Rebuild

My buddy has a 1993 Heritage and wants to do some engine work over the winter. He isn't looking to really gain any power. He just wants to freshen it up a little. It's starting to blow smoke out the rear pipe and uses excessive oil. Otherwise it seems to run pretty good. He is disabled and doesn't have a ton of money. That's why we're going to do it ourselves.

I am thinking right now that we might be able to get away with just a new set of valves, pistons/rings and just honing the cylinders, unless of course we find some major scores in the cylinder walls or something. The bike already has a cam and stage I that was done around 1999, although I don't know the specs of the cam. Is there anything else we should consider mandatory while we're there? Like I said, the labor is free and we're trying to do this for as little dough as possible. I do think he wants to add the "cure" oil vent kit as well for the extra $30.

Any thoughts would be greatly appreciated.

Thanks,
Dave

reply to rebuild

did you guys contact harley davidson they have engine rebuild program that takes your engine any mods you did will come back stock but you will have a fresh motor and there might be payment plan iam not sure on that

Yup

You have it figured out. Any of my thoughts would just cost you guys more money. The "cure" is one of a few good oil-vent systems out there, its functional.

Thanks for the input.

We have not even considered contacting Harley because I already know that my buddy will not have the funds that would require. He is disabled and on a very limited income. That's why we are doing it over the winter. That way he can save up a little at a time.

Any other thoughts would be greatly apreciated.

Thanks,
Dave

You have a limited budget so why not do only what is needed to keep the EVO running correctly and freshen the top end? The top ends are good for well over 50k and more. The bottom ends are pretty bullet proof stock. Depending on the mileage you may or may not need the valve guides replaced and the cylinders bored. If the guides are good and the valves are not burned, gouged etc you just saved a bunch there. Generally a well maintained EVO has little deep scoring in the cylinders but you will need to wait until teardown to see.

Do a wet / dry compression test. If your compression is good, your valve seals are probably leaking. This is also indicated by when it is smoking when you close the throttle on a down shift. High manifold vacuum sucks the oil in past the seals.
This can get long...too long. Here it is in a nut shell. You plan on tearing it down for a top end right? Depending on mileage you can simply re-hone and use use fresh rings, bore it .005 and use .005 rings and stock pistons. If you have to go .010 or more then you will need new slugs (pistons).
Find a local well respected indy shop and tell them you are trying to do this yourself and why. They will be able to do any of the head and cylinder work needed.
A top end gasket set will have all you need in gaskets and seals. Get the service manual!!!!! It is a mandatory tool. The parts book is a great reference for that "how did that go together" stuff.

CD,

Thanks for the detailed input. I will do the wet/dry compression test and see where we stand on the valve seals. It may be possible that we can stop right there.

The bike has around 35,000 miles on it now. When we rip it down, I don't expect to see any scored cylinder walls. If that is the case, I will hone the cylinders, mic them and replace the rings, hopefully with stock ones. That would save him a bundle.

I already have the Harley service manual so that's covered. I think we might be able to get this done for even less than he was hoping if everything goes well during tear down.

We have seven or eight weeks of good riding whether left so it will be after that. I will do the compression test in the next week or two just so we have a better idea of where we stand ahead of time.

Thanks again,
Dave