99 80 inch softail,,,

started with an oil leak on the front cylinder at the base of the rocker box on valve side,,,, removed rocker box,,, gasket blown on front edge right off front bolt of valve chamber,,, bolt broken,, extracted bolt no problem no damage,,,, replaced gaskets, pushrods checked (not bent and have proper play when lifters bleed down)and back into proper place,(bike ran fine before take off),, didnt remove jug,,, didnt remove carb,, did all in the bike,,, I have a velocity stack with joker breathers,,, after install,,, no idle,, but starts right up and dies,, pushing air out of breather on that cylinder and puffs out carb,,, got fuel,,, nothing changed, valves seem to open and close with no problems,,,,, i have gone back three times and rechecked and even replaced with different gaskets, proper torque specs any ideas as to what the hell is going on here,,,, any help would be greatly appreciated... I have installed new plugs,wires,coil before this repair,,, checked plugs they are good,,,,, an after thought tells me that possibly someone has been here before and the pushrods color coded yellow to intake and green to exhaust might have been switched at some point and time,, does any know whether the longer of the two push rods goes to exhaust or intake?[/align]

 

Was it running before you worked on it?

 

This might not be helpful but what does the service manual say about all this?

 

If I had to guess, I'd put my money on intake being longer.Out of the 2 you woul want the intake to open further than the exhaust.

 

rear exhaust: purple
rear intake: blue
front intake: yellow
front exhaust: green
Whan all else fails cut them out with bolt cutters so you dont have to take the heads offand install a set of aftermafket rods that can be adjusted.

 

Any popping when you rev it up? I would take a good look at the head, do you have a burned valve or a cracked head? how is all that compression getting back in to the head ask your self? what seals the compression in the head?, only a couple parts could have failed..
The head could have cracked into the bolt hole?
Did you check the mating surfaces with a straight edgeto make sure they are straight?
Wish I lived close I love digging in to engines...

 

 

Good thing this is a thread that has been dormant for 16 years, because your explanation makes no sense.

 

Haha Dan. You have a way with words.

 

For anyone who came here looking for the correct positions of Evo pushrods:

Longest pushrod, front exhaust.

Next longest pushrod, rear exhaust.

Nest longest, front intake.

Shortest pushrod, rear intake