Content      ..     12      13      14      15     ..

Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 14

HOME

a. Install primary cam sprocket onto splines of rear

camshaft. Install long flange bolt with thicker flat

washer to secure sprocket to end of camshaft.

b. Install crank sprocket onto crankshaft. Install short

flange bolt with smaller diameter flat washer (that is,

washer from bulk inventory) to secure sprocket to

end of crankshaft.

NOTE

Use of smaller diameter flat washer with crank sprocket

flange bolt allows room on sprocket face for placement of

straightedge under step 22(e).

c. To prevent rotation, position the CRANKSHAFT/

CAMSHAFT SPROCKET LOCKING TOOL (HD-

f2142b3x

42314) between the crank and primary cam sprock-

ets. See Figure 3-52. The handle of the tool is

Figure 3-53. Check Alignment of Crank and

stamped “Crank” and “Cam” to ensure proper orien-

Primary Cam Sprocket Faces

tation. Tighten the crank and primary cam sprocket

flange bolts to

15 ft-lbs

(20.3 Nm). Remove the

sprocket locking tool.

e. Place a straightedge across the crank and primary

cam sprocket faces. Try to insert a 0.010 inch feeler

d. Push on rear camshaft to remove end play.

gauge between the straightedge and each sprocket

face. See Figure 3-53. If the feeler gauge does not

fit at either location, then proceed to step 22(f).

On the other hand, if the crank sprocket is “proud”

(that is, rises above the face of the primary cam

sprocket) more than 0.010 inch, remove the flange

bolt and primary cam sprocket, and noting the part

number stamped on the existing spacer, replace it

with the next larger size. See spacer sizes listed in

Table 3-4. Replace the spacer with the next smaller

size only if the primary cam sprocket is “proud”

(rises above the face of the crank sprocket) more

than 0.010 inch. Return to step 21 to repeat the

Figure 3-51. Crankshaft/Camshaft Sprocket Locking Tool

check with the new spacer installed.

(Part No. HD-42314)

Table 3-4. Primary Cam Sprocket Spacers

Spacer Size

H-D Part Number

0.287

25722-00

0.297

25723-00

0.307

25721-00

0.317

25719-00

0.327

25717-00

0.337

25725-00

Sprocket

f.

Remove both crank and primary cam sprockets.

Locking Tool

Discard smaller diameter flat washer obtained from

f2139x3x

bulk inventory.

Figure 3-52. Lock Crank and Primary Cam Sprockets

23. Install the primary cam chain and sprocket assembly as

Before Tightening Flange Bolts

follows:

2006 Touring: Engine

3-47

HOME

NOTE

Crank

If the punch marks are not in alignment, then the sprockets

Primary Cam

Sprocket

must be removed and reinstalled. The vehicle will not run

Sprocket

properly if the sprockets are misaligned by even one tooth.

NOTE

Both crank and primary cam sprocket flange bolts are spe-

cially hardened, while the flat washers are of a special diam-

eter and thickness. Therefore, use only genuine Harley-

Davidson parts when replacement is necessary. The crank

and primary cam sprocket flange bolts and flat washers are

NOT interchangeable.

25. Install crank sprocket and primary cam sprocket flange

bolts and flat washers as follows:

NOTE

Exercise caution to avoid mixing oil on washer with thread-

locker on bolt or sealing integrity may be compromised.

a.

Apply a thin film of clean H-D 20W50 engine oil to

both sides of flat washers.

b.

Install thinner flat washer on short flange bolt.

f2138b3x

Punch Marks

c.

Install thicker flat washer on long flange bolt.

d.

Apply Loctite Primer

7649

(P/N

98968-99) to

Figure 3-54. Verify Alignment of Crank and

threads of flange bolts.

Primary Cam Sprocket Punch Marks

e.

Apply one drop of Loctite High Strength Thread-

locker 262 (red) to threads of flange bolts.

a. Place the primary cam sprocket in the cam chain.

Hold the sprocket allowing the chain to hang loose.

f.

Install short flange bolt with thinner flat washer to

Rotate the sprocket so that the punch mark on the

secure crank sprocket to end of crankshaft.

sprocket root faces straight downward.

g.

Install long flange bolt with thicker flat washer to

secure primary cam sprocket to end of camshaft.

NOTE

To maintain the original direction of rotation, verify that the

h.

Position CRANKSHAFT/CAMSHAFT SPROCKET

colored mark placed on the chain link and crank sprocket is

LOCKING TOOL (HD-42314) between the crank

facing away from the cam support plate during installation.

and primary cam sprockets to prevent rotation. See

Figure 3-52. The handle of the tool is stamped

b. Place the crank sprocket in the opposite end of the

“Crank” and “Cam” to ensure proper orientation.

chain with the punch mark on the sprocket tooth fac-

i.

Alternately tighten the crank and primary cam

ing straight upward.

sprocket flange bolts to 15 ft-lbs (20.3 Nm).

c. Maintaining the position of the sprockets on the

j.

Loosen each flange bolt one full turn.

chain with the punch marks in alignment, start the

primary cam sprocket onto the splines of the rear

k.

Tighten the crank sprocket flange bolt to 24 ft-lbs

camshaft. Apply a thin film of clean H-D 20W50

(32.5 Nm).

engine oil to the splines before installation.

l.

Tighten the primary cam sprocket flange bolt to 34

d. Maintaining the position of the crank sprocket on the

ft-lbs (46.1 Nm).

chain, rotate the primary cam sprocket in a clock-

m.

Remove the sprocket locking tool.

wise direction until the flat on the crank sprocket is

aligned with the flat on the crankshaft. Install the

crank sprocket.

1CAUTION

24. Rotate the primary cam sprocket in a clockwise direction

Ease the primary cam chain tensioner into the unloaded

until the punch mark on the root is aligned with the

position using the proper tool. Do not pull the retention

punch mark on the crank sprocket tooth. Lay a straight-

pin to unload the tensioner or the pin may be damaged.

edge across the centerline of the crank and primary cam

Furthermore, if the tensioner should contact fingers or

sprocket flange bolt holes to verify that the punch marks

other parts of the hand, minor or moderate injury may

are in alignment. See Figure 3-54.

occur.

3-48

2006 Touring: Engine

HOME

26. Hold the retracted primary cam chain tensioner with the

CAM CHAIN TENSIONER UNLOADER (HD-42313),

7

6

pull retention pin from hole in cam support plate and

Torque: 125-155 in-lbs

4

ease the assembly into the unloaded position.

1

27. Apply clean H-D 20W50 engine oil to crank and primary

cam sprockets.

CAUTION

Before cam cover installation, verify cleanliness of blind

holes in the crankcase flange. Tightening screws with

9

dirt, water or oil in the holes can cause the casting to

crack or break. Damage to the casting requires replace-

10

ment of the right crankcase half.

28. Align holes in new cam cover gasket with those in the

5

crankcase flange.

8

29. Install the cam cover using ten allen head socket screws

(1/4 x 1-1/4 inches). Alternately tighten screws to 125-

155 in-lbs (14.1-17.5 Nm) following the pattern shown in

Figure 3-55.

3

2

f1616b3x

30. If performing a complete engine overhaul, see Section

3.9 TOP END OVERHAUL, ASSEMBLY, steps 1-39. If

Figure 3-55. Cam Cover Torque Sequence

only cam compartment components were serviced, just

see steps 29-39.

2006 Touring: Engine

3-49

HOME

Legend:

1.

Bolt

24.

Upper Push Rod Cover

2.

Bolt

25.

Spring Cap Retainer

3.

Rocker Cover

26.

Spring Cap

2

4.

Rocker Cover Gasket

27.

Spring

5.

Breather Bolt

28.

Flat Washer

6.

Breather Cover

29.

O-Ring

1

7.

Breather Cover Gasket

30.

Lower Push Rod Cover

8.

Umbrella Valve

31.

O-Ring

9.

Breather Baffle

32.

Lifter Cover Screw

10.

Filter Element

3

33.

Lifter Cover

11.

Breather Baffle Gasket

34.

Anti-Rotation Pin

12.

Rocker Arm Bolt

35.

Lifter Cover Gasket

13.

Rocker Arm Support Plate

5

36.

Hydraulic Lifter

14.

Rocker Arm Bushing

37.

Push Rod

15.

Rocker Arm

16.

Rocker Arm Shaft

17.

Rocker Arm

18.

Breather Baffle O-Ring

4

19.

Rocker Housing Bolt

20.

Rocker Housing Bolt

21.

Rocker Housing

7

22.

Rocker Housing Gasket

23.

O-Ring

6

9

12

8

14

11

15

12

10

13

14

23

19

24

17

16

18

20

16

25

26

21

28

27

29

30

22

31

32

33

37

34

36

35

f2239x3x

Figure 3-56. Rocker Arm/Breather/Lifter Assemblies (Exploded View)

3-50

2006 Touring: Engine

HOME

SUBASSEMBLY SERVICE AND REPAIR

3.11

TOP END

f2176x3x

1

BREATHER ASSEMBLY

2

Removal

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

3

BLY, steps 1-7.

Disassembly

1.

Remove two bolts and lift breather assembly from rocker

arm support plate. See Figure 3-57.

2.

Remove the breather cover and gasket. Remove the

breather baffle and gasket. Discard gaskets.

3.

Pull filter element from bore on inboard side of breather

4

5

baffle. Pull stem of umbrella valve from hole at top of

breather baffle. Discard both filter element and umbrella

valve.

Cleaning and Inspection

6

1.

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

vent.

7

2.

Thoroughly dry all parts with low pressure compressed

air.

1.

Bolt

3.

Set a straightedge diagonally across the length of the

2.

Breather Cover

5.

Breather Baffle

breather cover intersecting the opposite corners of the

3.

Cover Gasket

6.

Filter Element

gasket surface. Slide a feeler gauge beneath the

4.

Umbrella Valve

7.

Breather Baffle Gasket

straightedge to check the breather cover for warpage.

Repeat the step checking the opposite diagonal. Discard

Figure 3-57. Breather Assembly

the breather cover if any low spot exceeds 0.005 inch

(0.13 mm).

4.

Repeat step 3 to inspect the gasket surface of the

breather baffle for flatness. Discard the breather baffle if

any low spot exceeds 0.005 inch (0.13 mm).

3.

Place breather baffle gasket on a clean flat surface.

Aligning holes, place breather baffle, cover gasket and

breather cover on top. Slide two screws through stackup

Assembly

to keep assembly together until time of installation.

1.

Insert stem of new umbrella valve through center hole at

top of breather baffle. Carefully pull rubber bead on stem

through hole in baffle. Use denatured alcohol or glass

cleaner to lubricate stem, if necessary. Verify that rubber

Installation

bead is pulled completely through hole and resides on

1.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

bottom side of baffle.

steps 33-39.

2.

Press new filter element into bore at bottom of baffle.

Hole in filter element accommodates umbrella valve

stem.

2006 Touring: Engine

3-51

HOME

3.

Remove the rocker arms from the rocker arm support

ROCKER ARM ASSEMBLY

plate. Mark the rocker arms to indicate location.

Removal

Cleaning and Inspection

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-9.

1.

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

vent. Thoroughly dry with low pressure compressed air.

Disassembly

2.

Check rocker arms for uneven wear or pitting where con-

tact is made with the valve stem tips. Check for concave

1.

Remove the four bolts from the rocker arm support plate.

wear where rocker arms contact the push rod ends.

If necessary, slightly wiggle the two bolts on the push rod

Replace rocker arm if excessive wear is found at either

side (right) to disengage them from the notches in the

location.

rocker arm shafts.

3.

Verify that oil holes in rocker arms and rocker arm sup-

2.

Using a hammer and brass drift, tap left side of rocker

port plate are clean and open.

arm shafts so that the notched ends exit the rocker arm

support plate first. Mark the shafts so that they are

4.

Inspect rocker arm shafts for scratches, burrs, scoring or

installed in their original locations at time of assembly.

excessive wear. Replace as necessary.

A

B

C

D

Figure 3-58. Measure Rocker Arm Assembly for Wear

3-52

2006 Touring: Engine

HOME

5.

Measure the inside diameter of the rocker arm support

plate bore. See A of Figure 3-58. Measure the outside

Remove Bushings.

diameter of the rocker arm shaft where it fits in the bore.

See B of Figure 3-58. Repeat the measurement on

opposite side of support plate and shaft. Replace the

shaft or support plate if any measurement equals or

exceeds 0.0035 inch (0.089 mm).

Driver

Discarded Shaft

6.

Measure the inside diameter of the rocker arm bushing.

See C of Figure 3-58. Measure the outside diameter of

the rocker arm shaft where it rides in the bushing. See D

of Figure 3-58. Repeat the measurement on opposite

side of rocker arm and shaft. Replace the shaft or bush-

ings if any measurement equals or exceeds 0.0035 inch

(0.089 mm).

7.

To replace rocker arm bushings, proceed as follows:

NOTE

9/16”-18 Tap

Remove, install and ream one bushing at a time.

6916

a. Obtain a 9/16”-18 (14.29 mm) tap. Turn tap into

bushing until tight. Place rocker arm under ram of

arbor press with tap at bottom. Slide a discarded

Install Bushings.

rocker arm shaft through open end of rocker arm

until contact is made with tap. Using shaft as driver

(and untapped bushing as pilot), press against shaft

until both tap and bushing are free. See upper

Driver

frame of Figure 3-59.

b. Using a suitable driver, press new bushing into side

of rocker arm until flush with casting. See center

frame of Figure 3-59. Be sure to orient bushing so

that split line faces top of rocker arm.

CAUTION

Never back reamer out of rocker arm or new bushing will

be damaged.

c. Lock rocker arm in a vise using brass jaw inserts or

shop towels to prevent casting damage. Insert

6922

tapered end of ROCKER ARM BUSHING REAMER

(HD-94804-57) into old bushing in rocker arm. Note

that old bushing on drive side of reamer serves as

pilot. See lower frame of Figure 3-59. Rotate reamer

Ream Bushings.

until new bushing on far side is reamed, and then

continuing in the same direction, draw drive side of

reamer from new bushing.

Bushing Reamer

d. Repeat steps 7(a) thru 7(c) to remove, install and

Part No. HD-94804-57

ream second bushing.

Assembly

1.

Place the rocker arms into position on the rocker arm

support plate.

2.

Push the un-notched ends of the rocker arm shafts into

the right side of the support plate and then into the

rocker arms. As they approach their fully installed posi-

tions, rotate the shafts so that the notches are aligned

with the bolt holes in the support plate.

6923

Figure 3-59. Replace Rocker Arm Bushings

2006 Touring: Engine

3-53

HOME

3.

To check for proper end play, insert a feeler gauge

between the rocker arm and support plate. See Figure 3-

60. Repeat measurement on other rocker arm. Replace

the rocker arm, rocker arm support plate, or both if end

play exceeds 0.025 inch (0.635 mm).

4.

Install the four bolts in the rocker arm support plate. For

proper assembly, remember that the two bolts on the

push rod side (right) must engage the notches in the

rocker arm shafts.

Installation

1.

See Section 3.9 TOP END OVERHAUL, ASSEMBLY,

steps 31-39.

6917

Figure 3-60. Check End Play

3-54

2006 Touring: Engine

HOME

PUSH RODS/LIFTERS/COVERS

Spring Cap

Retainer

O-Ring

Removal

Small

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-14.

Disassembly

1.

With the exception of the lifter covers, all parts should

have been disassembled and marked during the

Spring Cap

removal procedure. Disassemble the lifter covers as fol-

lows:

Spring

a. Separate upper and lower push rod covers.

b. Remove O-ring from seat at bottom of lower push

Flat

rod cover. Discard O-ring.

O-Ring

Washer

Intermediate

c. Remove O-ring from seat at top of upper push rod

cover. Slide O-ring, flat washer, spring and spring

cap from body of upper push rod cover. Discard O-

rings.

Upper

Push Rod

Cover

Cleaning and Inspection

Flared End

1.

Scrape old gasket material from the lifter cover flange.

Old gasket material left on mating surfaces will cause

leaks.

2.

With the exception of the hydraulic lifters, clean all parts

in a non-volatile cleaning solution or solvent. Verify that

the O-ring seats and contact surfaces of the push rod

covers are completely clean.

Lower

3.

Thoroughly dry all parts with low pressure compressed

Push Rod

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

Cover

4.

Verify that the hydraulic lifter rollers turn freely and are

free of flat spots, scuff marks and pitting. If flat spots

exist, examine the cam lobe on which the lifter operates.

5.

Inspect the lifter socket for signs of wear. Verify that the

plunger of the hydraulic lifter is fully extended up against

the C-clip. Use index finger to pump plunger to verify

O-Ring

lifter operation.

f1584x3x

Large

6.

Examine the push rods. Replace any push rods that are

bent, dented, broken or discolored. Replace the rod if

Figure 3-61. Push Rod Cover Assembly

the ball ends show signs of excessive wear or damage.

7.

Cover all parts with a clean plastic sheet to protect them

CAUTION

from dust and dirt.

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

Assembly

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

sure. Use of the wrong O-ring will have the same results.

1.

With the exception of the lifter covers, all parts will be

Since many O-rings are similar in size and appearance,

assembled during the installation procedure. Assemble

always use new O-rings keeping them packaged until

the lifter covers as follows:

use to avoid confusion.

2006 Touring: Engine

3-55

HOME

Legend:

1.

Tapered Keepers

2.

Spring Retainer

1

3.

Valve Spring

4.

Spring Seat/Valve Stem Seal

5.

Lock Ring

2

7

6.

Valve Guide

7.

Cylinder Head Bolt

8.

Cylinder Head Bolt

3

9.

Cylinder Head

10.

Valve Seat

11.

Valve

12.

Cylinder Head Gasket

4

8

13.

Cylinder

14.

Ring Dowel

5

15.

O-Ring Seal

6

16.

Cylinder Stud

17.

Piston

18.

Piston Pin

19.

Circlip

20.

Top Compression Ring

21.

Second Compression Ring

22.

Oil Rail

9

23.

Oil Rail Spacer

10

11

12

14

20

22

13

21

22

19

23

18

17

19

15

16

f2412x3x

Figure 3-62. Cylinder Head/Cylinder/Piston Assemblies (Exploded View)

3-58

2006 Touring: Engine

HOME

CYLINDER HEAD

Removal

1.

See Section 3.9 TOP END OVERHAUL, DISASSEM-

BLY, steps 1-11 and 15-19.

Disassembly

1.

Before proceeding with the disassembly procedure,

determine if cylinder head reconditioning is necessary.

Figure 3-65. Valve Spring Compressor

Proceed as follows:

(Part No. HD-34736B)

a. Raise valve ports of cylinder head to strong light

source. If light is visible around edges of seats, then

move to step 2 to recondition cylinder head.

f1648x3x

b. Fill ports at top of cylinder head with solvent. Wait

ten full seconds and then check for leakage into

combustion chamber. If solvent leakage into com-

bustion chamber is evident, then move to step 2 to

recondition cylinder head.

14mm End

12mm End

Figure 3-63. Cylinder Head Holding Fixture

Figure 3-66. Compress Valve Springs

(Part No. HD-39786)

2.

Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

f2403x3x

39786) and proceed as follows:

a. Note that both ends of the fixture are threaded, one

end at 14mm and the other at 12mm. Thread the

12mm end of the tool into the spark plug hole of the

cylinder head.

b. Clamp tool in vise at a 45 degree angle (or one that

offers a comfortable working position). See Figure

3-64.

3.

Obtain the VALVE SPRING COMPRESSOR

(HD-

34736B) and proceed as follows:

a. Place tool over cylinder head so that the blunt end is

centered on the valve head and adapter at end of

forcing screw is seated on the valve spring retainer.

Cylinder Head

See Figure 3-66.

Holding Fixture

b. Rotate forcing screw to compress valve spring.

c. If spring retainer has not broken free of tapered

keepers, give head of tool a sharp tap with a soft

mallet. Using magnetic rod or small screwdriver,

Figure 3-64. Install Cylinder Head Holding Fixture in Vise

remove the keepers from the valve stem groove.

2006 Touring: Engine

3-59

HOME

Tapered Keepers

1.

Inspect parts for damage or rust pits. Replace as neces-

Intake Seat

sary.

Adapter

2.

Inspect inboard side of tapered keepers for excessive

Part No. HD-39782A-3

Cylinder Head

wear. Upraised center must be pronounced and fit

Support Stand

snugly in valve stem groove. Place keepers into groove

and verify that they grip tightly without sliding.

Valve Seats

1.

Inspect seats for cracking, chipping or burning. Replace

seats if any evidence of these conditions are found.

Exhaust Seat

2.

Check seats for recession by measuring valve stem pro-

Adapter

trusion. See VALVE AND SEAT REFACING in this sec-

Part No. HD-39782A-4

tion, steps 5-6.

Figure 3-67. Cylinder Head Support Stand

VALVE GUIDE REPLACEMENT

(Part No. HD-39782A)

Removal

NOTE

Valve Guide

If valve guide replacement is necessary, always install new

Driver

guide before refacing valve seat.

1.

Obtain the CYLINDER HEAD SUPPORT STAND (HD-

39782A) and proceed as follows:

a. Insert sleeve of intake or exhaust seat adapter into

tube at top of support stand. See Figure 3-67.

Valve Guide

Installer Sleeve

b. Position cylinder head so that valve seat is centered

on seat adapter. Support stand ensures that valve

guide and seat are perpendicular. If perpendicular-

Figure 3-68. Valve Guide Driver (Part No. B-45524-1) and

ity is not achieved, the cylinder head valve guide

Valve Guide Installer Sleeve (Part No. B-45524-2A)

bore will be damaged during the press procedure.

Valves

f2404x3x

1.

Replace the valve if there is evidence of burning or

Ram

cracking.

Valve Guide

2.

Inspect the end of the valve stem for pitting or uneven

Driver

wear. Replace the valve if either of these conditions are

found.

3.

Inspect for burrs around the valve stem keeper groove.

Remove burrs with a fine tooth file if found.

4.

To determine if the valve stem is excessively worn, see

INSPECTION, VALVE GUIDES, step 2.

Valve Springs

1.

Inspect springs for broken or discolored coils. Replace

springs if either of these conditions are found.

2.

Set the intake and exhaust valve springs on a level sur-

face and use a straightedge to check for proper square-

ness and height.

Cylinder Head

3.

Check free length of springs using a dial vernier caliper

Support Stand

or load test with the VALVE SPRING TESTER (HD-

96796-47). Replace springs if free length or compres-

sion force do not meet specifications. See Section 3.1

Figure 3-69. Remove Valve Guide

SPECIFICATIONS.

2006 Touring: Engine

3-61

HOME

NOTE

f2405x3x

Since some material is typically removed when the guide is

pressed out, it is normal to go to the next larger size for the

Valve Guide

proper interference fit.

Driver

Valve Guide

2.

Measure cylinder head bore and outside diameter of

Installer Sleeve

selected oversize guide to verify correct interference fit.

3.

Obtain the CYLINDER HEAD SUPPORT STAND (HD-

39782A), VALVE GUIDE DRIVER

(B-45524-1) and

VALVE GUIDE INSTALLER SLEEVE (B-45524-2A). Pro-

ceed as follows:

a. Insert sleeve of intake or exhaust seat adapter into

tube at top of support stand. Position cylinder head

so that valve seat is centered on seat adapter. Sup-

port stand ensures that valve guide and seat are

perpendicular. If perpendicularity is not achieved,

cylinder head valve guide bore will be damaged dur-

ing the press procedure.

Cylinder Head

b. Apply Vaseline to lightly lubricate external surfaces

Support Stand

of valve guide. Spread lubricant so that thin film cov-

ers entire surface area.

c. At top of cylinder head, start valve guide into bore.

Figure 3-70. Install Valve Guide

d. Place installer sleeve over valve guide, and then

insert tapered end of valve guide driver into sleeve.

e. Center valve guide driver under ram of arbor press

CAUTION

and apply pressure only until valve guide is started

in bore and then back off ram slightly to allow guide

Do not press out the valve guide from the bottom of the

to center itself. See Figure 3-70.

cylinder head. Carbon buildup on the combustion cham-

ber side of the guide can deeply gouge the cylinder head

bore diminishing the likelihood of achieving the proper

CAUTION

interference fit and possibly requiring replacement of

Always back off ram to allow the valve guide to find cen-

the cylinder head casting.

ter. Pressing guide into cylinder head in one stroke can

2.

Remove lock ring from valve guide groove. Discard lock

bend driver, break guide, distort cylinder head casting

ring.

and/or damage cylinder head valve guide bore.

NOTE

f.

Verify that support stand and driver are square.

Center driver under ram and press valve guide fur-

Lock ring is present on both OEM intake and exhaust valve

ther into bore, but then back off ram again to allow

guides.

valve guide to find center.

3.

At the top of the cylinder head, insert VALVE GUIDE

g. Repeat step 3(f) and then apply pressure to driver

DRIVER (B-45524-1) into valve guide bore until stopped

until installer sleeve contacts machined area of cyl-

by shoulder.

inder head.

4.

Center valve guide driver under ram of arbor press.

h. Install new lock ring into valve guide groove. Verify

Apply pressure until valve guide drops free of cylinder

that lock ring is square and fully seated in the

head. Discard the valve guide. See Figure 3-69.

groove.

4.

Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

Installation

39786) and proceed as follows:

a. Thread the 12mm end of the tool into the spark plug

1.

Measure the outside diameter of a new standard valve

hole of the cylinder head.

guide, and then measure the cylinder head valve guide

bore. The valve guide should be 0.0020-0.0033 inch

b. Clamp tool in vise at a 45 degree angle (or one that

(0.051-0.084 mm) larger than the bore.

offers a comfortable working position).

If clearance is not within specification, then select one of

NOTE

the following oversize guides - 0.001 inch (0.025 mm),

Valve guides must be reamed to within 0.0005 - 0.0001 inch

0.002 inch (0.05 mm) or 0.003 inch (0.08 mm).

(0.013 - 0.0025 mm) of finished size.

3-62

2006 Touring: Engine

HOME

d. Continue rotating reamer T-handle until entire bit

has passed through valve guide bore and shank of

reamer rotates freely.

Valve Guide

Reamer

CAUTION

Never back reamer out of valve guide or bore will be

damaged.

e. Remove T-handle from reamer, and carefully pulling

on bit, draw shaft of reamer out combustion cham-

Reamer

ber side of valve guide.

T-Handle

CAUTION

Figure 3-71. Valve Guide Reamer (Part No. B-45523) and

Reamer T-Handle (Part No. HD-39847)

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

f2406x3x

6.

Direct compressed air into the valve guide bore to

remove any metal shavings or debris.

7.

Clean valve guide bore with the VALVE GUIDE CLEAN-

Valve Guide

ING BRUSH (HD-34751).

Reamer

8.

Obtain the VALVE GUIDE HONE

(B-45525) and

REAMER LUBRICANT (HD-39964). Proceed as follows:

Reamer

T-Handle

Figure 3-72. Ream Valve Guide Bore

Figure 3-73. Valve Guide Hone (Part No. B-45525)

5.

Obtain the VALVE GUIDE REAMER

(B-45523),

REAMER T-HANDLE (HD-39847) and REAMER LUBRI-

CANT (HD-39964). Proceed as follows:

f2407x3x

a. Install T-handle on reamer.

b. Apply a liberal amount of reamer lubricant to valve

guide bore and bit of reamer. Start bit of reamer into

bore at top of cylinder head.

c. Placing thumb on drive socket of reamer T-handle,

apply slight pressure on reamer while rotating in a

clockwise direction. See Figure 3-72. Squirt addi-

tional lubricant onto reamer and into guide as nec-

essary.

CAUTION

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

sure to the reamer handle. While excessive pressure

results in a rough cut, bore will be tapered if pressure is

not centrally applied.

Figure 3-74. Hone Valve Guide Bore

2006 Touring: Engine

3-63

HOME

a. Install hone in a high speed electric drill.

f2409x3x

b. Apply reamer lubricant to finishing stones of hone

and valve guide bore.

c. Start finishing stones of hone into bore.

Dial Vernier

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

Caliper

ishing stone arrangement forward and backward

through the bore for 10 to 12 complete strokes. See

Figure

3-74. Work for a crosshatch pattern of

approximately 60˚.

CAUTION

Abrasive particles can damage machined surfaces and

plug oil passageways possibly resulting in engine fail-

ure.

9.

Direct compressed air into the valve guide bore to

remove any debris and then clean with the VALVE

GUIDE CLEANING BRUSH (HD-34751). See Figure 3-

76.

f2410x3x

Figure 3-75. Valve Guide Brush (Part No. HD-34751)

Figure 3-77. Measure Valve Stem Protrusion

f2408x3x

NOTE

Always verify valve stem to valve guide clearance after hon-

ing, since a worn reamer may cut the bore undersize.

10. Measure the inside diameter of the valve guide with an

inside ball micrometer. Measure the outside diameter of

the valve stem with an outside micrometer. The valve

stem may be excessively worn or the valve guide bore

undercut if the clearance is not within the limits (low end

preferable) shown in Table 3-6.

Table 3-6. New Parts Limits

Valve

Valve Stem to Guide Clearance

Intake

0.001 - 0.003 inch (0.0254-0.0762 mm)

Exhaust

0.001 - 0.003 inch (0.0254-0.0762 mm)

11. Using cleaning solvent, thoroughly clean cylinder head

and valve guide bore. Scrub valve guide bore with the

VALVE GUIDE CLEANING BRUSH (HD-34751). For

Figure 3-76. Scrub Valve Guide Bore

best results, use a thin engine oil and clean valve guide

3-64

2006 Touring: Engine

HOME

bore with the type of swabs or patches found in gun

Seat wear and valve refacing causes the valve stem pro-

cleaning kits. Continue to wipe bore until clean cloth

trusion to change. If protrusion exceeds 2.069 inches

shows no evidence of dirt or debris. Follow up with a

(52.55 mm), then replace the valve seat or cylinder

thorough wash in hot soapy water. Blow dry with com-

head.

pressed air.

CAUTION

VALVE AND SEAT REFACING

Do not shorten the valve by grinding on the end of the

stem. Grinding replaces the hardened case with mild

NOTE

steel which results in accelerated wear.

Verify correct valve stem to valve guide clearance before

refacing. See Table 3-6. If new guides must be installed,

7.

Remove valve from cylinder head. Apply magic marker

complete that task before refacing valves and seats.

or similar product to valve seat and allow to thoroughly

dry.

1.

Hold the valve firmly against a wire wheel in a bench

grinder. Remove all carbon deposits from the valve

8.

Insert the valve stem into the valve guide. Push on bot-

head, face and stem, but exercise caution to avoid

tom of valve until it contacts the valve seat.

removing any metal. Carbon left on the stem may affect

alignment in the valve refacer. Polish the valve stem with

9.

Obtain the VALVE LAPPING TOOL (HD-96550-36A) and

steel wool or crocus cloth to remove any marks that

proceed as follows:

might be left by the wire wheel.

2.

Install valve (both intake and exhaust) in a valve refacer

a. Attach suction cup at end of tool to valve head.

set to a 45 degree angle. The valve refacer is required

equipment, since accuracy in matching the angle of the

valve face with the angle of the valve seat is critical.

Do not remove any more metal than is necessary to

clean up and true the valve face. Removing metal

reduces the service life of the valve. The amount of

grinding needed to retrue the valve is a clear indication

of its condition. Discard the valve if it cannot be quickly

refaced while maintaining a good margin. Valves that do

not clean up quickly are either warped, excessively worn

or too deeply pitted to be used.

Obtain a new valve if grinding leaves the margin less

than 0.0313 inch (0.795 mm). A valve in this condition

does not seat normally, burns easily and may crack or

cause pre-ignition.

Figure 3-78. Valve Lapping Tool (Part No. HD-96550-36A)

3.

Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

39786) and proceed as follows:

6873

a. Thread the 12mm end of the tool into the spark plug

hole of the cylinder head.

b. Clamp tool in vise at a 45 degree angle (or one that

offers a comfortable working position).

4.

Obtain the NEWAY VALVE SEAT CUTTER SET (HD-

35758A) and cut valve seat angle to 46°.

NOTE

Valve Lapping

Tool

Do not remove any more metal than is necessary to clean up

the seat (that is, to provide a uniform finish and remove pit-

ting).

5.

From the bottom of the cylinder head, insert the valve

stem into the valve guide. Push on bottom of valve until it

contacts the valve seat.

6.

Placing finger at bottom of valve to keep valve seated,

use a dial vernier caliper to check the distance from the

Figure 3-79. Oscillate Tool to Create Contact Area

top of the valve stem to the machined area on the cylin-

der head. See Figure 3-77.

2006 Touring: Engine

3-65

HOME

14. Remove the valve and perform a final inspection of the

f1655x3x

contact pattern. If necessary, return to step 11.

15. Remove the valve from the cylinder head. Use contact

Head

cleaner to thoroughly clean magic marker and/or dye

from valve face and seat, if present.

Seat

60˚

16. Release the cylinder head holding fixture from the vise

0.040-0.062 in.

and then remove the tool from the spark plug hole.

(1.02-1.57 mm)

17. To confirm quality of valve and seat refacing work, pro-

ceed as follows:

Valve

a. Insert valve in guide, and holding valve to seat,

raise port to strong light source. If light is visible

31˚

46˚ Cutting

Margin

around edge of seat, then valves and seats must be

45˚ Grinding

0.0313 in.

reconditioned.

(0.795 mm)

b. Holding valve to seat, fill port at top of cylinder head

with solvent. Wait ten full seconds and then check

Figure 3-80. Valve Seat Angles

for leakage into combustion chamber. If solvent

leakage into combustion chamber is evident, then

valves and seats must be reconditioned.

b. Holding shank of tool between the palms of both

18. Clean valves, cylinder head and valve seats in solvent.

hands, oscillate the tool back and forth a few times.

Follow up with a thorough wash in hot soapy water. Blow

See Figure 3-79.

dry with compressed air.

10. Remove the valve from the cylinder head and carefully

inspect the mating surfaces under a good light.

Assembly

Inspection of the valve seat should show an unbroken

1.

Obtain the CYLINDER HEAD HOLDING FIXTURE (HD-

contact area of uniform width. If the seat is not concen-

39786) and proceed as follows:

tric with the valve guide, then the cutter will remove more

a. Thread the 12mm end of the tool into the spark plug

material in one spot than another. Carbon deposits may

hole of the cylinder head.

have caused the guide to be pressed in crooked, the

b. Clamp tool in vise at a 45 degree angle (or one that

guide may be cracked, or the cutter blade or cutter pilot

offers a comfortable working position).

have not have been properly cleaned.

NOTE

NOTE

At the time of disassembly, all parts should have been

If the results are not acceptable, then recut the valve seat or

marked or tagged so that they are installed on the same

replace the valve guide.

valve (and in the same head).

11. Inspect the contact pattern on the valve seat to be sure

2.

Run the VALVE GUIDE CLEANING BRUSH (HD-34751)

area is 0.040-0.062 inch (1.02-1.57 mm) wide and con-

through the valve guide bore to verify cleanliness.

tacts the valve two-thirds of the way towards the outer

3.

Using TORCO MPZ or another suitable product, apply a

edge of the valve face. See Figure 3-80. If necessary,

liberal amount of engine assembly lube to valve stem.

modify the seat pattern as follows:

4.

From the bottom of the cylinder head, insert the valve

a. Use the 31° angle cutter to lower the valve seat sur-

stem into the valve guide.

face and reduce its width.

5.

To distribute the assembly lube evenly around the valve

stem and guide, hand spin the valve as it is installed.

b. Use the 60° angle cutter to raise the valve seat sur-

Work the valve back and forth in the bore to verify that it

face and reduce its width.

slides smoothly and seats properly.

c. Use the 46° angle cutter to widen the valve seat sur-

6.

Remove the valve and apply a second coat of assembly

face.

lube to the valve stem. Install the valve in the valve

guide.

12. Using a magic marker, mark three equally spaced verti-

cal lines across the valve face and then insert the valve

CAUTION

back into the cylinder head.

Failure to install plastic capsule will cause the valve

13. Attach suction cup of VALVE LAPPING TOOL (HD-

stem seal to catch the edge of the valve stem keeper

96550-36A) to valve head, and holding shank of tool

groove. The resulting damage will lead to leakage around

between the palms of both hands, oscillate the tool back

the valve stem, excessive oil consumption and valve

and forth a few times.

sticking.

3-66

2006 Touring: Engine

Content      ..     12      13      14      15     ..