EVO All Evo Model Discussion

1996 flht

Thread Tools
 
Search this Thread
 
Old Mar 24, 2022 | 06:22 AM
  #61  
Architect's Avatar
Architect
Seasoned HDF Member
15 Year Member
Joined: Apr 2010
Posts: 9,503
Likes: 7,806
From: Long Island, New York
Default

You want this wrench for removing the bolts under the frame, worth the $$$ because it is ratcheting:

https://www.denniskirk.com/lang-tool...SABEgJGlPD_BwE

Looks like the previous owner either lived off a dirt road or had been to the Buffalo Chip at some time. Lots of dust!!!!
 
Reply
Old Mar 24, 2022 | 06:29 AM
  #62  
Bubba Zanetti's Avatar
Bubba Zanetti
Seasoned HDF Member
15 Year Member
Liked
Loved
Community Favorite
Joined: Nov 2006
Posts: 20,972
Likes: 19,064
From: The Wasteland
Default

Wow, that air filter is scary looking. I don't recall all of your posts here, but have you been inside the carb yet?
 
Reply
Old Mar 24, 2022 | 10:06 AM
  #63  
flhchaz's Avatar
flhchaz
Stellar HDF Member
10 Year Member
Liked
Loved
Community Favorite
Joined: Sep 2011
Posts: 3,120
Likes: 1,733
From: In The Woods, PA
Default

Originally Posted by rhedengr
If you don't want to cut down an allen there are various rocker box wrenches available. Here is one example:

https://www.jpcycles.com/product/910...ker-box-wrench
These work great
 
Reply
Old Mar 24, 2022 | 10:15 AM
  #64  
panz4ever's Avatar
panz4ever
Thread Starter
|
Seasoned HDF Member
20 Year Member
Liked
Loved
Community Favorite
Joined: Oct 2005
Posts: 7,481
Likes: 3,677
From: Santa Klaus County, Cali
Default

Originally Posted by Architect
You want this wrench for removing the bolts under the frame, worth the $$$ because it is ratcheting:

https://www.denniskirk.com/lang-tool...SABEgJGlPD_BwE

Looks like the previous owner either lived off a dirt road or had been to the Buffalo Chip at some time. Lots of dust!!!!
K...that looks like the price of admission. Thanks

Originally Posted by Bubba Zanetti
Wow, that air filter is scary looking. I don't recall all of your posts here, but have you been inside the carb yet?
.

Carb will come off today so haven't been inside it yet for a rebuild. Looking at the filter element I am surprised the bike even ran.
 
Reply
Old Mar 24, 2022 | 02:57 PM
  #65  
98hotrodfatboy's Avatar
98hotrodfatboy
Seasoned HDF Member
15 Year Member
Liked
Loved
Top Answer: 5
Joined: Mar 2010
Posts: 21,019
Likes: 7,547
From: Poolville
Default

Originally Posted by panz4ever
K...that looks like the price of admission. Thanks

.

Carb will come off today so haven't been inside it yet for a rebuild. Looking at the filter element I am surprised the bike even ran.
Yeah me too.... Can't kill them Evo's......
 
Reply
Old Mar 24, 2022 | 09:34 PM
  #66  
panz4ever's Avatar
panz4ever
Thread Starter
|
Seasoned HDF Member
20 Year Member
Liked
Loved
Community Favorite
Joined: Oct 2005
Posts: 7,481
Likes: 3,677
From: Santa Klaus County, Cali
Default

So....got the carb off today and began the top end tear down. All went well until I came to removing the front head.

The cylinder base stud on the intake manifold side decided to come out with the screw. Fortunately there was enough clearance to get the front head off.



Then came the rear head....and of course the learning curve just got a bit steeper (and more expensive).

The rear exhaust stud came out with the screw. There is no way to fanagle that bolt and stud to clearance the backbone of the frame and remove the rear head. So unless someone has Bullwinke-esk abilities to pull the rabbit out of the hat, I only see two outcomes. I can pull the motor or I can cut the stud and insert a replacement.



And it looks as tho Colony sells replacement studs.

 

Last edited by panz4ever; Mar 24, 2022 at 09:50 PM.
Reply
Old Mar 25, 2022 | 04:59 AM
  #67  
98hotrodfatboy's Avatar
98hotrodfatboy
Seasoned HDF Member
15 Year Member
Liked
Loved
Top Answer: 5
Joined: Mar 2010
Posts: 21,019
Likes: 7,547
From: Poolville
Default

If you can get a bolt cutter in there I would try that but other than that I wouldn't use any kind of cutting tool only because of all the metal fibers that would be going all over the place.. At that point I would probably pull the motor..
 
Reply
Old Mar 25, 2022 | 07:06 AM
  #68  
RGranville's Avatar
RGranville
Intermediate
10 Year Member
Liked
Loved
Community Favorite
Joined: Jun 2015
Posts: 27
Likes: 7
From: Baltimore, MD
Default

Is there a chance you could apply heat to the visible part of the head bolt to expand it a bit, then grip the stud with a vise grip and hopefully remove the head bolt? If successful, replace the bolt and the stud.
 
Reply
HD Forum Stories

The Best of Harley-Davidson for Lifelong Riders

story-0

7 Surprising Harley-Davidson Products that Are Not Motorcycles

 Verdad Gallardo
story-1

8 Best Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-2

10 Worst Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-3

Killer Custom's Jail Break Is The Breakout That Refused to Blend In

 Verdad Gallardo
story-4

Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

 Verdad Gallardo
story-5

Harley-Davidson Reveals Super Cool Cafe Racer Concept

 Verdad Gallardo
story-6

Engraved Rebellion: Inside Bundnerbike's Glam Rock II

 Verdad Gallardo
story-7

10 Motorcycles You Should Never Buy

 Joe Kucinski
story-8

10 Things Harley-Davidson Needs to Fix in 2026

 Verdad Gallardo
story-9

Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider

 Verdad Gallardo
Old Mar 25, 2022 | 09:18 AM
  #69  
Dan89FLSTC's Avatar
Dan89FLSTC
Seasoned HDF Member
Veteran: Navy
Active Streak: 30 Days
Top Answer: 3
Top Answer: 5
Joined: May 2008
Posts: 21,031
Likes: 12,555
From: South Carolina
Default

I like the idea suggested by RGranville, but if that does not work you are going to need to cut the stud off.

Cover the top of the cylinder with plastic and tape it down, cover everywhere that could allow debris to get into engine.

Wrap some tape around the stud to seal against the cylinder head to prevent shavings from going down the stud opening.

Sawsall or hack saw the stud.

Vacuum everything you can before removing any tape or plastic covering.
 

Last edited by Dan89FLSTC; Mar 25, 2022 at 09:25 AM.
Reply
Old Mar 25, 2022 | 09:29 AM
  #70  
Architect's Avatar
Architect
Seasoned HDF Member
15 Year Member
Joined: Apr 2010
Posts: 9,503
Likes: 7,806
From: Long Island, New York
Default

Get an assistant and vacuum while cutting, after fully protecting.

I would try the heat trick first, maybe you get lucky. Removing the entire motor seems like a lot of extra work, I would avoid until I couldn't.
 
Reply



All times are GMT -5. The time now is 02:33 PM.

story-0
7 Surprising Harley-Davidson Products that Are Not Motorcycles

Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.

By Verdad Gallardo | 2026-04-29 16:50:35


VIEW MORE
story-1
8 Best Harley-Davidson Motorcycles Ever

Slideshow: Not every Harley gets it right, but these are the ones that genuinely earned their reputation.

By Pouria Savadkouei | 2026-04-15 14:23:21


VIEW MORE
story-2
10 Worst Harley-Davidson Motorcycles Ever

Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.

By Pouria Savadkouei | 2026-04-01 20:01:09


VIEW MORE
story-3
Killer Custom's Jail Break Is The Breakout That Refused to Blend In

Slideshow: Killer Custom's "Jail Breaker" build focuses more on stance and visual aggression than mechanical overhaul.

By Verdad Gallardo | 2026-03-18 19:20:32


VIEW MORE
story-4
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.

By Verdad Gallardo | 2026-03-07 16:15:30


VIEW MORE
story-5
Harley-Davidson Reveals Super Cool Cafe Racer Concept

Slideshow: Harley-Davidson's new RMCR concept revives the café racer formula with modern hardware-and it may be exactly the reset the company needs.

By Verdad Gallardo | 2026-03-04 12:23:37


VIEW MORE
story-6
Engraved Rebellion: Inside Bundnerbike's Glam Rock II

Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.

By Verdad Gallardo | 2026-02-24 18:19:44


VIEW MORE
story-7
10 Motorcycles You Should Never Buy

Slideshow: There is no shortage of great motorcycles to buy, but we would avoid these ten.

By Joe Kucinski | 2026-02-19 14:50:51


VIEW MORE
story-8
10 Things Harley-Davidson Needs to Fix in 2026

Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.

By Verdad Gallardo | 2026-01-13 18:33:17


VIEW MORE
story-9
Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider

Slideshow: Graeme Billington's left-hand-drive Shovelhead is as much about problem-solving as it is about classic Harley form.

By Verdad Gallardo | 2025-12-30 11:27:08


VIEW MORE