Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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CHAPTER FOUR

ENGINE

All Dyna Glide models covered in this manual

ENGINE PRINCIPLES

are equipped with the Twin Cam 88 engine, an

air-cooled 4-stroke, overhead-valve V-twin engine.

Figure 1 explains basic four-stroke engine opera-

The engine consists of three major assemblies: en-

tion.

gine, crankcase and gearcase. Viewed from the en-

gine’s right side, engine rotation is clockwise.

SERVICE PRECAUTIONS

Both cylinders fire once in 720 degrees of crank-

shaft rotation. The rear cylinder fires 315 degrees

Before servicing the engine, note the following:

after the front cylinder. The front cylinder fires

1. Review the information in Chapter One, espe-

again in another 405 degrees. Note that one cylinder

cially the Basic Service Methods and Precision

is always on its exhaust stroke when the other fires

Measuring Tools sections. Accurate measurements

on its compression stroke.

are critical to a successful engine rebuild.

This chapter provides complete service and over-

2. Throughout the text there are references to the

haul procedures, including information for disas-

left and right side of the engine. This refers to the

sembly, removal, inspection, service and engine

engine as it is mounted in the frame, not how it may

reassembly.

sit on the workbench.

Tables 1-6 at the end of the chapter provide

3. Always replace worn or damaged fasteners with

spacer, shim and specification information.

those of the same size, type and torque require-

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ENGINE

101

FOUR-STROKE OPERATING PRINCIPLES

Carburetor

Intake

valve

Air

Air/fuel

Cylinder

INTAKE

COMPRESSION

Intake valve opens

Intake valve closes

as piston begins

and piston rises

downward, drawing

in cylinder,

air/fuel mixture into

compressing

the cylinder, through

air/fuel mixture.

the valve.

Exhaust

valve

Exhaust

EXHAUST

POWER

Exhaust valve

Spark plug

opens as piston

ignites

rises in cylinder,

compressed

pushing spent

mixture, driving

gases out through

piston downward.

the valve.

Force is applied

to crankshaft

causing it to

rotate.

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102

CHAPTER FOUR

ments. Make sure to identify each bolt before re-

placing it. Lubricate bolt threads with engine oil,

unless otherwise specified, before tightening. If a

specific torque value is not listed in Table 4, refer to

the general torque specifications in Chapter One.

CAUTION

The engine is assembled with hard-

ened fasteners. Do not install fasten-

ers with a lower strength grade

classification.

4. Use special tools where noted.

5. Store parts in boxes, plastic bags and containers

(Figure 2). Use masking tape and a permanent, wa-

terproof marking pen to label parts.

6. Use a box of assorted size and color vacuum

hose identifiers, Lisle (part No. 74600) (Figure 3)

for identifying hoses and fittings during engine re-

moval and disassembly.

7. Use a vise with protective jaws to hold parts.

8. Use a press or special tools when force is re-

quired to remove and install parts. Do not try to pry,

hammer or otherwise force them on or off.

9. Replace all O-rings and oil seals during reassem-

bly. Apply a small amount of grease to the inner lips

of each new seal to prevent damage when the en-

gine is first started.

10. Record the location, position and thickness of

all shims as they are removed.

SPECIAL TOOLS

Engine service requires a number of special tools.

These tools and their part numbers are listed with

the individual procedures. For a complete list of the

special tools mentioned in this manual, refer to Ta-

ble 9 in Chapter One. The engine tools used in this

chapter are either Harley-Davidson or JIMS special

tools. JIMS special tools are available through some

Harley-Davidson dealerships or many aftermarket

motorcycle suppliers.

When purchasing special tools, make sure to

specify that the tools required are for the 1999-on

Dyna Glide Twin-Cam 88 models. Many of the

tools are specific to this engine. Tools for other en-

gine models may be slightly different.

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ENGINE

103

9. Starter motor and gears.

10. Alternator and electrical systems.

ENGINE

Removal

1. Thoroughly clean the engine of all dirt and debris.

2. Remove the seat as described in Chapter Thirteen.

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

the battery or the siren will sound.

3. Disconnect the negative battery cable as de-

scribed in Chapter Eight.

4. Support the motorcycle on a stand or floor jack.

See motorcycle Stands in Chapter Nine.

5. Remove the fuel tank as described in Chapter

Seven.

6. Remove the air filter and backing plate as de-

scribed in Chapter Seven.

7. Remove the carburetor as described in Chapter

Seven.

8. Remove the exhaust system as described in

Chapter Seven.

9. Remove the rear brake pedal and right side foot

peg bracket as described in Chapter Twelve.

10. Drain the engine oil as described in Chapter

Three.

11. Remove the bolts securing the oil line cover

and remove the cover (Figure 4).

12. Disconnect the three oil lines from the crank-

case. Plug the oil lines to prevent dirt from entering

the hoses.

13. On 1999-2000 models, remove the camshaft

position sensor as described in Chapter Eight.

14. Disconnect the following electrical connectors:

SERVICING ENGINE IN FRAME

a. Crankshaft position sensor (Figure 5).

b. Alternator stator and voltage regulator (Fig-

The following components can be serviced while

ure 6).

the engine is mounted in the frame:

c. Oil pressure switch (Figure 7).

1. Rocker arm cover and rocker arms.

d. MAP sensor (A, Figure 8).

2. Cylinder heads.

15. Remove the ignition coil and spark plug assem-

3. Cylinders and pistons.

bly as described in Chapter Eight.

4. Camshafts.

16. Remove the primary chain case assembly, includ-

5. Gearshift mechanism.

ing the inner housing, as described in Chapter Five.

6. Clutch.

17. Remove the engine oil dipstick.

7. Transmission.

18. Remove the alternator rotor (A, Figure 9) as

8. Carburetor.

described in Chapter Eight.

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104

CHAPTER FOUR

19. On the right side of the engine stabilizer, per-

form the following:

a. Remove the link nut and spacer from the

frame tab (B, Figure 8).

b. Remove the two bolts from the horn bracket

and cylinder heads.

c. Remove the stabilizer link and horn bracket

as an assembly (Figure 10).

20. Remove the clutch cable from the lower por-

tion of the crankcase as described under Clutch Ca-

ble Replacement in Chapter Five.

21. Wrap the frame front down tubes (A, Figure

11) with protective tape to prevent surface damage

in the following steps.

22. Support the transmission case with a jack or

wooden blocks. Apply enough jack pressure on the

transmission prior to removing the en-

gine-to-transmission mounting bolts.

23. Using a ratchet strap, secure the transmission to the

frame so it will not shift after the engine is removed.

24. Remove the four bolts and washers (B, Figure

9) securing the engine to the transmission.

25. Support the engine with a floor jack. Apply

enough jack pressure on the crankcase to support it

prior to removing the engine mounting bolts.

26. Remove the two bolts and washers securing the

engine to the front isolator.

27. Straighten the lockplate tabs and remove the three

bolts, oil filter and oil filter mount (B, Figure 11).

28. Check the engine to make sure all wires, hoses,

and other related components have been discon-

nected from the engine. Check that nothing will in-

terfere with the removal of the engine from the right

side of the frame.

NOTE

Due to the weight of the engine as-

sembly, a minimum of two people are

required to safely remove the engine

from the frame.

29. Slide the engine assembly forward to clear the

two locating dowels on the lower en-

gine-to-transmission mounting bolt locations. The

dowels stick out approximately 1/2 in. (12.7 mm).

The engine may have to be rotated slightly to clear

the dowels.

30. Remove the engine from the right side of the

frame.

31. If the transmission was removed along with the

engine, remove the four bolts securing the transmis-

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ENGINE

105

Installation

NOTE

Due to the weight of the engine as-

sembly, a minimum of two people is

required to safely install the engine

into the frame.

1. If removed, install the two lower locating dowels

in the transmission case (Figure 13).

2. Re-check that all wiring, hoses and other related

components are out of the way and will not interfere

with engine installation.

3. Correctly position a floor jack and piece of wood

under the frame to support the engine when it is in-

stalled into the frame.

4. Install the engine from the right side of the frame

and place it on the floor jack. Apply enough jack

pressure on the crankcase to support it prior to in-

stalling the engine mounting bolts.

5. Slide the engine assembly toward the rear and onto

the two transmission locating dowels. The engine may

have to be rotated slightly to clear the dowels.

6. Install the four engine-to-transmission bolts and

washers hand-tight at this time.

7. Install the two bolts and washers securing the en-

gine to the front isolator. Tighten finger-tight at this

time.

8. Tighten the engine-to-transmission bolts in a

criss-cross pattern in the following sequence:

a. Tighten to 15 ft.-lb. (20 N•m).

b. Tighten to 30-35 ft.-lb. (41-47 N•m).

9. Tighten the front isolator bolts to the specifica-

tion in Table 4.

10. Remove the ratchet strap from the transmission

and frame.

11. Remove the floor jack.

NOTE

Step 12 is shown with the engine re-

moved from the frame to better illus-

trate the procedure.

12. Install the oil filter mount as follows:

sion to the engine. Remove the transmission from

a. Install new O-ring seals (Figure 14) onto the

the engine.

mount.

32. Mount the engine in an engine stand (Figure

b. Apply ThreeBond TB1342, or an equivalent,

12)

(JIMS part No. 1022 or an equivalent).

to the bolt threads prior to installing them

33. Service the front engine mount, if necessary.

onto the new lockplate.

34. Clean the front and rear engine mount bolts and

c. Install the oil filter mount onto the crankcase

washers in solvent and dry thoroughly.

and install the lockplate, three bolts and

35. Replace leaking or damaged oil hoses.

washers (Figure 15).

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ENGINE

107

d. Install the two bolts securing the horn bracket

PUSHROD ASSEMBLY

to the cylinder heads and tighten to the speci-

fication in Table 4.

e. Install the link nut and spacer onto the frame

tab (B, Figure 8).

16. Install the alternator rotor (A, Figure 9) as de-

scribed in Chapter Eight.

17. Install the engine oil dipstick.

18. Install the primary chain case inner housing

and assembly as described in Chapter Five.

19. Adjust the clutch and primary chain as de-

scribed in Chapter Three.

20. Install the ignition coil and spark plug assem-

bly as described in Chapter Eight.

21. Connect the following electrical connectors:

a. Crankshaft position sensor (Figure 5).

b. Alternator stator and voltage regulator (Fig-

ure 6).

c. Oil pressure switch (Figure 7).

d. MAP sensor (A, Figure 8).

22. On 1999-2000 models, install the camshaft po-

sition sensor as described in Chapter Eight.

O-ring

Lower cover

23. Connect the three oil lines onto the crankcase

Upper cover

Allen bolt

and install new hose clamps.

Spring cap

Lifter cover

24. Install the oil line cover and bolts (Figure 4).

retainer

10.

Anti-rotation pin

Tighten the bolts to the specification in Table 4.

Spring cap

11.

Gasket

Spring

12.

Hydraulic lifter

25. Install the rear brake pedal and right side foot

Washer

13.

Pushrod

peg bracket as described in Chapter Twelve.

26. Install the exhaust system as described in

Chapter Seven.

27. Install the carburetor as described in Chapter

d. Tighten the bolts to the specification in Table

Seven.

28. Install the air filter and backing plate as de-

e. Bend down the locking tab against the top and

scribed in Chapter Seven.

bottom bolt heads.

29. Install the fuel tank as described in Chapter

f. Install the oil filter.

Seven.

13. Remove the protective tape from the frame

30. Remove the stand from under the motorcycle

front down tubes.

and place the motorcycle on the jiffy stand.

14. Install the clutch cable onto the lower portion

31. Connect the negative battery cable as described

of the crankcase as described under Clutch Cable

Chapter Eight.

Replacement in Chapter Five.

32. Install the seat.

15. On the right side of the engine stabilizer, per-

33. Refill the engine oil as described in Chapter

form the following:

Three.

a. Install the stabilizer link and horn bracket as

34. Check vehicle alignment as described in Chap-

an assembly (Figure 10).

ter Nine.

b. Place a spacer between the frame tab and the

stabilizer link.

ROCKER ARMS AND PUSHRODS

c. Position the horn ground wire beneath the

bracket and the front cylinder head.

Refer to Figure 16 and Figure 17.

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108

CHAPTER FOUR

The rocker arm and pushrod procedures are

shown on the rear cylinder. The same procedures

also relate to the front cylinder. If differences occur

they are identified.

NOTE

The rocker arms and pushrod proce-

dures are shown with the engine re-

moved to better illustrate the steps.

Removal

1. If the engine is mounted in the frame, perform

the following:

a. Perform Steps 1-8 under Engine Removal in

this chapter.

b. Remove the upper cylinder head mounting

bracket.

2. Using a crisscross pattern, loosen and remove

the rocker arm cover bolts (Figure 18).

3. Remove the rocker arm cover and gasket.

4. Disassemble the breather as follows:

a. Remove the bolts (A, Figure 19) and remove

the cover (B) and gasket.

b. Remove the breather baffle (A, Figure 20),

valve (B), and gasket (Figure 21).

c. Install new gaskets during installation.

5. Remove both spark plugs as described in Chap-

ter Three, to make it easier to rotate the engine by

hand.

CAUTION

Do not rotate the engine using the

camshaft sprocket mounting bolt.

Doing so may break the bolt head and

damage the camshaft.

CAUTION

The piston must be at top dead center

(TDC) to avoid damage to the

pushrods and rocker arms in the fol-

lowing steps.

6A. With the primary chain cover in place, position

the piston for the cylinder being worked on at top

dead center (TDC) on the compression stroke as fol-

lows:

a. Support the motorcycle on a stand with the

rear wheel off the ground. See motorcycle

Stands in Chapter Nine.

b. Shift the transmission into fifth gear.

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ENGINE

109

closed. This indicates that the piston is at top

dead center (TDC) on the compression stroke

and both valves are closed. Also, the push

rods are in the unloaded position.

f. Look into the spark plug hole with a flashlight

and verify that the piston is at TDC.

7. Using a crisscross pattern, loosen, then remove

the four bolts and washers (Figure 22) securing the

rocker arm support and remove the support.

8. Remove the O-ring seal (Figure 23) from the

rocker arm housing.

9. Mark each pushrod with its top and bottom posi-

tion and its operating position in the cylinder head.

c. Rotate the rear wheel in the direction of nor-

mal rotation.

NOTE

d. Stop rotating the rear wheel when both the in-

When removing the pushrods in the

take and exhaust valves are closed.

following steps, do not intermix the

e. Wiggle both rocker arms. There should be

parts from each set. When reinstalling

the original pushrods, install them so

free play indicating that both valves are

that each end faces its original oper-

closed. This indicates that the piston is at top

ating position. The pushrods develop

dead center (TDC) on the compression stroke

a set wear pattern and installing them

and both valves are closed. Also, the push

upside down may cause rapid wear to

rods are in the unloaded position.

the pushrod, lifter and rocker arm.

f. Look into the spark plug hole with a flashlight

and verify that the piston is at TDC.

10. Remove the intake (A, Figure 24) and exhaust

6B. With the primary chain cover removed, position

(B) pushrods up through the cylinder head.

the piston for the cylinder being worked on at top dead

11. Remove the pushrod covers as follows:

center (TDC) on the compression stroke as follows:

a. Using a screwdriver, pry the spring cap re-

a. Shift the transmission into NEUTRAL.

tainer (Figure 25) out from between the cyl-

b. Install the sprocket shaft nut onto the end of

inder head and spring cap.

the left side of the crankshaft.

b. Slide the upper cover down (A, Figure 26)

c. Place a socket or wrench on the compensating

and remove the pushrod cover assembly (B)

sprocket shaft nut.

from the cylinder head and the lifter cover.

d. Rotate the compensating sprocket shaft coun-

c. Repeat for the opposite pushrod cover.

terclockwise until both the intake and exhaust

valves are closed.

NOTE

e. Wiggle both rocker arms. There should be

In order to clear the cylinder’s lower

free play indicating that both valves are

cooling fins, the lifter cover’s two in-

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110

CHAPTER FOUR

ner Allen bolts must be loosened with

a short 90-degree Allen wrench (A,

Figure 27).

12. Remove the lifter cover mounting bolts and re-

move the cover (B, Figure 27).

13. Remove the lifter cover gasket from the crank-

case.

NOTE

Do not intermix the lifters when re-

moving them in Step 13. Mark them so

they can be installed in their original

positions.

14. Remove the anti-rotation pin (A, Figure 28)

and both hydraulic lifters (B).

15. Cover the crankcase opening with duct tape

(Figure 29) to prevent the entry of debris.

16. Loosen the rocker housing six bolts (Figure

30) 1/8 turn at a time in the pattern shown in Figure

31.

17. Tap the rocker arm housing with a rubber mal-

let to free it, then lift it off the cylinder head.

18. Remove the rocker arm housing gasket.

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112

CHAPTER FOUR

Installation

1. Position the new rocker arm housing gasket onto

the cylinder so that the breather channel (Figure 32)

is covered and install the gasket (Figure 33).

2. Install the rocker arm housing onto the cylinder

head.

3. Apply ThreeBond TB1342, or an equivalent,

threadlocking compound to the bolt threads. Install

the rocker housing six bolts (Figure 30) and tighten

1/8 turn at a time in the pattern shown in Figure 31.

Tighten to the specification in Table 4.

4. Install a new O-ring seal (Figure 23) onto the

rocker arm housing. Apply a light coat of clean en-

gine oil to the O-ring.

5. Install the hydraulic lifters (B, Figure 28) into

the crankcase receptacles with both flat surfaces

facing toward the front and rear of the engine. This

is necessary for installation of the anti-rotation pin

in the next step.

CAUTION

Failure to install the anti-rotational

pin will allow the lifter to rotate off the

camshaft lobe, resulting in severe in-

ternal engine damage.

6. Install the anti-rotation pin (A, Figure 28) and

make sure it is seated correctly within the crankcase

receptacle and against the flats on both hydraulic

lifters (C, Figure 28).

7. Rotate the engine until both lifters for the cylin-

der head being serviced seat onto the cam’s lowest

position (base circle). The lifter’s top surface will

be flush with the top surface of the crankcase sur-

face as shown in Figure 34.

8. Install a new lifter cover gasket (Figure 35) onto

the crankcase.

NOTE

In order to clear the cylinder’s lower

cooling fins, the lifter cover two inner

Allen bolts must be tightened with a

short 90-degree Allen wrench (A, Fig-

ure 27).

9. Install the lifter cover and the mounting bolts (B,

Figure 27). Tighten the bolts to the specification in

Table 4.

10. Install new O-ring seals (Figure 36) onto each

end of the pushrod covers. Apply a light coat of

clean engine oil to the O-rings.

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ENGINE

113

11. If the pushrod cover assembly was disassem-

bled, reassemble it as described under Pushrods in

this chapter.

CAUTION

The pushrod covers and the pushrods

must be installed in the correct loca-

tion in the cylinder head and pushrod

cover as indicated in Table 3.

12. Compress the pushrod cover and install it into

the correct location in the lifter cover and cylinder

head (Figure 37). Do not install the spring cap re-

tainer at this time.

13. Repeat Steps 11 and 12 for the other pushrod

cover.

14. Install the pushrods as follows:

CAUTION

Two different length pushrods are

used in the Dyna Glide’s engine. The

black exhaust pushrod (A, Figure 38)

is longer than the silver intake

pushrod (B).

a. If installing the existing pushrods, install each

pushrod in its original position and in the cor-

rect orientation. Refer to (A, Figure 24) for

intake and (B) for exhaust. The pushrods are

symmetrical and can be installed with either

end facing up.

b. Make sure the pushrod is centered into its re-

spective lifter.

15. Install the rocker arm support assembly and

bolts (Figure 39).

CAUTION

To avoid damaging a pushrod,

rocker arms or valves, tighten the

rocker arm support mounting bolts

evenly and in a crisscross pattern.

When tightening the mounting bolts,

spin each pushrod by hand to ensure

that the rocker arm support is being

tightened evenly. If one or both

pushrods cannot be rotated, loosen

the mounting bolts and determine

the cause.

16. Tighten the rocker arm support assembly and

bolts evenly in a crisscross pattern to the torque

specification in Table 4.

17. Ensure that the pushrod cover O-rings are cor-

rectly seated in the cylinder head and lifter cover.

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CHAPTER FOUR

Depress the spring cap (A, Figure 40) and install

the spring cap retainer (B). Make sure the spring cap

retainer is correctly seated. Repeat for the remain-

ing pushrod cover.

18. Assemble the breather as follows:

a. If removed, install the valve onto the breather

baffle and pull the tip through from the other

side (Figure 41) to seat it.

b. Install a new gasket (Figure 42).

c. Install a new filter element.

d. Hold the filter element in place and install the

breather baffle (Figure 43).

e. Install the cover and bolts (Figure 44), and

tighten them securely.

19. Install a new rocker arm cover gasket (Figure

45).

20. Install the rocker arm cover.

NOTE

There are two different length bolts

(Figure 46) securing the rocker arm

cover.

21. Apply ThreeBond TB1342, or an equivalent,

threadlocking compound to the bolt threads. Install

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ENGINE

115

ROCKER ARM COVER TORQUE SEQUENCE

Short bolts

Long bolts

d. Replace the rocker arm and/or the rocker arm

support if the side clearance is greater than

the specification in Table 2.

2. Prior to disassembling the rocker arms, mark each

one with an IN (intake) or EX (exhaust) (Figure 50)

to ensure they are installed in their original positions.

3. Remove the rocker arm shafts (A, Figure 51)

and remove the rocker arms (B).

4. Clean all parts in solvent. Blow compressed air

through all oil passages.

5. Install the rocker arm shaft (A, Figure 52) part

way into the rocker arm support (B) in its original

position.

the rocker arm cover six bolts (Figure 47) and

6. Install a rocker arm (C, Figure 52) into its origi-

tighten 1/8 turn at a time in the sequence shown in

nal position and push the shaft part way through the

Figure 46. Tighten to the specification in Table

rocker arm.

7. Align the notch in the rocker arm shaft (A, Fig-

ure 53) with the mating bolt hole (B) in the support

and install the shaft all the way. Check for correct

Rocker Arm Disassembly/Assembly

alignment (Figure 54).

8. Repeat Step 6 and Step 7 for the remaining

Refer to Figure 48.

rocker arm and shaft.

1. Before removing the rocker arms, measure the

rocker arm end clearance as follows:

Rocker Arm Component Inspection

a. Insert a feeler gauge between the rocker arm

and the inside rocker arm support boss as

When measuring the rocker arm components,

shown in Figure 49.

compare the actual measurements to the specifica-

b. Record the measurement.

tions in Table 2. Replace any part that is damaged or

c. Repeat for each rocker arm.

out of specification as described in this section.

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ENGINE

117

1. Inspect the rocker arm pads and ball sockets

(Figure 55) for pitting and excessive wear.

2. Examine the rocker arm shaft (Figure 56) for scor-

ing, ridge wear or other damage. If these conditions are

present, replace the rocker arm shaft. If the shaft does

not show any wear or damage, continue with Step 8.

3. Check the rocker arm bushing (Figure 57) for

wear or scoring.

4. Measure the rocker arm shaft diameter (Figure

58) where it contacts the rocker arm bushing and

rocker arm support. Measure both ends of the shaft.

Record each measurement.

5. Measure the rocker arm bushing inside diameter

(Figure 59) and the rocker arm support bore diame-

ter. Record each measurement.

6. Subtract the measurements taken in Step 4 from

those taken in Step 5 to obtain the following rocker

arm shaft measurements:

a. Shaft-to-rocker arm support.

b. Shaft-to-rocker arm bushing.

7. Replace the rocker arm, the bushings or the

rocker arm support if the clearance exceeds the

specifications in Table 2. Rocker arm bushing re-

placement is described in this chapter.

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118

CHAPTER FOUR

8. Inspect the rocker arm shaft contact surfaces in

the rocker arm support (Figure 60) for wear or elon-

gation.

9. Inspect the gasket surface of the rocker arm

cover for damage or warp.

10. Inspect the rocker arm support (Figure 61) for

damage or warp.

11. Inspect both gasket surfaces of the rocker arm

housing for damage or warp.

Rocker Arm Bushing Replacement

Each rocker arm is equipped with two bushings

(Figure 57). Replacement bushings must be reamed

after installation. Use the JIMS rocker arm bushing

line reamer (part No. 94804-57). If the correct size

reamer is unavailable, have the bushings replaced

by a Harley-Davidson dealership.

NOTE

Since the new bushings must be

reamed, remove one bushing at a time.

The opposite bushing is then used as a

guide when reaming the first bushing.

1. Press one bushing (Figure 57) out of the rocker

arm. Do not remove the second bushing. If the bush-

ing is difficult to remove, perform the following:

a. Thread a 9/16 × 18 tap into the bushing.

b. Support the rocker arm in a press so that the

tap is at the bottom.

c. Insert a mandrel through the top of the rocker

arm and seat it on top of the tap.

d. Press on the mandrel to force the bushing and

tap out of the rocker arm.

e. Remove the tap from the bushing and discard

the bushing.

2. Position the new bushing with the split portion

facing toward the top of the rocker arm.

3. Press the new bushing into the rocker arm until

the bushing’s outer surface is flush with the end of

rocker arm bore.

4. Ream the new bushing with the bushing line

reamer as follows:

a. Mount the rocker arm in a vise with soft jaws

so that the new bushing is at the bottom.

CAUTION

Turn the reamer clockwise only. Do

not rotate the reamer counterclock-

wise or the reamer and bushing will

be damaged.

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ENGINE

119

CYLINDER HEAD

1. Valve keepers

2. Upper retainer

3. Inner valve spring

4. Outer valve spring

5. Oil seal

6. Lower retainer

7. Valve guide

8. Bolt-short

9. Bolt-long

10. Cylinder head

11. Valve seat

12. Valve

13. Gasket

b. Mount a tap handle on top of the reamer and

3. Replace any damaged pushrod.

insert the reamer into the bushing. Turn the

reamer clockwise until it passes through the

CYLINDER HEAD

new bushing and remove it from the bottom

side.

Refer to Figure 63.

5. Remove the rocker arm from the vise and repeat

Steps 1-3 to replace the opposite bushing. The first

The cylinder head procedures are shown on the

bushing will now serve as a guide while reaming the

rear cylinder. The same procedures also relate to the

second bushing.

front cylinder. If differences occur they are identi-

6. After installing and reaming both bushings,

fied.

clean the rocker arm assembly in solvent. Then

NOTE

clean with hot, soapy water and rinse with clear,

The following procedures are shown

cold water. Dry with compressed air.

with the engine removed to better il-

7. Measure the inside diameter of each bushing.

lustrate the steps.

When properly reamed, the bushings must provide

the shaft clearance listed in Table 2.

Removal

Pushrod Inspection

1. Remove the rocker arm assemblies and pushrods

1. Clean the pushrods in solvent and dry with com-

as described in this chapter.

pressed air.

2. Using a crisscross pattern, loosen the four cylin-

2. Check the pushrods for bending, cracks and

der head bolts (Figure 64) 1/8 turn at a time. Re-

worn or damaged ball heads (Figure 62).

move the four bolts and note the different lengths.

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 6