Your opinions on installing a 95" kit

Road_Clam · #1 10-23-2007, 11:02 AM

Hey guys,
I am thinking going to a 95" kit this winter. My question is for those who have installed one, is it fairly easy? Any special tools needed?I have about 25 years of bike wrenching experience at the "hobby" level, and did a top end on my GS1100 Suzuki. I am however a little intimidated at tearing down a HD twin........ Thanks!

Kingofcubes · #2 10-23-2007, 11:18 AM

Pretty basic and easy to do especially if your going to gear drive cams. The main important thing is to get the quench right and although we usually trim the cylinder length to do this because we have the ability you can get it done with different thickness gaskets now a days.

PhilM · #3 10-23-2007, 11:26 AM

It's very straight forwad Rich.

Get yourself an HD service manual for your bike and it will be very clear.

Really, the only non-standard tool is the inner cam bearing puller & intaller. You can get that for a good price from GeorgesGarage.com and there are some folks that rent them. There are also a some gear lock and camchain tensioner tools that make things easier, but are not totally mandatory.

Other than that, basic tools including torque wrench and ring compressor are just about all ya need.

You will find the Harley much easier to work on than the GS1100.

riskyfool · #4 10-23-2007, 11:30 AM

Having just finished doing this last weekend, I can tell you that it is a doable project to take on yourself. I don't know if all of the specialty tools are necessary, but I bought them and was glad to have them. They aren't cheap and a real pro either already has them or knows how to improvise. I would recommend accumulating the specialty tools. I haven't tallied up the cost of everything I spent but at least $500 for tools, and really probably closer to $1k. For that price you could have a pro do the install for you, but I wanted the experience of doing it.

maineultraclassic · #5 10-23-2007, 04:57 PM

Quote:

ORIGINAL: Road_Clam

Hey guys,
I am thinking going to a 95" kit this winter. My question is for those who have installed one, is it fairly easy? Any special tools needed?I have about 25 years of bike wrenching experience at the "hobby" level, and did a top end on my GS1100 Suzuki. I am however a little intimidated at tearing down a HD twin........ Thanks!

I did mine last fall with no problems at all, with the internet, service manual, and a phone.............anything is doable.

Only special tool needed is the inner cam bearing puller.............and you get borrow that for free from AutoZone. That's it, all the other tools are basic common tools that most people have in their toolbox already.

Steve

mentor70 · #6 10-23-2007, 09:33 PM

I spent around 400$ on tools, I bought all the Jims stuff for cam bearing work and the press tools for the outer cam bearings and cams, went like butter.

thing I picked up the HD special tools from Smap-onfor the rocker boxes and the small dog bone for torquing the rocker and head bolts down.

the rest of the stuff I had already. It took me all weekend, but I had to grind my cases for the cams.
a butt load of masking you know!

Im looking forward to helping some one on the board here or doing my bike again with higher compresion pistons!

JLOCKHART29 · #7 10-23-2007, 09:59 PM

Compared to the 1100 the HD will be a piece of cake. I used to do some light wrenching on my Honda Vtwin and even the twin was 2002 tech. My 04 HD maybe an 04 motor but the tech is mid 1900's. The metelergy and tolarances are 21st century but not desighn. They really are just big Clinton lawnmower engins.lol You can get by with almost no speciality tools but I suggest the Georges inner cam bearings installer and the remover tools. These bearings are needle bearings and the tools incase the bearings if you happen to crush one of the cages. Would spoil your day if you dropped a needle inthe crank and had to split cases. Also the oil pump alighnment pins are cheap and good insurance it is lined up right for good flow.( Good oil flow is pretty important). As Mentor said you do need 2 small dogbone torque adaptors to proprley torque rocker boxes under the frame backbone. I ordered mine from a tool distributer. They are made by Protro and 1/2 cheeper than the Snap On. Jim tools are great and might consider them if doing for a living but the Georges are lifetime garantee and cheaper and work great. Can get dogbone sizes for you if you need.

Road_Clam · #8 10-24-2007, 07:05 AM

Hey guys thanks a lot for all the input on the 95 kit!

My local dealer quoted me 9 hours to install the 95 kit. I can save myself a good chunk of coin by doing it myself, but again I am a bit nerveous about tearing down a fairly new engine, that is also still under the factory 2 year waranty.
Some of you speak of a cam bearing puller, but I am not planning on changing cams, I am only doing the big bore kit. Is it still necessary to pull the cams just doing a big bore swap?
Rich

PhilM · #9 10-24-2007, 07:12 AM

No it's not. I was assuming you were doing cams to.

That makes it REALLY easy! You will save some $$$$ then. Nine hrs for a bigbore kit!!!! Wow!

Road_Clam · #10 10-24-2007, 08:02 AM

Quote:

ORIGINAL: PhilM

No it's not. I was assuming you were doing cams to.

That makes it REALLY easy! You will save some $$$$ then. Nine hrs for a bigbore kit!!!! Wow!

You think they are gouging me?
I also just placed and order for the factory service manual. After some reading, then I think I will have a clear picture as to what's involved. Sounds like I can handle it.