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How to Remove a Cylinder Head From a 1988 Sportster

Head removal for a 1988 Evolution-powered Sportster is the same whether the motorcycle has an 883 cubic centimeters or 1200 cubic centimeters engine. It can be accomplished by a skilled mechanic without removing the engine from the frame or removing the gas tank. It is a chore that is easier to describe than to do, but the tear down should not take longer than 90 minutes. An entire top end job including the removal of both cylinder heads and reassembly is considerably more complicated and takes significantly longer.

Instructions

1

Close the petcock. Run the motorcycle in neutral until the bike stops. Disconnect the enrichener knob and cable from the clip under the fuel tank.

2

Remove the air cleaner cover after loosening the two the bolts on the front of the cover with an Allen socket and a socket wrench. Disconnect the breather tubes from the top of the air cleaner.

3

Remove the air cleaner, then the air cleaner backing plate with an Allen socket and socket wrench.

4

Loosen the fuel line from the carburetor with a flathead screwdriver and remove the fuel line by hand. Remove the idle and throttle cables from the throttle cam on the top front of the carburetor.

5

Remove the carburetor and the enrichener assembly from the engine by pulling the carburetor from the intake manifold.

6

Disconnect both header pipes from the exhaust manifold on the right side of the motorcycle with a hex socket and socket wrench. Remove the copper crush gaskets from the exhaust manifold.

7

Loosen both oxygen sensors from the header pipes with an open end wrench. Disconnect the mufflers from the muffler support bracket with an open end wrench.

8

Pull the entire exhaust system from the motorcycle.

9

Disconnect the spark plug wire from the cylinder head you intend to remove. Remove the spark plug with a spark plug socket and a socket wrench.

10

Loosen the 6 bolts that hold the rocker cover to the cylinder head one half turn at a time in a crossing pattern with an Allen wrench. Remove the rocker box cover.

11

Remove the metal D-ring. Remove the rocker box cover gasket.

12

Unbolt the breather assembly from the rocker arm support plate with a hex socket and a socket wrench.

13

Cut both pushrods under the head you intend to remove with bolt cutters. Remove the pieces.

14

Gradually loosen all four cylinder head bolts in the exact sequence described in the service manual for your motorcycle one quarter turn at a time with a hex socket and socket wrench. Remove the head after all four head bolts are completely loose.

Posted by Unknown at 6:23 PM

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