50 Years of Harley Rebuilding Experience

Published on April 4, 2024
Duration: 8:15

This video details advanced Harley-Davidson engine rebuilding techniques, focusing on replacing cam cover bushings using a tap or bolt method and boring cylinders for engine size conversions. It also covers proper flywheel assembly and runout measurement, offering practical tips for experienced mechanics.

Quick Summary

For easy removal of Harley-Davidson cam cover bushings, use a tap (e.g., 5/8 fine thread). Thread it in until it bottoms out against the cam cover; this action automatically pushes the bushing out. For flywheel runout, torque, let settle overnight, then measure for accuracy.

Chapters

  1. 00:01Introduction & Packing Jobs
  2. 00:31Engine Component Repair: Insert Replacement
  3. 00:43Transmission to Hawaii & Knucklehead Repair
  4. 00:50New Job from New Jersey & Packing Advice
  5. 01:16Fixing O-Ring Groove with Welding
  6. 01:37Knucklehead to Hawaii Completion
  7. 01:45Bushing Replacement: Panhead/Shovelhead Tip
  8. 02:00Bushing Removal Technique with a Tap
  9. 02:28Pinion Shaft & Sprocket Shaft Spacer Installation
  10. 03:38Flywheel Assembly: Rebuilt Rods & Crankpin
  11. 03:51Flywheel Runout Measurement & Settling Tip
  12. 04:26Cylinder Conversion: 74ci to 80ci
  13. 05:14Boring Bar Operation: Centering the Cylinder
  14. 06:04Boring Bar Operation: Cutter Installation & Measurement
  15. 06:42Boring Bar Operation: Cutting & Completion
  16. 07:34Contact Information & Closing

Frequently Asked Questions

How can I easily remove old bushings from a Harley-Davidson cam cover?

A common and effective method is to use a tap, such as a 5/8 fine thread tap. Insert the tap into the bushing and thread it in until it bottoms out against the cam cover. This action will automatically push the old bushing out, simplifying the removal process.

What is the correct procedure for measuring Harley-Davidson flywheel runout?

After initial assembly and torquing, it's recommended to 'chew' the flywheels once. Leave them overnight to settle. The next morning, take your final runout measurements. This settling period is crucial for obtaining an accurate reading.

Can I use 74 cubic inch cylinders on an 80 cubic inch Harley-Davidson engine?

Yes, you can use 74 cubic inch cylinders on an 80 cubic inch engine, but they must be bored out to accommodate the larger piston. The cylinders need to be bored to a 3 1/2 inch diameter to match the requirements of an 80 cubic inch motor.

What is the purpose of the three fingers on a boring bar?

The three fingers on a boring bar are essential for centering the cylinder accurately beneath the cutting tool. This precise centering ensures that the boring process is straight and results in a perfectly round and dimensionally accurate bore.

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