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EVO: Engine Mechanicals - Sub-04A

Removing / Installing the Rocker Box

Installing or removing the rocker boxes is not complicated. 1)
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.
Simply unbolting things and throwing them back together can cause harm to engine parts.

First, it is suggested to acquire a Factory Service Manual (FSM) before doing any work on your bike.
The FSM is quite clear in the proper order to remove the bolts. 2)
Removing them in the proper order also prevents potentially warpage of the cover(s).
It also mentions making sure that both valves are closed prior to removal.

On assembly, it's even more important to slowly tighten things in the proper order to allow the lifters to bleed down.
(prevents things like bent push rods and destroying the cam bushings).
Also, make sure you can spin the push rods BEFORE turning the motor over the first time.
Obviously, you can skip these steps and get lucky.
But, why? Just follow the manual, it's easy enough to do correctly.

Below is a picture of the lower rocker box (with no hardware),
The circled areas are where the bolts would be:

On disassembly: 3)

  • The yellow bolts would be removed first, then the red, and then slowly and incrementally loosen the ones in blue.
    (the FSM suggests 1/4-1/2 turns at a time to relieve spring pressure evenly)
  • An easy way to remember the order is to work on the smaller bolts first and then larger ones.

On assembly: 4)

  • Work in the opposite order. Blue→red→yellow.
    It is suggested to do this slowly (one turn at a time) and for the blue ones to do it in a cross pattern.
    This is to bleed the lifters properly.
  • An easy way to remember the order is to work from the larger bolts to the smaller ones.

Torque values:
Installing the bolts in the correct order doesn't take much longer and saves some potential headaches.
While many experienced guys won't use a torque wrench on the smaller fasteners, it is suggested to use one.
It doesn't take much to strip one of these for new or experienced mechanics.

  • Blue - 18-22 ft-lbs
  • Red - 135-155 in-lbs
  • Yellow - 135-155 in-lbs

5)


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