HARLEY DAVIDSON EVO ENGINE , Why it Smoked So Bad.

[@TheKiloG69]

1300 miles later this bike runs great no further issues. Thanks for all the comments good & bad.

[@rdh5695]

Did you replace the metal thrust washer on the breather gear. Should have been a plastic gear and washer. Metal would have been early model application.

[@charliedee9276]

I picked up a 98 Softail Custom that had sat for a couple years indoors. Smoked a lot, turned out to be the exhaust valve seals were toast. Replaced all of them, ran a hone through the barrels and fit a fresh set of rings. Screaming Chicken lifters, ignition box, Andrews EV3 cam, Super E, 2 into 1, and the best modification, chain conversion. Dropped the gearing, put a fatter tire on the back and it's a pretty good runner now, surprises quite a few stoplight to stoplight.

[@tomsmith1390]

So what is the dropped gearing doing to your top end running that EV3? They kick in at about 3000 RPM normally. Have you ever ran an EV46 in a light bike, Pulls off at about 2200 and runs out well to about 6200. 84 CI Stock crank / What I like is with this build [Other secrets maintained] is on the Dino the engines pull almost equal 1HP to one foot pound torque at 9.5 to 1 is a keeper. I am seeing about 92 HP.

[@mr.j1400]

It's good to know that there is someone out there that knows what they doing, you teach young people 👍🏽

[@daveg1208]

Don't ya just love it when people stick their fingers into things when they don't know what they are doing. They either didn't know or didn't care. That's why I work on my own machines. God bless you brother.

[@derekheuring2984]

Great video, thanks for posting it. I bought a 1997 FLHR with 25,000 original miles and a "rebuilt top end" two years ago. I asked the seller what had been done to the "rebuilt top end" but he had no idea. Oh well, it still runs strong and doesn't burn or drip oil. I plan on doing most of the maintenance on it myself and videos like this (and a shop manual) will help immensely.

[@TheKiloG69]

Thank U. I cant imagine why any one would do top end work on a Evo at 25,000 miles that's nothing. I used 2nd hand parts with 24,000 miles on them to repair this engine, jugs & pistons. Over the years I have had many top end jobs cyl.heads & jugs messed up by incompetent machine shops, sadly the shop I used to use closed over a decade ago. Good luck & best wishes on your new bike.

[@58astroboy]

Always good to see someone who knows what they’re doing and talking about than to hear someone who doesn’t know what they’re talking about or doing. It’s a crying shame to see what someone done to that bike!

[@TheKiloG69]

Thank you. 3 years later still runs great no issues.

[@SebSar-ef4zj]

No irritating background jingle makes for much nicer videos, specially when someone knows what he is talking about. By the way I installed a hard drive starter button on my FXR, best thing I ever did. Thank you .

[@TheKiloG69]

Thanks. This bike still runs smooth as silk no issues with it whatsoever.

[@SebSar-ef4zj]

Glad to know she's running great with no problems. I've had my FXR since new from 1992 and she's going so well too, over 120000 Klms & going strong. Keep the shiny side up and the rubber down. Cheers .

[@TheCalgarydoug]

Some people should never touch wrenches. My buddy Bill rebuilt the flathead engine on his 54 Ford and wondered why he couldn't get it to turn over. We tried towing it to bum start it and all it did was drag the rear wheels. He took the oil pan off and I got under the car to see if I could find what he did wrong and he was insulted when I laughed seconds after looking at it. He had installed the bearing caps backwards. I told him as a mechanic he'd make a good butcher.

[@pcofranc]

I think you meant a GREAT butcher - wanna be psudo mechanics mechanic voodoo practitioner

[@nathanburns4345]

The last Flathead Ford was 53.

[@tomsmith1390]

@@pcofranc Ever do any work or just win spelling bee's?

[@savgeryplayz9258]

Thank you for leaving out You Tube video "music." Great video. Well shot as well. Easy to listen too. Good info. Many happy miles to you and your bike. :)

[@simonmerrin7967]

Had exactly the same on my brothers new evo fatboy. No wristpin clip fitted. Absolutely trashed the cylinder. Harley dealership insisted the bike was fine when he collected it later when the work was done. Brother rejected it after stating that all that milled metal went into the whole engine. Eventually, the dealer bought it back. Someone else bought the bike and sometime later it got stolen ! Never had another Harley, All this across the pond in the U.k

[@toolmaker5150]

I used Teflon pin retainer buttons on my last Evo build. First time using them. Sounded like a good idea. So far , so good. Thanks for the video.

[@MrTheHillfolk]

I'm sure they are fine. Some aircraft engines use that and if I recall correctly some truck engines might use em too.

[@rodgeranderson4922]

Hate to say it but the oil pump body will be toast, the broken bits of the clip will have gone thru it and scored the return side of the pump. Seen it many times. A quick look in the breather chamber will also reveal damage.

[@VndNvwYvvSvv]

Yeah, redo the whole engine from the crankpin up. It has has metal through it. Needs to be checked.

[@ElectraWillem]

Nice to here someone talk about Harley engines, and nows what he is talking about. Thanks for sharing the video

[@TheKiloG69]

Thanks .Still running fine.

[@jameshaines3370]

My 97 had 41thousand miles when I took it apart. Oil rings was wore the same size as the pistons. I put 26 thousand mile pistons and cylinders on it. Still runs good. Better since I converted to a s&s carb. It was fuel injected. I saved everything. I did buy a carb tank for it. My original cylinders where in good shape and stock bore. They get high dome pistons and rings soon.

[@Jeffy2n]

So, you don't think that missing clip is in the crankcase? It kinda makes me want to split the case just to be sure.

[@pcofranc]

It probably didn't just pop off it probably got ground up gradually into metal shavings in the oil filter.

[@fireball1322]

You can bet all the metal taken off the cylinder by the wrist pin is in the crankcase. Seen this before. Split the cases !

[@daveg1208]

Jeffy2n I was wondering where the clip was myself. I'd pull it down and inspect just to bee sure.

[@TheKiloG69]

found it in breather cavity .

[@jesusacovarrubias1390]

Well done. I am in the market for a 1998 Harley Electra Glide Ultra Classic and I truely enjoyed watching your breakdown on the Evo engine. How much does it cost to restore a 1998 Evo engine? You also mentioned how the Andrew's cam is a mild cam, the bike is not a hot rod. In your opinion, why wouldn't you want to increase the engines performance with bored out jugs, higher compression pistons, and higher performance cam? Thank you. Jesse

[@TheKiloG69]

Easy I have a 1996 fat boy also. 10-1 pistons,street performance heads Andrews EV 57 cam. Fast tire smoking beast. Down side U need real gas 93+ octane. FL.heat 100f on a hot day it real finicky bitch. will not run on shitty gas at all. That's why this is built like it is ,easy to ride no issues.

[@jesusacovarrubias1390]

TheKilog69 makes sense, thank you for you response.

[@moparerrnocar]

Pin walk out was more than likely due to detonation. Typically the pin will pound out the opposite side of the flame front/kernel (spark plug). Also, rings rotate. Cant assume they were installed incorrectly. Hope you thoroughly flushed the case and flywheel, that pin powdered that motor good.

[@austinjunkman2449]

it's not a pratice that happens here, but I have seen a few mismatched cylinder bores. Also 1996, 97 and 98 are notorious for the lower end failing because the factory didn't put enough oil clearance in the rod bearings and the rods end up tight on the crank pin, and the bearing surface of the crank pin and or rod races ends up eaten. A bad lower end will spit a wrist pin clip out. that's not necessarily what happened there, but that is one of the magic years.

[@danielwoodhouse1870]

Harleys are not my thing but I found this really interesting, thanks!

[@JohnJohnson-sr6zt]

New wrist pin bushings. You'll be glad you did.

[@russelllaumann50]

it would appear I struck a nerve with a couple people..............one referred to me as a moron. Well if this person laid down $20,000 +for a machine that is as technology advanced as a farm tractor and as reliable as a condum bought in a bar bathroom...........I would think long and hard about whom you call a moron. By the way with Harleys recent issues with their unveiling of the much Herolded 8 valve motor (no oil pressure right off the show room floor) have you seen what happened to their stock price?

[@TheRealCreepinogie]

I've put together different sized shovelhead cylinders from front to back sometimes as off as 20 thou and they've ran just fine. Your big problem as you pointed out was the wristpin clip.

[@patrickteto]

Wow.I can't believe you admitted to that.I guarantee your lower end thanked you for not equalizing the combustion chambers on a twin cylinder.Keep up the good work man. LMFAO

[@TheRealCreepinogie]

But they're still running just fine after years.

[@thomaspokorny9487]

Just ran across your vid.I`ve been a Factory dealership mechanic for over 45 yrs. Your Wrist pin clip issue is probably NOT due to bad installation.On a rear rod,there are roller bearings on the left and right.If the crankpin starts to erode,or the bearings go bad on ONE side,the wrist pin is thrust to one side.This will force the wrist pi to one side-dislodging the wrist pin clip If you look at the W.P. boss on top of the rear rdo,you will see a shiny spot on the upper part of the rod.The inside of the piston will have a matching shiny spot around the wrist pin boss.Even though you don`t feel any play in the rod bearings,they still will be bad.If you cut your oil filter apart on white paper towl,you will see lots of metal particles.I`m sure this is too late for you,but by now I`m sure it developed the SAME problem.Also after 2 put-togethers,the return side of the oil pump is most likely toast,too.Also early head gaskets used o rings around the return holes-lates do not.

[@thomaspokorny9487]

I know that in my 50+ yrs,Ive never seen a HONDA BREAK! I guess Honda mechanicsNeed no technical advice-As they`re not needed anyway (AS per YOUR opinion). I just like helping out people when they don`t always get the WHOLE STORY! If you check out the cylinder on thr other side,You`ll see where the piston dome rocked to the OTHER side upon firing.That wouldn`t happen if both sides of the rod bearings were good!

[@thomaspokorny9487]

If the previous mechanic only did wha HE WAS TOLD,no surprise! If the mech was afraid of losing the job by not standing up for hi knowlege,His name would be being laughed at.If they couldn`t listen to my explaination,I allowed them to leave. I saw this happen at least a dozen times! As far as a cam BEARING problem,It was a hardness problem of camshafts vs.cam bearing.Aftermarket cams needed Torrington brngs.Stock cams will work fine w/INA! Inspections of failed"BEARINGS" would always yield perfect,non-marked rollers!

[@thomaspokorny9487]

N.E.Ohio Gled to offer it to help.Sorry if I ramble so much,but sometimes friends need details!

[@TheKiloG69]

Hi Tom ,Wow all the comments! Yes who ever worked on this bike was a ideit I took the whole bike apart every were I looked things were screwed up I mean everwere primary drive chain New but way loose brocken clucth plate by the snap ring, on & on . Update on this bike 1300 miles later runs like a champ no issues ,no leaks no oil use, cylinder bores look great. Many comments many suggesting on how to work on my bike. Not my first rodeo, I did many more things to this bike I never said anything about in this video this is my third Evo , I have had iron head sportsers, Shovels , Panheads many years ago 63 years old been working on bikes cars & trucks since about 12 years old,had no choice my dad had a car lot. I also did dyno tuning & testing had a Dnyojet 150,all around the country for about 2 years in the early 90s. Lots of good comments , lots of stupid ones too Thanks for watching.

[@thomaspokorny9487]

During your disassembly,I`m sure you pulled the breather gear and checked the case and gear for scoring.I`m surprised you didn`t find any damage.Anything that is oil lubricated and can fall apart,will come through the breather into the cam chest and into the oil pump return gears.

[@hwy6163]

Very nice video. No background music and a good clear voice. Your assessment of the issues was what I would agree with. I am looking forward to seeing more of your work. I have two HD 1988 evo and a 1970 Electra Glide. I have had my engine tear downs done by proven local shops. My expertise is welding, fabrication and paint. This tech engine rebuild or repair can be very unforgiving for a amateur.

[@TheKiloG69]

Steve Webb, Thanks I have had Pan heads , 3 shovels & this my 2nd Evo. I bought a new FLSTF back in 95. I use to tour the bike circuit back in 96/98 with my Dyno-Jet 150 mobile Dyno. I have seen lots of stuff like this. This bike has remained trouble free since I fixed it. Next I have to replace the clutch pressure plate that I found 25% of the snap ring broken, I have seen this a lot also when guys don't use the proper tool to remove them.

[@hwy6163]

I recently completed my resto mod on a basket case 1970 Electra Glide - I put a 97 CI evo SS stroker in it. The Bike cost 1000 on craigslist and was in 1000 pieces. The new engine was 2000 brand new from a friend. The original shovel engine cases where ruined so this was the best deal I could find at the time. I did the painting and the custom steel brackets as needed. I had Heathers Leathers restore a solo pan seat. I rebuilt the wheels by ordering new rims and spokes and laced my original powder coated hubs. J.P. Cycles has been a great help for many of needed parts along the way. Most recently I encountered a starter problem being I was using the original, weak and tired HD starter intended for a stock shovel. It just had trouble turning over a fresh high compression engine. And kick starting it really is not easy when the bike is cold. Until I swap out my stock 4 speed for one of those new 5 in 4 spooth transmissions I will be living with this original 4 speed kicker. Thank HD for having so little confidence in their first generation electric starters they kept the kickers. I purchased a All Balls High performance starter and was amazed at the increased power this new starter put out. Some minor bracket work and welding for my battery support. My 1970 battery support components used one of the stock starter bolts as a anchor point. This starter was actually shorter than the original. I installed the recommended larger starter power cable and now she turns over like a rocket. Anyway your videos are great because you move at normal pace and cover things from a builders point of view. Thanks for posting them. And thanks for not putting background music in. Enjoyable to watch. And I like that you chose a bike with some challenges. Makes for a better experience doing your own work. Saves loads of cash and is gratifying in the end. I really like the paint you worked into your bike using some old and some new. Custom all the way.

[@randymcvay308]

i bought a used 97 sporty. wrist pin broke and the mechanic that disassembled it found that the front jug was a 883 and rear was 1200. you ever see that before? good video, thanks for sharing.

[@alexpearson7693]

Good thing you caught it before the motor locked on the road!

[@markthompson242]

piston rings rotate in the grooves it is possible for them at some stage to line up, especially with a damaged bore such as yours ,the groove in the bore probably ccaused thier location

[@Larwenful]

I'm no mechanic but I literally winced when I saw that gouged cylinder.

[@andymonk9505]

You could still see the factory hone marks and.005 Piston was in it for some reason.I figured it out after I measured it and I saw the 5 on the Piston.It only had 13,000 miles when I got it,late 1985 FLTC.The guy put anS&S carb and was running rich and had a lot of carbon build up on the head and piston.I replaced the rings and gaskets.It never fouled another plug in 11 years.

[@genedavis1205]

I bought a '96 Bad Boy from a guy who's Dad was original owner. Seems someone had "wrenched" it a bit. Shortly after I got it, it began to smoke and puke oil from rear cylinder. I found the same thing with the wrist pin. It was missing a circlip and it gouged the cylinder beyond normal repairs. Replaced cylinder, bored then + 0.010, Screaming Eagle pistons/rings. Long story short, it lives again. That was 11 years ago. Still have it..

[@craigkeller]

The “mechanic” hopefully had lots of ink to indicate his skill set. Glad you could save it.

[@PeterDad60]

Harley flat trackers used to bore out the rear cylinder for a larger displacement knowing full well that the tech inspectors only removed and checked the dimension's on the front cylinder only. So these riders were getting away with having a larger displacement motor for the class they raced in. Get it? More power! My point in that it does not hurt a motor to have one cylinder and piston larger than the other one. Just like this bike had. Yes, certainly installing the wrist pin improperly so that it worked lose and the result was a severely gouged cylinder is a real bone head thing to do. That sucks. Lining up the spaces in the rings is without question a newby move indicating a non mechanical inclined individual do the work.

[@capttom7772]

PeterDad60 EXACTLY, That's what balancing is for, remove the difference from the heavier piston's wrist pin boss with a drill and compensate on the flywheels the same way!!!

[@justinpucino]

Awesome video I can’t believe they bored out one and left the other I never seen that!!

[@OneEye.]

Suggest that you check inside the bottom end look for the missing pin retainer.

[@Roadghost88]

It's amazing how some people will screw up a bike, then go around saying "Harley's are junk, I know because I owned one and it never ran right..." Blockhead has to be one of the most reliable, easy to fix engines made.

[@hedonisticpunkvatos]

Cool vid. I got mad watching how someone put it together wrong.

[@wyattoneable]

That's actually good news. You found the issue and now it's just a matter of the right parts and the correct reassembly, which I know you can do so that thing will be running in no time. HQ cams (I've been told) are suppose to be good. Maybe lack of oil caused the wear? Let's see that baby run!

[@TheKiloG69]

Damage Update ! Wow unbelievable stuff I have been finding. After making this video I removed the lifter blocks & I found the cause of the strange cam were. Who ever installed the cam never relived the engine block under the cam lobe causing the cam lobe to hit the block under the bearing & make its own clearance by wearing it out. HOW Do U Miss That one! witch also destroyed the inner roller lifters! More parts on there way ,I cleaned up interior of engine case & oil tank I think it will be OK . Man I hope this same guy did not touch anything else. Luckily the bottom ends are pretty tough. If new lifters get here Friday? Maybe a test fire this weekend

[@wyattoneable]

Your right about that guy not knowing what he was doing. What a mess. Your inspections are valuable and finding this stuff now will be beneficial in the long run.

[@JCcanU]

2012 I added oring to the heads , but the gaskets today no longer use the o rings , I jacked up the oil return on the heads 14th and oil was buy passing the return hole onto the top of the piston , oil got hot and carboned up in the jug. only set me back 400$ pop the heads off rebore the jug and went 10 over on the pistons , 150$ for the bore 200$ for forged pistons and new gaskets 50$

[@My1911goldcup]

Worked on an 03 sporty same issue, came from the factory without the wrist pin retainers. Both cylinder looked the sam as yours.

[@michaelcarey125]

Excellent video cant wait to hear it well done

[@SyberPrepper]

You are an engine wizard! I tinker with engine stuff but nothing to that extent. Appreciate you sharing this with us. Remarkable what horrible workmanship there is out there.

[@TheKiloG69]

Thank U. I just take engines apart & fix them been at it close to 50 years seen lots of stuff like this over the years. Thanks for watching.

[@critchley3819]

Many years ago I bought a 46 Indian 74 chief engine, I pulled it down and found it had no wrist pin retainers , someone had gouged them out with a screw driver or chisel, and ruined the groove so they assembled it without them, luckily the motor had never been started, the bore was fine the pistons were fine in size, I fitted Teflon buttons in the wrist pin to just touch the bore, never had a problem, did thousands of miles, A friend purchased a new road king in 2013 it used oil from the start he after been told this was normal he persisted in taking it back, eventually they pulled the rear cylinder off and there was no oil control rings, I am Aussie 65, have enjoyed motorcycles since my first bike at 14,BSA Bantom, Motorcycles are a incurable affliction...

[@carlomonde8293]

TheKilog69 yeah, strange how people can be assembly an engine without even find out how to do.. no good to be buying a second hand motor then..

[@47485ksc]

I finally quit as a mechanic after 43 years of working for and with blithering idiots. I worked on them all: fleet buses and vans, John Deere Industrial, equipment rental yards, I mean, everything but cars. Don't like bending over engine compartments. Last place I worked was small engine repair. "Boss" (a kid) hires some big, fat, chain smoking moron to help me. I asked him: "Ever work on small engines before?" "No, but I'm a fast learner." Oh, holy fuck... He's got this Honda-powered lawn mower engine that won't start pulled apart. Mower cost maybe $175 new. I asked what he was doing. "Needs new rings." I asked how he determined that: "Only has 65 pounds compression." I told him that for the last 1/2 century, all these engines have [a] built-in compression release on the camshaft and that 65 pounds was actually very good! I've had flat head Briggs engines run showing NO compression on a gage! Anyway, he took 4 weeks on and off to do the job, sinking maybe $1170 shop labor into it. Charged the poor lady $175. Big profit there, huh? When he was done, I watched and it took 17 pulls of the rope to start and he called it "good". On his day off, I brought the mower in and found the choke wasn't closing at all. A 20 second adjustment and it started first pull. Even in 25 degree weather, first pull. I told him all it needed was a minor choke adjustment. "It still needed rings" he said. What a fucking stoop! Idiots are everywhere!

[@MrJimmy1437]

You may have worked on a lot of stuff in your day but you are still an overbearing idiot You should have known

[@windshieldrepair5961]

I Love the way you said that the wrist oin was rocking and rolling".......I know ots not funny....but I got a good laugh.....How did that happen you must have bought it this way.....and they must have got the install all wrong......when You dont know what your doing you get this type of outcome.......Looks like you did a good job catching it by identifying the smoking......I want to further my learning curve and I have a motorized bike small engine to work on".......So that when I go to make mods to my Buell Blast I dont do installs like you have their......Minimal damage you can get that back to worki g order no problem!!

[@dominicracca6955]

I too have never seen the over bore on a bike done like this, but in cars and trucks I have seen this many times. I worked for Ford at the time and we would get 5.4 and 4.6L engines that would break a ring and the repair by the book (written by Ford) was to remove the engine, disassemble and machine only the bad hole by .010-.020" order a piston based on the bore and reassemble. More often than not this would lead to the engine never running smooth again. Usually we would see the vehicles we did this to back many more times. I didn't like being a mechanic for Ford... Though I was always busy.

[@Monkeywrenchmotorcycles]

Hard to tell is that still the plastic breather gear? I would change that while your in there with the S+S metal one since they are prone to scoring and breaking teeth especially if its the original. I would never run old lifters with a new cam especially with the old cam having alot of wear which is most likely from the lifter on that lobe... Can't go wrong with the EV27 cam though. Good all around cam and works great with stock compression on heavier bikes.

[@sircarloniusyorkehotspur1027]

Thank you Sir for the upload....and it was really informative. I had a question Sir in regards what you think is the BEST Evo engine year with the least problems? I'm saving up for my first bike and am looking into an Evo Softail for a bobber project....Thank you for your advice...

[@TheKiloG69]

They are all good but I like the later years my self 96 0n. No twincams for me.

[@Wanous-hv7zo]

twin cams suck

[@jennydiazvigneault5548]

If you are concerned about getting a good engine and you want to be sure, just get something Japanese.

[@BWGPEI]

Nice to watch a craftsman at work - my best wishes for clear roads and good rides.

[@fireball1322]

You should remove, clean,inspect, the oil pump, it's housing, it's pump gears and the breather gear and it's hole in the casing.. Also great idea to clean out the engine case, which means complete engine disassembly. All that metal from the wrist pin and cylinder is likely in oil pump and bottom end. I had a Shovel head toss it's wrist pin keeper due to overrev . The above was what needed to be done.

[@thomaspokorny9487]

Proof is in the very small verticle scratches in the FT.piston!

[@pcofranc]

Or just rebuild entire engine with an S&S kit or complete motor.

[@bcubed72]

I was told ring gaps rotate with use. No guarantee they were lined up on install.

[@slappopotamus1001]

if the cylinder is bored and honed propperly and ring end gaps set, the rings will only rotate so far, just a few degrees maybe, with the cross hatch in the cylinder finish. the rings should not rotate and end up lined up perfectly like this. some one put it together like this.

[@bcubed72]

Well, I've been told...in both aviation and in automotive...not to immediately condemn a car with one bad cylinder on a compression test, if the engine was otherwise sound, and the "random alignment of piston ring gaps" was the reason. Let it continue in service a while and re-test.

[@capttom7772]

Sorry, you were told wrong.

[@masonryjoe]

Good job , everyone needs a mechanic like you , where do you live lol ,so many hacks in all the trades now a days .

[@rayb7414]

The good thing is it's easy to put it back together.

[@DirtMcGert29054]

On large marine diesels , I have replaced just one piston and liner , done the same on a jet ski , in both those situations on piston was destroyed and the others were fine so I only replaced what was needed , usually the customer cant afford a full rebuild , espescaly on the large marine diesel's , one liner , piston and gaskets plus labor is over $5000

[@thomaspokorny9487]

I`ve run a std and a +70 on the other with NO ill effects! (Over 70,000 Mi!)

[@hyperluminalreality1]

If the piston was jacked in the cylinder that badly I would split the cases and flywheels to check the rollers and crankpin. They should be 3 piece where the pinion and sprocket shafts are part of the flywheel half. All 90's evos had 3 piece flywheels from the factory. It is pretty much needed to insure no galling on the crank rollers or pin that will cause premature failure or rapid wear.

[@RVerFrank]

I am binge watching today. Liked/Thumbs Up

[@CHIBA280CRV]

Wow looks like you caught it early enough to keep from doing some worse damage ! Thanks for the video.

[@pkokelaar]

hello, i had the same problem years ago my harley had a crooked rear connecting rod i had it fixed three times before they discovered it, the motorcycle would run fine for 500 km and the it would start smoking and missing on the rear cilinder it was under warranty, so they changed the cilinder 3 times and every time it would smoke at about 500km at the end i fixed it by straightening the connecting rod and installing a new cilnder

[@jerryhubbard4461]

did the crankcase have any medal in it from the cylinder failure?

[@gregorykaey4880]

I see a lot of top end repairs, but not much on the bottom. Why are you not concerned about the condition of the bottom end?

[@TheKiloG69]

Bottom ends are stout & run roller bearings not babbet type like in a normal engine..

[@gregorykaey4880]

The connecting rods on the pin aren't on bearings?

[@patrickteto]

I agree man.With the major gouges within the cylinder walls,and the power loss from the damage just meant the previous owner twisted the throttle all the way too keep up with his or her friends and being the rear jug just multiplied the heat to the point of real not happiness for all other parts.That could have led to the camshaft leaning over to the point of just being a dog. ;)

[@47485ksc]

No. Bearings can't take thousands of explosions every hour on the hour for years on end. You should have known.

[@carlomonde8293]

TheKilog69 that's what I was thinking too. .and the debris is somehow gathered in the lower pan, and might will stick too the magnetic rod of the tap screw, ?

[@ChrisDIYerOklahoma]

Glad you found what was wrong. Once it is straightened out, she will run like a champ! Really looks like you know what your doing! Looks like whomever worked on it before was an idiot.

[@TheKiloG69]

Yup! The damage is done now up to me to fix it . I hope to fire it up this weekend if all the extra parts get here Friday thanks for watching.

[@brucemoyers1006]

It's AMAZING how many people will TRY to save money by having their cousin's neighbor's best bud work on their stuff. "But he spent 2 years working the counter at Auto Zone!"

[@thatanglerguy9550]

Lol i know what you mean..some can tell you every part name and every number and not know shit on how it goe's togathere..i have a problem remembering the proper names to each part but you can bet your sweet ass its put togather properly and by the book.

[@kiranbhaskar6783]

You, sir, are an artist. Thank you.

[@Cpcsof1]

Do you have an opinion on the Andrews EV3 cam? I have one in my 93 fxr and really like it. It keeps pulling hard all the way to red line without leveling off at all.

[@tomsmith1390]

Yes EV46 Light bike way to go.

[@scottytherambler6919]

hope you are doin well rider. i loved watching the video in 2019.

[@moorefab8192]

"A real wizard" haha that's good. I had a 76 shovel head that this happened to. I was redone before I got it and within a month it sounded like the tank was being beat with a hammer when running. All the cylinder material got ran through the motor and wrecked the crank pin. $2,000 later it runs like a top

[@TheKiloG69]

Lots of Wizards in this world some good sum bad.

[@looneytunes47]

The Harley Oem Valve Guide Seal,s Pop off all the time too!

[@michaelhutson9268]

the heading for the video said headgasket installed with no o-rings,but turns out the retainer clips on the rear cylinder wristpin were not installed-with predictable results! never heard of two different sizes of pistons,that's a new one! when i got my Triumph 500 scrambler it had extra parts with it,one aluminum racing rod,and a complete gearbox cluster still in the brown waxed paper! made me worry about where the other rod might be!(in the engine?)

[@TraceyAllen]

Michael Hutson actually the different size piston was a common repair, especially when warranty would only pay for the actual damage. Definitely better to keep them the same, no one would ever notice the difference. In stock form the rear does not have the same power as the front due to timing always being retarded slightly.

[@hutchins36]

looks like you got it figured out. I cant wait for the crank up video.

[@TheKiloG69]

Yup, I should have it back together & test fire it this weekend.

[@JerryLee..]

Incompetence is all around us in every field. Reading internet post doesn't make one an expert!!

[@reynaldoelias1626]

you are right about it !!!!!

[@mrschwifty5564]

Crazy it even ran

[@goldwingman1500]

Is there a notch on every piston so that your rings when fitted can not line up like your piston has dont there used to be a little pin half way round the piston groove every ring grove has the pin in a differant plave so the two comp rings an oil rings can not line up cheers Mate .

[@TraceyAllen]

goldwingman1500 on a 2 stroke engine yes there are pins. That is so the rings will not get caught in the exhaust port. This is a 4 stroke engine. It uses valves not ports. The rings are free to spin around as they are want to do.

[@bobwarren3898]

Had a Harley deliver brand new and it would never fire on the front cylinder. Tried everything to no avail. Had the shop look into it and when they took the heads off, there was part of a plastic bag and the remains of a chicken salad sandwich in the top end. Brand new bike!

[@cydonianman]

Bob Warren great quality control at it's finest.

[@dzl8596]

Costs too much to stop the assembly line. Cheaper to fix it under warranty.

[@ltsgarage7780]

Bob Warren. That's called "Built on Friday or Monday after a hard weekend."

[@FJ80Coop]

I've bought literally 100s of HD,and atv parts from Pinwheel via fleaBay,and have never been mislead,or gotten a bad part from them...I would still wonder about that wrist pin circlip,and whether it made it into the bottom end,or was left out....

[@TheKiloG69]

I forgot to say that I did find pieces of the clip inside of the engine case it was caught inside of the rotating breather tube. I found it when I took it apart to clean out the cam chest.

[@billwelter4101]

Can you use piston pin C-Clips instead or wire clips ? Those wont come out

[@edspencer7121]

I just subbed your channel 👍 I have no experience with motorcycles but a ton of hours in tractors. I just went through a 3010 John Deere gas tractor with every nightmare scenerio of what not to do performed by a previous "amateur" mechanic! From the steering motor to the final drive assemblies! It's to much to get into to. Which brings me around to saying I have a great appreciation for people that put the effort into getting the job done right.

[@ALtheDoctorWho]

Amazing what were they thinking. Good luck with the motor.

[@pauld5818]

hello great video ,,i own a 1993 flhs which seem to wobble or to go different directions on an uneven surface it feels like the front wheel wants to go one direction and the read the opposite direction for a split second,,and ideas please my bike has probably 80.000 miles on it with original belt and pullies could it be the swing arm mounts worn out?

[@TheKiloG69]

Check your swing arm bushing & rear swing arm alignment. Very common issue.

[@pauld5818]

Thankyou for the advice

[@MrSpongie1]

Ouch.... no wonder she was smokin. That's crazy rough.... marked her up really bad.

[@tangledline]

That is engine building 101. How the hell did they make such a huge mistake? Nice job on the recovery!

[@murph55]

Where's the clip? It has to be somewhere in the engine

[@billthomas6873]

2 clips ?

[@maniyan_wanagi]

Yup, Pinwall has done good business for a long time.

[@capttom7772]

OMG........ Just what do you think happened to all the rear barrel shavings from the out of place wrist pin???? Split them cases and reset the crank assembly with all new bearings. IMO DO IT RIGHT, NOT HALF WAY!!! You will be tearing it apart very soon if you don't. If it seizes at highway speeds it could shatter your cases. Good Luck.

[@whassigo]

Very interesting and informative - thanks for posting.

[@henryfurll2020]

It looks like a salvage bike from a large yard..... love to see skills greater the average dealer.

[@jimsimpson4385]

I have seen this before in my shop ck oil filter for metal and that will tell ya if it was even installed, I pour off over a magnet and oil drain with magnet as well. Cheers!

[@TheKiloG69]

Cutting open the filter is on my list. Thanks for watching.

[@finneasbaldwin2069]

Wow, you some guys a keyboard and they turn into raging a-holes. I liked your videos. Keep it up!

[@joesurfer9754]

If you change that cam, you better change those lifters. Been there, done what you are doing. Learned my lesson. It might take a few miles but when you start hearing that very loud tapping/ knock, but you could destroy a lot more.

[@TheKiloG69]

If? There was nothing in there usable.

[@bluedoorrv]

I have seen many engines with these problems. The wrist pin keepers will come out and end up in the oil pump, ruining that also. And actually, if you replace one oversized piston and not the other, technically, the flywheels are closer to "balance" than if you do both.

[@MrIndian24]

do you have a video on the removal of the rear cylinder?

[@keveichhorn5404]

Gotta love this, not that it probably made a lot of noise, vibration and lastly, that u didn’t go flying off the bike when it should’ve locked up and Seized. EVO were infamous for wearing rings over time, especially the quakes out there today that don’t even check their Oil before they go out, or tires or anything for that matter. Only fuel is important to these knuckleheads Lmao I love the scorch on the piston too, probably ran splitfire plugs thinking his 883 was gonna set a new track record in the school zone.

[@keveichhorn5404]

Good Video Bud !!! Happy trails to ya ........

[@pilotlang1]

Great Video! Thanks for sharing!

[@dougankrum3328]

....1:30......retainer either left out or got loose in there and scored the cylinder?

[@VndNvwYvvSvv]

Piston rings move around and can line up sometimes, but that does look botched

[@Koshunae]

Good lord, man. I can't even comprehend how someone could make that many mistakes. Probably some shadetree "mechanic" that decided a 5 beer job means drinking all 5 before you even dig in.

[@davidson2004fatboy]

Koshunae EX SHOE SALESMAN

[@tomsmith1390]

​@@davidson2004fatboy Sounds like you have no fear buying the correct tools and to take the time rebuilding the top end. If you have time this winter follow through and find that clip or its parts or the damage that is or is not as was spoken of. Clues abound. Ever done a bottom end? Here is hope you can enjoy the machine and not ever have to. I always - If I may, split the filter and use a magnet to pull out the steel particles, this can but not always give us a better understanding of the mess.

[@davidson2004fatboy]

@@tomsmith1390 POINT IS , IF YOU CAN'T DO the FUCKING JOB RIGHT ! DON'T DO the FUCKING JOB at ALL . MYSELF😎 ALL MOTOR WORK, I WOULD BRING to MY QUALIFIED HARLEY MECHANIC

[@andymonk9505]

I suggest every Harley Davidson owner get a manual when the bike is purchased.

[@tomsmith1390]

@@davidson2004fatboy I took off my first Harley head in 1964 and have been working on them and everything else ever since. Some of us like repairing engines or making them go faster. You have to start somewhere or you never learn anything.

[@buckotte1414]

Be careful that the rear rod is not 'twisted', and loosened a circlip before---thus the overbore rear.

[@pdg907ie]

Did you ever get in touch with the owner and fins out who did the job?

[@TheKiloG69]

No idea got this one at a online auction.

[@tomconner5067]

Wow, what a special Fly By Night tech, probably some pill head that got paid up front had the bike for several months, didn't know how to do the job, and pressured someone else to slap it together.

[@samuelmorris3661]

I've always seen in service manuals that clips need to be in 6 or 12 position don't know if it matters never seen one come off but I've always put them at 12oclock position never had a problem

[@WisdomVendor1]

The piston rings being lined up isn't a problem at all. The rings actually rotate around the piston while the engine is running. If they didn't, there would be a ridge the size of the end gap running from one end of the cylinder to the other.

[@jimksa67]

lol yeah right , and the moon goes backwards at night..

[@markheberling3962]

you probably should take the bottom end down metal shavings have to be down in bearings oil bag flush it all and inspect

[@thomaspokorny9487]

NAH! they`re tough! (the cause of tese problems ARE DOWNSTAIRS) I hate to see folks keep replacing parts without fixing anything!

[@pcofranc]

Or do a kerosene flush at idle & then chg oil.

[@7316bobe]

A good video but why do these H-D's wear out in the first place. This does not look like an old motorcycle but there was the need for all the bad work that was done in the first place. The engine had worn out parts that had to be replaced. A Harley like this costs 28,000 Australian dollars where I live. I am 65 years old and I would like some body to buy me a Harley-Davidson motorcycle that I could ride around on to just see how long one of these motorcycles will last if it is treated properly. I had a 1980 Yamaha XJ 650 motorcycle that I put 140.000 miles on. I changed the rings at 100,000 miles and this bike was still going good when I sold it. I would just like to see how long a new H-D would last if I was to ride it.

[@AutoBikeTruck]

Damn if i took that engine that far apart i would have did the lower end too just to be safe after seeing that top end done like that what a hack i see that kind of shit work on bikes all the time when people dont know what there doing and just slap it together and sell it for the next person to get fuck over and think there getting a good deal on a used bike that really sucks Good Luck i Hope you get it right

[@tomsmith1390]

Nothing like cleaning things up after a major malfunction. Bottom end I mean.

[@royamberg9177]

did you find the fragments of a pin retainer in bottom if the crankcase

[@TheKiloG69]

No!

[@TheKiloG69]

Maybe never installed like the O-rings on the heads.