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Preface
At around 127K km (80K miles), the front rocker box gasket of my '98 FLTRI
(Road Glide) began leaking quite badly. For 2 years prior, the the rear base
gasket had been weeping as well. At that mileage, it seemed now was a good time
to do a top-end job on the bike. Maybe also a good time to replace
the drive belt as well.
Although I'm not especially knowledgable in the wrenching department, I thought
I'd save some money and, in the process, learn a few new things doing this work
myself. Especially since there's lots of time. It's winter right now in
Edmonton.
When discussing my plans to do the work, my son-in-law gave me an interesting
suggestion. He thought I should use my digital camera to visually record
things; so I would have a reference when it came time to put things back
together. That sounded like a good idea (digital photos don't cost anything,
after all). The idea seemed even better once I realized I could augment that
by using the camera's audio-attachment feature - permitting me to
attach spoken commentary to any picture taken. That combination has given
me a simple means of creating a comprehensive, running record. Fast,
cheap and easy to do. I like it!
What I have done below is posted each of the pictures I took for record
purposes and placed a link under each picture that you can click to hear the
audio commentary. You can also click on each image to get a
larger, high-resolution view.
Why put the pics on the Web? Well, it's handy for sharing information when I
ask more knowledgable friends for suggestions and advice. Second, it just might
be useful to somebody else who is planning to do the same work on a similar
bike.
It's not without its challenges, doing a job like this one for the first time.
As you will see/hear from the photo entitled "Rocker Box Removal - Part 2", I
kinda screwed up... (as you can hear by clicking
here)
Additional, miscellaneous photos of this top-end rebuild can be found
here.
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Gas Tank Removal - Part 1
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Gas Tank Removal - Part 2
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(click for larger view)
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(click for larger view)
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Spark Plugs
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Top Engine Mount
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(click for larger view)
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(click for larger view)
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Horn Removal
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Air Cleaner Back Plate - Part 1
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(click for larger view)
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(click for larger view)
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Air Cleaner Back Plate - Part 2
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Air Header Removal
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(click for larger view)
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(click for larger view)
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Induction Module Removal - Part 1
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Induction Module Removal - Part 2
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(click for larger view)
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(click for larger view)
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Induction Module Removal - Part 3
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Induction Module Removal - Part 4
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(click for larger view)
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(click for larger view)
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Rocker Box Removal - Part 1
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Rocker Box Removal - Part 2
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(click for larger view)
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(click for larger view)
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Top Rocker Box Removed
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Modified Allen Keys Used
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(click for larger view)
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(click for larger view)
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Rocker Arm Order
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Rocker Boxes Removed
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(click for larger view)
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(click for larger view)
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Pushrod Order
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Oil Sensor Orientation
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(click for larger view)
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(click for larger view)
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Pushrod Covers
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Engine, Pushrods Removed
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(click for larger view)
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(click for larger view)
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Lower Rocker Box Removed
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Head - Rocker Boxes Removed
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(click for larger view)
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(click for larger view)
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Front/Rear Rocker Boxes Labelled to Match Rocker Arms
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Removal of Head Bolts (stuck stud)
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(click for larger view)
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(click for larger view)
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Engine Temperature Sensor Note
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Left Side Exhaust Removal
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(click for larger view)
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(click for larger view)
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Right Side Exhaust Removal
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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Outer Primary Case Removal - Rider Floorboard
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Outer Primary Case Removal - Shifter
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(click for larger view)
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(click for larger view)
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Outer Primary Case Removal - Passenger Floorboard
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Outer Primary Case Removal - Bolting Pattern
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(click for larger view)
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(click for larger view)
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View of Primary w/o Case
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(click for larger view)
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Preface
At around 127K km (80K miles), the front rocker box gasket of my '98 FLTRI
(Road Glide) began leaking quite badly. For 2 years prior, the the rear base
gasket had been weeping as well. At that mileage, it seemed now was a good time
to do a top-end job on the bike. Maybe also a good time to replace
the drive belt as well.
Although I'm not especially knowledgable in the wrenching department, I thought
I'd save some money and, in the process, learn a few new things doing this work
myself. Especially since there's lots of time. It's winter right now in
Edmonton.
When discussing my plans to do the work, my son-in-law gave me an interesting
suggestion. He thought I should use my digital camera to visually record
things; so I would have a reference when it came time to put things back
together. That sounded like a good idea (digital photos don't cost anything,
after all). The idea seemed even better once I realized I could augment that
by using the camera's audio-attachment feature - permitting me to
attach spoken commentary to any picture taken. That combination has given
me a simple means of creating a comprehensive, running record. Fast,
cheap and easy to do. I like it!
What I have done below is posted each of the pictures I took for record
purposes and placed a link under each picture that you can click to hear the
audio commentary. You can also click on each image to get a
larger, high-resolution view.
Why put the pics on the Web? Well, it's handy for sharing information when I
ask more knowledgable friends for suggestions and advice. Second, it just might
be useful to somebody else who is planning to do the same work on a similar
bike.
It's not without its challenges, doing a job like this one for the first time.
As you will see/hear from the photo entitled "Rocker Box Removal - Part 2", I
kinda screwed up... (as you can hear by clicking
here)
Additional, miscellaneous photos of this top-end rebuild can be found
here.
|
|
Gas Tank Removal - Part 1
|
Gas Tank Removal - Part 2
|
(click for larger view)
|
(click for larger view)
|
|
|
|
Spark Plugs
|
Top Engine Mount
|
(click for larger view)
|
(click for larger view)
|
|
|
|
Horn Removal
|
Air Cleaner Back Plate - Part 1
|
(click for larger view)
|
(click for larger view)
|
|
|
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Air Cleaner Back Plate - Part 2
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Air Header Removal
|
(click for larger view)
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(click for larger view)
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Induction Module Removal - Part 1
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Induction Module Removal - Part 2
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(click for larger view)
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(click for larger view)
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Induction Module Removal - Part 3
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Induction Module Removal - Part 4
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(click for larger view)
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(click for larger view)
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Rocker Box Removal - Part 1
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Rocker Box Removal - Part 2
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(click for larger view)
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(click for larger view)
|
|
|
|
Top Rocker Box Removed
|
Modified Allen Keys Used
|
(click for larger view)
|
(click for larger view)
|
|
|
|
Rocker Arm Order
|
Rocker Boxes Removed
|
(click for larger view)
|
(click for larger view)
|
|
|
|
Pushrod Order
|
Oil Sensor Orientation
|
(click for larger view)
|
(click for larger view)
|
|
|
|
Pushrod Covers
|
Engine, Pushrods Removed
|
(click for larger view)
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(click for larger view)
|
|
|
|
Lower Rocker Box Removed
|
Head - Rocker Boxes Removed
|
(click for larger view)
|
(click for larger view)
|
|
|
|
Front/Rear Rocker Boxes Labelled to Match Rocker Arms
|
Removal of Head Bolts (stuck stud)
|
(click for larger view)
|
(click for larger view)
|
|
|
|
Engine Temperature Sensor Note
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Left Side Exhaust Removal
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(click for larger view)
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(click for larger view)
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Right Side Exhaust Removal
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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(click for larger view)
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Outer Primary Case Removal - Rider Floorboard
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Outer Primary Case Removal - Shifter
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(click for larger view)
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(click for larger view)
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Outer Primary Case Removal - Passenger Floorboard
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Outer Primary Case Removal - Bolting Pattern
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(click for larger view)
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(click for larger view)
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View of Primary w/o Case
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(click for larger view)
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