I'm Worried
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Tourer
Joined: Sep 2008
Posts: 440
Likes: 1
From: NW Burbs of Chicago
I'm Worried
65K miles on an 84 Evo FLHTC.
I've been stranded 3 times in the last year for non-motor related issues. Ruins the whole day and my riding buds are starting to make noise about staying closer to home when I'm along.
What I'm asking for advice on is - what should I have done to the the motor and potentially other systems to prevent some future issues. Not really seeking performance upgrades although if there were some easy/cheap ones as long as it's open I might go that way since it's feeling more like a dog all the time.
I'm not much of a wrench. I'll have this done or at least contracted out by a local indy I use. I am going to limp through the summer and have any work done over the winter.
I know I have a bent shifter fork so we'll be cracking the transmission open. I have a new stator and regulator. No engine trouble so far; no leaks.
At some point in refurbing a motor it probably makes sense to just replace the whole d_mn thing so I want to get a sense for what I should have done so I can compare it to the price of new/refurbed options. But then it starts cascading into a decision of buying a newer/lower mileage bike for a few dollars more.
I've been stranded 3 times in the last year for non-motor related issues. Ruins the whole day and my riding buds are starting to make noise about staying closer to home when I'm along.
What I'm asking for advice on is - what should I have done to the the motor and potentially other systems to prevent some future issues. Not really seeking performance upgrades although if there were some easy/cheap ones as long as it's open I might go that way since it's feeling more like a dog all the time.
I'm not much of a wrench. I'll have this done or at least contracted out by a local indy I use. I am going to limp through the summer and have any work done over the winter.
I know I have a bent shifter fork so we'll be cracking the transmission open. I have a new stator and regulator. No engine trouble so far; no leaks.
At some point in refurbing a motor it probably makes sense to just replace the whole d_mn thing so I want to get a sense for what I should have done so I can compare it to the price of new/refurbed options. But then it starts cascading into a decision of buying a newer/lower mileage bike for a few dollars more.
Cruiser
Joined: Aug 2007
Posts: 131
Likes: 0
From:
I feel your pain!
I ride an '86 FLHTC, with 52000 miles. Started giving me little problem last summer, so I bit the bullet this winter.
Installed a Revtech 6 speed, Thunder heart 3 phase charging system, new starter, solenoid, battery, battery cables and did a total engine rebuild, complete with SE heads, Andrews EV27 cam, S&S Shorty carb etc. The only original parts on the motor and tranny are the cases!
Replace all engine mounts with delrin mounts and even replace the drive pulley and belt. With the exception of the rear wheel bearings (they get done at the next tire change) the bike is brand new mechanically.
Wasn't cheap, but it is a "new" bike.
Still cheaper than buying a new bike and it is now reliable!
The bikes runs great! Night and day, 78 ft/lbs of torque and 59 hp. HP could be higher but the torque peaks at 2500 - 3500 rpm and since I ride 2 up most of the time, it is right where I need it.
I've always ridden older bikes and have found that it is the part you don't replace is the one that gives you grief at the worst possible moment.
I can't afford/justify payments on $23000, but I can manage payments on $5000.
Just my $0.02
I ride an '86 FLHTC, with 52000 miles. Started giving me little problem last summer, so I bit the bullet this winter.
Installed a Revtech 6 speed, Thunder heart 3 phase charging system, new starter, solenoid, battery, battery cables and did a total engine rebuild, complete with SE heads, Andrews EV27 cam, S&S Shorty carb etc. The only original parts on the motor and tranny are the cases!
Replace all engine mounts with delrin mounts and even replace the drive pulley and belt. With the exception of the rear wheel bearings (they get done at the next tire change) the bike is brand new mechanically.
Wasn't cheap, but it is a "new" bike.
Still cheaper than buying a new bike and it is now reliable!
The bikes runs great! Night and day, 78 ft/lbs of torque and 59 hp. HP could be higher but the torque peaks at 2500 - 3500 rpm and since I ride 2 up most of the time, it is right where I need it.
I've always ridden older bikes and have found that it is the part you don't replace is the one that gives you grief at the worst possible moment.
I can't afford/justify payments on $23000, but I can manage payments on $5000.
Just my $0.02
Outstanding HDF Member
Joined: Apr 2009
Posts: 3,071
Likes: 89
From: NEPA
I FEEL YOUR PAIN BROTHER!! I bought A 90 FXR with a factory rebuilt motor in it 3 years ago. I had to replace the starter, charging system, wiring harness and had to take care of a few leaks. I know what its like to sit on the side of the road. The first year I had it I sat many times. Once I got caught up with all the minor stuff, not that it was minor; I was able to start enjoying it. This winter I'm going to repaint it and do some bolt in performance upgrades. When all is said and done I'm spending less then a new one would have cost me. Yes I did the math already.
I feel the same way ozzie65 does. The price of a new one is just not reasonable for me.
I feel the same way ozzie65 does. The price of a new one is just not reasonable for me.
Road Captain
Joined: Jun 2008
Posts: 640
Likes: 13
From: Hickory, NC area
Not just the price, but the feel of an older bike just suits me better. I don't want all that fancy stuff on there and I tinker on mine most of the time myself. Haven't actually paid for anyone else to fix it .... yet!
The problem with the electrical stuff is that there is little way to know when it is going to bite the dust. Very unpredictable, even new bikes will get electrical problems. Seems to me that a good cleaning of connections and tightening of grounds would be well worth the time. That's a job that is easy to do yourself. As to mechanical things, the EVOs are a pretty sound motor, so I am planning to run mine into the ground before I spend the money to rebuild it.
As for the rest, you might start doing a little wrenching yourself, some of the things can be fixed on the side of the road with enough duct tape, some bailing wire, and a decent set of tools.
The problem with the electrical stuff is that there is little way to know when it is going to bite the dust. Very unpredictable, even new bikes will get electrical problems. Seems to me that a good cleaning of connections and tightening of grounds would be well worth the time. That's a job that is easy to do yourself. As to mechanical things, the EVOs are a pretty sound motor, so I am planning to run mine into the ground before I spend the money to rebuild it.
As for the rest, you might start doing a little wrenching yourself, some of the things can be fixed on the side of the road with enough duct tape, some bailing wire, and a decent set of tools.
Advanced
Joined: Apr 2009
Posts: 99
Likes: 0
From: forest city n.c.
the elect/charging system I believe will be the thing that will leave you stranded. I plan on going through mine untill everything is replace. cables will be next on my list. I have a beach trip plan in a couple of weeks. 300 miles one way. I just bought my harley fltc and although it hasn't given me any problem, I'm debating which bike to ride. my head tell's me to take the 2007 vulcan, but my heart tell's me to take the old girl. it's nice to have a choice. knowing me as I do, I'll be on the hog. hey, you only live once.
Grand HDF Member
Joined: Aug 2008
Posts: 3,596
Likes: 9,900
From: Florida's gorgeous East coast
One of the side benefits of doing as much of the regular maintenance as you can, is that it gives you the opportunity to PAY ATTENTION and look things over. Look for wear, looseness, weak points, leaks, drips, fraying, etc,etc. For example: Watch your clutch cable end @ the grip. Carry a small set of vise grips. When the end of the cable breaks off..loosen it @ the tranny end, pull it through the back of the clutch handle, clamp the end that's left with those vise grips, tighten everything back up and keep going. Get yourself a spare "clutch relase finger". Carry it along with a good set of allen wrenches. When your's breaks...it's a pretty easy roadside fix...IF you have this small, inexpensive part. Those two suggestions are just a couple of things that come to mind, which have gotten me home on my '85 FXR, on 4 separate occasions, in 219,000 mi. of riding. Thought you might find them useful.
Seasoned HDF Member
Joined: May 2008
Posts: 21,029
Likes: 12,550
From: South Carolina
If it is a 5 speed you can change the shift forks in an afternoon, you don`t have to crack open the tranny.
Last edited by Dan89FLSTC; May 5, 2009 at 04:56 AM. Reason: mistake
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HDF Community Team
Joined: Dec 2005
Posts: 5,375
Likes: 2,572
From: NC USA
Carry a small set of vise grips. When the end of the cable breaks off..loosen it @ the tranny end, pull it through the back of the clutch handle, clamp the end that's left with those vise grips, tighten everything back up and keep going. Get yourself a spare "clutch relase finger". Carry it along with a good set of allen wrenches. When your's breaks...it's a pretty easy roadside fix...IF you have this small, inexpensive part.
Personally, I'd be more concerned about the company your keeping, if they ain't willing to help....
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Seasoned HDF Member
Joined: Aug 2007
Posts: 8,195
Likes: 3,085
From: NW AR
Naw, he means the clutch release finger that's on the end of the clutch arm on the right side of the transmission. They tend to break. I'm on my 3rd and #4 is in my tour pack. #2 was aftermarket and I insisted on an OEM one for #3, which has been holding up just fine. It's an easy fix. You don't even lose any oil if you're careful about it. Maybe put the tires on a low board, then kickstand down and the proper oil level is below the bottom of the cover.
Road Master
Joined: Sep 2006
Posts: 1,121
Likes: 6
From: Huntersville, NC
I've never broken that finger but I have had the dime sized bearing disintegrate twice. Carry a spare. Also be sure to carry a #0 Phillips screwdriver to take off the speedometer reset dial in case you have to get under the speedo.
If your battery cables are still original replace them. Clean that ground connector under the frame real good.
I wouldn't replace that motor, just rebuild it. It's built with the good stuff. My 84 FLTC has never leaked, even at the base gaskets. Let a good mechanic give it a once over and you'll be good to go. Good luck.
If your battery cables are still original replace them. Clean that ground connector under the frame real good.
I wouldn't replace that motor, just rebuild it. It's built with the good stuff. My 84 FLTC has never leaked, even at the base gaskets. Let a good mechanic give it a once over and you'll be good to go. Good luck.