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Harley Davidson 2005 touring models. Service repair manual - page 16

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3. Slide spring into bypass port until seated in open side of

piston.

4. Start new roll pin into hole in cam support plate. Com-

press spring using the blade of a small screwdriver.

5. Holding spring compressed, tap roll pin into cam support

plate until it approaches pin hole on opposite side.

6. Remove screwdriver to release spring. Verify that spring

is straight and square in bore.

7. Using a 1/8 inch punch with a small hammer, carefully

tap roll pin until flush with casting.

6908

8. Install primary cam chain tensioner assembly. See CAM

CHAIN TENSIONERS, INSTALLATION, in this section.

Figure 3-116. Oil Pressure Relief Valve Assembly

Cam Needle Bearings

1WARNING

Removal

Always wear proper eye protection when installing re-

1. Obtain the CAMSHAFT NEEDLE BEARING RE-

taining rings. Use the correct retaining ring pliers. Verify

MOVER/INSTALLER (HD-42325).

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

2. Remove four button fasteners from threaded holes in

support plate, if installed. See Figure 3-117.

cause eye injury.

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

3. Sparingly apply graphite lubricant to threads of collet to

groove of post. Verify that the ring is fully seated in the

prolong service life and ensure smooth operation.

groove.

4. Slide collet through support plate so that threaded end

3. If retracted prior to disassembly, place cup of CAM

exits stamped side of plate.

CHAIN TENSIONER UNLOADER

(HD-42313) over

5. Aligning two large holes in support plate with needle

spring coil of cam chain tensioner assembly. Retract the

bearing bores, hang right side of plate on ring dowel in

tensioner inserting a retention pin through hole in boss

crankcase flange.

on the primary cam chain side of cam support plate.

Oil Pressure Relief Valve

f1303x2x

Graphite

Lubricant

Removal

Button

1. Before removal, see CLEANING AND INSPECTION in

Hex Nut

Fastener (4)

this section.

Nice

2. Remove primary cam chain tensioner assembly. See

Bearing

CAM CHAIN TENSIONERS, REMOVAL.

Support

Plate

3. Secure the cam support plate in a vise with access to

the roll pin. Be sure to install a pair of brass jaw inserts in

the vise to avoid damage to the casting.

Pilot

4. Using a 1/8 inch punch with a small hammer, carefully

tap roll pin from pin hole in cam support plate. Discard

roll pin.

5. Remove spring and piston from bypass port.

Flat

Washer

Installation

Installer

Collet

1.

Secure the cam support plate in a vise. Install a pair of

Shaft

Collet

Threaded End

Expandable End

brass jaw inserts to avoid damage to the casting.

2.

Lubricate piston with clean H-D 20W50 engine oil. Slide

piston into bypass port with the open side facing out-

Figure 3-117. Camshaft Needle Bearing Remover/Installer

(HD-42325)

ward.

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6.

Align four holes at corners of support plate with threaded

Install support plate with collet.

holes in crankcase flange. Install button fasteners in

Install Nice bearing, flat washer and hex nut.

these holes to secure support plate to crankcase. See

upper frame of Figure 3-118.

Support

Button

7.

Center expandable end of collet in bearing bore and

Plate

Fastener

slide Nice bearing and flat washer on threaded end.

Start hex nut on threaded end.

8.

Push expandable end of collet through bearing bore into

flywheel compartment. Feel for inside edge of needle

Nice

Ring Dowel

bearing using end of collet and then back off slightly.

Bearing

Hole

9.

Holding collet to prevent lateral movement, finger tighten

hex nut until Nice bearing contacts support plate.

10.

Using a 7/16 inch open end wrench, hold flat on collet to

prevent rotation. Using a second 7/16 inch open end

Flat

wrench, expand collet by turning hex at end of shaft in a

Washer

clockwise direction. See center frame of Figure 3-118.

Collet

Expandable end of collet makes contact with needle

Threaded End

bearing ID.

Hex

11.

Using a 15/16 inch open end wrench, turn hex nut in a

Nut

f1586x3x

clockwise direction until bearing is free. If necessary,

hold flat on collet to prevent rotation. See lower frame of

Holding flat, turn hex in a

f1587x3x

Figure 3-118.

clockwise direction to expand collet.

12.

Remove four button fasteners and pull support plate

from crankcase.

13.

Holding flat on collet, turn hex at end of shaft in a coun-

terclockwise direction to close collet. Remove and dis-

card needle bearing.

14.

Remove hex nut, flat washer and Nice bearing from

threaded end of collet. Pull collet from support plate.

15.

Return to step 1 to remove second needle bearing.

Installation

Hex

Flat

1.

Obtain the CAMSHAFT NEEDLE BEARING RE-

MOVER/INSTALLER (HD-42325).

2.

Sparingly apply graphite lubricant to threads of installer

shaft to prolong service life and ensure smooth opera-

tion.

3.

Thread installer shaft into stamped side of support plate

Turn hex nut in a clockwise direction

to remove bearing.

until threads begin to emerge from opposite side.

4.

Install pilot at end of installer shaft.

5.

Place new needle bearing on pilot with lettered side fac-

ing shoulder.

6.

Aligning two large holes in support plate with needle

bearing bores, hang right side of plate on ring dowel in

crankcase flange.

7.

Align four holes at corners of support plate with threaded

holes in crankcase flange. Install button fasteners in

these holes to secure support plate to crankcase. See

upper frame of Figure 3-119.

8.

Using 15/16 inch open end wrench, turn hex at end of

installer shaft in a clockwise direction until resistance is

felt. See lower frame of Figure 3-119.

9.

Turn end of installer shaft in a counterclockwise direction

until pilot is free of needle bearing bore.

f1588x3x

Figure 3-118. Remove Cam Needle Bearing

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a. Measure distance from edge of cam support plate

Install support plate with installer shaft (and pilot).

to inboard side of piston. Insert straight stiff wire into

unplugged hole outboard of roll pin until it bottoms,

Support

and then mark and measure wire. With piston fully

Plate

Button

seated in the bore, depth should be approximately

Fastener

2.25 inches (57.15 mm). If it is not, continue with

step 1(b).

b. Remove oil pressure relief valve. See OIL PRES-

SURE RELIEF VALVE, REMOVAL, in this section.

Ring Dowel

c. Inspect spring for stretching, kinking or distortion.

Hole

d. 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.

e. Install piston in bore and measure running clear-

ance. If running clearance exceeds

0.003 inch

(0.076 mm), install new piston and remeasure.

Replace cam support plate if running clearance still

Installer

exceeds specification.

Shaft

f1589x3x

2.

Clean cam support plate as follows:

Turn hex on installer shaft in a clockwise direction

to install bearing.

a. Using a small screwdriver, carefully pry cleaning

plug from cam support plate. See Figure 3-120.

b. Thoroughly flush cam support plate with a non-vola-

tile cleaning solution or solvent and then blow dry

with low pressure compressed air.

c. Reinstall cleaning plug replacing O-ring if damaged

or deteriorated.

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

CAUTION

Exercise caution to avoid enlarging the oil holes or oil

pressure will be adversely affected.

Installation

f1590x3x

1.

See Section 3.10 BOTTOM END OVERHAUL, ASSEM-

BLY, steps 12-29.

Figure 3-119. Install Cam Needle Bearing

2.

Remove wireforms to release hydraulic lifters.

3.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

steps 29-39.

10.

Remove four button fasteners and pull support plate and

installer shaft from crankcase.

11.

Remove pilot from installer shaft. Unthread installer

shaft from support plate.

12.

Return to step 1 to install second needle bearing.

13.

Thread four button fasteners into threaded holes in sup-

port plate to prevent loss.

Cleaning and Inspection

1.

Inspect oil pressure relief valve as follows:

NOTE

If diagnosing low oil pressure, start with step 1(a). If diagnos-

6891

ing high oil pressure, then begin with step 1(b).

Figure 3-120. Remove Cleaning Plug

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OIL PUMP

Inner Gerotor

Outer Gerotor

Removal

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11.

NOTE

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

disturb the lifter assemblies if a method is devised to prevent

the hydraulic lifters from dropping into the cam compartment.

Wear

One such method is provided in the following step. Leaving

Limit

the lifter assemblies intact simplifies the procedure, since the

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

be left in place.

f1563x3x

2. Fashion lifter holding tool as follows:

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

Figure 3-122. Measure Gerotor Sets for Wear

supply store). Squeeze wireforms to remove from

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

b. Compress wireform slightly and insert free ends into

2.

Thoroughly dry all parts with low pressure compressed

outer and inner lifter cover bores so that legs

air. Verify that all oil passages are clean and open.

engage walls of both hydraulic lifter sockets. See

3.

Look for scoring, gouging or cracking caused by foreign

lower frame of Figure 3-101.

material that may have passed through the oil pump.

3. See Section 3.10 BOTTOM END OVERHAUL, DISAS-

4.

Look for grooves or scratches on the cam support plate,

SEMBLY, steps 1-15.

which serves as the outboard side of the oil pump.

5.

Check for excessive wear or damage on lobes of outer

Cleaning and Inspection

gerotors and between lobes on inner gerotor.

6.

Mesh pieces of one gerotor set together as shown in

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

Figure 3-122. Use a feeler gauge to determine clear-

vent.

ance between tips of lobes on inner and outer gerotors.

The maximum allowable clearance is

0.004 inch

(0.10 mm). Replace gerotor set if clearance exceeds

specification. Inspect second gerotor set in the same

Oil Pump

O-Ring

manner.

Housing

7.

Measure thickness of inner gerotor of one set with a

micrometer. Measure the outer gerotor of the same set.

Wide

Replace the gerotor set if the difference exceeds 0.001

Gerotor Set

inch (0.025 mm). Inspect second gerotor set in the same

(Scavenge)

manner.

Wave

8.

Assemble the oil pump. Verify that feed gerotors stand

Washer

Narrow

proud of the oil pump surface

0.0215-0.0305 inch

Gerotor Set

(0.546-0.775 mm). If measurement is less than 0.0215

(Feed)

inch (0.546 mm), remove feed gerotor set and reassem-

ble using new wave washer. Repeat measurement and

replace oil pump body if still not within specification.

O-Ring

Separator

Plate

Installation

1.

See Section 3.10 BOTTOM END OVERHAUL, ASSEM-

Separator

BLY, steps 11-29.

Plate

f1530b3x

2.

Remove wireforms to release hydraulic lifters.

3.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

Figure 3-121. Oil Pump Assembly

steps 29-39.

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Legend:

f2070x3x

1.

Crankshaft Bearing

2.

Ring Dowel

3.

Cam Needle Bearing

4.

Oil Inlet Fitting

5.

Oil Outlet Fitting

6.

Crankcase Breather Fitting

7.

Right Crankcase Half

8.

O-Ring

9.

Piston Jet

10.

T20 TORX Screw

11.

Lock Ring

12.

Sprocket Shaft Bearing

13.

O-Ring

14.

Ring Dowel

15.

Plug

16.

O-Ring

17.

Oil Filter Mount

18.

Oil Filter Adapter

19.

Flat Washer

20.

Bolt

28

21.

Lockplate

22.

Oil Filter

27

23.

Crankcase Bolt

24.

Ring Dowel

25.

O-Ring

26.

Left Crankcase Half

29

27.

Thrust Washer

28.

Oil Seal

29.

Sprocket Shaft Spacer

26

25

24

6

7

12

11

23

9

10

5

8

4

13

3

14

19

2

20

21

1

18

15

16

22

17

Figure 3-123. Crankcase Assembly (Exploded View)

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CRANKCASE

3

1.

Ram

2.

Pilot/Driver

Removal

3.

Support Tube

1. See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-29.

“A”

End Up

2. See Section 3.10 BOTTOM END OVERHAUL, DISAS-

SEMBLY, steps 1-18.

1

f2126x3x

Disassembly/Assembly

2

RIGHT CRANKCASE HALF

Crankshaft Bearing

Removal

1CAUTION

Never move or lift the crankcase by grasping the cylin-

der studs. The crankcase is too heavy to be carried in

this manner and may be dropped. Dropping the crank-

case may result in parts damage and minor or moderate

injury.

1.

See Figure 3-124. Obtain CRANKSHAFT/SPROCKET

SHAFT BEARING REMOVER/INSTALLER PILOT/

DRIVER

(B-45655) and CRANKSHAFT/SPROCKET

SHAFT BEARING REMOVER/INSTALLER SUPPORT

Figure 3-125. Remove Crankshaft Bearing

TUBE (HD-42720-5).

2.

Place support tube on hydraulic press table with the “A”

4.

Slide pilot/driver through bearing into support tube.

end up. The ends of the support tube are stamped “A”

and “B” to ensure proper orientation.

5.

Center pilot/driver under ram of press. Apply pressure to

3.

With the outboard side of the right crankcase half facing

pilot/driver until bearing is free. See Figure 3-125.

upward, position crankshaft bearing bore over support

6.

Remove right crankcase half, pilot/driver and bearing

tube.

from support tube. Discard bearing.

Support Tube

Installation

Part No. HD-42720-5

1.

See Figure 3-124. Obtain CRANKSHAFT/SPROCKET

SHAFT BEARING REMOVER/INSTALLER PILOT/

DRIVER

(B-45655) and CRANKSHAFT/SPROCKET

SHAFT BEARING REMOVER/INSTALLER SUPPORT

TUBE (HD-42720-5).

2.

Turn support tube over so that the “B” end is up. The

ends of the support tube are stamped “A” and “B” to

ensure proper orientation.

3.

With the outboard side of the right crankcase half facing

Pilot/Driver

upward, position crankshaft bearing bore over support

Part No. B-45655

d0687x3x

tube.

4.

Obtain new crankshaft bearing and apply a thin film of

Figure 3-124. Crankshaft/Sprocket Shaft Bearing

clean engine oil to O.D.

Pilot/Driver and Support Tube

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Installation

3

1. Ram

2. Pilot/Driver

CAUTION

3. Support Tube

4. Crankshaft Bearing

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

“B”

damaged will result in either oil leakage or low oil pres-

End Up

sure. 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

1

use to avoid confusion.

f2127x3x

2

1.

Install new O-ring in groove of jet mounting flange. Apply

a very thin film of clean H-D 20W50 engine oil to O-ring

before installation.

4

2.

Apply Loctite Low Strength Threadlocker 222 (purple) to

threads of two T20 TORX screws.

3.

With the jet pointed upward, install TORX screws to

secure piston jet to crankcase. Tighten screws to 25-35

in-lbs (2.8-4.0 Nm).

LEFT CRANKCASE HALF

Sprocket Shaft Bearing

Removal

Figure 3-126. Install Crankshaft Bearing

1CAUTION

Never move or lift the crankcase by grasping the cylin-

der studs. The crankcase is too heavy to be carried in

5.

Start crankshaft bearing into bore with the lettered side

this manner and may be dropped. Dropping the crank-

up. Lubricate leading edge of bearing before placement.

case may result in parts damage and minor or moderate

6.

Slide pilot/driver through bearing into support tube.

injury.

7.

Center pilot/driver under ram of press. Apply pressure to

pilot/driver until resistance is felt and bearing bottoms in

1WARNING

support tube. See Figure 3-126.

Do NOT rotate left crankcase half in the engine stand so

8.

Remove pilot/driver and right crankcase half from sup-

the stator mount flange (sprocket shaft side) is facing up

port tube.

or the flywheel assembly will drop to the floor. Dropping

the flywheel assembly may result in parts damage and

minor or moderate injury.

1.

Holding flywheel assembly so that it does not drop out of

Piston Jets

left crankcase half, rotate cradle so that engine is upright

and crankshaft and sprocket shaft are horizontal.

Removal

2.

Carefully slide flywheel assembly out of left crankcase

1.

Remove two T20 TORX screws to free piston jet from

half.

crankcase.

3.

Remove left crankcase half from engine stand and move

2.

Remove O-ring from groove in mounting flange of jet.

to bench area. Remove thrust washer from outboard

Discard O-ring.

side of crankcase by pulling it past the oil seal. Set thrust

washer aside for inspection or reuse.

4.

Using a suitable drift, tap oil seal from bearing bore. Dis-

card oil seal.

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f2136x3x

1

f2132x3x

2

1

2

4

3

3

f2129x3x

f2129x3x

1.

Ram

1. Ram

3

2.

Pilot/Driver

3

2. Pilot/Driver

3.

Support Tube (“A” end up)

3. Support Tube (“A” end up)

4.

Sprocket Shaft Bearing

Figure 3-127. Remove Sprocket Shaft Bearing

Figure 3-128. Install Sprocket Shaft Bearing

5.

See Figure 3-124. Obtain CRANKSHAFT/SPROCKET

Installation

SHAFT BEARING REMOVER/INSTALLER SUPPORT

TUBE (HD-42720-5) and CRANKSHAFT/SPROCKET

1CAUTION

SHAFT BEARING REMOVER/INSTALLER PILOT/

DRIVER (B-45655).

Never move or lift the crankcase by grasping the cylin-

der studs. The crankcase is too heavy to be carried in

6.

Place left crankcase half on work bench with inboard

this manner and may be dropped. Dropping the crank-

side of facing upward.

case may result in parts damage and minor or moderate

7.

Using the tip of a flat blade screwdriver, carefully lift end

injury.

of lock ring out of groove in bearing bore. Working the

1.

See Figure 3-124. Obtain CRANKSHAFT/SPROCKET

screwdriver around the edge, lift the lock ring up and out

SHAFT BEARING REMOVER/INSTALLER SUPPORT

of the groove. Be careful not to damage the lip of the

TUBE (HD-42720-5) and CRANKSHAFT/SPROCKET

groove during removal.

SHAFT BEARING REMOVER/INSTALLER PILOT/

8.

Place support tube on hydraulic press table with the “A”

DRIVER (B-45655).

end up. The ends of the support tube are stamped “A”

2.

Place support tube on hydraulic press table with the “A”

and “B” to ensure proper orientation.

end up. The ends of the support tube are stamped “A”

9.

With the outboard side of the left crankcase half facing

and “B” to ensure proper orientation.

upward, position sprocket shaft bearing bore over sup-

3.

With inboard side of the left crankcase half facing

port tube. See Figure 3-127.

upward, position sprocket shaft bearing bore over sup-

port tube.

10.

Slide pilot/driver through bearing into support tube.

4.

See Figure 3-128. Obtain new sprocket shaft bearing

11.

Center pilot/driver under ram of press. Apply pressure to

and apply a thin film of clean engine oil to O.D.

pilot/driver until bearing is free.

5.

Start sprocket shaft bearing into bearing bore with the

12.

Remove left crankcase half, pilot/driver and bearing from

lettered side down. Lubricate leading edge of bearing

support tube. Discard bearing.

before placement.

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6.

Slide pilot/driver through bearing into support tube.

Hold-Down

7.

Center pilot/driver under ram of press. Apply pressure to

Clamp

pilot/driver until bearing lightly bottoms in the bore.

8.

Remove left crankcase half and pilot/driver from support

tube.

9.

Place left crankcase half on work bench with inboard

side of facing upward.

10. Obtain new lock ring and work into groove in bearing

bore. Be careful not to damage the lip of the groove dur-

ing installation. Verify that lock ring is fully seated in the

groove.

Locating Pin

NOTE

If lock ring will not fit into groove, bearing bore may not have

Figure 3-129. Flywheel Fixture (Part No. HD-44358)

been properly cleaned and/or bearing may not be fully

seated in the bore.

f2154x3x

1

Sprocket Shaft Bearing Inner Race

2

Removal

3

1.

If reusing flywheel, remove bearing inner race and thrust

washer as follows:

a. Obtain FLYWHEEL SUPPORT FIXTURE

(HD-

44358). See Figure 3-129. Install brass jaws or

shop towels around teeth of vise to prevent damage

7

4

to tool. Clamp tool in vise with the round hole top-

side.

b. Insert crankshaft end through hole resting flywheel

assembly on fixture. Slide knurled locating pin down

slot in tool to engage crank pin hole. Hand tighten

6

5

locating pin.

c. Slide hold-down clamp down slot to engage inboard

side of right flywheel half, and then hand tighten

knurled nut at bottom to secure. Repeat step to

secure hold-down clamp on opposite side of fly-

wheel.

NOTE

For proper clamping force, hold-down clamp must not be

tilted. Rotate hex on outboard stud until clamp is level.

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

on inboard side of thrust washer and turn hex nuts

an equal number of turns to draw halves of wedge

together.

1.

Forcing Screw

4.

Hardened Plug

2.

3/8-16 Inch Bolt

5.

Wedge Attachment

CAUTION

with Flat Washer

6.

Bearing Inner Race

Install wedge attachment only so far as necessary to

3.

Bridge

7.

Sprocket Shaft

ensure positive contact with thrust washer. Installing

tool with more contact than absolutely necessary will

Figure 3-130. Remove Inner Race From Sprocket Shaft

result in damage to flywheel.

e. Obtain two 3/8-16 inch bolts 6-1/2 inches long (with

flat washers). Install flat washers on bolts. Obtain

f.

Slide one bolt into channel on each side of bridge

bridge, forcing screw and hardened plug from

so that flat washer is between bridge and bolt head.

MAINSHAFT BEARING INNER RACE PULLER/

Thread bolts into wedge attachment an equal num-

INSTALLER (HD-34902B).

ber of turns.

3-104

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f2265x3x

1. Install Thrust Washer and Bearing Inner Race On

Sprocket Shaft. Assemble Tool.

1

2

3

4

Figure 3-131. Sprocket Shaft Timken Bearing

Cone Installer (Part No. HD-97225-55B)

6

5

7

g. 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

bridge.

CAUTION

f2152x3x

Failure to use hardened plug may result in damage to

forcing screw and/or sprocket shaft.

2. Press Bearing Inner Race Onto Sprocket Shaft.

h. Place cupped side of hardened plug against end of

sprocket shaft. Thread forcing screw into bridge until

f2153x3x

the steel ball at the end of the screw makes firm

contact with hardened plug.

i.

Using the Robinair Heat Gun (HD-25070), uniformly

heat the bearing inner race for about 30 seconds

using a circular motion.

NOTE

To faciliate removal without heat, apply a light penetrating oil

to shaft and leading edge of bearing inner race.

1WARNING

Never use both heat and penetrating oil. Use only one or

the other. Excessive heat can cause the penetrating oil

1. Pilot Shaft

5.

Sleeve

to ignite resulting in flames or fire. Inadequate safety

2. Handle

6.

Inner Race

precautions can result in death or serious injury.

3. Flat Washer

7.

Thrust Washer

4. Nice Bearing

j.

Turn forcing screw until thrust washer and bearing

inner race move approximately 1/8 inch (3.2 mm).

Figure 3-132. Press Inner Race Onto Sprocket Shaft

k. Turn hex nuts an equal number of turns to separate

halves of WEDGE ATTACHMENT.

CAUTION

l.

After bottoming thrust washer on shaft, reposition

WEDGE ATTACHMENT

(HD-95637-46A) on

Install wedge attachment only so far as necessary to

inboard side of bearing inner race. Turn hex nuts an

ensure positive contact with bearing inner race. Install-

equal number of turns to draw halves of wedge

ing tool with more contact than absolutely necessary

together.

will result in damage to flywheel.

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f2266x3x

9

8

7

6

5

3

4

2

5.

Bearing

1. Flywheel Assembly

6.

Left Crankcase Half

2. Thrust Washer

7.

Thrust Washer

3. Inner Race

8.

Oil Seal

1

4. Lock Ring

9.

Spacer

Figure 3-133. Sprocket Shaft Bearing Assembly

m. Verify that the tool assembly is square, so that the

NOTE

bearing inner race is not cocked during removal.

To faciliate installation without heat, apply a light penetrating

See Figure 3-130.

oil to shaft and leading edge of bearing inner race.

n. Using the Robinair Heat Gun (HD-25070), uniformly

heat the bearing inner race for about 30 seconds

using a circular motion.

1WARNING

Never use both heat and penetrating oil. Use only one or

NOTE

the other. Excessive heat can cause the penetrating oil

To faciliate removal without heat, apply a light penetrating oil

to ignite resulting in flames or fire. Inadequate safety

to shaft and leading edge of bearing inner race.

precautions can result in death or serious injury.

o. Turn forcing screw until bearing inner race is pulled

4.

Obtain the SPROCKET SHAFT TIMKEN BEARING

free of sprocket shaft.

CONE INSTALLER (HD-97225-55B). See Figure 3-131.

p. Remove thrust washer from sprocket shaft.

Assemble tool as described below.

a. Thread pilot onto sprocket shaft until contact is

2.

Discard thrust washer and bearing inner race.

made with shoulder.

b. Sparingly apply graphite lubricant to threads of pilot

Installation

shaft to prolong service life and ensure smooth

1.

Place new thrust washer over sprocket shaft with the ink

operation.

stamp facing outside

(and the chamfer on the ID

c. Slide sleeve over pilot until it contacts bearing inner

inboard).

race.

2.

Place new bearing inner race on bench top. Using the

Robinair Heat Gun (HD-25070), uniformly heat bearing

d. Slide Nice bearing and large flat washer over pilot

inner race for about 60 seconds using a circular motion.

until contact is made with sleeve.

3.

Wearing suitable gloves to protect hands from burns,

e. Thread handle onto pilot shaft. See upper frame of

place heated bearing inner race over sprocket shaft.

Figure 3-132.

3-106

2005 Touring: Engine

HOME

FLYWHEEL/CONNECTING ROD

ASSEMBLY

Removal

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-29.

2.

See Section 3.10 BOTTOM END OVERHAUL, DISAS-

SEMBLY, steps 1-18.

3.

See Section

3.11 SUBASSEMBLY SERVICE AND

REPAIR, CRANKCASE, LEFT CRANKCASE HALF,

SPROCKET SHAFT BEARING, REMOVAL.

f1690x3x

Inspection

1.

Replace the flywheel/connecting rod assembly if any of

Figure 3-135. Check Connecting Rod Side Play

the following conditions are noted:

● The crankshaft/sprocket shaft bearing inner races

CAUTION

are brinelled, burnt, scored, blued or damaged.

Do not attempt to straighten connecting rods. Straight-

ening rods will damage both the upper bushing and

2. Orient the assembly as shown in Figure 3-134. Holding

lower bearing.

the shank of each rod just above the bearing bore, pull

up and down on the connecting rods. Any discernable

● Connecting rods are bent or twisted.

up and down movement indicates excessive lower

● Connecting rods do not fall under their own weight

bearing clearance. Replace the flywheel/connecting rod

or are in a bind.

assembly.

NOTE

3. Insert a feeler gauge between the thrust washer and the

Bluing on connecting rods is from induction hardening and is

outboard side of the connecting rod. See Figure 3-135.

considered a normal condition.

Replace the assembly if rod side play exceeds 0.020

inch (0.51 mm).

NOTE

If the flywheel, connecting rods or right side bearing inner

race need to be replaced, then replace the entire flywheel

assembly.

Installation

1.

See Section

3.11 SUBASSEMBLY SERVICE AND

REPAIR, CRANKCASE, LEFT CRANKCASE HALF,

SPROCKET SHAFT BEARING, INSTALLATION.

2.

See Section 3.10 BOTTOM END OVERHAUL, ASSEM-

BLY, steps 1-29.

3.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

steps 1-39.

f1689x3x

Figure 3-134. Check Connecting Rod Bearing Clearance

3-108

2005 Touring: Engine

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SPECIFICATIONS

4.1

CVH CARBURETOR JET SIZES

TORQUE VALUES

Main Fuel

Slow Fuel

Model

Item

ft/in-lbs

Nm

Jet No.

Jet No.

Enrichener cable

49 state

190

45

20-35 in-lbs

2.3-4.0 Nm

mounting bracket hex nut

HDI

195

45

Cylinder head breather

120-144 in-lbs

13.6-16.3 Nm

bolts

California

185

45

Air cleaner cover bracket

20-40 in-lbs

2.3-4.5 Nm

screws

Air cleaner cover screw

36-60 in-lbs

4.1-6.8 Nm

FUEL TANK CAPACITY

Fuel valve hex jam nut

15-20 ft-lbs

20-27 Nm

Fuel tank adapter

22-26 ft-lbs

30-35 Nm

Capacity

English

Metric

Fuel tank rear mounting

15-20 ft-lbs

20-27 Nm

bolt

Total

5.0 Gallons

18.9 liters

Fuel tank front mounting

Reserve

0.9 Gallons

3.4 liters

15-20 ft-lbs

20-27 Nm

bolts

Battery hold-down clamp

15-20 ft-lbs

20-27 Nm

bolt

Console mounting bolt

50-90 in-lbs

5.7-10.2 Nm

acorn nut

2005 Touring: Fuel

4-1

HOME

FUEL SYSTEM TROUBLESHOOTING (CARBURETED)

4.2

\

CARBURETOR TROUBLESHOOTING

OVERFLOW

Check for:

Remedy:

1.

Restricted fuel tank vent system.

1.

Correct restricted hose. Replace vapor valve.

2.

Loose float bowl screws.

2.

Tighten screws.

3.

Damaged float bowl O-ring.

3.

Replace O-ring.

4.

Improper fuel level in float bowl.

4.

Adjust float tab for correct fuel level.

5.

Damaged or leaking float assembly.

5.

Replace float assembly.

6.

Particle contamination in fuel inlet fitting cavity.

6.

Clean and clear cavity and fuel supply tract.

7.

Worn or dirty inlet valve or seat.

7.

Clean or replace valve and clean seat.

POOR IDLING

Check for:

Remedy:

1.

Idle speed improperly adjusted.

1.

Adjust operating idle speed.

2.

Inlet system air leak (faster idling).

2.

Correct as required.

3.

Loose low speed jet.

3.

Tighten jet.

4.

Contaminated or plugged low speed system.

4.

Clean contaminants and clear passages.

5.

Enrichener valve not seated or leaking.

5.

Adjust, clean or replace.

6.

Leaking accelerator pump.

6.

Repair.

POOR FUEL ECONOMY

Check for:

Remedy:

1.

High speed riding style.

1.

Modify riding habits.

2.

Excessive use of enrichener system.

2.

Limit system use.

3.

Fuel level too high.

3.

Adjust float level.

4.

Restricted fuel tank vent system.

4.

Correct restricted hose. Replace vapor valve.

5.

Dirty air cleaner element.

5.

Clean or replace as required.

6.

Excessive accelerator pump output.

6.

Check and clean accelerator pump bypass orifice.

7.

Plugged or restricted bowl vent.

7.

Clean and clear passages.

8.

Vacuum piston assembly malfunction.

8.

See Vacuum Piston Troubleshooting.

9.

Loose jets.

9.

Tighten jets.

10. Worn or damaged needle or needle jet.

10. Replace needle or needle jet.

11. Plugged air jets or passages.

11. Clean and clear passages.

12. Enrichener valve not seated or leaking.

12. Adjust, clean or replace.

13. Idle speed improperly adjusted.

13. Adjust operating idle speed.

POOR ACCELERATION

Check for:

Remedy:

1. Throttle cables misadjusted.

1.

Adjust throttle cables.

2. Inlet system air leak.

2.

Correct as required.

3. Restricted fuel tank vent system.

3.

Correct restricted hose. Replace vapor valve.

4. Restricted fuel supply passages.

4.

Correct and clear restriction.

5. Plugged bowl vent or overflow.

5.

Clean and clear passages.

6. Enrichener valve not seated or leaking.

6.

Adjust, clean or replace.

7. Worn or damaged needle or needle jet.

7.

Replace assembly.

8. Vacuum piston malfunction.

8.

See Vacuum Piston Troubleshooting.

9. Plugged jets or passages.

9.

Clean and clear as required.

10. Fuel level (float chamber) too low.

10. Adjust float level.

11. Accelerator pump leaking or no output.

11. Repair as necessary.

4-2

2005 Touring: Fuel

HOME

HARD STARTING

Check for:

Remedy:

1. Enrichener system plugged, not properly functioning

1. Clean, adjust, or replace; or read Owner’s Manual.

or improperly operated.

2. Correct as required.

2. Inlet system air leak.

3. Check fuel supply and/or passages. Verify that vacuum

3. Restricted fuel supply.

operated fuel valve is functional.

4. Fuel overflow.

4. See Overflow Troubleshooting.

5. Plugged slow jet or passages.

5. Clean and clear jet or passages.

POOR PERFORMANCE ON ROAD

Check for:

Remedy:

1. Inlet system air leak.

1. Correct as required.

2. Restricted fuel tank vent system.

2. Correct restricted hose. Replace vapor valve.

3. Dirty or damaged air cleaner element.

3. Clean or replace.

4. Accelerator pump inoperative.

4. Repair as required.

5. Plugged bowl vent or overflow.

5. Clean and clear passages.

6. Vacuum piston assembly malfunction.

6. See Vacuum Piston Troubleshooting.

7. Loose or plugged fuel and air jets or passages.

7. Clean, clear and correct as required.

8. Worn or damaged needle or needle jet.

8. Replace assembly.

9. Restricted fuel supply tract.

9. Correct and clear restriction.

10. Enrichener valve not seated or leaking.

10. Adjust, clean or replace.

11. Idle speed improperly adjusted.

11. Adjust operating idle speed.

POOR HIGH SPEED PERFORMANCE

Check for:

Remedy:

1.

Inlet system air leak.

1.

Clean or replace.

2.

Restricted fuel tank vent system.

2.

Correct restricted hose. Replace vapor valve.

3.

Dirty or damaged air cleaner element.

3.

Clean or replace.

4.

Accelerator pump inoperative.

4.

Repair as required.

5.

Plugged bowl, vent or overflow.

5.

Clean and clear passages.

6.

Vacuum piston assembly malfunction.

6.

See Vacuum Piston Troubleshooting.

7.

Restricted fuel supply tract.

7.

Correct and clean restriction.

8.

Loose or plugged main jets or passages.

8.

Tighten, clean, clear as required.

9.

Improper fuel level.

9.

Adjust float level.

10. Worn or damaged needle or needle jet.

10. Replace assembly.

11. Enrichener valve not seated or leaking.

11. Adjust, clean or replace.

2005 Touring: Fuel

4-3

HOME

VACUUM PISTON ASSEMBLY TROUBLESHOOTING

PISTON DOES NOT RAISE PROPERLY

Check for:

Remedy:

1. Diaphragm cap loose, damaged or leaking.

1.

Tighten or replace cap.

2. Diaphragm pinched at lip groove.

2.

Reposition diaphragm lip.

3. Piston atmosphere vent blocked.

3.

Clear vent.

4. Piston vacuum passage plugged.

4.

Clean and clear passage.

5. Torn diaphragm.

5.

Replace piston diaphragm assembly.

6. Piston binding.

6.

Clean piston slides and body or replace piston.

7. Spring binding.

7.

Correct or replace spring.

8. Enrichener valve open, not seated or leaking.

8.

Adjust, clean or replace.

PISTON DOES NOT CLOSE PROPERLY

Check for:

Remedy:

1. Piston diaphragm ring dirty or damaged.

1.

Clean or replace piston.

2. Piston binding.

2.

Clean piston slides and body or replace piston.

3. Spring damaged.

3.

Replace spring.

4-4

2005 Touring: Fuel

HOME

ENRICHENER (CARBURETED)

4.3

GENERAL

f1381b2x

Idle Control

Cable

The carburetor is a constant velocity, gravity fed type with a

float operated inlet valve, a variable venturi, a throttle stop

screw for idle speed adjustment and a fuel enrichment sys-

Throttle Control

tem for starting. See Figure 4-1.

Cable

The fuel enrichment circuit will cause engine idle speed to

increase to approximately 2000 rpm with enrichener knob

Vacuum Fitting

pulled out fully and engine running at normal operating tem-

Vacuum Piston

(At Back)

perature. With enrichener knob pulled out partially and

Chamber

engine running at normal operating temperature, engine idle

speed will also increase above normal idle speed. The

increase in idle speed is intended to alert the rider that

engine is warmed up, and that enrichener knob should be

pushed in all the way. Continued use of enrichener after

engine is warmed up may cause fouled spark plugs.

Idle and transfer ports provide a balanced fuel mixture during

the transition period from stop to mid-range. A vacuum piston

controls venturi opening.

The carburetor is specifically designed to control exhaust

emissions. All jets are fixed. The idle mixture has been pre-

set at the factory.

The idle mixture screw is recessed in the carburetor casting.

The opening is sealed with a plug because it is intended that

Idle Speed

the idle mixture be non-adjustable.

Set Screw

NOTE

Air

Jets

Adjusting mixture setting by procedures other than specified

in this section may be in violation of Federal or State regula-

Accelerator

tions.

Pump Nozzle

Float Chamber

This system partially compensates for changes in the mixture

that are normally caused by changes in altitude. Because

Figure 4-1. CVH Carburetor

atmospheric pressure decreases as altitude increases, the

pressure difference in the upper and lower chambers is

reduced, which provides less fuel to the engine.

The carburetor is equipped with an accelerator pump. The

accelerator pump system uses sudden throttle openings

CAUTION

(rapid accelerations) to quickly inject fuel into carburetor ven-

turi to provide extra fuel for smooth acceleration.

Never accelerate the engine above 2500 RPM immedi-

ately after a cold start. Allow the engine to run slowly for

15-30 seconds. This will allow the engine to warm up and

OPERATION

let oil reach all surfaces needing lubrication. Extended

idling with enrichener in the full out position for a period

longer than 30 seconds is not recommended.

Enrichener

NOTE

The enrichener knob, located under the left side of the fuel

● H-D CV carburetors have an enrichener circuit that will

tank, controls opening and closing of the enrichener circuit in

cause the engine to idle at approximately 2000 rpm with

the carburetor. The enrichener knob can be adjusted to any

the engine at normal operating temperature and the

position, from full-in to full-out.

enrichener knob pulled fully out.

2005 Touring: Fuel

4-5

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