Hi Everyone,

I repair medical equipment for a living so tech stuff is right up my alley (pneu,hydo,elec,mech,etc). I just paid a local Indy to replace my lower jug gaskets and do a complete fluid change....... it ran 600 bucks!! ouchies.......

Now that you understand my request could anyone put together a list of known needed special tools that are required to work on anything concerning an ole 92 EVO? I have the Torx bits and sockets but I know there are more (ie axle alignment jig, etc)

love my ride and wanna keep her up to snuff ( 21,000 miles at 16 years old very clean and wanna keep her that way )

any advise is greatly appreciated in advance

 

not sure about the torx (they would only be on the valve covers if there), otherwise a ground short allen wrench. Just what you need to get the tank off, and standard simple hand tools is all you need. You can remove the jugs on most, without even taking the pistons out of them, so you don't have to re-ring them. It's a little tricky on the rear, but I've done it many times.

They're really basic machinery. With the exception of rebuilding the flywheel, rods, and crank bearings, you can totally re-do one with about 25.00 of simple tools.... plus a torque wrench

 

Axle alignment jig? Never heard of that one. Dunno how I've done 75K miles on my bike without it.

You need a basic tool set and that's about it.

 

A diaphram cutch tool is a good one to have, also the small pump with gauge for your air suspension, and the reardrive belt tension tester.

 

The best tool you must have is the Service Manual. In this manual you have specified the special tools you'll require to do some specific jobs in your bike.

Regards,

--
Javi

 

Thanks for the post's, I have ordered my Clymer manual ( seems shop manuals are hard to find for EVO's )

The alignment tool I am speaking of is a thin bent rod that has a movable ring that is placed in the center of the axle nut (when properly aligned ) and i believe the other end ( which has a few bends in it to get around the frame ) is placed/aligned in the swing arm.......

The only reason i have seen this used is I had another local shop put new tires on the bike but they only had a MU85 rear ( shop owner said it would be fine LOL what a joke ) not a MT90. This might work on Softails, Dyna's, etc. but not on the older touring models with the belt guard installed as the sidewall will hit the guard. After getting her back I turned around and told the owner the bike was whinning when rolling. He took it back and then gave it back to me in 30 mins ( no more whine )

I had the upper and lower gasket replacement done by Mikes American Customs in Goodview Va. ( if you need a good wrench for the older Pans,Shovels,EVOs then look him up ) last week. I had Mike go over the bike and he found my rear axle had been kicked back so the tire would not hit the drive belt guard. Needless to say I will not be using Motorcycles & More as a repair facility in the future. Hopefuly I can do my own maintenance and rely on Mike when expert advise is needed

 

A Clymer manual is Okay for minor stuff but you really need to go on E-bay or something and find yourself a model specific HD shop manual. I have both type of manuals for both of my bikes and would have been a world of hurt trying to do some intricate work with just the Clymers. The special tools depend on what you are doing. There are clutch tools, pinion gear pullers, cam bearing pullers etc. Some of these you can get by with making your own or using something similar and every once and a while you have to have the exact tool. Good luck, they are fun to work on.

 

Hi '92 FLHS, from '90 FLHS in the UK! I have owned my bike from new andagree withthe other suggestions.

The only special tool I own is the belt tension device (used it last weekend). The wheel alignment device is described on page 2-33 of the worshop manual, so you can make your own! There are also details of all the other workshop tools you may or may not want, from which you can choose. It's a great read for those sleepless nights...

As well as buying that book, also get the factory parts list. Just open your wallet, think of Milwaukee and buy'em! A Clymer is better than nothing, but not as useful as the real thing.

I have done my time doing major work on bikes, sonow visitmy local dealer if anything needing 'special tools' comes along, such as fitting a new alternator a few weeks ago.

Get those HD books! [sm=smiley20.gif]

 

Yup, Genuine HD shop manual is a must. And I do have the belt tension guage. And a clutch hub puller, but that's about it besides regular hand tools. I basically did a top end job behind the motel in S.D. this year coming back from Sturgis. Bought a torque wrench and a few other small things that I didn't have with me.

 

No torx on Evo rocker boxes, never. The jig can be easily bent up with a thin piece of brass rod and a couple of o-rings from Lowe's.