I've been riding and wrenching on Panheads since 1972 when I got my first '50 EL. In 2000, I picked up a brand-new Harley TC-88 EFI Road King. I still have my old trusty '50 Pan, but felt I needed a trusty cruiser to get me where I had to go. I swore I wasn't going to get emotionally attached to the Road King, and for a few years I didn't.
The five-year factory warranty ran out this summer, so I decided that it was time to get my hands dirty with her. I didn't see anything new in the marketplace to make me want to trade her in, and since she has proved reliable, it was time to customize!
We're gonna try and get her into the Panhead spirit by redoing her in the scheme of an old Duo-Glide.
The first thing we needed to do was change the look of the top-end of the engine to fit the project.
Custom Chrome had the solution with its Xotic Pan-style rocker boxes for Twin Cam 88 models (CCI PN 02-017). Everything came in the box for the instillation except new gaskets for the lower rocker housing, (we strongly recommend changing these gaskets since you'll have them off anyway). Custom Chrome recommends that you have the unit installed by a professional mechanic, but after seeing the operation, we think that anyone with the proper tools and basic wrenching knowledge can handle the job in an afternoon.
I wanted this done right the first time, and since my area of expertise is Panheads and not the new-fangled T.C. engines, I took my ride and the kit up to Broadway Choppers in Schenectady, New York. A few of the guys in the shop helped me out: Lee and Ryan. Lee has a sterling reputation as an engine god, and Ryan has been wrenching at Harley dealerships for quite a few years before Lee snagged him for Broadway.
These were the guys I wanted working on my main transportation.
The only modification we had to perform was to grind approximately 1/8 inch off the side of the washers that hold on the horn bracket. The total time for the project was three hours, including me slowing Lee and Ryan down to take the photos and ask stupid questions.
Everything was included in...
Everything was included in the kit (except the lower rocker gaskets we mentioned earlier.)
Here's what the bike looked...
Here's what the bike looked like before with the original factory rocker boxes.
We removed the seat and gas...
We removed the seat and gas tank...
...then the air filter un...
...then the air filter unit.
Using a 7/16 box-end wrench,...
Using a 7/16 box-end wrench, we loosened and removed the rocker cover bolts.
We rotated the rear wheel...
We rotated the rear wheel in Fifth gear to be sure that the lifters were at the lowest point, or the piston at top dead center of its compression stroke.
We carefully removed the rocker...
We carefully removed the rocker assembly.
Next, to go were the lower...
Next, to go were the lower rocker box covers.
After installing the new gaskets...
After installing the new gaskets and new bottom rocker housing, we tightened down the bolts using blue loctite and torquing down the bolts to 13 lb-ft.
Once we reinstalled the rocker...
Once we reinstalled the rocker assembly, the bolts were torqued down to 18 lb-ft.
We installed new gaskets (included...
We installed new gaskets (included in the kit), the new Panhead covers, and the retaining ring using the screws provided.
The same operation was repeated...
The same operation was repeated on the rear cylinder.
We replaced the air clean...
We replaced the air cleaner.
After replacing the gas tank...
After replacing the gas tank and seat, we were done.