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What a frustrating day! I was going to run some errands on my Dyna, but the year old battery was dead, sitting for two weeks. That doesn't seem right, does it? Did some troubleshooting, got it on the charger, and started on the Springer.
I had hoped to install both rocker boxes today, but only got one done. It was two steps forward, one back the whole time! Most of the trouble was following the HD shop manual but doing it in the frame. They designed the evo rocker boxes so it can be done, but there are some bolts that have to be installed with the lower box, not after. I also didn't need to tighten up the little bolts before installing the rocker arms. They needed to be loosened to gradually compress the lifters.
I also didn't realize the copper washers in the James kit supplement the factory steel ones, not replace them, so I broke the fiber washers and have to buy more tomorrow. Did I get it right the second time?
It's looking halfway good and hopefully tomorrow it'll be together.
I noticed you decided not to use the chrome lifter block covers. They look ok. But it always kinda annoyed me that Harley didn’t just chrome the blocks or polish high grade aluminum ones.
I noticed you decided not to use the chrome lifter block covers. They look ok. But it always kinda annoyed me that Harley didnt just chrome the blocks or polish high grade aluminum ones.
I had Custom Chrome glue on covers on my Wide Glide, I also was annoyed that HD did not chrome them in the factory. Then my ex-BIL buys a new Deuced in 2000, blocks are chrome!?!?!?
When I did the cam swap they lifter blocks got chromed and I ditched the covers. Don't remember if I bought chrome aftermarket or had mine chromed, but they are chrome. Carry on.
This bike had the covers, too. I totally forgot to put them back on! I'll dig them out and clean them up. I'm going to keep the original 'chrome everything' theme as a tribute to the '90s.
The motor is complete! I installed the front rocker box and intake manifold today. It took a lot less time than the rear, now that I know what I'm doing. I've built three shovelheads, but this 'modern' stuff threw me a few curves
When this bike was flooded during the hurricane a couple years ago, water was up to the carburetor. Besides rusting the motor internals, the manifold was cruddy inside and out. I took care of that, and gave it all a coat of clear. I ran the carb mounting flange over sandpaper on a flat surface, and was happy to see it wasn't warped like shovel manifolds often are. I have a spare Super E that I will use here.
Installing the manifold was a PITA! What should have taken 15 minutes took over an hour! Besides doing it twice because I had to chase the last bolt hole a second time, the only tool that fit in the space was a short allen wrench, and then it was one flat at a time...
But I'm happy how it all came out, it looks like the original motor again!
I am embracing the bike's patina from use, but these are way too ugly to reuse, so I'll buy new ones. After you guys mentioned it, the motor does look like its missing something.
Because the holes in the chin spoiler were all torn up, I needed to put fender washers under the nuts below. Rather than buy longer bolts (maybe fitted?) I used thinner grade 8 washers under the heads. Anybody see a problem with doing it that way? I may paint them silver, too.
When I arrived in Florida last month, I saw a lot of the ATF I put in the trans to preserve the gears was on the floor. I cleaned it up and told myself I'd deal with it after I put the motor together. Well the time has come. Fortunately it appears to be an easy fix, as long as I can take the seal out with the inner primary bearing race installed. Can it be done?
I ordered the IPB race tool, and will order gaskets and seals from the shop tomorrow. Taking everything apart will ensure its done right and done once.
Meanwhile I met @Old Sport for lunch and bought his whole collection of Live to Ride parts. They will be replacing the Eagle Spirit ones the original owner installed.
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.
Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.
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.
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.
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.
