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Old 03-22-2007, 06:52 PM   #1 (permalink)
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Time to put it back together

I thought that at 55k, it might be a good time to freshen (and juice) things up a bit on my Ultra Classic's FI Evo so back in November, I bought an EV-27, +20 over Keith Black performance pistons/rings, brought the heads and jugs to a local shop over the winter where they did the jugs along with head porting and valve job. I also bought new lifters and adjustable pushrods. My buddy had offered to help me put it back together, but it seems he is always too busy lately. Outside of matching up the notches on the bolt in cam, tourqeing to specs, any re-assembly tips? I have never done this job, but I am not afraid to try with help as close as the computer thanks to you guys. Also, I would probably want a new map for the Power Commander, though I did not see any that fit this new configuration on the website?
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Old 03-22-2007, 09:48 PM   #2 (permalink)
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Buy a HD shop manual, this is imperitive.
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Bi-polar and loving it!!
Bi-polar and hating it!!
95" w/ KB pistons (flattops)
HQ575 cams
Atwood's Road Warrior Heads
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Old 03-23-2007, 08:00 AM   #3 (permalink)
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Just got my 95 Electra Glide together last sat.I pretty much did the same as you with the exception of 10.1 pistons.I agree with route66paul get a manual,take your time,double check,clean clean clean.I think you will be impressed i know i am with mine it really woke it up.Good luck.
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Old 03-23-2007, 08:15 AM   #4 (permalink)
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the above are correct.
Clean is imperative. Alternate cleaning (washing) your bored and honed jugs
with hot/soapy water, then clean with mineral spirits (I use laquer thinner).
I washed mine 3 or 4 times till I got no dark residue on a towel when wiping
the bore. Clean your pistons the same way.

The easiest way to install the jugs/pistons (especially the rear) is to install
the piston in the jug, get the jug installed on the studs, tie off the jug with
a small cord, push the piston down till the wrist pin hole is exposed, line
up the connecting rod with the hole in the piston, install the wrist pin and
keepers, then untie the jug and push it down to the case.

Take your time with the rocker box gaskets and make sure they are located
correctly when you tighten the bolts for the covers. (you don't want leaks)

Go by the factory torq specs and use lots of blue locktite.

Also use moderate amounts of your favorite refreshing adult beverage.
(not too much at the time)
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Old 03-24-2007, 09:28 PM   #5 (permalink)
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Cylinder Cleaning

What happens if you don't get all the honing oil out of the cylinders? I did not clean mine anything like you described. Should I pull it all back apart again and clearn them like you described? I just finished my first HD rebuild, so I'm still learning and picking up bits and pieces as I go. Thanks.

-Br-
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Old 03-26-2007, 04:20 PM   #6 (permalink)
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I don't think you'll kill it if you didn't clean it to death.

Maybe have a little more ring/cylinder wear and get your oil a little dirtier
for the first couple of oil changes. I'd hate to pull her back apart
just for that. I might change the oil a little sooner for the first couple
of times.

If it ain't broke, don't fix it.
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