HOME

CYLINDER 3.23
CLEANING INSPECTION
1. See Figure 3-53. Scrape any remaining cylinder head
gasket material from the gasket surface at the top of the PART NUMBER TOOL NAME
cylinder (3). HD-42324-A CYLINDER TORQUE PLATES
TA360 SNAP-ON TORQUE ANGLE GAUGE

Compressed air can pierce the skin and flying debris from FASTENER TORQUE VALUE
compressed air could cause serious eye injury. Wear Cylinder torque plate bolts, 1st 120-144 13.6-16.3 Nm
safety glasses when working with compressed air. Never torque in-lbs
use your hand to check for air leaks or to determine air
Cylinder torque plate bolts, 15-17 ft-lbs 20.3-23.0 Nm
flow rates. (00061a)
2nd torque
2. Clean cylinder in a non-volatile cleaning solution or solvent. Cylinder torque plate bolts, 90 degrees 90 degrees
Dry parts with low pressure compressed air. Verify that oil final torque
passageways are clean and open.
3. Inspect the cylinder bore for obvious defects or damage 1. Using dye penetrant, inspect the cylinder for cracks. If no
in the ring travel area. Replace cylinders that are severely cracks are found, thoroughly wash cylinder to remove
scored, scuffed, scratched, burnt or gouged. traces of dye.
4. Use a file to carefully remove any nicks or burrs from the 2. See Figure 3-54. Check the machined surfaces for flatness
machined surfaces of the cylinder. using a feeler gauge and CYLINDER TORQUE PLATES
(Part No. HD-42324-A):
sm02529 a. Lay gasket side of the upper torque plate (3) flat
against the head gasket surface of the cylinder.
2 b. As a preliminary check, see if the plate rocks from
side to side. A cylinder on which the plate rocks is
1 immediately suspect.
c. Insert a feeler gauge between the plate and cylinder
at various locations.
d. The head gasket surface must be flat within 0.006 in.
(0.15 mm).
e. Lay the seal side of the lower torque plate (2) flat
against the O-ring seal surface and check flatness
3 using a feeler gauge.
f. The O-ring seal surface must be flat within 0.004 in.
(0.102 mm).
g. Replace the cylinder (and piston) if either surface
exceeds specification.
4
NOTE
Failure to use cylinder torque plates can produce measure-
ments that vary by as much as 0.001 in. (0.025 mm). This may
result in the use of parts that are unsuitable for service.
5

1. Cylinder head gasket

2. Dowel pin
3. Cylinder
4. O-ring seal
5. Cylinder stud
Figure 3-53. Cylinder Assembly

2015 Touring Service: Engine 3-53

HOME

3. Install CYLINDER TORQUE PLATES (Part No. HD-42324- 4. See Figure 3-57. Using an inside micrometer or dial bore
A): gauge, check cylinder bore for out-of round and taper:
a. Remove O-ring seal from cylinder sleeve, if installed. a. At the top of the piston ring travel zone, measure the
cylinder diameter at two locations; parallel and per-
b. See Figure 3-55. Clamp the stepped side of the lower
pendicular to the crankshaft. Record the readings.
plate in a vise with soft jaws.
b. Repeat the two measurements at the center of the
c. Lightly oil threads and shoulders of four bolts (1) with
piston ring travel zone and again at the bottom of the
clean engine oil and slide through holes of lower plate
bore at a point below the piston ring travel zone.
(2).
c. See 3.3 SERVICE WEAR LIMITS. If the out-of-round
d. Slide cylinder onto bolts with the indent in the cooling
or taper measurements are not within specification,
fins facing upward.
the cylinder must be rebored and/or honed to accept
e. Place a used head gasket on cylinder and install the next standard oversize piston. See 3.23 CYL-
upper plate with blind holes aligned with dowel pins INDER, Boring and Honing Cylinder.
in cylinder. Secure with bolts (1).
d. If cylinders are not scuffed or scored and are not worn
f. See Figure 3-56. Tighten the bolts to 120-144 in-lbs beyond the service limits, see 3.23 CYLINDER,
(13.6-16.3 Nm) in the sequence shown. Deglazing Cylinder.
g. Following the same sequence, tighten each bolt to
15-17 ft-lbs (20.3-23.0 Nm). sm02530
2
h. Final-tighten each bolt an additional 90 degrees (90 1
degrees) in the same sequence.

NOTE
For best results use SNAP-ON TORQUE ANGLE GAUGE
(Part No. TA360). If the tool is not available, mark a straight
line on each bolt head continuing the line onto the lower plate.

sm02506
3

1. Bolt (4)
2 2. Lower plate
4 3. Vise
1
Figure 3-55. Attaching Cylinder Torque Plates
1. Bolts
2. Lower plate
3. Upper plate
4. Vise grip step sm02531
3
Figure 3-54. Cylinder Torque Plates 4

NOTE
Maximum cylinder wear occurs at the top of top ring travel.
Minimum wear occurs below ring travel. Always take measure-
ments in both areas.
2
1

Figure 3-56. Cylinder Torque Plate Bolt Sequence

3-54 2015 Touring Service: Engine

HOME

6. Thoroughly wash the cylinder bore with liquid dishwashing

sm02532
soap and hot water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth shows
no evidence of dirt or debris.
7. Hot rinse the cylinder and dry with moisture free com-
pressed air. Immediately apply a thin film of clean engine
oil to a clean white paper towel and thoroughly wipe the
inside of the cylinder to prevent the cylinder bore from
rusting.
NOTE
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
remains white. The cylinder is now clean.
8. With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See
3.24 PISTON, Inspection.

BORING AND HONING CYLINDER

1. Bore cylinder with gaskets and torque plates attached.
Refer to Table 3-36. Bore the cylinder to 0.003 in. (0.08
mm) under the desired finished size.
Figure 3-57. Measure for Out-of-Round and Taper

DEGLAZING CYLINDER An incorrect crosshatch pattern or too fine a hone will

NOTE result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00538c)
Deglazing removes wear patterns, minor scuff marks and
scratches without enlarging the bore diameter. 2. Hone the cylinder to its finished size using a 280 grit rigid
hone followed by a 240 grit flexible ball hone. Honing must
1. Lightly swab the cylinder bore with a cloth dipped in clean be done with the torque plates attached. All honing must
engine oil. be done from the bottom (crankcase) end of the cylinder.
2. Obtain a 240 grit flexible ball-type deglazing tool with a Work for a 60 degree crosshatch pattern.
bristle tip or finishing stone arrangement able to produce 3. Stop frequently to examine the cylinder bore and/or take
a 60 degree crosshatch pattern. measurements. Remember, a precise 60 degree
3. Install the deglazing tool in a slow-speed drill. The speed crosshatch pattern in the piston travel area is important.
at which the tool rotates determines the speed at which it
must be stroked up and down the bore to produce the
desired crosshatch pattern.
Failure to remove all abrasive particles may result in pre-
4. Starting at the bottom of the cylinder, move the deglazing mature cylinder, piston and ring wear and engine failure.
tool up and down the entire length of the cylinder bore for (00537c)
10 to 12 complete strokes.
4. Thoroughly wash the cylinder bore with liquid dishwashing
5. Stop to examine the cylinder bore and/or take measure- soap and warm water to remove all abrasive particles and
ments. A precise 60 degree crosshatch pattern in the residual grit. Continue cleaning until a clean cloth shows
piston travel area is the most important. no evidence of dirt or debris.
5. Hot rinse the cylinder and dry with moisture free com-
pressed air.
The angular crosshatch pattern ensures an even flow of 6. Immediately apply a thin film of clean engine oil to a clean
oil onto the cylinder walls and promotes longer cylinder, white paper towel and thoroughly wipe the inside of the
piston and ring life. An incorrect cross hatch pattern will cylinder. This prevents the cylinder bore from rusting.
result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00536c) NOTE
After wiping the cylinder with a clean, oiled paper towel, the
towel will be dark with contamination. Repeat this process
using a new lightly oiled paper towel each time until the towel
Failure to remove all abrasive particles may result in pre- remains white. The cylinder is now clean.
mature cylinder, piston and ring wear and engine failure.
(00537c)

2015 Touring Service: Engine 3-55

HOME

7. With the cylinder at room temperature, check the piston 3.24 PISTON, Inspection.
clearance in the cylinder in which the piston will run. See

Table 3-36. Oversize Pistons and Cylinder Bores, Twin Cam 103

PISTON CYLINDER BORE FINISHED SIZE

TYPE SIZE MINIMUM MAXIMUM
Standard STD 3.8750 in (98.425 mm) 3.8755 in (98.438 mm)
Oversize 0.010 in (0.25 mm) 3.8850 in (98.679 mm) 3.8855 in (98.692 mm)

3-56 2015 Touring Service: Engine