 2(e).

the machined area and the secondary cam

Once the bearing inner race has been started onto the

sprocket. Discard O-ring.

machined area, remove the flange bolt, washer and sprocket,

and then reassemble using the spacer. Repeat step 2(e) to

NOTE

fully install bearing inner race.

Since the O-ring is not used in production, it will only be

found if the cams were serviced at the dealer level.

e. Wrap a shop rag around camshaft to get a firm grip

and also to protect hand from sharp edges of

sprocket. Using a 9/16 inch box wrench, turn flange

Installation

bolt in a clockwise direction. Bearing inner race is

1.

Obtain new rear cam roller bearing kit (Part No. 8983).

fully installed when it makes firm contact with the

See Figure 3-110.

thrust washer. See B of Figure 3-109.

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7.

Apply a small dab of Loctite Medium Strength Thread-

locker 243 (blue) to threads of four bearing retainer plate

Roller Bearing

Ball Bearing

Rear Cam

Front Cam

screws. Using a T20 TORX drive head, secure bearing

retainer plate to cam support plate. Tighten screws to

20-30 in-lbs (2.3-3.4 Nm) in a crosswise pattern. Verify

that hole in retainer plate is properly aligned with sec-

ondary cam chain oiler.

8.

Place cam support plate back on support block, if

removed. Block properly supports inner races of bear-

ings as camshafts are installed.

9.

Align pin stamped timing lines on teeth of secondary

cam sprockets

(outboard faces). See Figure

3-112.

f1804x3x

Using a colored marker, carefully mark the timing line

locations on the inboard side of the sprocket teeth.

Figure 3-111. Cam Bearings

These marks are needed to observe proper orientation

of the camshafts when they are pressed into the bear-

f.

Verify that the thrust washer is locked in place and

ings.

cannot be rotated. If necessary, install shaft in vise

using brass jaw inserts, and further tighten flange

10.

Place the secondary cam chain around the sprockets of

bolt until the desired result is achieved.

both the front and rear camshafts. To maintain the origi-

nal direction of rotation, be sure that the colored mark

g. Remove flange bolt, flat washer, sprocket and

placed on the chain link during disassembly is facing

spacer.

opposite the cam support plate during installation.

CAUTION

11.

Orient the camshafts so that they are positioned on

opposite ends of the chain, and then verify that the col-

Always install new bearings. Only use genuine Harley-

ored marks placed on the inboard side of the sprocket

Davidson bearings. Reusing old bearings or using bear-

teeth are still in alignment.

ings from a supplier other than Harley-Davidson will

result in engine damage.

12.

Maintaining the position of the camshafts on the chain

with the colored marks in alignment, place the sprocket

3. Obtain the CAMSHAFT/CAMSHAFT BEARING RE-

ends of the camshafts into the bearings.

MOVER/INSTALLER (HD-43644).

4. With the secondary cam chain side facing upward, place

cam support plate on support block, so that outer races

of bearings are properly supported. Note that one corner

Front

of the support block is contoured to accommodate the

Camshaft

chain guide blocks cast into the front of the support

Rear

plate.

Camshaft

5. Center new bearing over bearing bore with the lettered

side up. Slide pilot shaft of bearing driver through

bearing into hole of support block.

NOTE

Be aware that the front and rear cam bearings are not inter-

changeable. The rear bearing is the roller type, while the front

is the ball bearing kind. See Figure 3-111.

6. Center bearing driver under ram of arbor press. Press

on driver until bearing makes firm contact with counter-

bore in cam support plate. See upper frame of Figure 3-

113. Repeat steps to install second bearing.

NOTE

Pin Stamped

Timing Lines

f2067x3x

Bearings may be a press to loose fit. If deemed necessary,

clean bearing OD and apply Loctite Low Strength Thread-

Figure 3-112. Align Timing Lines on Teeth

locker 243 (Blue) before installation, but exercise caution to

of Camshaft Sprockets

avoid getting compound on rollers or bearing ID.

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NOTE

Press bearings into cam support plate.

Do not mix camshafts during the press procedure. The rear

Bearing

camshaft, which can be identified by the splined shaft, must

Pilot/Driver

go into the roller bearing at the rear of the cam support plate.

Bearing

13. Place cup of camshaft driver over end of front camshaft

only.

Support

CAUTION

Block

Verify that splined end of rear camshaft has been started

into support block. Damage to the camshaft and/or sup-

port block can occur if end of camshaft catches top of

block during the press procedure.

NOTE

f1618x3x

To reduce the likelihood of such contact occuring, use 7/8

Center front camshaft under ram. Start front cam-

inch drill bit to enlarge rear cam bore in support block. For

shaft into cam bearing.

best results, radius top inside edge of bore after drilling.

Ram

Camshaft

CAUTION

Driver

Be sure that the tensioner shoe is clear of the secondary

cam chain during the press procedure. Contact can

result in damage that requires replacement of the ten-

Front

Support

Camshaft

sioner assembly.

Block

14. Center end of front camshaft under ram and slowly apply

pressure to driver just to start front camshaft into bear-

ing ID. See center frame of Figure 3-113.

CAUTION

If rear camshaft is not properly aligned, edge of installed

f1822x3x

inner race can catch on bearing rollers. Bearing damage

can result if contact occurs during the press procedure.

While applying pressure to front camshaft, wiggle

rear camshaft to guide inner race between bearing

15. Slowly apply pressure to driver on front camshaft, while

rollers.

wiggling rear camshaft as necessary to guide inner race

between bearing rollers. See lower frame of Figure 3-

Rear

113.

Camshaft

16. When inner race on rear cam is started into roller bear-

ing, apply pressure to driver until front camshaft is fully

seated. If necessary, keep finger pressure at top of rear

camshaft to ensure that assembly remains square and

inner race moves to installed position in roller bearing.

17. Since the pin stamped timing lines on the secondary

sprockets cannot be observed once the camshafts are

pressed into the bearings, note that the outboard ends of

the shafts have a second set of timing lines (although

they may be somewhat difficult to see). Using a straight-

edge, verify that these timing lines are in alignment. See

Figure 3-114. If they are not, then the camshafts must be

removed and reinstalled (with a new bearing set).

f1821x3x

Figure 3-113. Install Cam Bearings/Camshafts

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Cam Chain Tensioners

Rear

Front

Camshaft

Camshaft

Removal

1CAUTION

Do not pull the retention pins from the primary or sec-

ondary cam chain tensioners with the chains and

sprockets removed. With 35-40 pounds of spring pres-

sure behind the tensioner, allowing it to accelerate

through its full length of travel will cause spring stretch-

ing and/or cracking of the tensioner shoe, damage which

requires replacement of the assembly. Furthermore, if

the tensioner should contact fingers or other parts of the

hand, minor or moderate injury may occur.

1. If retracted, hold the cam chain tensioner with the CAM

CHAIN TENSIONER UNLOADER (HD-42313), pull the

retention pin and ease the assembly into the unloaded

position.

Pin Stamped

f2068x3x

Timing Lines

1WARNING

Figure 3-114. Verify Alignment of Timing Lines

Always wear proper eye protection when removing re-

on Ends of Camshafts

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

cause eye injury.

1WARNING

2.

Remove retaining ring from groove in tensioner post.

Discard retaining ring.

Always wear proper eye protection when installing re-

taining rings. Use the correct retaining ring pliers. Verify

3.

Slide cam chain tensioner assembly from post disengag-

that the tips of the pliers are not damaged or excessively

ing spring pin from hole in cam support plate.

worn. Slippage may propel the ring with enough force to

cause eye injury.

Installation

18. With the sharp edge out, install new retaining ring in

1.

Slide cam chain tensioner assembly onto post inserting

groove at end of front camshaft.

spring pin into hole in cam support plate.

f1676x3x

Acceptable Wear

Unacceptable Wear

Unacceptable Wear

Continue use of the tensioner shoe

Replace the tensioner shoe assembly

Replace the tensioner shoe assembly

assembly (and chain) if worn to a depth

(and chain) if worn to a depth that is

(and chain) if there is any evidence of

that is less than half the thickness of the

equal to or greater than half the thick-

melting, burning or cracking.

shoe material.

ness of the shoe material.

Figure 3-115. Cam Chain Tensioner Shoe Wear

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