It's in there!

Twistedpairs · Sep 13, 2025

2008 ultra classic, developed an intake leak. Ordered new Cometic intake seals and decided to order new bolts as well. Everything arrived, removed the intake manifold, noticed the new bolts included washers. Looked them over, figured because the head was a bit smaller and the bolt was a bit longer, that's why the washers were there. Damn washers kept getting in the way of inserting the intake flanges so I decided to go back to the original bolts. As I was pulling the rear bolt, the washer slid off the bolt, into the head intake port and down the open valve into the cylinder. Of course the washer is bigger than the spark plug hole. I bought some tiny magnets and used heat-shrink to attach to a wire and they aren't strong enough to pull the washer out. Tried a shop vac. Tried blowing compressed air in the spark plug hole while having the shop vac sucking at the intake. Nothing.

Anyone deal with anything like this before and have a solution or am I stuck pulling the head off?

Old n Slow · Sep 14, 2025

Desperate times call for desperate measures. No, I haven't ever had anything exactly like this happen. And I am not familiar with the head/valve configuration of the Harley engine. But I have had experience with small block Chevy V8 engines.

I haven't done this with the Chevy engine but I think it would be possible. Is there any way you could drop one of the valves, fish out the washer(s) with a magnet, then lift the valve back up with a magnet, install the spring, clip and keepers?

Or is it just so different there is no way it will work? At any rate, good luck with it.

Alan S · Sep 14, 2025

A hook out of stainless wire at full valve opening?

maubuchon · Sep 14, 2025

Turn the bike upside down and shake it. Sorry, that was mean. I actually like your magnet on a wire idea. Maybe find a stronger magnet and maneuvering while looking through the spark plug hole with your borescope. The only problem is that the magnet is going to also be attracted to the valve and the cylinder wall. If it would fit, maybe one of those grabber tools that has little fingers that pop out of the end of a coiled wire tube.

Roberto145 · Sep 14, 2025

Pull the head. That washer isn't coming out through the plug hole. Trying to start the engine to blow it out will destroy your piston and cylinder. It's a pain, but it's the only safe way.

Dan89FLSTC · Sep 14, 2025

Get a length of .032 or .041 aircraft lock wire (stainless) and bend a hook at one end.

You will find a lot of uses for this stuff once you have a roll of it in your toolbox.

Twistedpairs · 2025-09-15T19:26:40-0400

Been awhile since I used that wire. Got out in '96. I like the idea though! I'll give that a try before pulling the head. Last ditch effort! Thanks for the idea!

gb1500 · 2025-09-15T19:12:34-0400

i would try the wire gig...you can see it that's a big plus and keep bending it to suit....move the piston to the top...and go thru the spark plug hole....if no go then you can take the plunge...but then again its not a big deal to pull the head off

gb1500 · 2025-09-16T19:10:13-0400

ok noted...so the washer is bigger than the spk plg hole but maybe you can position it to grab it with the wire

Dan89FLSTC · 2025-09-16T19:20:32-0400

If you can see it through the spark plug hole, send the hook in through the spark plug hole and hook it, then send another hook in from the intake or exhaust, you may be able to hook the wire and drag it out.

Don`t spend a lot of time trying, because pulling the head is no big deal.

Twistedpairs · 2025-09-22T15:53:39-0400

Pulled the head, reassembled and rode. Ran great, kind of. Made a stop, came out and started the bike and my intake leak was back, until it heated up. Guess I will be torquing the intake a little more...

It's in there!

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