Hi there - so I`m planing to do a top end rebuild and also clean the cylinder heads. I have the part numbers for all needed thing now the question is what should definitely be changed and what not.

I understand new gaskets are a must but should i also use new rubber seals around the push rods for example or just reuse the old ones. Additionally as I will clean the heads should i also change the gasket under the cylinder or just on top of it ?

Last - any idea if the service manual for 2013 sportsters and 2015 ones has any difference ? I have 2105 seventy two but manual for 2013 one.

 

Buy a gasket set, which should come with all the gaskets and O-rings etc you need. Easier than making up a long list of parts! You may find there are sets for a total engine rebuild, which you obviously don't need, and a lesser set for doing cylinder/heads overhaul, which is what you do want.

 

I was thinking about it but for some reason at least in Grmany the price doesn't add up at all.
What i need for the top end is part numbers 17049-08 and 17036-08 (i.e. top and rocker gasket kits) which add up to about 350 euro and then if i just buy the separate gaskets it is about 120. I`m unsure to what reason the difference is - maybe the sets contain new screws and all

 

Mihail, you say you're in the UK, but mention Germany! In both countries there are plenty of suppliers of gaskets, both dealers and indies. What I suggest you need is:

#17049-08 GASKET KIT TOP OVERHAUL, which here in the UK at a H-D dealer costs around £120 plus taxes.

For future reference you can check such things using a parts website.

 

I used to be in the UK but moved to Germany sorry need to update that.

Thanks for the website - quite nicely made one actually.

I`m not sure this kit is all tho - there is everything for the cylinder top in there but it doesnt say anything about the rocker box

 

A top end kit should have all the gaskets, O rings etc from the cylinder base upwards, including the rocker box IMHO. Hopefully someone with recent experience of actually using one will chime in soon! Been a while since I did and that was on an Evo big twin.

 

Curious why you need a top end rebuild on a 3 year old bike.

If pulling the heads you may wish to consider changing the base gaskets under the cylinders. Not required but sometimes they start leaking when disturbed by pulling the heads. To do so you will either need to remove the wrist pin and keep the piston in the cylinder (I never had luck with this) or use a ring compressor so you can slide the cylinder over the piston when reinstalling.

 

It`s because I had issues with pinging and there was a big thing going with the dealer which did say they have repaired it but it came back after a while. The ping was supposed to be due to bad o2 sensor but now right now I`m pretty certain it is because of carbon buildup and possibly sole leaky oil somewhere.

As for the pin removal - i was under the impression that removing it should be somewhat of an easy job. Tho a ring compressor is really not that much of a tool I`m pretty certain i can even DIY it if i cant find one

P.S.

I`m planning to go ans ask them to reset the ECM beforehand in case that works and if not then will do the top end rebuild

 

Makes sense. I've always tried to remove the wrist pin on bikes that had higher miles on them and they did not want to come out easily and I did not want to force them. A ring compressor here in the US was about $35 if I recall and to me that was the easiest solution. It does require specific positioning of the compressor so you can compress the rings without the stud getting in the way but I found it to be simple.

Good luck and hope you don't have to tear it down.

Another thought is to see if you can find a borescope that will connect to your phone and allow you to look inside the cylinder. You should be able to see the top of the piston through the spark plug hole.


to what I am talking about

And for reference, this is what the inside of my engine looked like last year when I pulled a head and cylinder to replace a leaking base gasket. I had no pinging but my bike was a 2006 running stock exhaust and a RSD air cleaner. I did open up the jets a little but do not feel it was overly rich based on the plugs. I had no pinging when running premium gas during the summer or lower grades in the winter

 

Thanks a lot the pictures are quite informative actually. Well i hope it is pinging cause if its not i have no idea what is it - nor does the dealer But i had a whole another thread about it and people seem to agree its pinging - plus it does get better with higher octane fuel tho i dont really believe you need to run racing fuel under normal circumstances just so you dont ping.

I just had the ECM reflashed so lets see i hope i dont have to open it as well.

Also on the topic of what is inside that kit here is the list:

11110 - O-Ring
11190 - O-Ring Push rod upper
11202 - O-Ring breather bolt
11290 - O-Ring neutral gear switch
11377 - O-Ring
11621 - O-Ring Breather
11625 - O-Ring
16664-86D - Gasket cylinder head
16771-84F - Gasket cylinder head
16771-08 - Gasket cylinder head
16789-04 - Gasket cylinder base
16800-84B - Gasket rocker box
17362-07B - Gasket rocker cover
17393-07 - Gasket Breather
17633-08B - Gasket rocker cover
17695-07B - Gasket rocker cover
18094-02A - Valve seal kit
26995-86B - Seal intake
65324-083B - Seal exhaust
6589 - Washer
all of the items are the respective number of required ones for both cylinders

So yes the kit turns out is enough for everything even the valve seals