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techtalk:evo:engmech04a [2019/02/12 17:41] hippysmack [About Relieving Valve Pressure] |
techtalk:evo:engmech04a [2024/01/03 21:29] (current) hippysmack |
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| - | First, it is suggested to acquire a Factory Service Manual (FSM) before doing any work on your bike. ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?t=1488750)) \\ | + | First, it is suggested to acquire a Factory Service Manual (FSM) before doing any work on your bike. ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?t=1488750)) \\ |
| - | Installing or removing the rocker boxes is not complicated. ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?s=c412e43a4339648eaaa7872371a84820&p=4008995)) \\ | + | Installing or removing the rocker boxes is not complicated. ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?s=c412e43a4339648eaaa7872371a84820#post2932234)) \\ |
| But, it could very easily be done the wrong way with bad results. \\ | But, it could very easily be done the wrong way with bad results. \\ | ||
| While it is mostly just unbolting parts and bolting them back on, some care should be taken. \\ | While it is mostly just unbolting parts and bolting them back on, some care should be taken. \\ | ||
| Line 14: | Line 14: | ||
| ======= Plan Ahead ======= | ======= Plan Ahead ======= | ||
| - | Mark all valve train components as they are removed so they will be re-installed in there original locations. ((Turbota of the XLFORUM http://xlforum.net/forums/showthread.php?t=870)) \\ | + | Mark all valve train components as they are removed so they will be re-installed in there original locations. ((Turbota of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/763-04-05-cam-install-how-to-complete-with-pics?t=870)) \\ |
| Remove one rocker cover / box assembly at a time. | Remove one rocker cover / box assembly at a time. | ||
| + | |||
| ===== Make Room for Parts ===== | ===== Make Room for Parts ===== | ||
| - | |||
| Plan ahead to have a place to store bolts and parts. \\ | Plan ahead to have a place to store bolts and parts. \\ | ||
| This way they won't get mixed up or lost and it'll make reassembly go smoother. \\ | This way they won't get mixed up or lost and it'll make reassembly go smoother. \\ | ||
| You can use a Ziplock bag or an old piece of cardboard for each set of rocker bolts and parts. \\ | You can use a Ziplock bag or an old piece of cardboard for each set of rocker bolts and parts. \\ | ||
| - | {{:techtalk:evo:engmech:06_rocker_box_removal_3_by_jackattack.jpg?direct&300|}} ((photo by JackAttack of the XLFORUM http://xlforum.net/forums/showthread.php?p=4435889)) {{:techtalk:ref:tools:cardboard_rocker_box_screw_holder_by_sep69.jpg?direct&300|}} ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1332901&page=4)) | + | {{:techtalk:evo:engmech:06_rocker_box_removal_3_by_jackattack.jpg?direct&300|}} ((photo by JackAttack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) {{:techtalk:ref:tools:cardboard_rocker_box_screw_holder_by_sep69.jpg?direct&300|}} ((photo by sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion/page4?t=1332901&page=4)) |
| ===== Keeping / Discarding Gaskets ===== | ===== Keeping / Discarding Gaskets ===== | ||
| Line 28: | Line 28: | ||
| This is a judgment call. \\ | This is a judgment call. \\ | ||
| Most gaskets can be easily replaced if you have a leak from re-using the old ones (except the lower cover gasket). \\ | Most gaskets can be easily replaced if you have a leak from re-using the old ones (except the lower cover gasket). \\ | ||
| - | If installing new gaskets, the old ones can be stored for spares if needed. ((photos by JackAttack of the XLFORUM http://xlforum.net/forums/showthread.php?p=4435889)) \\ | + | If installing new gaskets, the old ones can be stored for spares if needed. ((photos by JackAttack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) \\ |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_10_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_11_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_18_by_jackattack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:06_rocker_box_removal_10_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_11_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_18_by_jackattack.jpg?direct&300|}}| | ||
| ====== Make Room to Work ====== | ====== Make Room to Work ====== | ||
| - | + | Disconnect and remove the fuel tank: ((Turbota of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/763-04-05-cam-install-how-to-complete-with-pics?t=870)) \\ | |
| - | Disconnect and remove the fuel tank: ((Turbota of the XLFORUM http://xlforum.net/forums/showthread.php?t=870)) \\ | + | |
| The tank will be cumbersome to work around if left on. \\ | The tank will be cumbersome to work around if left on. \\ | ||
| Turn the petcock valve off. Remove the fuel line and vacuum line (if applicable) attaching to the petcock. \\ | Turn the petcock valve off. Remove the fuel line and vacuum line (if applicable) attaching to the petcock. \\ | ||
| Line 45: | Line 44: | ||
| Then you can nudge the harness out of the way for removal of the rear left rocker bolts. \\ | Then you can nudge the harness out of the way for removal of the rear left rocker bolts. \\ | ||
| - | |Fuel tank and other appurtenances removed. ((photos by JackAttack of the XLFORUM http://xlforum.net/forums/showthread.php?p=4435889))|| | + | |Fuel tank and other appurtenances removed. ((photos by JackAttack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003))|| |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_2_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_5_by_jackattack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:06_rocker_box_removal_2_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_5_by_jackattack.jpg?direct&300|}}| | ||
| Line 58: | Line 57: | ||
| And the inner cover (aka lower cover). \\ | And the inner cover (aka lower cover). \\ | ||
| - | |Rocker box on a 95 883R ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1332901))|Rocker box on an 09 883C ((photo by willypscustoms of the XLFORUM http://xlforum.net/forums/showthread.php?t=1615475))| | + | |Rocker box on a 95 883R ((photo by sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901))|Rocker box on an 09 883C ((photo by willypscustoms of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/148798-black-top-engine-covers?t=1615475))| |
| |{{:techtalk:evo:engmech:1995_rocker_boxes_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_boxes_bywillypscustoms.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:1995_rocker_boxes_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_boxes_bywillypscustoms.jpg?direct&300|}}| | ||
| **Remove the 4 screws with captive steel washers and fiber washers on the top section**. \\ | **Remove the 4 screws with captive steel washers and fiber washers on the top section**. \\ | ||
| Line 64: | Line 63: | ||
| However, new ones are cheap enough to have some on hand as spares when needed also. \\ | However, new ones are cheap enough to have some on hand as spares when needed also. \\ | ||
| - | |These two screws can be more difficult to get to with \\ the wiring harness attached to the frame. ((photo by JackAttack of the XLFORUM http://xlforum.net/forums/showthread.php?p=4435889))|Put the screws and washers safely away. ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1332901))| | + | |These two screws can be more difficult to get to with \\ the wiring harness attached to the frame. ((photo by JackAttack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003))|Put the screws and washers safely away. ((photo by sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901))| |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_4_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_3_by_sep69.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:06_rocker_box_removal_4_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_3_by_sep69.jpg?direct&300|}}| | ||
| | An Allen wrench end cut shorter with a Dremil cut-off blade works good. ((photos by Hippysmack)) || | | An Allen wrench end cut shorter with a Dremil cut-off blade works good. ((photos by Hippysmack)) || | ||
| |{{techtalk:ref:tools:cut_down_allen_1_wrenches_by_hippysmack.jpg?direct&400|}}|{{techtalk:ref:tools:cut_down_allen_3_wrenches_by_hippysmack.jpg?direct&400|}}| | |{{techtalk:ref:tools:cut_down_allen_1_wrenches_by_hippysmack.jpg?direct&400|}}|{{techtalk:ref:tools:cut_down_allen_3_wrenches_by_hippysmack.jpg?direct&400|}}| | ||
| - | |||
| - | |||
| **Then remove the outer cover and put it safely away**. \\ | **Then remove the outer cover and put it safely away**. \\ | ||
| - | |Most of the time, it will be easy to lift off. \\ However, you may have to nudge it a bit with a rubber mallet to break it loose to lift it. ((photo by daggar rider of the XLFORUM http://xlforum.net/forums/showthread.php?t=453930)) ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1332901))|| | + | |Most of the time, it will be easy to lift off. \\ However, you may have to nudge it a bit with a rubber mallet to break it loose to lift it. ((photo by daggar rider of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/68286-bottom-and-top-rocker-gasket-replacement-step-by-step?t=453930)) ((photo by sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901))|| |
| |{{:techtalk:evo:engmech:04_rocker_box_removal_1_by_daggar_rider.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_4_by_sep69.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:04_rocker_box_removal_1_by_daggar_rider.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_4_by_sep69.jpg?direct&300|}}| | ||
| Line 83: | Line 80: | ||
| Remove and replace them now so they don't cause you problems later. \\ | Remove and replace them now so they don't cause you problems later. \\ | ||
| - | | Middle rocker box spacers on a 95 model ((photos by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1332901)) || | + | | Middle rocker box spacers on a 95 model ((photos by sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901)) || |
| |{{:techtalk:evo:engmech:1995_rocker_boxes_6_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_5_by_sep69.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:1995_rocker_boxes_6_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_5_by_sep69.jpg?direct&300|}}| | ||
| ====== Before Removing Lower Cover ====== | ====== Before Removing Lower Cover ====== | ||
| ===== About Relieving Valve Pressure ===== | ===== About Relieving Valve Pressure ===== | ||
| + | See also [[techtalk:ref:svcproc16#hydraulic_lifter_-_disassembly_inspection_assembly|Hydraulic lifter disassembly - inspection - assembly]] in the REF section of the Sportsterpedia. \\ | ||
| + | |||
| (also known as "Bleeding the Lifters") \\ | (also known as "Bleeding the Lifters") \\ | ||
| You are not actually doing anything but allowing the oil time to leave the lifter body out of the holes in the each lifter before removing the lower rocker mounting bolts. \\ | You are not actually doing anything but allowing the oil time to leave the lifter body out of the holes in the each lifter before removing the lower rocker mounting bolts. \\ | ||
| Due to viscosity of the oil and hole locations, it usually takes 20-30 minutes. | Due to viscosity of the oil and hole locations, it usually takes 20-30 minutes. | ||
| - | Internal clearance and parts determine bleed rates. ((bustert of the XLFORUM http://xlforum.net/forums/showthread.php?t=2039673&highlight=bleed+lifters)) | + | Internal clearance and parts determine bleed rates. ((bustert of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/191107-tappets-testing-and-change?t=2039673&highlight=bleed+lifters)) |
| **The 86-03 FSMs state to rotate the crankshaft so both valves are closed on the head being repaired**. \\ | **The 86-03 FSMs state to rotate the crankshaft so both valves are closed on the head being repaired**. \\ | ||
| Line 104: | Line 103: | ||
| This could cause the camshafts to crook sideways and gouge the bushings. \\ | This could cause the camshafts to crook sideways and gouge the bushings. \\ | ||
| - | **The 04-Up FSMs changed the sequence of removing the bolts**. \\ | + | **They 04-Up FSMs still state to rotate the crankshaft so both valves are closed on the head being repaired**. \\ |
| - | Removing them in the proper order also prevents potentially warpage of the cover(s). ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?t=1488750)) \\ | + | **But they changed the sequence of removing the bolts**. \\ |
| + | |||
| + | Removing them in the proper order also prevents potentially warpage of the cover(s). ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?t=1488750)) \\ | ||
| It also mentions making sure that both valves are closed prior to removal for each cylinder (separately) of the rocker box you're removing. \\ | It also mentions making sure that both valves are closed prior to removal for each cylinder (separately) of the rocker box you're removing. \\ | ||
| Line 121: | Line 122: | ||
| |Photos of a dry lifter. (L) assembled - (R) with spring pressure at rest. On dry assembly, the pushrod cup is \\ relatively easy to push in with you finger to install the retainer clip. If oil was poured into the lifter body and \\ then the cup was compressed, it would be more difficult to push the cup down to install the retainer. ((photos by Hippysmack)) || | |Photos of a dry lifter. (L) assembled - (R) with spring pressure at rest. On dry assembly, the pushrod cup is \\ relatively easy to push in with you finger to install the retainer clip. If oil was poured into the lifter body and \\ then the cup was compressed, it would be more difficult to push the cup down to install the retainer. ((photos by Hippysmack)) || | ||
| |{{:techtalk:ref:svcproc:lifter_disassembly_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:svcproc:lifter_disassembly_6_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:ref:svcproc:lifter_disassembly_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:svcproc:lifter_disassembly_6_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| **Cam lobe positions**: | **Cam lobe positions**: | ||
| - | Rocker boxes should really only be removed and installed when the cams are positioned such that the lifters are let all the way down. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?p=5041422&highlight=rocker+box#post5041422)) \\ | + | Rocker boxes should really only be removed and installed when the cams are positioned such that the lifters are let all the way down. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/171860-intake-valve-issues?highlight=rocker+box#post3669740)) \\ |
| Compression TDC is the best place to do this, because it's just about exactly halfway through the valve-closed window. \\ | Compression TDC is the best place to do this, because it's just about exactly halfway through the valve-closed window. \\ | ||
| If you install the rocker boxes at overlap TDC instead, both valves are slightly open. So it's important to be able to tell compression TDC from overlap TDC. \\ | If you install the rocker boxes at overlap TDC instead, both valves are slightly open. So it's important to be able to tell compression TDC from overlap TDC. \\ | ||
| Line 132: | Line 132: | ||
| But if you're sitting at overlap TDC, you may never see the valves close because the lifter will shorten as far as it goes and still be too long. \\ | But if you're sitting at overlap TDC, you may never see the valves close because the lifter will shorten as far as it goes and still be too long. \\ | ||
| - | **There are two TDC's for EACH cylinder**. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1874585)) \\ | + | **There are two TDC's for EACH cylinder**. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/174732-finding-top-dead-center?t=1874585)) \\ |
| The reason there are two TDC's for each is that a 4-stroke motor requires two full revolutions of the crank to complete it's 4 cycles. \\ | The reason there are two TDC's for each is that a 4-stroke motor requires two full revolutions of the crank to complete it's 4 cycles. \\ | ||
| Therefore the piston passes through TDC twice; \\ | Therefore the piston passes through TDC twice; \\ | ||
| Line 150: | Line 150: | ||
| It doesn't have to be precise. Both valves are fully closed from about halfway up the compression stroke to about halfway down the following power stroke. \\ | It doesn't have to be precise. Both valves are fully closed from about halfway up the compression stroke to about halfway down the following power stroke. \\ | ||
| Compression TDC is about halfway between those events, so it's a good reference point, but the window is fairly wide. \\ | Compression TDC is about halfway between those events, so it's a good reference point, but the window is fairly wide. \\ | ||
| + | |||
| ===== Bolt Removal Sequence ===== | ===== Bolt Removal Sequence ===== | ||
| Line 161: | Line 162: | ||
| The circled areas are where the bolts would be: \\ | The circled areas are where the bolts would be: \\ | ||
| - | **On disassembly**: ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?s=c412e43a4339648eaaa7872371a84820&p=4008995)) \\ | + | **On disassembly**: ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?s=c412e43a4339648eaaa7872371a84820#post2932234)) \\ |
| Remove each color set below in slight increments while moving back and forth between them: \\ | Remove each color set below in slight increments while moving back and forth between them: \\ | ||
| Line 171: | Line 172: | ||
| * An easy way to remember the order is to work on the smaller bolts first and then the larger ones. | * An easy way to remember the order is to work on the smaller bolts first and then the larger ones. | ||
| - | |91-03 style lower rocker box ((photo by Hippysmack))|04 and up style lower rocker box ((photo by Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?s=c412e43a4339648eaaa7872371a84820&p=4008995))| | + | |91-03 style lower rocker box ((photo by Hippysmack))|04 and up style lower rocker box ((photo by Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?s=c412e43a4339648eaaa7872371a84820#post2932234))| |
| |{{:techtalk:evo:oil:91-03_lower_rocker_box_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_box_screw_locations_by_screw_loose_dan.jpg?direct&300|}}| | |{{:techtalk:evo:oil:91-03_lower_rocker_box_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_box_screw_locations_by_screw_loose_dan.jpg?direct&300|}}| | ||
| Line 189: | Line 190: | ||
| Or for a better visual: \\ | Or for a better visual: \\ | ||
| - | | Loosen these two bolts first. ((photos by JackAttack of the XLFORUM http://xlforum.net/forums/showthread.php?p=4435889)) || | + | | Loosen these two bolts first. ((photos by JackAttack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) || |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_12_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_13_by_jackattack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:06_rocker_box_removal_12_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_13_by_jackattack.jpg?direct&300|}}| | ||
| - | | Then these three. ((photo by JackAttack of the XLFORUM http://xlforum.net/forums/showthread.php?p=4435889)) | And finally these four. ((photo by JackAttack of the XLFORUM http://xlforum.net/forums/showthread.php?p=4435889)) | | + | | Then these three. ((photo by JackAttack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) | And finally these four. ((photo by JackAttack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) | |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_15_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_16_by_jackattack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:06_rocker_box_removal_15_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_16_by_jackattack.jpg?direct&300|}}| | ||
| Line 198: | Line 199: | ||
| Mark each one so you can replace them back in the same locations upon installing the rocker boxes. \\ | Mark each one so you can replace them back in the same locations upon installing the rocker boxes. \\ | ||
| Each one has it's own wear patterns in the rocker arm cups. \\ | Each one has it's own wear patterns in the rocker arm cups. \\ | ||
| - | If yours are not painted or labeled, check the lengths. The exhaust pushrods are longer than the intake pushrods. ((Turbota of the XLFORUM http://xlforum.net/forums/showthread.php?t=31258&page=3)) \\ | + | If yours are not painted or labeled, check the lengths. The exhaust pushrods are longer than the intake pushrods. ((Turbota of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/18835-installing-cams-how-to-with-pics/page3?t=31258&page=3)) \\ |
| Mixing intake and exhaust pushrods can result in bent pushrods,damaged valves, pistons and more. \\ | Mixing intake and exhaust pushrods can result in bent pushrods,damaged valves, pistons and more. \\ | ||
| **Note**: The intake pushrods have an colored painted bands. Newer pushrods may be labeled instead of painted. \\ | **Note**: The intake pushrods have an colored painted bands. Newer pushrods may be labeled instead of painted. \\ | ||
| Line 215: | Line 216: | ||
| The hole for the breather is also threaded on the correct side for installation. \\ | The hole for the breather is also threaded on the correct side for installation. \\ | ||
| - | |91-03 Inner Rocker Cover ((photo by Hippysmack))|04 an Up Inner Rocker Cover ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1422877&page=9))| | + | |91-03 Inner Rocker Cover ((photo by Hippysmack))|04 an Up Inner Rocker Cover ((photo by JohnK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/132786-fixing-a-leaky-top-end-with-pics/page9?t=1422877&page=9))| |
| |{{:techtalk:evo:engmech:lower_rocker_box_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:05_rocker_box_removal_1_by_johnk.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:lower_rocker_box_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:05_rocker_box_removal_1_by_johnk.jpg?direct&300|}}| | ||
| + | |||
| ====== Remove the Crankcase Breather ====== | ====== Remove the Crankcase Breather ====== | ||
| ===== 86-90 ===== | ===== 86-90 ===== | ||
| 86-90 engines do not have a crankcase breather valve incorporated into the rocker boxes. \\ | 86-90 engines do not have a crankcase breather valve incorporated into the rocker boxes. \\ | ||
| ===== 91-03 ===== | ===== 91-03 ===== | ||
| + | \\ | ||
| ===== 04 and Up ===== | ===== 04 and Up ===== | ||
| - | Remove the plastic crankcase breather from the already removed lower rocker cover. It’s attached with 1 screw. ((Turbota of the XLFORUM http://xlforum.net/forums/showthread.php?t=870)) \\ | + | Remove the plastic crankcase breather from the already removed lower rocker cover. It’s attached with 1 screw. ((Turbota of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/763-04-05-cam-install-how-to-complete-with-pics?t=870)) \\ |
| Once the breather is removed, the rubber upper rocker cover gasket can be removed and discarded. \\ | Once the breather is removed, the rubber upper rocker cover gasket can be removed and discarded. \\ | ||
| Mark the breather, as it needs to be installed back to it’s original rocker cover. \\ | Mark the breather, as it needs to be installed back to it’s original rocker cover. \\ | ||
| (The breathers are not interchangeable between front and rear lower rocker covers) \\ | (The breathers are not interchangeable between front and rear lower rocker covers) \\ | ||
| - | | Breather screw takes a T20 Torx driver or bit ((photo by chris_b_owens of the XLFORUM http://xlforum.net/forums/showthread.php?t=1832762&page=47)) | Remove the screw holding the breather valve. ((photos by daggar rider of the XLFORUM http://xlforum.net/forums/showthread.php?t=453930)) | | + | | Breather screw takes a T20 Torx driver or bit ((photo by chris_b_owens of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/cafe-racer-sportster-motorcycle-talk/170788-my-2013-iron-883-cafe-build/page47?t=1832762&page=47)) | Remove the screw holding the breather valve. ((photos by daggar rider of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/68286-bottom-and-top-rocker-gasket-replacement-step-by-step?t=453930)) | |
| |{{:techtalk:evo:oil:2013_crankcase_breather_2_by_chris_b_owens.jpg?direct&300|}}| {{:techtalk:evo:engmech:04_rocker_box_removal_4._by_daggar_rider.jpg?direct&300|}}| | |{{:techtalk:evo:oil:2013_crankcase_breather_2_by_chris_b_owens.jpg?direct&300|}}| {{:techtalk:evo:engmech:04_rocker_box_removal_4._by_daggar_rider.jpg?direct&300|}}| | ||
| - | | Lift the breather up and place it safely away. ((photo by chris_b_owens of the XLFORUM http://xlforum.net/forums/showthread.php?t=1832762&page=47)) ((photo by daggar rider of the XLFORUM http://xlforum.net/forums/showthread.php?t=453930)) || | + | | Lift the breather up and place it safely away. ((photo by chris_b_owens of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/cafe-racer-sportster-motorcycle-talk/170788-my-2013-iron-883-cafe-build/page47?t=1832762&page=47)) ((photo by daggar rider of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/68286-bottom-and-top-rocker-gasket-replacement-step-by-step?t=453930)) || |
| |{{:techtalk:evo:oil:2013_crankcase_breather_3_by_chris_b_owens.jpg?direct&300|}}| {{:techtalk:evo:engmech:04_rocker_box_removal_5_by_daggar_rider.jpg?direct&300|}}| | |{{:techtalk:evo:oil:2013_crankcase_breather_3_by_chris_b_owens.jpg?direct&300|}}| {{:techtalk:evo:engmech:04_rocker_box_removal_5_by_daggar_rider.jpg?direct&300|}}| | ||
| - | |||
| - | |||
| ====== Remove the Rocker Arm Shafts ====== | ====== Remove the Rocker Arm Shafts ====== | ||
| Line 242: | Line 242: | ||
| **Be careful when handling the inner rocker box (cover) so that the rocker arm shaft does not slide out and hit the floor**. \\ | **Be careful when handling the inner rocker box (cover) so that the rocker arm shaft does not slide out and hit the floor**. \\ | ||
| This could result in dings on the shaft and scarred bushings later. \\ | This could result in dings on the shaft and scarred bushings later. \\ | ||
| - | It is held in place by one of the assembly screws and can fall out with the screw removed. ((Left photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1422877&page=9)) ((Right photo by JackAttack of the XLFORUM http://xlforum.net/forums/showthread.php?p=4435889)) | + | It is held in place by one of the assembly screws and can fall out with the screw removed. ((Left photo by JohnK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/132786-fixing-a-leaky-top-end-with-pics/page9?t=1422877&page=9)) ((Right photo by JackAttack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) |
| |{{:techtalk:evo:engmech:05_rocker_box_removal_2_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_17_by_jackattack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:05_rocker_box_removal_2_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_17_by_jackattack.jpg?direct&300|}}| | ||
| Line 262: | Line 262: | ||
| These rubber parts will become brittle over time and will be rendered useless. \\ | These rubber parts will become brittle over time and will be rendered useless. \\ | ||
| It's best to replace them while you have them apart. \\ | It's best to replace them while you have them apart. \\ | ||
| + | |||
| ====== Inspect the Rocker Box and Rocker Arms ====== | ====== Inspect the Rocker Box and Rocker Arms ====== | ||
| The rocker box, rocker arms, bushings and shafts should be inspected for wear, pitting and proper clearances per the FSM. \\ | The rocker box, rocker arms, bushings and shafts should be inspected for wear, pitting and proper clearances per the FSM. \\ | ||
