Cylinder Head Service

3.11

Figure 3-41. Cylinder Head Fasteners

PART NO.

SPECIALTY TOOL

HD-39786

Cylinder head holding fixture

HD-45333

Cylinder head holder

HD-45312

Cam chain tensioner guide pin remover/ installer

HD-45491

Tappet compressing tool

HD-34736-B

Valve spring compressor

GENERAL

If TAPPET COMPRESSING TOOL (HD-45491) is in place from the cam drive removal process, remove it before proceeding. Removing the head with valves extended could result in damage.

REMOVAL AND DISASSEMBLY

1. See Figure 3-41. Remove seven fasteners retaining head. The four main headbolts are external TORX E14. Use Snap-on tool 1MFLE140 to remove main headbolts.

2. Remove the cylinder heads.

3. See Figure 3-40. Use CYLINDER HEAD HOLDING FIXTURE (HD-39786) and CYLINDER HEAD HOLDER (HD-45333) to secure cylinder head for service.

Figure 3-41. Cylinder Head Fasteners

Figure 3-40. Cylinder Head Holder

Harley Davidson Rod Head Cylinder

Figure 3-45. Valve Spring Coils

4. See Figure 3-42. Use CAM CHAIN TENSIONER GUIDE PIN REMOVER/INSTALLER (HD-45312) to remove cam chain tensioner pins.

5. See Figure 3-43. Clean oil film from tappets and use marker to number tappets according to the cast in number at each valve. Remove tappets and shims and keep together for assembly in same position.

6. See Figure 3-44. Install VALVE SPRING COMPRESSOR (HD-34736-B). Remove valves, springs and keepers. Keep removed parts organized so they will be assembled in same position.

7. See Figure 3-45. Tightly wound coils are always installed to the bottom.

Figure 3-42. Cam Chain Tensioner Guide Pins

Figure 3-44. Valve Spring Compressor

Figure 3-45. Valve Spring Coils

Figure 3-43. Number Tappets

Figure 3-46. Valve Spring Compressor

Figure 3-48. Valve Stem and Guide Measurement

Figure 3-46. Valve Spring Compressor

8. See Figure 3-46. Check valve spring height and compression rate. Replace if spring height or spring rate is not within specification. See 3.1 SPECIFICATIONS.

Figure 3-47. Valve Seal

9. See Figure 3-47. Remove valve guide seal with Snap-on tool number YA8230.

10. See Figure 3-48. Measure valve stem diameter and valve guide bore.

11. Subtract the valve stem measurement from the valve guide bore measurement to calculate the running clearance.

12. Compare the measurements to the following table. See Table 3-29.

Table 3-29. Valve Guide Running Clearance

Valve Guide

MM

IN

Intake

Min

0.0285

0.0012

Max

0.0585

0.0023

Exhaust

Min

0.0385

0.0016

Max

0.0685

Do not remove valve guides within valve guide running clearance. See Table 3-29.

Figure 3-51. Valve Guide Installation

Figure 3-49. Valve Guide Removal

Figure 3-50. Valve Guide Dimensions

13. See Figure 3-49. Remove and replace the valve guides that do not meet specifications. Position head for removal of valve guide. Use CYLINDER HEAD SUPPORT STAND (HD-39782) with CYLINDER SUPPORT ADAPTER (HD-39782-13) for intake valves and CYLINDER SUPPORT ADAPTER (HD-39782-14) for exhaust valves.

Figure 3-49. Valve Guide Removal

14. See Figure 3-50. Measure cylinder valve guide bore to determine valve guide diameter needed. Select valve guide no larger than 0.051 mm (0.0020 in.) to 0.022 mm (0.00086 in.) over size of cylinder bore.

15. See Figure 3-51. Use VALVE GUIDE REMOVER/ INSTALLER (HD-45320) to install valve guide at correct height.

Figure 3-51. Valve Guide Installation

16. See Figure 3-52. Use VALVE GUIDE REAMER (HD-45319) to return installed guide to correct diameter.

17. See Figure 3-53. Use VALVE GUIDE FLEX HONE (HD-45321) to get the correct surface finish for proper valve stem-to-guide fit and lubrication.

18. See Figure 3-54. Clean valve guide with VALVE GUIDE CLEANING BRUSH (HD-34751).

19. See Figure 3-55. Verify stem to guide clearance is correct after reaming.

20. Clean valve stem bore and insert 6 MM PILOT (HD-35758-51) in bore.

NOTE

ALWAYS clean valve stem bore before inserting pilot. Clean bores of all valve guides not replaced as well.

Figure 3-52. Ream Valve Guide
Figure 3-53. Hone Valve Guide
Figure 3-54. Valve Guide Cleaning Brush (HD-34751)
Figure 3-55. Measure Stem to Guide Clearance
Harley Valve Angle
Figure 3-56. 6 mm Pilot (HD-35758-51)

Intake Valve and Seat

Min. 0.750 mm (0.029 in.) Max. 0.860 mm (0.033 in.)

Exhaust Valve and Seat

Min. 1.050 mm (0.041 in.). Max. 1.170 mm (0.046 in.)

There is no bottom angle on the exhaust seat

Figure 3-57. Valve and Seat Dimensions

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  • Oskari
    How to clean vrsc cylinder head valves?
    3 years ago

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