This guide details critical steps for rebuilding Harley-Davidson Evolution engines, focusing on common pitfalls. It covers correctly installing cam covers by matching pinion shaft bushings to the correct model year to ensure proper oiling of connecting rods. The guide also provides detailed instructions on bleeding and adjusting hydraulic lifters, emphasizing the importance of an oil-free lifter for accurate adjustment and preventing valve damage. Additionally, it addresses spark plug selection for dual-plugged engines and correct head gasket and piston orientation for Sportsters.
Mel Bernstein, 'The Dragon Man,' provides an advanced guide on rebuilding 1976 Shovelhead Harley-Davidson flywheels. The process involves meticulous cleaning, precise torquing of critical components like the pinion shaft and crank pin nuts, using specialized jigs and a press for alignment, and truing the assembly with dial indicators. A key emphasis is placed on using the correct pinion shaft bushings to ensure proper oiling, preventing catastrophic engine failure.
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