The 1,340-cc Evolution engine was used by all Harley-Davidson motorcycles built between 1984 and 1998, when it was largely replaced by the new Twin-Cam 88 engines. As of 2011, the Sportster remains the only model from the Harley-Davidson that still employs the Evolution engine, in both 883-cc and 1,200-cc variants. Although the Evolution was praised for its reliability, keeping the engine at its operational peak required regular oil changes every 2,500 miles. The task is fairly straightforward, but there are a few differences between varying Harley-Davidson models.
Instructions
1. Let the engine idle in place for 3 to 5 minutes to warm the engine oil supply. Stop the engine once the oil has warmed, then let the oil settle for another 3 to 5 minutes.
2. Remove the oil cap from the right side of the oil tank, below the front seat. This will allow air to enter into the tank and speed up the oil drain process.
3. Locate the engine oil drain hose near the left rear frame rail, below the transmission unit. Pull the drain hose out of its retaining bracket, then remove the drain plug with a flat-head screwdriver. Alternatively, 1993 to 1998 Touring models use a crankcase drain plug, located under the front of the engine. Unscrew the drain plug, using a 5/8-inch socket and a socket wrench. Drain the engine oil into a sealable oil catch pan.
4. Clean the crankcase drain plug, if removed from a 1993 or newer Touring model, with a shop towel. Remove the drain plug washer and replace it with a new washer. Screw the drain plug into the engine by hand, then tighten it to 22 foot-pounds, using a 5/8-inch socket and a torque wrench. Skip this step if your are working on an Evolution-equipped Sportster, Softail or Dyna motorcycle.
5. Push the drain plug into the oil drain hose and tighten the hose clamp, using a flat-head screwdriver. Push the oil drain hose into its retaining bracket on the left rear frame rail.
6. Unscrew the oil filter from the oil pump at the front of the engine, using an oil filter wrench. Empty the oil filter into your oil catch pan, then set the oil filter aside for recycling. Wipe away the old oil from the oil pump threads, using a shop towel.
7. Fill a new oil filter with SAE 20W-50 motorcycle-grade engine oil, then coat the oil filter's sealing O-ring with oil. Screw the new filter onto the oil pump by hand, until the O-ring makes contact with the oil pump. Tighten the oil filter an additional half-turn by hand to seal the filter.
8. Pour 2.5 quarts of engine oil into the oil tank tank filler neck, using a funnel. Reinstall the oil cap, then start the engine. Let the engine idle for three minutes, then stop the engine and lift the motorcycle into an upright position. Check the oil level, using the dipstick built into the bottom of the oil cap. Add 1 to 2 ounces of oil into the oil tank, if the oil level is below the lower mark cut into the dipstick. Clean the dipstick with a shop towel, then reinstall the oil cap.
Tags: drain plug, drain hose, into tank, shop towel, 8-inch socket