Getting on the big bore bandwagon
Road Warrior
Joined: Apr 2008
Posts: 1,899
Likes: 8
From: Aurora, IL
I kinda thought the same thing about the intake bolts. I love buying tools, but I just cant justify it right now. I only build 1 or 2 engines a year.
If you use a long extension and a ball end allen socket, it is much easier to install them while the rocker boxes are off. I also have an allen wrench cut down to make it easier.
If you use a long extension and a ball end allen socket, it is much easier to install them while the rocker boxes are off. I also have an allen wrench cut down to make it easier.
Road Master
Joined: Sep 2007
Posts: 821
Likes: 1
From: In the wind
I just bought a 2002 wideglide with a 1550 kit on it and wow that thing rocks I know there is faster out there but I love it. I don't need any faster than that Id just end up in trouble. And besides I now have the fastest bike of all I run with so I am good LOL.
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Elite HDF Member
Joined: Apr 2007
Posts: 4,919
Likes: 23
From: Seattle, WA
More disassembly pics ... started reassembly
As noted, got kind of a late start ... started by removing the cylinders:
got the ring compressor tool and inserted the pistons into the cylinders ... not in accordance with the manual ... but, seen it done like that on several 'how-tos' ....
put the o-rings on the base of the cylinders and the 'dowels' ... with a little coating of oil the wrist pins slipped in pretty easily ... but, when I put the second cylinder on the motor, I thought 'well, that wrist pin clip ring was a bastard ... uh, wait ... I don't remeber doing the other one' ... took a look ... nope:
after getting both cylinders and pistons on the motor ... 1550 ... oh, yeah ...! :
got the rear head on:
p.s. battery in my camera died and only had cell phone for back up ... the rest of the photos might be a little crappy ....
got the ring compressor tool and inserted the pistons into the cylinders ... not in accordance with the manual ... but, seen it done like that on several 'how-tos' ....
put the o-rings on the base of the cylinders and the 'dowels' ... with a little coating of oil the wrist pins slipped in pretty easily ... but, when I put the second cylinder on the motor, I thought 'well, that wrist pin clip ring was a bastard ... uh, wait ... I don't remeber doing the other one' ... took a look ... nope:
after getting both cylinders and pistons on the motor ... 1550 ... oh, yeah ...! :
got the rear head on:
p.s. battery in my camera died and only had cell phone for back up ... the rest of the photos might be a little crappy ....
Thread Starter
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Elite HDF Member
Joined: Apr 2007
Posts: 4,919
Likes: 23
From: Seattle, WA
Reassembly photos ...
Another photo with the rear head in place:
with front head in place:
with rocker assemblies in place:
close up of rear rocker assembly:
That's the way I left it this evening at closing ....
* * *
Spent a good bit of time cleaning up the combustion chambers ... seemed to be an inordinate amount of carbon build-up for only about 30,000 miles ... but, considering some of the auto and other internal combustion engine heads I've seen, maybe not ... cleaned them back to the original surface as well as I could ....
Didn't do anything with the valves or the ports ... since I didn't disassemble the valve springs, valves, etc. From what I could see, they didn't look too bad ... practically pristine when considering how the pistons and combustion chambers looked ....
I was a little concerned that I didn't have a wrist pin puller when I went to disassemble the stock pistons ... fortunately, they came out with a good firm tug ... I had a carriage bolt the head of which I was going to use to fashion a makeshift puller had they not come out as easily as they did ....
So, the agenda for tomorrow: install rocker covers, install manifold and throttle body, hook up cables and sensors, install upper motor mount/horn, install A/C, install exhaust ... I think I'll need to update my EFI map ... then fire it up and break it in ....
Well ... that's all I have for today ... let me know if anyone has questions ....
with front head in place:
with rocker assemblies in place:
close up of rear rocker assembly:
That's the way I left it this evening at closing ....
* * *
Spent a good bit of time cleaning up the combustion chambers ... seemed to be an inordinate amount of carbon build-up for only about 30,000 miles ... but, considering some of the auto and other internal combustion engine heads I've seen, maybe not ... cleaned them back to the original surface as well as I could ....
Didn't do anything with the valves or the ports ... since I didn't disassemble the valve springs, valves, etc. From what I could see, they didn't look too bad ... practically pristine when considering how the pistons and combustion chambers looked ....
I was a little concerned that I didn't have a wrist pin puller when I went to disassemble the stock pistons ... fortunately, they came out with a good firm tug ... I had a carriage bolt the head of which I was going to use to fashion a makeshift puller had they not come out as easily as they did ....
So, the agenda for tomorrow: install rocker covers, install manifold and throttle body, hook up cables and sensors, install upper motor mount/horn, install A/C, install exhaust ... I think I'll need to update my EFI map ... then fire it up and break it in ....
Well ... that's all I have for today ... let me know if anyone has questions ....
Road Master
Joined: Jun 2008
Posts: 868
Likes: 1
From: Trenton,N.J.
Had been mulling over a bunch of the threads on 107, 106, 103, etc ... of course being as I have a 88, the corresponding kits are 98, 97 and 95 ....
So ... doing my part to keep the MoCo in business ... going with a SE 95 from the local dealership ... price was right ....
They didn't have it on hand, but should take delivery around the middle of next week ....
So, will be watching Drew's (Dr V-Twin) write up and photos with interest ... I know there have been a bunch of guys who've done it recently as well ... JRK5892 earlier in the year ....
I have not gotten heads or lined any porting work up or anything ... think I'll see what the additional cubes add and hold that off until next year maybe .... We'll see ....
R/
'Chop
So ... doing my part to keep the MoCo in business ... going with a SE 95 from the local dealership ... price was right ....
They didn't have it on hand, but should take delivery around the middle of next week ....
So, will be watching Drew's (Dr V-Twin) write up and photos with interest ... I know there have been a bunch of guys who've done it recently as well ... JRK5892 earlier in the year ....
I have not gotten heads or lined any porting work up or anything ... think I'll see what the additional cubes add and hold that off until next year maybe .... We'll see ....
R/
'Chop
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Elite HDF Member
Joined: Apr 2007
Posts: 4,919
Likes: 23
From: Seattle, WA
Day three ... assembly phase
So ... started right in on getting the intake manifold and throttle body assembly reinstalled ... was a little dubious whether I'd be able to get all of the wiring straight since I didn't label anything ... but, all the wiring is the correct length and over time had kind of formed itself along the channel in the direction in which it was to go ... so, no worries ....
The bracket for the throttle and idle cables attaches at the side of the throttle body and on top of the idle air controller ... it also has a tab that retains the manifold absolute pressure sensor (and blocks it if installed before the MAP sensor is installed) ... had to remove it to put the MAP sensor and then re-install it ...
another shot with the throttle position sensor in the foreground ....
a view from the rear ... fuel rail above the manifold ...
after installing the air cleaner mounting bracket (with integral head breather passages) and the air cleaner backing plate ....
The bracket for the throttle and idle cables attaches at the side of the throttle body and on top of the idle air controller ... it also has a tab that retains the manifold absolute pressure sensor (and blocks it if installed before the MAP sensor is installed) ... had to remove it to put the MAP sensor and then re-install it ...
another shot with the throttle position sensor in the foreground ....
a view from the rear ... fuel rail above the manifold ...
after installing the air cleaner mounting bracket (with integral head breather passages) and the air cleaner backing plate ....
Thread Starter
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Elite HDF Member
Joined: Apr 2007
Posts: 4,919
Likes: 23
From: Seattle, WA
After getting the manifold installed, the head temperature sensor can be installed (otherwise it interferes with access to the bolts) ...
after installing the upper motor mount, air cleaner cover, and front rocker cover ...
rear rocker cover installed ...
left side of bike after installing upper motor mount, rocker covers and horn ...
after installing the upper motor mount, air cleaner cover, and front rocker cover ...
rear rocker cover installed ...
left side of bike after installing upper motor mount, rocker covers and horn ...