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techtalk:evo:engmech04c [2019/01/06 21:11]
hippysmack [Installing the Rocker Boxes]
techtalk:evo:engmech04c [2024/01/04 01:22] (current)
hippysmack
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 [[:​techtalk:​menu|{{ ​ :​techtalk:​gototechnicalmenu.jpg|}}]] [[:​techtalk:​menu|{{ ​ :​techtalk:​gototechnicalmenu.jpg|}}]]
-====== EVO: Engine Mechanicals - Sub-04A ======+====== EVO: Engine Mechanicals - Sub-04C ======
 ====== Installing the Rocker Boxes ====== ====== Installing the Rocker Boxes ======
 See also in the Sportsterpedia;​ See also in the Sportsterpedia;​
  
   * [[techtalk:​evo:​engmech04a#​removing_the_rocker_boxes|Removing the Rocker Boxes]] \\   * [[techtalk:​evo:​engmech04a#​removing_the_rocker_boxes|Removing the Rocker Boxes]] \\
-  * [[techtalk:​evo:​engmech04b#​rocker_box_rocker_arm_inspection_and_repair|Rocker Box / Rocker Arm Inspection and Repair]] \\+  * [[techtalk:​evo:​engmech04b#​rocker_box_rocker_arm_inspection_and_servicing|Rocker Box / Rocker Arm Inspection and Servicing]] 
 +\\ 
 +One issue in installing the rocker box is that it has no alignment method. ((aswracing of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​179904-s-s-hl2t-and-jims-hydrosolid-question/​page13?​t=1933342&​page=13)) \\ 
 +Basically, every time you put it on, it's in a different place. \\ 
 + 
 +When installing the rocker boxes, be sure to put them on with the engine positioned such that the cams aren't trying to open the valves. ((aswracing of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​59164-i-think-i-screwed-up-with-new-cam-install/​page3?​t=322680&​page=3)) \\ 
 +Else you can damage parts. \\ 
 + 
 +===== Compatibility ===== 
 +Middle rocker box: \\ 
 +The 86-90 doesn'​t incorporate the area were the umbrella flapper valve would go. ((dave76 of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​frame-mount-evo-sportster-talk-1986-2003-models/​90479-rocker-box-difference?​t=732143)) \\ 
 +So due to functionality,​ the 86-90 mid section won't fit 91-03 boxes. \\ 
 +But the 91-03 middle cover will fit 86-90 boxes. \\ 
 + 
 +===== Gaskets ===== 
 +Clean the mating surfaces of all oil / trash before setting the gaskets in place. \\ 
 +With the bolts '​lightly'​ hand seated, check all around the box for a gasket squirting out the side before tightening the bolts. \\ 
 +It's easy to 'just nudge' the top section and squeeze a portion of the rubber gasket out while positioning it. \\ 
 +See [[http://​sportsterpedia.com/​lib/​exe/​fetch.php/​pdf-bulletin:​tt0253.pdf|TT#​253]] regarding the top rocker box gasket. 
 + 
 +{{:​techtalk:​evo:​engmech:​pinched_rocker_box_gasket_1_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/​page5#​post2761096)) {{:​techtalk:​evo:​engmech:​pinched_rocker_box_gasket_2_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/​page5#​post2761096)) ​\\
  
 ===== Bolt Installation Sequence ===== ===== Bolt Installation Sequence =====
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 The circled areas are where the bolts would be: \\ The circled areas are where the bolts would be: \\
  
- **On assembly**: ((Screw Loose Dan of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​s=c412e43a4339648eaaa7872371a84820&​p=4008995)) \\+ **On assembly**: ((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)) \\
  
   * Work in this 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.   * Work in this 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.   * An easy way to remember the order is to work from the larger bolts to the smaller ones.
 +  * If you start with the red ones, you can easily strip the threads in the heads.
  
 **Torque values**: \\ **Torque values**: \\
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     * Yellow - 135-155 in-lbs     * Yellow - 135-155 in-lbs
  
-|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|}}| ​
 +
 +===== Check Pushrod Length =====
 +A hydraulic lifter has a plunger in it's body that has about .200" of movement. ((http://​www.hammerperf.com/​ttpushrodlength.shtml)) Oil sits under the plunger and pushes it up to take the slack out of the valve train. \\
 +In the ideal world, the plunger is approximately centered in it's travel, meaning it's preloaded about .100". \\
 +So in theory,\\
 +It could move up, thus lengthening the effective length of the lifter to compensate for a pushrod that's up to .100" too short. \\
 +And likewise, it could move down, thus shortening the effective length of the lifter to compensate for a pushrod that's up to .100" too long. \\
 +This self adjusting action is also useful for compensating for changes in needed pushrod length due to engine temp variations. \\
 +As the motor heats up, the top end grows and the lifter automatically takes up the slack. \\
 +In reality, \\
 +The useful operating range of the lifter plunger is only about .050" in either direction away from centered (.050" to .150" of preload). \\
 +Outside of this range, the self adjusting function doesn'​t work nearly as well. 
 +
 +You can measure lifter pre-load to determine if the pushrods are in the size range needed. This method will get you close. ((http://​www.hammerperf.com/​ttpushrodlength.shtml)) \\
 +The cam lobes should be down (as they should be when installing a rocker box). \\
 +Set the pushrods in place (the longer one goes on the exhaust) and then place the gasket and rocker box on top installing the four big screws only. \\
 +Finger tighten the left (spark plug) side, while making sure the right side is resting with the upper pushrod ends sitting in the cups on the rocker arms. \\
 +Use a caliper to measure how much gap you have between the rocker box and the rocker box gasket. \\
 +The lifter preload should be app. .100" but anywhere between .050" and .150" should work. \\
 +Aftermarket pushrods can be purchased in longer or shorter lengths than stock ones to get the measurement within .100".
 +
 +{{:​techtalk:​evo:​engmech:​lifter_preload_by_aswracing.jpg?​direct&​200|}} ((photo by aswracing of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​59164-i-think-i-screwed-up-with-new-cam-install/​page5?​t=322680&​page=5)) \\
  
 \\ \\