Harley Davidson 2018 softail models. Service manual

Disassemble

See Figure 1. Remove saddlebag lid.

a. Open saddlebag lid (4).

b. Remove screws (7) and tether bracket (14).

c. Remove screws (8) and medallion (15).

d. Remove saddlebag lid.

Remove reflector.

a. Remove retainer clips (11).

b. Remove reflector bracket (9) and reflector (10).

Remove lock assembly.

a. Remove nut (6) and lockwasher (5).

b. Remove lock (1), gasket (2) and bezel (3).

See Figure 3. Remove lockset.

a. Place key in lock.

b. Turn key half way between locked and open so the

tumbler (3) shows in the access hole (2).

c. Place a pin in the access hole. Press down the

tumbler and slide out the lockset (4).

See Figure 1. Remove saddlebag gasket.

a. Open saddlebag lid (4).

b. Remove screws (7) from the tether bracket (14) and

saddlebag lid.

c. Completely remove gasket (13).

NOTE

Do not remove stitching.

Assemble

1. See Figure 2. Install saddlebag gasket.

a. Align the new gasket (1) with the center of the tether

(2) on the saddlebag lip.

b. Press the gasket firmly onto saddlebag lip.

c. Continue pressing gasket around saddlebag lip until

gasket ends meet.

d. Trim gasket to length and press onto lip.

e. See Figure 1. Place tether bracket (14) beneath

tether (12) and install screws (7) into bracket on the

lid (4). Tighten.

Torque: 0.9-1.6 N·m (8-14 in-lbs) Saddlebag tether

to lid screw

2. See Figure 4. Install lockset.

a. Place key in lockset (2).

b. Align notches (1) on lockset as shown. Pull key out.

c. Align cam (6) and housing notches (5) in the open

position as shown.

d. Verify the cam is in the open position by pressing

down on the spring loaded lockset housing.

NOTE

If you can not press down on the spring loaded

lockset housing the cam is in the locked

position.

e. Align the lockset notches with the housing notches

and slide together.

f. Verify the operation of the lock.

NOTE

In the locked position the lockset should not be

able to be pressed in.

See Figure 1. Install lock assembly.

a. Place bezel (3) through opening on saddlebag lid

(4).

b. Place gasket (2) on lock (1).

c. Place lock through bezel.

d. Place lockwasher (5) on bottom of bezel and install

nut (6).

e. Tighten nut.

Torque: 5-6.2 N·m (44-55 in-lbs) Saddlebag

lockset nut

Install reflector.

a. Place reflector (10) and bracket (9) on saddlebag as

shown.

b. Install retainer clips (11).

Install saddlebag lid.

a. Place medallion (15) on saddlebag lid (4).

b. Align the holes on hinge with holes on lid.

c. Install screws (8) through hinge and into medallion.

Tighten.

Torque: 2-2.8 N·m (18-25 in-lbs) Saddlebag hinge

screw

d. Place tether bracket (14) beneath tether (12) and

install screws (7) into bracket on the lid. Tighten.

Torque: 0.9-1.6 N·m (8-14 in-lbs) Saddlebag tether

to lid screw

Consumables

Description

Part Number

Size

LOCTITE 243 MEDIUM STRENGTH

99642-97

6 ml (¼ fl oz)

THREADLOCKER AND SEALANT

(BLUE)

Disassemble

See Figure 1. Remove outer clamshell.

a. Open saddlebag.

b. Pry out slightly on damper clip (9) on lower damper

(1) while pulling damper from stud (7).

NOTE

Do not remove clip from damper.

c. Remove two screws (4) attached to the outer

clamshell (6).

d. See Figure 2. If necessary remove gasket (2) from

outer clamshell (1).

e. Remove hinge screws (4) from outer clamshell.

f. Remove outer clamshell.

See Figure 1. Remove damper.

a. Pry out slightly on damper clip (9) on upper damper

(1) while pulling damper from stud (7).

NOTE

Do not remove clip from damper.

b. Remove damper (1).

Remove tether.

a. Remove remaining screw (4) from inner clamshell

(3).

b. Remove studs (7).

c. Remove tether (5).

See Figure 2. Remove strikes.

Remove screws (9).

Remove strikes (8).

Remove medallions. See Remove.

See Figure 3. Remove hinges.

Remove screws (6).

Remove hinges (7).

Remove docking rod.

a. Remove docking rod screws (8).

b. Remove docking rod (5).

Remove latch assembly.

a. Remove screw (11).

b. Remove latch lever (4) and O-ring (3) from inner

clamshell (2).

c. Remove screws (12) on front of latch.

d. Remove latch assembly (1).

Remove lock.

a. Place lock (10) in the unlocked position.

b. Remove screws (9).

c. Remove lock.

10.

See Figure 4. Remove lock knob assembly.

a. Remove screws (8) and indicator flag cover (9).

b. Remove cap (17).

c. Remove nut (16) and screw (7).

d. Remove lock knob (15).

e. Remove screws (1) and cover (13).

f. Remove latching arm cover (10), spacer (4) and

spring (5).

g. Remove indicator flag (12) and latching arm (11)

from latching arm cover.

h. Remove grommets (6).

Remove seals (14).

11.

Remove Retaining clip.

Pry center of clip (2) out.

Remove clip.

Assemble

1. See Figure 2. Install strikes.

a. Place strikes (8) on outer clamshell (1).

b. Apply threadlocker to screws (9).

LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (BLUE)

(99642-97)

c. Install screws. Tighten.

Torque: 2.3-3.4 N·m (20-30 in-lbs) Saddlebag

strike screw

2. Install medallions and reflectors.

a. Clean mounting surface. See Remove

b. With the adhesive backing still in place, test fit the

medallions (10) and reflectors.

c. Remove the adhesive backing.

d. Install medallions and reflectors.

e. Press firmly to make sure that there is good

adhesion.

Install hinges.

a. Position hinges (6) on outer clamshell (1).

b. Apply threadlocker to screws (4).

c. Install screws. Tighten.

Torque: 2.3-3.4 N·m (20-30 in-lbs) Saddlebag

hinge screw

Install gasket.

a. Clean gasket surface (3). See Remove.

b. Trim gasket (2) to length.

NOTE

Do not stretch gasket. Gasket split (5) should

be located on the bottom of clamshell.

c. Install gasket at midpoint (7) of hinge area. Press

gasket firmly in place.

See Figure 4. Install lock knob assembly.

Install bushings (6) to latching arm cover (10).

NOTE

Grommet tabs must be fully seated.

Replace seals (14) on locking knob cover (13).

Place indicator flag (12) on latching arm (11) and

slide through opening on latching arm cover.

Place spring (5) and spacer (4) on latching arm.

Place locking knob cover on inner clamshell (3)

aligning the holes.

Place locking knob cover (13) on inner clamshell.

Install screws (1). Tighten.

Torque: 11-14 N·m (97-124 in-lbs) Saddlebag

locking knob cover screw

Place pins on locking knob (15) into holes on

latching arm.

Install screw (7) through assembly and install new

lock nut (16). Tighten.

Torque: 11-14 N·m (97-124 in-lbs) Saddlebag

locking knob screw

Install cap (17).

Place indicator flag cover (9) on latching arm cover.

Apply threadlocker to screws (8).

Install screws. Tighten.

Torque: 2.7-4 N·m (24-35 in-lbs) Saddlebag

indicator flag cover screw

Verify operation.

Install retaining clips.

a. Place new clips (2) in position and press in place.

See Figure 3. Install lock.

a. Place lock (10) in the unlocked position.

b. Place lock onto latch assembly (1).

NOTE

Lock pin should be toward inner clamshell.

c. Install screws (9). Tighten.

Torque: 1.7-2.3 N·m (15-20 in-lbs) saddlebag lock

screw

d. Verify lock installation.

Install latch assembly.

a. Place latch (1) in position on inner clamshell (2).

b. Install screws (12). Tighten.

Torque: 1.7-2.3 N·m (15-20 in-lbs) Saddlebag

latch assembly

c. Place O-ring (3) on latch lever (4) and position on

inner clamshell.

d. Install screw (11). Tighten.

Torque: 2.3-3.4 N·m (20-30 in-lbs) Saddlebag

latch lever screw

Install docking rod.

a. Place docking rod (5) on inner clamshell (2).

b. Apply threadlocker to screws (8).

c. Install screws. Tighten.

Torque: 17-21 N·m (13-15 ft-lbs) Saddlebag

docking rod

10.

Install outer clamshell.

a. Align outer clamshell with inner clamshell.

b. Position outer clamshell hinges (7) in inner

clamshell hinge slot.

c. Apply threadlocker to screws (6).

d. Install screws. Tighten.

Torque: 2.3-3.4 N·m (20-30 in-lbs) Saddlebag

hinge screw

e. See Figure 1. Place tether (5) in position.

f. Apply threadlocker to screws (4).

g. Install screws.

Torque: 5-6 N·m (44-53 in-lbs) Saddlebag tether

screw

h. Install studs (7).

Torque: 5-6 N·m (44-53 in-lbs) Saddlebag tether

stud

Slide damper (1) through tether loop (2).

NOTE

1. Mark location of emblem with masking tape.

NOTE

Wear protective gloves.

2. Saw behind emblem with mono-filament fishing line or waxed dental floss to remove emblem.

NOTE

Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components may occur.

For maximum bond, surface must be clean and dry.

3. Use 3M GENERAL PURPOSE ADHESIVE REMOVER to remove remaining foam backing tape and adhesive from

mounting surface.

4. Clean with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water.

NOTE

Apply medallion within minutes of cleaning.

5. Allow to dry completely.

NOTE

Apply in ambient temperatures between 21-38 °C (70-100 °F).

Parts cannot be repositioned after initial installation. Do not remove protective film from adhesive until ready to

apply.

Do not bend emblem to fit contour of mounting surface.

Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or

extremem weather.

The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.

1. Test fit medallion in intended location.

a. Check medallion against curve of mounting surface.

b. Match left and right sides of fuel tank.

NOTE

Protect adhesive from grease, oil, dust, dirt and fingerprints.

Once applied, do not shift medallion.

The adhesive bonds in 72 hours at room temperature.

2. Remove protective film from back of medallion.

3. Apply even pressure across entire surface with palms and fingers of both hands. Hold in place for 15 seconds.

4. Wait 20 minutes before touching medallion.

5. Wait 24 hours before washing.

FASTENER

TORQUE VALUE

NOTES

Breather screw

10.2-13.6 N·m

4.14 BREATHERS, Install

(90-120 in-lbs)

Cam chain tensioner fasteners

10.2-13.6 N·m

4.21 CAM COMPARTMENT AND

(90-120 in-lbs)

COMPONENTS, Install

Cam needle bearing installation

33.9 N·m

4.21 CAM COMPARTMENT AND

maximum torque

(25 ft-lbs)

COMPONENTS, Camshaft Needle

Bearings

Cam sprocket screw, final torque

46.1 N·m

4.21 CAM COMPARTMENT AND

(34 ft-lbs)

COMPONENTS, Install

Apply LOCTITE 262 HIGH

STRENGTH THREADLOCKER AND

SEALANT (red)

Cam sprocket screw, first torque

20.3 N·m

4.21 CAM COMPARTMENT AND

(15 ft-lbs)

COMPONENTS, Install

Cam support plate screws

10.2-13.6 N·m

4.21 CAM COMPARTMENT AND

(90-120 in-lbs)

COMPONENTS, Install

Camshaft cover screws

10.2-13.6 N·m

4.21 CAM COMPARTMENT AND

(90-120 in-lbs)

COMPONENTS, Remove and

Install: Camshaft Cover

Camshaft timer cover screws

2.8-4 N·m

4.21 CAM COMPARTMENT AND

(25-35 in-lbs)

COMPONENTS, Remove and

Install: Camshaft Cover

Crankcase oil check valve or plug

24.4-29.8 N·m

4.9 OIL COOLER, Oil Check Valve

with O-ring

(18-22 ft-lbs)

Crankcase oil check valve or plug

24.4-29.8 N·m

4.24 CRANKCASE, Plugs and Oil

with O-ring

(18-22 ft-lbs)

Fittings

Crankcase screws, first torque

13.6 N·m

4.24 CRANKCASE, Assemble

(120 in-lbs)

Crankcase screws, last torque

20.3-25.8 N·m

4.24 CRANKCASE, Assemble

(15-19 ft-lbs)

Crankcase tapered plugs

13.6-16.3 N·m

4.24 CRANKCASE, Plugs and Oil

(120-144 in-lbs)

Fittings

Crankshaft sprocket screw, final

32.5 N·m

4.21 CAM COMPARTMENT AND

torque

(24 ft-lbs)

COMPONENTS, Install

Crankshaft sprocket screw, first

20.3 N·m

4.21 CAM COMPARTMENT AND

torque

(15 ft-lbs)

COMPONENTS, Install

Apply LOCTITE 262 HIGH

STRENGTH THREADLOCKER AND

SEALANT (red)

Cylinder head nut torque step 1.

27.1-40.7 N·m

4.18 CYLINDER HEADS, Install

(20-30 ft-lbs)

Apply ENGINE OIL to cylinder head

bolt washers and threaded portion of

the cylinder head bolts. See

procedure for torque sequence.

Cylinder head nut torque step 2.

-360°

4.18 CYLINDER HEADS, Install

Loosen one turn.

(-360°)

Cylinder head nut torque step 3.

12.2-14.9 N·m

4.18 CYLINDER HEADS, Install

(9-11 ft-lbs)

Cylinder head nut torque step 4.

33.9-36.6 N·m

4.18 CYLINDER HEADS, Install

(25-27 ft-lbs)

Cylinder head nut torque step 5.

90°

4.18 CYLINDER HEADS, Install

Tighten additional degree value.

(90°)

Cylinder stud

13.6-27.1 N·m

4.24 CRANKCASE, Cylinder Studs

(120-240 in-lbs)

Cylinder temperature sensor

13.6-20.3 N·m

4.18 CYLINDER HEADS, Assemble

(120-180 in-lbs)

Engine mount bolt, front, lower

67.8-74.5 N·m

4.11 FRONT ENGINE MOUNT,

(50-55 ft-lbs)

Remove and Install: Lower Front

Engine Mount

Engine mount pinch bolt, front, lower

10.2-12.2 N·m

4.11 FRONT ENGINE MOUNT,

(8-9 ft-lbs)

Remove and Install: Lower Front

Engine Mount

Engine mount screw, front, upper

61-67.8 N·m

4.11 FRONT ENGINE MOUNT,

engine bracket

(45-50 ft-lbs)

Remove and Install: Upper Front

Engine Mount

Engine mount screw, front, upper

61-67.8 N·m

4.11 FRONT ENGINE MOUNT,

frame bracket

(45-50 ft-lbs)

Remove and Install: Upper Front

Engine Mount

Engine mount screw, front, upper

61-67.8 N·m

4.11 FRONT ENGINE MOUNT,

frame bracket-to-engine bracket

(45-50 ft-lbs)

Remove and Install: Upper Front

Engine Mount

Engine mount screw, left side,

61-67.8 N·m

4.12 LEFT SIDE ENGINE MOUNT,

bracket-to-frame

(45-50 ft-lbs)

Install

Engine mount screw, left side,

38-44.7 N·m

4.12 LEFT SIDE ENGINE MOUNT,

bracket-to-head

(28-33 ft-lbs)

Install

Engine oil drain plug

19-28.5 N·m

4.26 OIL PAN, Install

(14-21 ft-lbs)

Knock sensor screw

17.6-23 N·m

4.18 CYLINDER HEADS, Assemble

(13-17 ft-lbs)

Lifter anti-rotation device screw

10.2-13.6 N·m

4.17 PUSHRODS, LIFTERS AND

(90-120 in-lbs)

COVERS, Install

Lifter cover screws

14.9-17.6 N·m

4.17 PUSHRODS, LIFTERS AND

(132-156 in-lbs)

COVERS, Install

Lower rocker cover screws

10.2-13.6 N·m

4.15 LOWER ROCKER COVERS,

(90-120 in-lbs)

Install

Lower rocker cover stud

10.2-13.6 N·m

4.13 UPPER ROCKER COVERS,

(90-120 in-lbs)

Install

Apply LOCTITE 243 MEDIUM

STRENGTH THREADLOCKER AND

SEALANT (blue) to screws.

Oil cooler cover screw

9.5-11.3 N·m

4.9 OIL COOLER, Complete

(84-100 in-lbs)

Oil cooler screw

9.5-11.3 N·m

4.9 OIL COOLER, Install

(84-100 in-lbs)

Oil line manifold screws

10.2-13.6 N·m

4.10 OIL COOLANT LINES, Install

(90-120 in-lbs)

Apply LOCTITE 243 MEDIUM

STRENGTH THREADLOCKER AND

SEALANT (BLUE)

Oil pan fasteners

14.9-17.6 N·m

4.26 OIL PAN, Install

(132-156 in-lbs)

Torque sequence; LOCTITE 243

MEDIUM STRENGTH

THREADLOCKER AND SEALANT

(blue) with used fasteners

Oil pump screws, final torque

10.2-13.6 N·m

4.21 CAM COMPARTMENT AND

(90-120 in-lbs)

COMPONENTS, Install

Oil pump screws, first torque

1.4-6.8 N·m

4.21 CAM COMPARTMENT AND

(12-60 in-lbs)

COMPONENTS, Install

Piston jet screws

2.8-3.9 N·m

4.24 CRANKCASE, Repair Right

(25-35 in-lbs)

Crankcase Half

Rocker shaft screw

31.2-36.6 N·m

4.16 ROCKER ARMS, Install

(23-27 ft-lbs)

Spark plug

10-15 N·m

4.7 TROUBLESHOOTING,

(89-133 in-lbs)

Compression Test

Transmission drain plug

19-28.5 N·m

4.26 OIL PAN, Install

(14-21 ft-lbs)

Table 1. Engine: Milwaukee-Eight™ 107 Engine

ITEM

SPECIFICATION

Number of cylinders

Type

4-cycle, 45 degree

V-Type, air-cooled

Single camshaft

Dual balance shafts

Compression ratio

10.0:1

Bore

3.937 in

100 mm

Stroke

4.375 in

111.1 mm

Displacement

107 in³

1753 cm³

Fuel requirement

Premium unleaded

Lubrication system

Pressurized, dry sump

with oil cooler

Table 2. Engine: Milwaukee-Eight™ 114 Engine

ITEM

SPECIFICATION

Number of cylinders

Type

4-cycle, 45 degree

V-Type, air-cooled

Single camshaft

Dual balance shafts

Compression ratio

10.5:1

Bore

4.016 in

102 mm

Stroke

4.500 in

114.3 mm

Displacement

114 in³

1868 cm³

Fuel requirement

Premium unleaded

Lubrication system

Pressurized, dry sump

with oil cooler

Table 3. Engine Idle Characteristics

CONDITION

DOM *

ALL OTHERS *

Cold start

1450 rpm

1700 rpm

Hot idle

850 rpm

Hot idle; EITMS engaged

950 rpm

Low voltage

200 rpm increase from normal

* All values are approximate

Table 4. Oiling System

ITEM

SPECIFICATION

Capacity with filter

Air-Cooled (new system): 4.7 L (5 qt)

Service oil change (initial fill): 3.8 L (4 qt)

Recommended oil

Genuine Harley-Davidson H-D 360

Motorcycle Oil

Pump

Twin gerotor, dual scavenge, crank mounted and driven, internal oil pump, dry sump

Pressure

207-276 kPa (30-40 psi) at 2000 RPM and normal operating temperature of

110 °C (230 °F)

Filtration

5 micron media, filtered between pump and engine

Cooling

Oil cooler

Table 5. Rocker Arms Specifications

ROCKER ARMS

Shaft fit in bushing (loose)

0.0005-0.0022

0.013-0.056

End clearance

0.004-0.015

0.10-0.38

Table 6. Rocker Arm Shaft Specifications

ROCKER ARM SHAFTS

Diameter

0.5538-0.5543

14.067-14.079

Table 7. Hydraulic Lifter Specifications

HYDRAULIC LIFTERS

Fit in crankcase (loose)

0.0009-0.0026

0.023-0.066

Table 8. Cylinder Head Specifications

CYLINDER HEAD

Head gasket surface (flatness)

0-0.003

0-0.08

Table 9. Valve Specifications

VALVES

Exhaust: fit in guide

0.001-0.003

0.0254-0.0762

Intake: fit in guide

0.001-0.003

0.0254-0.0762

Seat width

0.040-0.080

1.02-2.03

Stem protrusion from cylinder head boss

1.714-1.721

43.54-43.71

Valve lash *

0.000-0.003

0.00-0.08

* Variation between valve pairs operated by a common rocker arm.

Table 10. Valve Spring Specifications

VALVE SPRINGS

Closed

63 lbs @ 1.535 in.

280 N @ 39.0 mm

Open

165 lbs @ 1.154 in.

735 N @ 29.3 mm

Free length

1.838 in.

46.69 mm

Table 11. Piston

PISTON

Fit in cylinder

0.0025-0.0036

0.064-0.091

Piston pin fit (loose)

0.0002-0.0005

0.005-0.013

Ring end gap

Top compression

0.010-0.016

0.25-0.40

2nd compression

0.016-0.024

0.40-0.60

Oil control ring

0.008-0.028

0.20-0.70

Ring side clearance

Top compression

0.0012-0.0027

0.030-0.068

2nd compression

0.0012-0.0027

0.030-0.068

Oil control rails

0.001-0.007

0.025-0.178

Table 12. Connecting Rod Specifications

CONNECTING ROD

Piston pin fit (loose)

0.0007-0.0012

0.018-0.030

Side play between flywheels

greater than 0.005

greater than 0.13

Connecting rod to crankpin (loose)

0.0004-0.0017

0.0102-0.0432

Table 13. Flywheel Specifications

FLYWHEELS

Runout (shaft measured in case)

0.000-0.010

0.0-0.254

Runout (measured in truing stand)

0.000-0.004

0.0-0.102

End play

0.003-0.013

0.076-0.330

Table 14. Crankshaft/Sprocket Shaft Bearing Specifications

CRANKSHAFT/SPROCKET SHAFT BEARINGS

Roller bearing fit (loose)

0.0002-0.0015

0.005-0.038

Bearing fit in crankcase (tight)

0.0038-0.0054

0.097-0.137

Bearing inner race on crankshaft (tight)

0.0004-0.0014

0.010-0.036

Wear limits are given here as a guideline for measuring used engine components. Replace components when they exceed

these values.

Table 1. Rocker Arm/Rocker Arm Shaft

ROCKER ARM/ROCKER ARM SHAFT

REPLACE IF WEAR EXCEEDS

Shaft fit in bushing

0.006

0.152

End clearance

0.025

0.635

Table 2. Hydraulic Lifter

HYDRAULIC LIFTER

REPLACE IF WEAR EXCEEDS

Fit in crankcase

0.006

0.152

Roller fit

0.0015

0.038

Roller end clearance

0.022

0.559

Table 3. Cam Support Plate

ITEM

REPLACE IF WEAR EXCEEDS

Cam chain tensioner shoe thickness

0.060 min.

1.52 min.

Crankshaft bore maximum ID

0.8545

21.704

Camshaft bore

1.1023

27.998

Flatness

0.010

0.25

Table 4. Oil Pump

OIL PUMP

REPLACE IF WEAR

EXCEEDS

Rotor tip clearance

0.004

0.10

Rotor thickness variation

0.001

0.025

Table 5. Cylinder Head

CYLINDER HEAD

REPLACE IF

Valve seat width (max)

0.080

2.03

Valve margin (min)

0.031

0.80

Valve stem protrusion (max)

1.752

44.50

Cylinder head warpage (max)

0.006

0.152

Valve lash (max) *

0.008

0.20

* Variation between valve pairs operated by a common rocker arm.

Table 6. Valve Stem to Guide

VALVE STEM TO GUIDE

REPLACE IF WEAR EXCEEDS

Intake

0.0038

0.0965

Exhaust

0.0038

0.0965

Table 7. Valve Springs

VALVE SPRINGS

Closed

56.8-66.1 lbs

253-294 N

@ 1.154 in

@ 29.3 mm

Open

150.0-172.7 lbs

667-768 N

@ 1.091 in

@ 27.70 mm

Free length

1.838 in

46.70 mm

Table 8. Cylinder

CYLINDER

REPLACE IF WEAR EXCEEDS

Taper

0.003

0.102

Out of round

0.003

0.102

Warpage of gasket surface: top

0.006

0.152

Warpage of gasket surface: base

0.004

0.102

Table 9. Piston

PISTON

REPLACE IF WEAR EXCEEDS

Fit in cylinder (loose)

0.0041

0.104

Piston pin fit (loose)

0.0008

0.020

Ring end gap

Top compression

0.020

0.508

Second compression

0.030

0.762

Oil control rails

0.050

1.27

Ring side clearance

Top compression

0.004

0.102

Second compression

0.004

0.102

Oil control rails

0.010

0.254

Table 10. Connecting Rod

CONNECTING ROD

REPLACE IF WEAR

EXCEEDS

Piston pin fit (loose)

0.002

0.051

Fit on crankpin (loose)

0.002

0.051

Table 11. Flywheel

FLYWHEEL

REPLACE IF WEAR EXCEEDS

Runout (shaft measured in case)

0.012

0.305

Runout (measured in truing stand)

0.005

0.127

End play

0.013

0.330

Table 12. Crankshaft Roller Bearing

CRANKSHAFT ROLLER BEARING

REPLACE IF

Milwaukee-Eight engines are dry sump engines meaning that they have external oil reservoirs. Air cooled engines have an

oil cooler and circulate oil between the exhaust ports for additional heat control.

Oil in from oil pan

Oil pump feed rotors

Oil pump scavenge rotors

Scavenge oil in from cam chest

Oil pressure switch

Oil out to oil cooler (oil cooled only)

Oil filter

Cam plain bearing

Oil to camshaft, lifters and piston jets

Piston jets

Oil through crankshaft to crankpin and rod bearings

Oil through pushrods to rocker arms

Oil spillover to lubricate valve stems

Hydraulic chain tensioner

Figure 1. Internal Engine Oil Flow

Internal Oil Distribution: All

See Figure 1.

Oil from the oil pan (1) is pulled through ports in the

oil pan (not shown), the transmission housing and

crankcase

Oil enters the oil pump feed gerotors.

Oil exits the pump and passes oil pressure switch

(5) and oil cooler port (6) headed to oil filter (7). Oil

cooler port is plugged on Twin-Cooled engines.

Oil exits filter and is directed back into cam support

plate where its split between crankshaft, hydraulic

chain tensioner (14), and lifters (9).

Crankshaft oil travels through crankshaft to the

crankpin and rod bearings (11).

Flow toward lifters splits to cam plain bearing (8),

lifters and on to piston jets (10).

Oil flows from lifters up through pushrods to rocker

arms (12).

Oil exits rocker arms to lubricate valve stems via

spillover (13).

Oil drains through passages in the heads and

cylinders back to the camchest cavity. Residual oil in

the camchest cavity and the crankcase cavity is

picked up by the scavenge port (4) in the pump.

Return oil is fed through the scavenge gerotors and

case passages back to the oil pan.

Main bearings, balancer bearing and left cam

bearing are lubricated by oil splash.

Figure 2. External Engine Oil Flow: Air Cooled

External Oil Distribution: Air Cooled Only

1. See Figure 2.

a. Pressurized oil exits crankcase and flows through

check valve (1), hose (2) to oil cooler (3).

b. Oil flows through oil cooler, hose (5) to oil supply

line (6).

c. Oil flow splits at oil supply line (6) and flows to

manifolds (4).

d. Oil flows through passages between the exhaust

ports (7) in cylinder heads and back to manifolds.

e. Oil flows through return line (8) to return oil line to

transmission (9).

f. Return fitting (10) connects to a passage in

transmission where it returns to the oil pan (11).

See Figure 1. The oil pump has two gerotor gear sets driven by the crankshaft.

The feed gerotor set distributes oil to the engine.

The scavenge gerotor set draws oil from the cam and flywheel compartments and returns it to the oil pan.

Each gerotor gear set has an inner and outer gerotor. The inner and outer gerotors have fixed centers that are slightly

offset to one another. Also, the inner gerotor has one less tooth.

Feed gerotor

Housing

Scavenge gerotor

Inner cover

Scavenge port O-ring

Feed port O-ring

Figure 1. Oil Pump

Seal

Oil out

Continuous flow

Figure 2. Outlet Side Oil Flow

See Figure 1. As the gerotors rotate, the cavity volume increases between the inner and outer gerotors on the inlet side of

the pump. This creates a vacuum causing oil to be drawn in. The cavity increases until the volume is equivalent to that of

the missing tooth on the inner gerotor.

See Figure 2. As the oil moves to the outlet side of the pump, the cavity decreases in volume. This forces pressurized oil

out the discharge port. In operation, the gerotors provide a continuous flow of oil.

A breather assembly is mounted to each cylinder head to prevent a buildup of pressure caused by the downward force of

the pistons. Burning crankcase vapor eliminates the pollutants normally discharged from the crankcase.

See Figure 1. As pistons push downward, displaced air in the crankcase is vented through the crankshaft roller bearing

into the cam compartment. The air flows up the pushrod covers (1) into the rocker housing. The moving air absorbs a

small amount of oil vapor as it travels through the engine.

The oil/air vapor passes through an opening in the breather assembly (3).

In the breather assembly, the flow of air passes downward through a labyrinth where most of the oil is separated from the

air. It then moves upward through the breather element (4) where the remaining oil is removed. Two small holes in the

bottom of the breather housing allow the separated oil to drain back into the crankcase.

Passing through the breather element, the vapor passes through the umbrella valve (2). Vapor passes down into the

cylinder head passageway and through the breather bolt (5). It passes through a breather tube (6) into the air filter

element where it combines with the intake air stream and is burned during normal combustion.

Pushrod cover

Umbrella valve

Breather assembly

Breather element

Breather bolt

Breather tube

Figure 1. Breather Air Flow

See Figure 1. The red OIL PRESSURE indicator lamp illuminates to indicate improper pressure of the engine oil. The lamp

illuminates when the ignition is initially turned on (before the engine is started), but should extinguish once the engine is

running.

NOTICE

If the oil pressure indicator lamp remains lit, always check the oil supply first. If the oil supply is normal and the lamp is

still lit, stop the engine at once and do not ride further until the trouble is located and the necessary repairs are made.

Failure to do so may result in engine damage. (00157a)

If the indicator lamp does not extinguish, it may be caused by low oil level or diluted oil supply. In freezing weather, the oil

feed and return lines can clog with ice or sludge. Other conditions that may cause the lamp to remain lit are:

Faulty lamp wiring

Faulty oil pressure sending unit

Damaged oil pump

Plugged oil filter element

Incorrect oil viscosity for the operating temperature

Fractured or weak spring in the oil pressure relief valve

Incorrectly installed O-rings in the engine

To troubleshoot the problem, always check the engine oil level first. If the oil level is OK, determine if oil returns to the oil

pan. If oil does not return, shut off the engine until the problem is located and corrected.

Figure 1. Oil Pressure Indicator Lamp (Typical)

Special Tools

Description

Part Number

Qty.

OIL PRESSURE TEST GAUGE KIT

HD-96921-52D

1. Verify that engine oil is at the proper level. See Check Engine Oil Level.

2. Run motorcycle until engine oil reaches at least 93.5 °C (200 °F). Stop engine.

3. Remove oil pressure switch from crankcase. See Prepare.

4. See Figure 1. Install OIL PRESSURE TEST GAUGE KIT (Part Number:HD-96921-52D).

a. Hand-tighten adapter HD-96921-106 (2) in oil pressure switch mounting hole.

b. Assemble banjo bolt (3), washer (4), oil pressure gauge (1), banjo fitting and second washer onto adapter.

Hand-tighten.

5. Check oil pressure.

a. Operate engine at various speeds.

b. Record results.

c. Stop engine.

6. Remove oil pressure gauge assembly.

7. Install oil pressure switch. See Prepare.

8. Verify that oil pressure is within specifications. Refer to Table 1.

Table 1. Oil Pressure

CHECK

SPECIFICATION *

SAE

METRIC

Oil pressure - min at idle

5 psi

34.5 kPa

Oil pressure - normal at 2000 rpm

30-38 psi

207-262 kPa

Oil pressure - max

50 psi

345 kPa

* With oil at normal operating temperature of 110 °C (230 °F)

Gauge

Typical Symptoms

Symptoms indicating a need for engine repair are often misleading. If more than one symptom is present, possible

causes can be narrowed to make at least a partial diagnosis.

For example, an above normal consumption of oil could be caused by several mechanical faults. However when

accompanied by blue-gray smoke from the exhaust and low compression, it indicates the rings need replacing. Low

compression by itself is more likely to be caused by improperly seated or burned valves, not worn rings.

Certain knocking noises may occur because of loose bearings, others by piston slap. Piston slap is a condition where

piston or cylinder or both are out of tolerance. This excessive clearance allows the piston to slap the cylinder as it

moves up and down.

Most frequently, valves, rings, pins, bushings and bearings need attention at about the same time. If the symptoms

indicate that any one of the above components is worn, service all related parts.

Special Tools

Description

Part Number

Qty.

CYLINDER COMPRESSION

HD-33223-1

GAUGE

BORESCOPE

HD-50549

Check for cylinder leakage with a compression test. Use CYLINDER COMPRESSION GAUGE (Part Number:HD-33223-

1) with a screw-in type adapter.

Remove all spark plug cables.

Remove one spark plug from each cylinder.

NOTE

Never use a metal object to hold the throttle plate

open.

Open throttle plate.

a. Remove air cleaner cover and filter. See Remove.

b. Disconnect TCA connector [211] from the induction

module.

c. Insert a 19 mm (0.75 in) diameter by 30.5 cm (12 in)

long wooden or nylon dowel to hold the throttle valve

open.

Test compression.

a. Connect compression tester to front cylinder following

manufacturer's instructions.

b. Crank engine continuously through 5-7 full

compression strokes.

c. Note gauge readings at the end of the first and last

compression strokes. Record test results.

d. Disconnect ACR and repeat test.

e. Connect ACR.

f. Repeat steps (a-e) on rear cylinder.

Compare with specifications. Refer to Table 1

a. If compression is within specifications and the

variance between cylinders is less than 10%,

compression is normal.

b. If readings do not meet specifications, inject 15 ml

(0.5 fl oz) engine oil into each cylinder and repeat the

compression tests on both cylinders. Readings that

are considerably higher during the second test

indicate worn piston rings.

c. Refer to Table 2 for possible causes of low

compression.

d. Inspect cylinder using borescope. Refer to Clean and

Harley Davidson 2018 softail models. Service manual - page 13