Chop, cut, rebuild

[kyle_dewald]

Since the bike is down, and so am I, I decided to fully dismantle it and clean everything, literally everything. I have a few pictures of the work so far.
After reading another thread about how they always went to a specific gas station because of the cleaning additives they have in the gas, I'm very curious as to how the inside of the motor is going to look. So far so good.

2003 XB9R 25,xxx

Todo:
Clean everything, inside and out.
Change all seals on motor
Replacing valves (if necessary)
Replace piston rings
Breather mod
LED turn signal mod
Custom tag mount

I started tearing the bike down:

Dropped the engine:

Engine:

I have taken the rocker boxes off so far, push rods look like they have never been used, almost no wear on anything so far. I plan to have the motor apart by this weekend so I can see what needs to be replaced.

 

[kyle_dewald]

A question for people who have done engine work themselves, is there anything I need to look out for or watch for when I'm dismantling and/or putting the motor back together. I've worked on harley motors alot since my entire family has them and this shouldn't be any differnet but you never know. Better safe than sorry.

 

[xtremelow]

Yeah make sure nothing gets into the engine, I dismantled one of my old truck engines and had a buddy helping needless to say while he was removing the lower intake a bolt fell into one of the inlet ports, well until we got everything back together and were a bolt short, he said he dropped one but heard it bouce across the floor. After starting it up it was clear it fell into the engine and destored it on the start up[down]

Just bag and tag every part you take off, it will make assembly much easier

 

[kyle_dewald]

oh man, that sucks. I've been bagn and tagn and putting the bolt count on everything and I'm making sure everything is kept clean.

 

[dave_xb12r]

I saw breather mod on the list down low and had to laugh. After you do it, you'll wonder why you never did it before. It's so simple.

 

[xtremelow]

I saw breather mod on the list down low and had to laugh. After you do it, you'll wonder why you never did it before. It's so simple

Like Dave says, do the reroute, it is very simple and you will only benifit from it[up]

 

[kyle_dewald]

If been wanting to do it for some time, but I spent every possible waking hour riding. I rode all winter long in snow, ice, rain, just about any weather so I didn't have much time, plus working 6 days a week. I've read up a lot on it and other mods so I hope it takes care of the problems I had before.

 

[bajabomber87]

What was wrong with the engine to make you rebuild it?

 

[303xb]

what was wrong with your bike to make you rebuild yours?

 

[kyle_dewald]

Well, nothing was actually "wrong" that I know of, mostly cosmetic things from the wreck. There were a few things about the bike that I had concerns about and so I figured that since both me and the bike will be down for a bit, might as well check everything out.

 

[bajabomber87]

what was wrong with your bike to make you rebuild yours?

The tranny blew up so Harley had to rebuild the engine in the process.

 

[onelogue]

Keep us posted on this. Next winter im rebuilding mine exactly how you described, and the more detail you give it will help all the more better.

Might throw in one of these [up] or two [smirk]

Oh and you are not alone on the breather reroute mod.... I have done quite a bit f mods to my bike I still cant seem to motivate myself to do the reroute haha

 

[303xb]

The tranny blew up so Harley had to rebuild the engine in the process.

touche

 

[303xb]

Oh and you are not alone on the breather reroute mod.... I have done quite a bit f mods to my bike I still cant seem to motivate myself to do the reroute haha

reroute takes 10 min.

 

[dave_xb12r]

bring out the gimp!

 

[onelogue]

reroute takes 10 min.

I knowwww, but Dave_xb12R said he would do it for me

Kyle, you going to rebuild the tranny too?

 

[kyle_dewald]

Oh god no, motor I'm fine with but I don't even wanna start with the tranny unless there is a prob

 

[black_xb12r]

i just did my xb12 motor... when you change the push rod tube o-rings that seal the heads to the push rod tubes make sure you use good seals NOT the harley o-rings.... and seat the o-rings into the grooves in the head instead of sliding the o-rings onto the push rod tubes... i had to take my motor back apar becaue of this... i put the o-rings on the tubes and then when the heads go on the sharp milled edges will cut the o-rings...

other than that theres really no tricks to doing anything... use a good high temp silicone on all the gaskets... there are some weird torgue specs for things so you may want to read up on them... i have another sheet that came with some gaskets that made some more sense for puttin on the heads and rocker boxes i can try to scan it and get it up for you...

when puttin your rings on make sure ou seat them in the cylinders and set the eng gap right and i would go a thousanth or 2 looser in the bore...

any questions hit me up...

 

[Fock347]

thats weird the service manual does not call for any type of silicone sealant, i didnt put any on, havent had any leaks .

 

[black_xb12r]

if you use factory harley gaskets you will want sealant...