Friday, June 6, 2014
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.
2Remove 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.
3Remove the air cleaner, then the air cleaner backing plate with an Allen socket and socket wrench.
4Loosen 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.
5Remove the carburetor and the enrichener assembly from the engine by pulling the carburetor from the intake manifold.
6Disconnect 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.
7Loosen 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.
8Pull the entire exhaust system from the motorcycle.
9Disconnect 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.
10Loosen 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.
11Remove the metal D-ring. Remove the rocker box cover gasket.
12Unbolt the breather assembly from the rocker arm support plate with a hex socket and a socket wrench.
13Cut both pushrods under the head you intend to remove with bolt cutters. Remove the pieces.
14Gradually 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.
Saturday, February 22, 2014
How to Replace Injectors in a 1988 Ford Diesel
Diesel engines are most common on larger pickup trucks, such as the Ford F-250. This truck has a rated carrying capacity of 3/4 ton, although it can actually carry much more weight. The only diesel engine available on a 1988 F-series truck was an eight-cylinder 7.3-liter engine. Each fuel injector delivers fuel to a cylinder in a specific sequence and amount. Its theore essential that you install each fuel injector into the correct cylinder.
Instructions
- 1
Release the clamps on the fuel lines to the fuel injectors and disconnect the fuel lines with a flare nut wrench. Discard the gaskets for the fuel lines and push the fuel lines to the side so you can access the fuel injectors.
2Cover the top end of the fuel injectors with plastic caps to keep them clean. Turn the fuel injectors counterclockwise and pull them from the engine. Record the cylinder of each fuel injector as you remove it. Cover the nozzle end of the fuel injectors with plastic caps.
3Remove the copper gasket from the nozzle of each fuel injector with tool T71P-19703-C and discard the gasket. Clean the bore of the fuel injectors with tool T83T-9527-A and blow compressed air into the bore to remove any carbon or metal particles.
4Remove the cap from the nozzle of each fuel injector. Apply a small amount of grease to the nozzle and install a new copper gasket to the fuel injector.
5Apply an anti-seize compound to the fuel injector threads to prevent the injectors from sticking. Install the fuel injector to its correct cylinder head and tighten it to 33 ft. lbs. with a torque wrench. Remove the protective caps from the open end of the fuel injectors.
6Install new O-rings on the fuel return line and connect the fuel lines to the fuel injectors with a flare nut wrench. Attach the clamps for the fuel lines. Start the engine and check for fuel leaks.
