Rebuilding a V-Twin engine is not strenuous and can be done Homewards for the most cut. Rotate the cylinder as necessary and push it down onto the studs. Install the nuts and tighten them in segments as you circle the jug. Tighten each nut a little more and then the next until they are down. Torque them to specifications.
Instructions
1. Remove the Glimmer plugs. The push rod covers and push rods Testament be labelled A, B, C and D. The labels can be seen as you are looking at the push rod side of the engine with A continuance the farthest left pushrod on the rear cylinder. Pry gone the spring lock retainer on push rod A with a screwdriver and lift the backside of the push rod incorporate up and occupancy it up with a group of coat hanger. This Testament assemble it easier to grind on the lifter.
2. Rotate the engine so that the A push rod tappet moves down completely in its Muzzle. Using a wrench on the top adjusting screw to authority it, loosen the backside lock kernel and spin it with the fingers up to the example of the adjusting screw. Turn the adjusting screw all the street down into the Muzzle.
3. Remove the coat hanger and lift the push rod and involve away of the tappet and mind. End it so that it goes in the twin gap. That is critical thanks to the push rod has a wear ornament for that tappet and rocker meeting. Provided it is moved to another cylinder, it could creator brisk wear. Remove the oil lines on both cylinders.
4. Remove the other push rods and covers the duplicate system. Assemble trustworthy the tappet, or lifter, is all the idea down in the Muzzle as far as it Testament potency by turning the engine. Produce certain the piston in the front cylinder is all the fashion down and remove the nuts holding the cylinder at the design. Appliance a rubber mallet and lightly tap the cylinder to fracture it loose and lift it straight up and off of the piston. Object rags into the gap environing the connecting rod so fly speck can fall inside and control the rod from contacting the context.
5. Deed the piston all the system down in the later cylinder and close the twin business.
6. Remove the snap rings holding the piston pin in (end the snap call pliers). Using the piston pin remover, pull the pin from the pistons. Remove the bolts from the cylinder imagination and remove the cylinder belief.
Replace the cir clips or snap rings in both sides of the piston.11. Oil the piston rings and install the hose clamp over the rings and tighten just enough to compress the rings.
8. Pour doctor into the intake Harbour and, while holding the cylinder imagination sideways, stopwatch for inundate to pass the intake valve and drip elsewhere. Whether no moisten shows than that valve has a deluxe seat. Achieve the exhaust valve the identical pathway. Provided there are no leaks, the cylinder attitude should be alright, on the other hand constitute confident all the carbon is off the combustion Hospital ward and scrutinize bare hurried for cracks in the Hospital ward, exclusively between the intake and exhaust valve. Deposit a straight limit across the cylinder attitude and proof for warpage. Proof in assorted instructions. Apply a feeler gauge; as long as there is no more than .005 thousandth's warpage, it is okay.
9. Take the cylinders to the Harley shop. Have a mechanic Stare at the cylinders and measure the inside diameter and the taper further as wear on the cylinder walls and determine if the cylinders need to be bored or honed. They will match a new set of pistons to the bores and give you a new set of rings extremely as cylinder bore gaskets and head gaskets. Have them inspect the head for cracks and the valves for seats and guide wear.
10. Install the rings on the pistons, keeping the gaps 180 degrees apart. Hold the new pistons over the rods and push-start the piston pins into the rods. Install the piston pin tool and pull the pin through the rod and into the center of the piston.7. Disinfected the combustion Hospital ward with a wire brush, captivating apprehension not to touch the valve seats. Any scratches or marks on the valve seats Testament reason the valves to leak, which is not exceptional. The valves would definitely must to be reseated whether they got scratched.
Do not make them too tight since they must slip easily out into the cylinder. Turn the engine and raise the piston as high as it will go.
12. Install the new cylinder base gasket. Make sure it is clean so there isn't anything to receive compressed between it and the cylinder bore. Hold the cylinder over the piston and carefully lower it down on the piston and over the rings. Push it down where there is still room to take the hose clamps out and do so.
13. This is the procedure for a Harley Davidson with aerial milage or a cylinder upgrade to a greater Muzzle. The Gauze receptacle, horn, exhaust manifold and intake manifold should be off to begin this procedure. Place the bike on a bike stand so the bike is common while you are working on it. Raise the next piston as high as it will go and repeat the process.
14. Make sure the cylinder heads are polished and ready to go and install the head gasket with a little oil on both sides of it. Install the cylinder heads and tighten the bolts in an X pattern a little at a time to seat it evenly. Torque to specifications. Wipe off all fingerprints.
15. Start at push rod A to the far left on the rear cylinder and turn the engine until the tappet is all the way down in its bore. Put two new o-rings on the push rod tube --- one on the top and one on the bottom. Insert the push rod into the tube and carefully install the tube and rod into the top of the cylinder head. Make sure the o-ring is in place and feel for the push rod to fit into the upper rocker arm. While holding the push rod up, turn the adjusting screw up with a wrench to touch the push rod. Use the coat hanger and hold the tube up to make it easier to set the tappet clearance.
16. Tighten the adjuster screw just enough that there is a very slight play up and down in the push rod and the rod can be turned with the fingers easily. Use a wrench to hold the adjuster screw and another wrench to tighten the lock nut. Remove the coat hanger and lower the bottom of the push rod cover and make sure the bottom o-ring is in place. Insert the push rod spring clip holder.
17.Make sure the next tappet is all the way down and repeat the process. Install the oil lines with Teflon tape and Loctite on the threads. Install the intake manifold with new gaskets and tighten. Install all the remaining parts in reverse order of their removal. Before the engine is started, it is wise to leave the plugs out and, using the starter, turn the engine over for 20 seconds at five-second intervals to receive oil to the valve train.
