Evo Motor Assembly, Part 9, Installing Pistons and Cylinders

Installing pistons, rings, and cylinders on this Evo Motor

[@truethought369]

Thanks Mike, That was interesting about the honing of the barrels, "using steeper cross hatching", which enables the bedding in! When you think about it: that makes perfect sense. Well I am always learning, which is good. Thanks again 👍

[@pacificmike9501]

Thank You. I'm always learning.

[@Francey4782]

' A little paranoia goes a long way' Like it ! Words of wisdom

[@pacificmike9501]

Thank you.

[@chrismason303]

Thanks Mike!!! Totally agreed, JIMS 1172 wrist pin clip tool is the coolest tools ever!

[@pacificmike9501]

I find it works quite well.

[@chrismason303]

Hi Mike, I’m confused the HD Service Manual for my FXR2/3 says “cast-in arrow points to the front of the engine”. No mention of any difference in direction between front and rear pistons. I totally get your super logical rational re piston pocket size, but wonder if the last of the Evo motors could have had both arrows pointing to the front of the engine? Your expert thoughts would be greatly appreciated as I’m just about to finish my engine rebuild - I’ve used your awesome videos all the way - THANK YOU

[@pacificmike9501]

Make sure of the intake valves being over the biggest pockets.

[@michaeldion8798]

Absolutely love your attention to detail. I thank my good buddy Jack at Thunder Alley in Vernon BC for pointing me to your videos. Your videos have helped me with some issues I've had with my evo engine. Keep up the great work Mike!!!

[@pacificmike9501]

Thank you. Kind words.

[@williamhomsher3418]

Thanks for the helpful and informative videos. My dad built Harley motors when I was a kid,mostly pans because I was a kid in the 70's and that's what people where putting in there choppers then.I don't always know what I'm doing but I learned a lot about what not to do by people who don't know what they're doing nowadays. It's nice to see oldtimers who know what they're doing still around with information I can trust. I ride a ridgid evo old school style chopper and I love it.I'm rebuilding the motor and these videos are helpful.I had the lower end rebuilt by 2 wheel world in Arlington Texas. Thanks again

[@pacificmike9501]

Thank you.

[@Strutzkiski]

You forget to pull the hose at the cylinder studs! ;-) Nevertheless, thanks for helping me from far away with the excellent videos and clear advices!

[@pacificmike9501]

Thank You.

[@noeljoncas9077]

Man, I swear you are like the Bob Ross of harley motors, so soothing. Love it thanks for your vids.

[@pacificmike9501]

Wow, thanks!

[@ryanbassett2091]

Mike, I was told along time ago by an old timer, when I was getting into this business, " Your hand is not a hammer, remember that and you"ll thank me later!" Great content!

[@pacificmike9501]

Thank You.

[@gwilliammaggs]

I have to agree with Ryan, I cringed when you banged the piston down with your hand. Your hand is not a hammer, I have a beautiful scar from surgery from too many years of using my right hand as a hammer. And yes it still aches. Great videos.

[@walterperrault]

The motor is coming together nicely using the right tools for the task helps things go smoothly awesome job Mike

[@pacificmike9501]

Thank you.

[@safeeffective385]

This is important stuff that's going to keep a lot of folks going down the road, for a long time to come. Thanks for doing this Mike.

[@pacificmike9501]

Thank you. That's the hope.

[@daniellewis37]

Hi Mike, I'm new to your channel, and I'd like to thank you for the invaluable information that you have provided. With all the mindless crap my grandchildren watch on the Internet, you're the 1st that provides me with knowledge AND entertainment. Thank you.

[@pacificmike9501]

Thanks and welcome

[@pacificmike9501]

Thanks and welcome

[@JimmieJohn]

Mike, your one cool dude! I enjoy watching your videos.

[@pacificmike9501]

Glad you like them! Thank You.

[@johnwarwick8636]

Can't wait for your video putting heads an rocker boxes on .thanks for the video s mate

[@pacificmike9501]

Thank you. Coming soon. Have to prep those heads first.

[@robertelstrom576]

Getting ready to do the top end on my 1993 EVO. I have learned a lot by watching your videos. Thank you.

[@pacificmike9501]

Glad to help.

[@pectonhjones1855]

You wouldn't believe how much you are boosting my confidence,I found myself speaking along with you. So it's a different style VW similarity. I feel very confident now after watching you. Thanks man.

[@pacificmike9501]

Wow, thank you!

[@caseykelso1]

Cant wait any longer. Need to change the base gasket on the rear barrel... thanks for these 3 particular videos, there going to help...

[@pacificmike9501]

If it's an Evo, change them both or you'll wish you had.

[@caseykelso1]

@@pacificmike9501 ya 97 FL , was thinking of that and just do the whole top end . At my age I wouldn't have to do it again 🤣🤣🤣

[@CavemannCycles]

Love the videos. When this EVO / BLOCKHEAD is finished , could you make a video of all the tools used is the entire tear down and assembly . Would love to see this info and tool knowledge from you. Keep up the great work .

[@pacificmike9501]

Thank you. The tools are the same for most Harley rebuilds, and, they're in your service manual.

[@MyPichet]

Another great video, thanks mike

[@pacificmike9501]

Thank you.

[@ricknicholson539]

Getting ready to build a 97 evo with a big bore in it. Have found your videos informative and very understandable. Going to be the first Harley Davidson engine I will be building so I'm sure I'll be watching them again if not several times. You explain it in ways I can understand. Thanks so much for the videos and explaining in a way the average guy can follow and enjoyable to watch. May you have safe travels and maybe see you out on the road one day.

[@pacificmike9501]

I hope you enjoy the build. And, I wish you the best on the road.

[@elsdp-4560]

THANK YOU...for sharing. Very much enjoyed. Wait a minute, you had to go and borrow a tool? I just lost a little faith in you. Just kidding, perhaps Bobby will buy that tool and give it to you as a gift for doing a nice rebuild on his engine. Come on Bobby, Mike needs another tool to add to his arsenal. Great video.

[@pacificmike9501]

Okay. My hand was sore and I didn't want to fumble too long on the video. That is an awesome tool. I don't know who made it, but Kenny said it costed about $125.00. I like it. I bet you did too. Bobby's doing his part. Thak you.

[@pacificmike9501]

That's "Thank" you.

[@shovelhead.]

Videos that will be studied every time. Thank you

[@pacificmike9501]

And, Thank you.

[@deadheadlights]

Thanks Mike! Always interesting to see how other mechanics do things. Keep up the good work. Al

[@pacificmike9501]

Thank you.

[@trenthitchcock4194]

Just bought my first bike last March, (1999 evolution sportser) tore it apart hardtailed it and built the bike up never opened the engine tho, I got a 1987 1340 engine I just bought I plan on doing the top end on, then building another custom, your videos will definitely be helping me along the way! Thanks for the great content!

[@pacificmike9501]

Wow. Thank You. I'm impressed.

[@bobgrim6735]

Absolutely Excellent

[@pacificmike9501]

Many thanks!

[@alstone5257]

Mike, what ever type and or year engine you work on, I learn technique's from you, that apply in general to building an engine of any type, and of course apply to the engine of the particular video. With that said i watch all of your video's, and learn technique's from them all. THANKS AGAIN for sharing your knowledge.

[@pacificmike9501]

Wow, thanks

[@Cacheola]

Come on people, 14000 views and only 604 likes. Help this guy out, he's a wealth of good quality info

[@pacificmike9501]

Thank You

[@eddiesargent4163]

Some of us watched it 100 times!😅

[@MikeFLHT]

Thank you

[@pacificmike9501]

Glad to be helping. Thank you.

[@medikusnsb516]

He is doing a great job very interesting Videos. I like your calm and relaxed way.

[@pacificmike9501]

Thank you very much!

[@finger175]

really Mike, you are the best

[@pacificmike9501]

Thank You

[@johnroethel5527]

Personally I prefer to put the piston in the cylinder and install the wrist pin last. Different strokes for different folks I guess. Love the vids!!!

[@pacificmike9501]

No reason why not. That's the way the old Indians were done.

[@dielauwen]

Install pistons in cylinders first , then install pin and clip, Much better . Do use atf or wd40 on rings and pistons . it burns right off and seats the rings quickly.

[@pacificmike9501]

Maybe so, maybe not.

[@beausbargarage6213]

You are my literal hero

[@pacificmike9501]

I don't know that I'm worth all that. But I certainly appreciate you.

[@roadrash8933]

I'm at a pause at the moment. I took apart my 97 wide glide evo due to a #3 rear stripped stud causing loose head bolt. Gasket leak Pistions on it had a clear visual of larger gap both facing in. I decided to buy all new stock cylinders/pistion kit from jp cycles and pay to get heads rebuild. The new pistons have save exact gap size but with arrows an confused which way they both point. I currently have it like this atm ⬅️➡️

[@pacificmike9501]

Probably fine. Check with the mfgr.

[@lawrest9561]

Great video, Mike. I'm always learning from you.

[@pacificmike9501]

Glad to help. Thank You.

[@Gentleboy80]

Hello Pacific Mike! I've watched now about 2,5 hours your videos and it is so enjoying watching that EVO coming back together. I have more experience with Twin Cam engines but I´ll do a Evo probably in the near future. Again Mike, it is so relaxing to see your videos and probably I will do something similar for my Spanish friends over here in Valencia / Spain. I usually fix all the bikes from our crew and I really enjoy to teach other peoples. I'm so glad that I found your videos here because there are a lot of good stuff that I didn't knew about the Evos. Thank you very much and a big SALUDOS from Valencia..... Muchas gracias Amigo!

[@Gentleboy80]

aaaand I didn´t forgot to subscribe :-D

[@pacificmike9501]

Thank you. Glad to be of service.

[@pectonhjones1855]

I can hear that motor already and it's not even finish. Mike,this shot of Tequila is to you man,cheers.

[@pacificmike9501]

Thank You. That motor is done and you can find the videos of it on our KZbin Homepage (Pacific Mike).

[@louisbarrettous8646]

Great videos installing top end on my 1988 evo today keep videos coming thanks

[@pacificmike9501]

Thanks, will do!

[@Freedomfighter916]

I Love watching your videos. 💯

[@pacificmike9501]

Glad you like them!

[@timj9209]

thanks mike old school tricks hard to beat! nice tj

[@pacificmike9501]

Thank you. But, I'm not "Old School," just an "Old Guy."

[@bigroryhollar5023]

🍻thank you

[@pacificmike9501]

And, Thank You.

[@69Busa08Nova]

Sooo, I pulled my Evo apart, had it bored .005 due to some scoring (this all started because of slight base gasket leak), the new pistons the machine shop supplied have an offset wrist pin bore. According to research, the shorter distance goes to the back of the motor, however, that would put one large valve relief at the intake valve, and one small relief at an intake valve. Also, when I pulled my engine apart, both arrows were pointing forward. My head is starting to smoke lol. I’ll figure it out, but, some insight from an experienced builder would be appreciated if you have the time. Thanks and great videos.

[@pacificmike9501]

I think I would be talking to the manufacturer of the pistons. You're checking things out carefully and I applaud you on that. You deserve answers from the manufacturer. When I question a product, I go to the source.

[@aircamry]

I live in Redlands ca ur vids are helpful I think I have to redo my im rings on my 2001 road king it’s smoking and burning oil

[@pacificmike9501]

Depending on how well the engine has been maintained and how many miles are on it, it might just be valve seals.

[@aircamry]

@@pacificmike9501 it has 40,000 miles and motor been Maintained well always took the bike in Wright bros customs here in Redlands, out skirts of Yucaipa Harley shop

[@pacificmike9501]

Then, there is probably a good reason it's burning oil. Maybe you ought to have Wright Brothers have a look at it. 40 thousand miles is not much. I doubt you need new rings. Probably valve seals either. Maybe no big deal at all.

[@aircamry]

@@pacificmike9501 thank u

[@stephenginoulias7440]

Mike interested in your timing mark setup you had on the inside of primary!

[@pacificmike9501]

Next time I'm in there, we'll show it.

[@lynntankersley4837]

What assembly Lube and Lithium grease do you use? Love your Channel. I'm a die hard EVO man. Now I want to freshen up my extra EVO motor !

[@pacificmike9501]

I don't know that those brands are important. I just use good name brands. Extra motors are cool things.

[@indywilly3602]

Thanks Mike. Great video and Very informative as always. Mike what's your thoughts on Axtell cylinders.

[@pacificmike9501]

It's all about the purpose. I've had them make special cylinders for a customer with serious race requirements, and he set records with them.

[@flight6.690]

Could you Explain shallow versus steep crosshatching?

[@pacificmike9501]

If you're honing cylinders, and this was taught to me by my favorite automotive machinist, a steeper crosshatch will carry oil better up and down the cylinder walls. It is steeper procedures today for an easier breakin, and supposedly, this comes from NASCAR.

[@jerryking1434]

@@pacificmike9501 im still not sure what you mean or what the difference is .. .??

[@corbinhbucknerjr558]

Do you have a preference for the type of piston rings, as far as cast or moly rings? Just for a stock re-ring in my case.

[@pacificmike9501]

I like cast rings. They seat more quickly.

[@marine052520031]

Awesome videos..new subscriber here...now I'm binge watching.. lol 😁

[@pacificmike9501]

Thank You.

[@marine052520031]

@@pacificmike9501 Mr Mike I've been trying to wrench my 2000 FLHTC TWIN 88. Learning to change can tensiors on my own. I could watch you all day sir. Keep up the great work 👍

[@markrottler8316]

What brand of shirt is that you wear? and great videos they are helping to rebuild my brothers Evo, Thanks

[@pacificmike9501]

Thank you. The Brand is Dickies.

[@daniilgumirov6654]

Why didn't you use a bolt to push the pin inside the piston? Don't you afraid to bend the rod with a hummer?

[@pacificmike9501]

A slight "tap" with a rawhyde mallet on a plastic screwdriver handle? No.

[@coreyaustin4715]

Thank you for all of the information. What is the name of the service manual you are using?

[@pacificmike9501]

I use Harley Davidson's own "Model and Year Specific" service manuals.

[@steveharvey2203]

As a question regarding the arrows in the piston crowns. In the service manual it says "If the piston has an arrow cast into the crown, install it so the arrow faces toward the front of the bike." So which is the correct way?

[@pacificmike9501]

Sometimes the pistons are identical front to rear. Sometimes they aren't. Sometimes you have to match up the size of the valve pockets in the top of the piston with the valve sizes. Not always easy, not always an explanation from the manufacturer.

[@joseornelas6383]

Hello Mike great video! But I am in the middle of putting together my 2002 sportster 1200 custom and I saw your video in how you showed how to position the pistons with the arrows pointing towards each other because of the size of the indents for the valve clearance . In your video the indents were different sizes in my situation they are the same size I double checked it with my caliper like you did and it confirmed it so how do I install the pistons in this situation? I would really appreciate your help thank you

[@pacificmike9501]

Both forward should be fine or check with the manufacturer.

[@joseornelas6383]

@@pacificmike9501 thank you sir for your quick response, I looked it up in my manual and there is no mention of the procedure so I will follow your advice thank you again

[@AL-fy7gp]

Mike, as always, your videos are invaluable. You have such a great way of teaching this stuff! Quick question for you. I picked up a 1988 evo motor. Mechanically the engine is in great shape, cosmetically it looks like dog.... well you know. Can I strip the black paint while the engine is assembled? I can pull the jugs off but would rather not split the cases as it's not needed at this point. Just wondering the best method to strip the paint when I'm not doing a rebuild on the motor? Thanks!

[@pacificmike9501]

No matter how you do it, stripping that paint off is a lot of work. I use paint remover, which also removes skin. Use gloves. It takes a lot of applications and a lot of water. Hard to keep it out of the motor. You could get some paint and repaint it without stripping it. Just clean and prep it. Then paint it. Picking your materials carefully might do it. Not an easy project. This is when I use Harley's own paint and talk to the guys at an automotive paint shop.

[@fmanion24]

Mike, I'm trying to figure out if I need to rebalance my crankshaft if I replace the pistons.

[@pacificmike9501]

Only if you're ready to rebuild that flywheel assembly. We don't call it a "crankshaft," even though it's same as. You balance the flywheel assembly when you rebuild it. You generally don't really need to rebalance every time you replace pistons. You can however, if you feel the need, match the weight of your new pistons with the old ones. Again, not really necessary.

[@fmanion24]

@@pacificmike9501 much appreciated.

[@BrianSmith-usmc]

I have a 1988 FXR low rider. It looks like stock pistons. When disassembling it both pistons arrows were facing the front. This is different than what you eat showing. What should I do?

[@pacificmike9501]

Look those pistons over. Notice that the pockets in the top of the pistons are slightly different sizes. The bigger pockets are for clearance from the intake valves. Feel better now? It's just the way they make them.

[@PhilSoussanOfficial]

I really enjoy watching your videos - I appreciate your true mechanical knowledge with so many "parts fitter" mechanics out there. It is truly a dying art! A quick question if I may; regarding a 1988 FXST Evo... been rebuilding the engine and will split the cases to re-seal them. I was wondering about the side to side clearance of the conn rods with the flywheels. The clearance between the rear rod base and the flywheels is 18 thou, and that between the front and rear rods is 32 thou. Is this still serviceable? As an aside I cannot imagine that there is any contact between these surfaces during the stroke of the engine so I cannot see how the clearance would "wear" or change? There is no discernible up/down play at all. Many thanks, Phil

[@pacificmike9501]

You're probably just fine. Wear limits, in the service manual, are generally quite good. But, what you're looking for is up and down movement. You don't want any.

[@PhilSoussanOfficial]

@@pacificmike9501 Thank you Mike! I appreciate the prompt reply :-)

[@stevengrossman6700]

Hi dumb question but if don't space the rings like the book says will cause oil to come out exhaust thank you for your knowledge

[@pacificmike9501]

On all piston rings "staggering" the end gaps is always necessary. The prescribed pattern shown in the Evo service manual is (in my opinion) ideal. However, if the bores are "oblong" the gaps will line up with each other. Very common on an Evo. This is why aluminum cylinders should always be "fixtured" when they are bored. If they line up together, oil will pass right through. Not a dumb question. Believe me, it is a real "live and learn" situation. Also, be sure the end gaps are set according to the manufacturer's specifications.

[@stevengrossman6700]

@@pacificmike9501 man I appreciate you help thank you. So what happen was I had bad valve seals I replaced them no problem but I took the jugs and pistons off to clean the carbon off and when I put it back together it smoked and oil was coming out of the exhaust port on both heads

[@joeabbott7839]

I think dun so many you could do one blind folded 6ou make it look so easy by now you mite know I am bullhead but to for first time I got put together lubalway used motor oil before

[@pacificmike9501]

Okay.

[@_2wheelsmovesthesoul_619]

Hey pacific mike! Would I be alright to do a top end rebuild on my buddy's 98 Evo big twin with used juggs that aren't in bad shape with new pistons, and rings? Was going to do a hone on the juggs to get a good cross hatch since they're out. As long as the sleeve isn't worn too well and the bore is in spec, it's ok to do it this way right? Thank you sir, just trying to rebuild it the best I can on a budget

[@pacificmike9501]

Have a qualified mechanic check the cylinders for wear. Refer to the "service wear" limits in the service manual. Apply a little common sense and go for it. Remember the cylinders need to be fixtured to be measured properly.

[@_2wheelsmovesthesoul_619]

@@pacificmike9501 Thank you Pacific mike, I appreciate that

[@driver1551]

Great video, Mike. You usually have little tips about every gasket, alignment, sealing, crush etc. Did you use any kind of sealant on the bottom gasket, when you put the cylinder on?

[@pacificmike9501]

No. It is dry, as per the gasket manufacturer's recommendation.

[@michelstellato6395]

Hi Mike, what do you think of the S&S service bulletin for an EVO engine how to position the piston,• (These pistons can be used in either the front or rear cylinder, however they must be installed with the arrow on the dome pointing to the front of the engine due to the offset wristpin. If pistons are received from S&S® fit to cylinders, pistons must be installed in cylinders they were fit to.)

[@pacificmike9501]

That's the way it's done. Always adhere to the manufacturer's recommendations.

[@hanskonrad5850]

hi mike! on front cylinder...whats the rear right hole for in the case . i know the front left is the oil return from top end. i have the same holes as your vid but you didnt cover that one! lol

[@pacificmike9501]

I'm not sure what you're speaking of. But, quite possibly, you're speaking of an access hole for machining the oil passages for the tappet blocks.

[@Cpcsof1]

@@pacificmike9501 I have the same access hole on my 93 evo motor case. It is plugged. The plug is recessed slightly. My base gasket covered the hole. I hope this is how its supposed to be.

[@michaelmitchell5909]

Great video brother... Tatro machine is a wizard with Harley motors...check out his channel if you haven't already.... Every one who works on their own bike should watch his channel...

[@pacificmike9501]

Thank you.

[@user-es1dy2xg4g]

i have a 1997 road king evo carb i am doing top end do you have a veido on doing all seals and gasgetsii place

[@pacificmike9501]

Go to KZbin. Put pacific mike in the search bar. When the homepage comes up, click on the word videos. A bunch of them will come up (approx. 275). Read the descriptions. We did an entire high performance job on a 97 Fatboy. It was a stroker, but everything you're asking for is there.

[@ronertromano7897]

Great video . I have one of the first EVO motors in 1985 Super Glide base gaskets leaked after about 30000 thousand miles. When I replaced the gaskets the first time they leaked again after about the same mileage. So the next time I cant remember who or where I got a set tubes for the oil passages to the upper end. Problem solved. Have you ever heard of them? I live in New York seems bikes shops around here know about them. What’s your take on this fix?

[@pacificmike9501]

Yes, they are a good fix. I remember them being available from several suppliers. They did come from Southern CA. Should be looking through some catalogs.

[@davidyager8817]

What size ring compressor are you using?

[@pacificmike9501]

I think it's a twenty gallon.

[@jamesdouthit4695]

Hey Mike, what service manual do you use for your evo motors? I have an Ultima 113 and looking for a good service manual. Thanks in advance. Jim

[@pacificmike9501]

I would use any Evo service manual that is for a Softail, if that's what you have or a bagger, if that's what you have. But I would mostly use whatever printed material Ultima has for the motor.

[@jamesdouthit4695]

@@pacificmike9501 Thanks Mike, Im running a 1989 Road King, Ultima 113 with rev tech 6 speed tranny, and open primary. Dropped a lifter...broke some stuff. Got it tore down to the cases...building back up now.

[@pacificmike9501]

Very cool. The appropriate service manual would be a 1989 FLT book. The motor specs will have to come from Ultima. Sounds like a fun ride.

[@davidmacedonia285]

Hey Mike! First of all, thanks so much for your videos. They're great! But, I have a question. I'm refreshing the top end of my 1993 FLHTCU, and sadly I removed both pistons without noting the direction of the arrow on the front cylinder. The service manual (FLT/FXR Models, 1993 and 1994 Official Factory Manual) says on Page 3-34 that "The arrow on top of the piston points to the front of the engine." In your video, you say that it should point toward the intake valve. You also said that the pockets on the piston are different sizes (the intake being larger), but that's not the case on mine. Well, they're not EXACTLY the same width. At the widest point, one is 1-3/8" and the other is 1-13/32". By the way, the part number of the pistons are 22091-83B. Help?

[@pacificmike9501]

What I said holds true. The biggest pockets point toward the intake valves.

[@davidmacedonia285]

@@pacificmike9501 Thanks, Mike!

[@markmcsheffreysr6890]

Can you please send where to put ring on pistons please

[@pacificmike9501]

The instructions shipped with the pistons normally tell the positions, locations and clearances for the installation of the piston rings onto the pistons.

[@johncasor9698]

@15:19 you say i think you can buy these fasteners nuts,,,. This is where you can buy those fasteners to hold down cylinders without the head on... 446 Kastar Cylinder Sleeve Hold Downs , part#446 Brand: Kastar Tools... price $25.78

[@pacificmike9501]

Thank You.

[@brianohara5696]

Boy I would have some rags covering the motor

[@pacificmike9501]

It's open while I'm working for you to see.

[@donm9951]

where can i get that tool

[@pacificmike9501]

Any major aftermarket supplier of parts for Harleys should have it.

[@brianbiggs3484]

👍👍🇨🇦✌️🇨🇦✌️🇨🇦👍

[@pacificmike9501]

Thank You.

[@richprince9901]

That was a dumb question sorry Mike,

[@pacificmike9501]

No big deal.