Harley Evolution Refresh Overview

•Tires: The Harley Evolution front and rear tires are over-due for replacement. The tires, tubes, and rim strips will be replaced. After dismounting the tires, any possible rust build up inside these old rims will be addressed. After scraping and cleaning inside the rim, it is also a good idea to coat the area with a little spray paint to hold the rust at bay.

•Wheel bearings: The Harley Evolution wheel bearings will be cleaned, inspected, and re-packed. Four new wheel seals will be installed. If bearings are in bad condition, the Timken bearings and races will be replaced. A new speedo drive seal will also be installed against the left front wheel seal.

•Spokes: Each spoke will be inspected visually and with a spoke wrench.

•Forks: Harley Evolution Fork oil will be serviced. If there is any evidence of a fork seal leak; fork seals will be replaced along with upper and lower fork tube bushings on both sets of forks.

•Fluids: Of course, Mike will be doing the motor oil and filter. Transmission and primary drive oils will also be changed.

•Fuel System: The petcock, fuel hoses, and hose clamps will be replaced. The Harley Evolution carburetor will be cleaned, inspected, and rebuilt. A stock CV carb will also get a new, brass fuel inlet to replace the original plastic inlet. If the enrichener cable is broken or in poor condition, it will also be replaced.

•Intake seals will be replaced. Intake flanges will be cleaned and inspected. If cracked or warped, flanges will be replaced. The air cleaner element will be replaced as well as the vacuum hose.

•Battery: The battery will be replaced along with battery/solenoid/starter cables if needed.
The starter relay will be inspected and replaced if needed.

•Belt: The belt will be closely examined. If the belt needs replacement, it will be replaced along with both front and rear pulleys. If the inner primary is to be removed, Mike will replace all primary seals as well as the inner primary bearing, bearing race, transmission mainshaft seal, main drive gear seal, quad seal, shift shaft seal, and front pulley spacer.

•Brakes: Harley Evolution brake pads, rotors, and lines will be scrutinized over and replaced as needed.
Front and rear brake systems will be flushed and bled with fresh DOT 5. Any issues with front or rear master cylinders; the cylinder(s) will be rebuilt.

•Shift linkage: shift arms and linkages will be closely inspected and repaired as needed.

•Electrical: Once a new battery is installed, all electrical operation will be tested. A charging system test will also be performed.

•Cables: Clutch, speedometer, and throttle cables will be inspected and replaced if needed. If cables are ok, they will be lubricated.

1984-1999 Harley-Davidson Evolution Buyers Guide

Harley Parts and Tools for Evolution Refresh Project

All Maintenance Videos on Fix My Hog