Top End Rebuild - 86 FLHTC

[gaillarry]

My 86 FLHTC with 50,000 kms is burning oil, along with a weeping rear base gasket and oil leak from the
rear rocker cover. Its embarrassing taking off in a cloud of smoke. 

My plan is for a top end rebuild.  The bike is all stock (carbs & pipes)  It runs great although some oil leak/burning problems.
This is my plan:

- new HD gaskets for the rocker covers
- James base and head gaskets with holymar
- replace the tappets with HDs, new adjustable pushrods
- EV27 cam  (bought new at a local swap meet)
- hone with ball-flex hone on cyls
- new Hasting rings.
- lap the valves
- new valve seals
- check the cylinder base/rocker covers for straightness

I have the top end removed and now ready to order parts.
Any comments/suggestions to my plan? .

[massheadcase1]

Get your cylinders measured.....bet they are beyond spec

have your cylinder bases cut to give you zero deck

Bump compression for the EV 27

Get a proper valve job..... valves and seats will be pitted..............Headcase

[PanHeadRed]

>Any comments/suggestions to my plan? <

Yes. STOP! measure EVERYTHING, don't assume.

Order what you need, not what you think you want.

Good luck.

[mark98012]

Whatever you do DON'T GO OVERBOARD. When I did my '86 a few years ago(originally base gaskets leaked and new lifters) I flowed the heads, bumped up comp. wit KB pistons (to 9.5:1), etc. It went like a raped ape BUT "the more you do, the more you have to do". If I had it to do all over again I would have just done what was needed (base gaskets, lifters, and MAYBE EV27). With headwork and higher comp., it will be cold blooded (not a real bother as long as you let it warm up properly), and higher comp. will put a strain on the crappy starter (get a high torque starter). I planned to keep it for a few more years but the wife talked me into a new bike and when I sold it anything over stock won't get you anymore money when you sell.

MarkR

[rdkng]

I think you have a good plan.   I'd measure and check everything, but with only
50KM on it, the cylinders should be fine.. a hone is probably all thats needed.
HD makes a top end kit with all the gaskets.  I've gone that route and bought
the James gaskets separately.  I think the EV27 has stock base circle diameter,
so you could reuse your stock pushrods if you wanted to.  You could also have
.050 shaved off the heads for a little compression bump.  IMO going beyond that
is entering a different catagorie  (& on a 1986-  I wouldnt do). 
just my 2 cents worth..
rdkng       

[dave_9113]

gaillary,

That's a pretty decent start plan.  If you are using James gaskets, you should not have to use any dressing.  Your call though.  Also, don't forget new CAM bearing.  These are optional things to consider:
1)  replace cylinder studs
2)  replace cyliner head bolts
3)  replace carb with decent Keihin CV

dave 

[gaillarry]

I like this phrase:  "the more you do, the more you have to do".  I want to keep it simple.

There is no pitting on the valves or seat. I do plan to have everything measured.  Since it's all apart I'll replace the studs and head bolts.  I've been watching fleabay for a decent CV carb.

I bought the EV27 as the price was right but still debating on installing it, but if I do,  a new bearing will be put in.   Is the EV27 worth installing on a stock bike??

[rdkng]

Yes, the EV27 is a nice cam for a stock-ish motor.   plus new bearing.
rdkng   

[massheadcase1]

ya great plan..... lap the valves...should run great