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  #111  
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Unhappy

That sucks. I would look into Keenserts, if they will hold the torque.
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  #112  
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Quote:
Originally Posted by Blue Scoot View Post
Sad Day Update:

You guys were right, studs didn't hold. Or at least something didn't, the head gasket is already leaking.
Last night I was going to get some more break in miles and when I started it up it was chirping louder than I have ever heard it before and could feel a ton of air coming out on the pushrod side.


So what's next:
I'm not sure if I should just try and helicoil the cases and put all new studs in or what?

Are you sure it's the head gasket this time and not leaking intake runners or air cleane to carburetor/intake flange? Can you try spraying the head and intake with soapy water to pinpoint the leak? If it is the head gasket, it might be cheaper to buy used cases and install all of your parts (including your crank if the miles are higher than yours) in it.

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  #113  
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Are you sure it's the head gasket this time and not leaking intake runners or air cleane to carburetor/intake flange? Can you try spraying the head and intake with soapy water to pinpoint the leak? If it is the head gasket, it might be cheaper to buy used cases and install all of your parts (including your crank if the miles are higher than yours) in it.
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  #114  
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Quote:
Originally Posted by Blue Scoot View Post
Sad Day Update:

You guys were right, studs didn't hold. Or at least something didn't, the head gasket is already leaking.
Last night I was going to get some more break in miles and when I started it up it was chirping louder than I have ever heard it before and could feel a ton of air coming out on the pushrod side.


So what's next:
I'm not sure if I should just try and helicoil the cases and put all new studs in or what?



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Or maybe a used engine, put on your new top end and sell off the uneeded parts. One example in the phoenix area:
https://phoenix.craigslist.org/wvl/m...960546997.html
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  #115  
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When I reached this point the first time I installed a keensert, the second time I installed a keensert and it destroyed the cases, ended up replacing the cases. The thing I am not getting is you are using standard gaskets in a standard engine, this is not a usual failure situation you have experienced.

Here in the UK I went for used replacement cases from the USA, in the USA it may well be better to go with a used engine. Good luck, this seems so unfair and does not seem to make sense.
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  #116  
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Unfortunately it is the head gasket on the rear cylinder. I confirmed this because very small pieces of the composite head gasket have blown onto the side of the case.

I'm wondering if I try and repair the cases if this would work? Worst case scenario I could probably sell the tool to someone else for a slight loss?

If that doesn't work then maybe try finding some different cases and swap everything over?

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  #117  
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Damn....
Run this by me one more time.
You installed the studs and they all torqued to (FSM) spec before you installed the heads?
You installed the heads and the stud backed out or pulled out?

I'd say try a thread repair.
The cheapest way to do this is to split the cases and take them to a Good machine shop.
(Hammer or NRHS would do a good job of this )

You know the engine already minus the thread problem.
A used bottom end is rolling the dice.
We will help all we can with the teardown if you decide to.

edit:
Also here is ReddTigger's timesert fix for that in the Sportsterpedia.
http://sportsterpedia.com/doku.php/t...evo:engmech03b
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  #118  
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This time I do not know what the studs have done. Originally it looked like they were backing out since the threads in the case appeared to be good.

I'm not sure what has caused the head gasket to leak this time. I'm assuming the threads are shot in the case and they are pulling out now? At least that's what others said would happen in this thread previously.



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  #119  
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If I were to split the cases and get the threads repaired can I just put the cases back together without replacing any bearings? Reason I ask is I was looking in the service manual and they appear to need to be pressed out/in if you need to replace them.

Any idea how much a shop would charge to fix threads/install new studs?

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