CHIP KASTELNIK PHOTOS - Revolution Performance

TECH
BIG-BORE EVO MOTOR BUILD
WORDS: CHIP KASTELNIK PHOTOS: MIKEY VAN SENUS
SKILL LEVEL // ADVANCED
5
p To begin, we installed a few drops of red Loctite onto
the cylinder studs prior to installing.
7
p To torque the cylinder studs, we installed a small ball
1
SOURCES:
COMETIC GASKET
cometic.com
Our 1997 bottom end
returns to us from
Revolution Performance
very well packed for
shipping. The engine case
and flywheel have been
rebuilt and reconditioned
and assembled for install.
Also included is the
Revolution Performance
85-inch bolt-on Nikasil
cylinder and piston kit as
well as its stage 4 heads.
SAN DIEGO CUSTOMS
sandiegocustoms.com
9
p Prior to installing the top end, be sure to first clean the
cylinders with soapy water to be certain there is no debris
that could cause damage. We re-cleaned the cylinders
with brake cleaner after washing.
10
p Then we laid out the piston rings and checked for
damage or bending in any ring surfaces.
BIG-BORE EVO MOTOR BUILD
2
a reconditioned flywheel assembly, balanced, trued, and
installed topped off with its 85ci Nikasil cylinder and piston
kit. The end result is a bolt-on Evo big-bore kit that provides
the extra power that any of you Evolution-engine owners
would welcome. HB
3
HOTBIKE.COM
bolts to the manufacturer’s recommended specs.
S&S CYCLE
sscycle.com
p We will be using the K&P stainless steel micronic oil filter,
70 /
8
p With the ball in the head bolt, we torqued the head
REVOLUTION
PERFORMANCE
revperf.com
emember the days when the ol’ evolution motor started
right up, didn’t leak all over the place, and didn’t make
your hands numb while riding? No? We don’t either,
so when it came time to refresh our 1997 Dyna motor,
we chose a Revolution Performance bottom end consisting of
which has a cleanable, reusable filter element.
p Using a stud installer tool, we were able to install all
the studs into their locations without marring the threads.
K&P ENGINEERING
kandpengineering.com
REVVING UP THE
EVOLUTION MOTOR
R
bearing into a head bolt. This enables a proper torque.
The ball bearing will allow you to remove the head bolt
without removing the stud.
6
p Included with the K&P filter kit is an additional O-ring, as
well as a proprietary oil filter wrench to install and remove
the K&P filter setup.
11
p Next we placed the piston ring into the cylinder and
level with the piston. We took a feeler gauge to measure
the gap of the piston ring then repeated the process on
all rings. Using a piston ring cutting tool, we cut the rings
to the appropriate sizes.
12
p After the rings are sized, we installed the piston using
a piston ring spreader tool. This tool ensures the piston
rings will not mar or scrape the pistons sides when
installing.
4
p Here’s our pile of new parts for the rebuild from
Revolution Performance, Cometic, and S&S. All you need
to go fast faster.
13
p Using the Revolution Performance-supplied assembly
lubricant, we coated the wrist pin prior to installing the
pistons onto the rods.
14
p Making sure to install the pistons in the correct
direction, we slid the wrist pin through the piston and
connecting rod.
TECH
“Style Made Easy”
20
23” Bolt on Front End Package
“
We want the rider to experience their own
“Style Made Easy” by offering many options
on the new Pickard Front End Package
“
Mitch Pickard / Jevon Lau
p We installed the rear piston, wrist pin, and retaining clip.
21
p Verify the piston rings are in the correct locations and
“X” pattern is the usual standard.
15
p Using the correct tool, we installed the wrist pin
retaining clip into the piston groove.
THE #1
SOURCE
FOR THE
DYNOJET
POWER
VISION
IZED
22
p We applied a healthy amount of assembly lubricant in
the cylinder and on the piston and rings.
23
p Lube is your friend; it prevents scratches, galling, and
metal-to-metal contact on startup.
AL
SON
S
AP
M
L
FUE
PER
16
p Here you can see the wrist pin clip is secure in the
appropriate groove.
2014 Street Glide
le Free
0%Wobb
tee
Guaran
24
10
17
p Using a piston ring compression tool, we squeezed
the rings so the cylinder slipped over them. Be sure to
remove any rags or tools before pushing the cylinder onto
the engine case.
25
p We removed the ring compression tool carefully,
repeating the procedure on the rear cylinder.
TED
I
M
I
UNLPPORT
SU
p Pictured here is the front piston, rings, base gasket,
and wrist pin clip installed.
Black or Raw
5 Styles
Bolt On
Package Includes
11 Styles
C_026231_HBK0614P.indd 1
18
p Then we installed the rear base gasket and repeated
- 23” Wheel
- 23” Tire
- Matching Rotors
- 23” Fender
- 23” Wobble Free Trees
- Front Lowering Kit
the same process as doing the front cylinder.
26
p Pictured here is the front and rear cylinder installed.
Note that the directional arrows point to the correct piston
direction.
27
p Next we installed our .030 Cometic MLS head gaskets.
SPECIALIZING IN EFI
TUNING AND EXHAUST
COMPONENTS
TOLL FREE:
1-877-729-4754
Dallas, Tx
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nd Spe
Front E
19
972-231-1298
facebook.com/pickardusa
www.PICKARDUSA.com
p Make sure to install the base gasket correctly.
WWW.FUELMOTOUSA.COM
28
p We simply placed the head gasket on the top of the
head and over the dowel pins.
3/7/14 9:35 AM
29
p Verify the cylinder heads are clean and free of debris.
These heads are Revolution Performance stage 4 heads,
ported and worked.
03.03.2014 18:49
AdID: 27222 HBK0614
30
p Here’s a peep into the exhaust chamber of the cylinder
head.
31
p We then installed the head over the head gasket and
installed the head bolts. For this build we chose S&S
stock-length head bolts.
42
p We used needle-nose pliers to pull the tab through the
rocker housing to be certain it can’t come loose.
43
p After installing the top rocker gasket and cover, we
installed the 1/4-20 screws and torqued to factory specs.
Starting at
$
52.49
32
p Next we torqued the head bolts as per the head gasket
manufacturer’s instructions.
33
p Pictured here is our motor with the cylinder heads in
place.
AXLE SPACER KITS
44
3/4” | 1” | 25MM
p After pre-soaking the lifters, we installed them into
the tappet blocks.
Starting at
$
45
p Then we installed the tappet blocks and gaskets into the
appropriate cavity. Each block is marked front and rear.
82.49
34
p Next we disassembled the rocker boxes to measure
the rocker bushings and replace the stock rockers to
upgraded S&S roller rockers.
35
p Knocking out the rocker arm shafts to measure and
removing the rockers only takes a few minutes and can
be the difference between a loud motor and a quiet one.
46
GRIPS & PEGS
p Lifters installed.
BRASS | ALUM. | BLACK
47
p We torqued the tappet black to 90–120 inch-pounds as
per the factory service manual.
Starting at
$
74.99
36
p We installed new S&S roller rockers and shafts into the
rocker support plate.
37
p After assembling the rocker supports we installed
the lower rocker gasket and the lower rockers onto the
cylinder head.
48
VELOCITY STACK KITS
p Next we installed the oil filter mount and tightened
the Torx bolts to factory specs.
BRASS | ALUM. | BLACK
$
Starting at
29.33
38
p We torqued the lower rocker to factory specs.
49
p Next we installed the OEM oil lines and their gaskets.
Be sure to tighten all fittings to factory specs.
39
p Then we installed the middle rocker gasket, making
sure it fell into the groove.
made the
old-school
way.
92 proof. bold & smooth as hell.
MIRRORS & MOUNTS
BRASS | ALUM. | BLACK
American Made
SE COUPON CODE
SAVE
USEUCOUPON:
HOTBIKE15
10%
40
p Next we installed the middle rectangle gasket.
41
p We installed a new umbrella valve breather gasket.
50
p Verify your oil system components are installed and
debris-free.
51
p Pictured here is our rebuilt, refreshed 1997 H-D Evolution motor that will provide ample power and a pleasing
ride. Check out revperf.com for any additional details.
©2014 Sailor Jerry Rum, 46% Alc./Vol.
William Grant & Sons, Inc. New York, NY.
RESPECT HIS LEGACY.
DRINK SAILOR JERRY RESPONSIBLY.