Cylinder Head Installation - Buell 2003XB9S Service Manual

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CYLINDER HEAD INSTALLATION

CAUTION
Thoroughly clean and lubricate the threads of the cylin-
der head screws before installation. Friction caused by
dirt and grime will result in a false torque indication.
1. Thoroughly clean and dry the gasket surfaces of cylin-
ders and cylinder heads.
2. Install new O-rings over two ring dowels at the top of the
cylinder. Apply a very thin film of clean H-D 20W50
engine oil to O-rings before installation.
CAUTION
To ensure proper head gasket alignment, install new O-
rings over cylinder ring dowels before installing the head
gasket. Improper head gasket alignment will cause leaks.
3. Install a new head gasket to cylinder.
4. Carefully lower cylinder head over studs and position on
dowels. Use great care so as not to disturb head gasket.
5. Lightly coat the threads and bottom face of the cylinder
head bolts in clean H-D 20W50 engine oil. Wipe off any
excess oil.
CAUTION
The procedure for tightening the head screws is critical
to proper distribution of pressure over gasket area. It
prevents gasket leaks, stud failure, and head and cylin-
der distortion.
6. Start the cylinder head screws onto the cylinder studs,
two short bolts on the left side of the engine, two long
bolts on the right.
7. See Figure 3-87. For each cylinder head, start with
screw numbered one, as shown. In increasing numerical
sequence (i.e. – 1, 2, 3 and 4):
a. Tighten bolts to 96-120 in-lbs (11-14 Nm).
b. Tighten bolts to 13-15 ft-lbs (18-20 Nm).
c. Loosen all screws.
8. After screws are loosened from initial torque, tighten
head screws in three stages. Tighten fasteners in
increasing numerical sequence (i.e. – 1, 2, 3 and 4).
a. Tighten each screw to 96-120 in-lbs (11-14 Nm).
b. Tighten each screw to 13-15 ft-lbs (18-20 Nm).
c. See Figure 3-88.
screw shoulder with a line as shown (View A).
d. Turn all bolts an additional 85 -95 .
3-60 2003 Buell XB9S: Engine
Mark cylinder head and head
° °
x0128x3a
Front Cylinder
1st
2nd
Rear Cylinder
2nd
1st
Head Screw Loosening/Tightening Sequence
Figure 3-87. Head Screw Loosening/Tightening Sequence
a0089x3x
View
A
Tighten head screws 1/4-turn in
the third stage of installation
Figure 3-88. Tightening Head Screws
3rd
4th
4th
3rd
View
B