My first HARLEY upper-end job. - Harley Forum

evoKENevo · #1 05-04-2009, 07:58 PM

Well...I finally quit putting it off, and tore the upper-end of my '98 Evo apart to get at the small but annoying amount of "blue-smoke" that was really only noticeable at an idle. As expected the valve guide seals were shot...everything else looking good at 55-K miles.

After cleaning up the carbon build up in the comb-chamber, exh ports, and valves, I took the heads to have them decked .050"...and ordered a Cometic upper-end gasket/seal set (incld'g .030" head gasket) along with new rings (why not) from Dennis Kirk, which should bring my C.R. up from 8.5 to 9.5:1 (as high as I care to take it) in conjunction with the EV-27 cam ETC already in the bike.

Question is...should I replace the cylinder studs while I'm at it ??
Some say yes...especially since I'm increasing the C.R. a bit
Some say don't worry about it because the '98 studs etc are better than earlier Evos...
None SO-FAR have been what I'd call "reliable-sources" or "authorities" on the matter...best are here.

And, of course, any other relative H.D."tips & tricks" ETC that ain't in the book would be welcomed

before I botch this.

botzman · #2 05-04-2009, 09:17 PM

Hey Ken,

Good luck on the top end rebuild. As you know I did mine last winter and have put on 10K since with no issues. I re-used the cylinder studs which were the old style with no problems. I believe you have the newer style with the ridge on them so they seat at the right height. Im no expert either but took my chances with the old ones and it worked out. As far as tricks go the only thing I did was make 4 plastic sleeves to slide over the cylinder studs on top of the jugs to hold the jug and base gasket seated when sliding the second jug down over the rings. There is a tendency for the connecting rod to push the seated jug off the block when installing the second jug. You can also turn the motor over manually without things slopping around this way. You can actually watch the piston travel in the cylinder this way before putting the heads back on. I attached a pic so you can see what I mean. If any info I've relayed is not wise please speak up and let Ken know. As i said Im no expert. MOST IMPORTANTLY - USE THE MANUAL AND FOLLOW TORQUE PROCEDURE EXACTLY. Also, make sure the torque wrench you use is in good working order and hasnt been left wound up for a few years like mine was. Dont ask. Heres pic:

Good luck. Botz

aceharleywrench · #3 05-05-2009, 07:05 AM

Botz,I use similar hold down nuts when I do a top end,so no prob there.As far as reusing the studs,I have done hundreds of Evo top ends without replacing the studs & have had no failures (I usually replace studs if it is an early Evo or if it has been apart a few times) Take your time,make sure everything is clean & follow the manual,you should be fine.

botzman · #4 05-05-2009, 07:42 AM

Hey Ace,

Thanks for the confirmation. Noticed your shop is at the foothills of the Adirondacks. You lucky dog! Botz

evoKENevo · #5 05-05-2009, 09:20 AM

Thanks Botz & Ace
Getting advise from friends who've been there and done that sure beats getting it from someone who's trying to sell you something or who's heard or read something somewhere.

Did'nt want to disturb any more than necessary (ain't broke don't fix it) and this gives me that much more confidence that I won't have to go back and re-do the whole thing due to cutting a corner. I've got both types of ft-lb torque wrenches (torsion bar & clicker) in good condition. I'll use the clicker first and follow up with the torsion-bar for that last 1/4 turn to compare results.

Yeah and since all the other multi-cylinder engines I've worked on have had "cylinder-blocks" I can see where the tip of holding one jug in place while working with the other will come in real handy...thanks again !!

Oh,hey...what about re-torqueing after intitial running & cooling. Should I follow my old(?)school conscience to re-use original gaskets on the rocker boxes at first and replace them after re-torqueing the heads (seems like a P.T.A. to me to R&R it all again--that I've never run into before) or is there anything to the story that Evos don't need all that ???

aceharleywrench · #6 05-05-2009, 10:52 AM

Absolutely do not re-torque the heads,once they are done forget about them.Use new gaskets (I like H-D or Cometic) if you are reusing your cylinder head bolts (actually nuts) it's a good idea to run a thread chaser (not a tap) into all the nuts to clear out any corrosion that would keep you from getting an accurate torque reading,also put a very light film of oil on the underside of the bolts and on the threads before assembling.Have at it!!!

Botz,
The Adirondacks are one of the reasons I don't leave this over taxed state & head West.

evoKENevo · #7 05-05-2009, 07:59 PM

"O.K" Ace...you and Botz have been just FULL of GOOD news

thanks again !!

Knock on wood...oh,never mind

I'm a little afraid to jinx what's been going SO well SO far

botzman · #8 05-06-2009, 07:49 AM

Ken,

Good luck. Let us know how it turns out. Good feeling when you do it yourself and you fire it up the first time. I was told to fire it up, let it warm up to the point where the cylinders are throwing some heat, then shut it down and completely let it cool off before a restart. Something about "seasoning the gaskets" After the rings seat you should drop the oil. It may be overkill but after the 1st 100 miles I dropped the oil. Ace? Gonna be out by Bobarosa this summer. How bout you? Botz

evoKENevo · #9 05-06-2009, 08:59 AM

Hi,Botz
Thanks for the good wishes. This is'nt my first engine rebuild/overhaul...just my first H.D. one. So I know the feeling you're talking about when it fires right up

and does'nt blow or whatever. In the past I've given engines an easy riding 100 miles to break in while making any tuning adjust'mts etc...changed oil & filter...and,ridden them as I normally would

from then on with no related problems. But this time, I'll give it 500 miles with 100mile and 500mile dino-oil changes etc. to break in...before I go back to synth-oil and won't be beating the snot out this one in my "old

age"

Like I said before, let me know when you're heading back down to the Bobarosa...and I'll try to get down to TN at the same time...looking forward to it

if only to get my old friend down there to S.T.F.U. about when !?!

And,hey...maybe we can get some of the other clowns (?) around here to join in...

aceharleywrench · #10 05-06-2009, 09:30 AM

I'm going to have to admit (against my will) that I have no idea what Bobarosa is. In my defense,I don't have much of a life beyond the walls of the shop.When I do get out I ride,so this may be a good destination,if one of you guys would be so kind as to clue me in.......