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techtalk:ref:tools124 [2018/05/20 07:01] ixl2relax ↷ Links adapted because of a move operation |
techtalk:ref:tools124 [2021/11/12 23:00] hippysmack [Evo Engine] |
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[[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | ||
- | ====== REF: Tools - Sub-024 ====== | + | ====== REF: Tools - 124 ====== |
====== Rocker Box Tools ====== | ====== Rocker Box Tools ====== | ||
- | ===== Ironhead Engine ===== | + | ====== Ironhead Engine ====== |
- | * Keep the extender straight out in front of the wrench. Don't let it move out of line more than a ratchet click or two, otherwise it can affect the torque reading. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2)) \\ [[techtalk:ref:tools01-023#torque_socket_wrench_extensions_horizontal_with_the_wrench|Read more about torque value changes with the use of extensions here]]. | + | * Keep the extender straight out in front of the wrench. Don't let it move out of line more than a ratchet click or two, otherwise it can affect the torque reading. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2)) \\ [[techtalk:ref:tools123#torque_socket_wrench_extensions_horizontal_with_the_wrench|Read more about torque value changes with the use of extensions here]]. |
|Torque rocker box bolts to 20 ft lbs. You can use a wrench cut down to 3 inches long and welded to a 3/8 drive socket to get in under the frame and torque those \\ rocker bolts to show 185 inch pounds on a 10 inch torque wrench, to give 240 at the bolt.||| | |Torque rocker box bolts to 20 ft lbs. You can use a wrench cut down to 3 inches long and welded to a 3/8 drive socket to get in under the frame and torque those \\ rocker bolts to show 185 inch pounds on a 10 inch torque wrench, to give 240 at the bolt.||| | ||
- | |{{:techtalk:ref:notes:torque_wrench_extension_1_by_hopper.jpg?direct&300|}}|{{:techtalk:ref:notes:torque_wrench_extension_2_by_hopper.jpg?direct&300|}}|{{:techtalk:ref:notes:torque_wrench_extension_5_by_hopper.jpg?direct&300|}}| | + | |{{techtalk:ref:tools:torque_wrench_extension_1_by_hopper.jpg?direct&300|}}|{{techtalk:ref:tools:torque_wrench_extension_2_by_hopper.jpg?direct&300|}}|{{techtalk:ref:tools:torque_wrench_extension_5_by_hopper.jpg?direct&300|}}| |
|1/2" wrench cut down (box also ground down to fit \\ confined areas) 3/4" socket notched with an angle \\ grinder. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))|Torque wrench extender welded and ready to use. \\ Extension Length: 3" from the center of the drive \\ square to the center of the (intended) bolt. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))|Torquing rear rocker box bolts with torque wrench \\ extender. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))| | |1/2" wrench cut down (box also ground down to fit \\ confined areas) 3/4" socket notched with an angle \\ grinder. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))|Torque wrench extender welded and ready to use. \\ Extension Length: 3" from the center of the drive \\ square to the center of the (intended) bolt. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))|Torquing rear rocker box bolts with torque wrench \\ extender. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))| | ||
- | |{{:techtalk:ref:notes:torque_wrench_extension_4_by_hopper.jpg?direct&400|}}|{{:techtalk:ref:notes:torque_wrench_extension_3_by_hopper.jpg?direct&300|}}| | + | |{{techtalk:ref:tools:torque_wrench_extension_4_by_hopper.jpg?direct&400|}}|{{techtalk:ref:tools:torque_wrench_extension_3_by_hopper.jpg?direct&300|}}| |
^ A little cutting, a little welding and you have a special wrench to reach the bolts under the frame. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2)) ^^ | ^ A little cutting, a little welding and you have a special wrench to reach the bolts under the frame. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2)) ^^ | ||
- | ===== Evo Engine ===== | + | ====== Evo Engine ====== |
+ | Cutting down Allen wrenches to make them shorter on the end will allow you to get into tight places easier. \\ | ||
+ | It also helps when the ends get rounded which allows the tool to slip in the socket head. \\ | ||
+ | Using a Dremil tool or a file on the end can get rid of the round and help to keep it from slipping. \\ | ||
|{{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|}}| | ||
- | ^ Allen wrench end cut shorter with a Dremil cut-off blade ((photos by Hippysmack)) ^^ | + | ^ Allen wrench end cut shorter with a Dremil cut-off blade ((photos by Hippysmack)) ^^ |
+ | |||
+ | You can also use a 1/4" ratcheting wrench with 1/4" attachments (cheap attachments are easy to replace). \\ | ||
+ | It's easier to get at Allen heads such as the speedo sender and the rear left rocker cover bolts easy to remove/replace. \\ | ||
+ | It's a slimmer profile ratchet that can be useful at times. ((Sportsterpaul of the XLFORUM http://xlforum.net/forums/showthread.php?p=5924506#post5924506)) \\ | ||
+ | This is a 'Snap On Blue Point' brand 1/4" and 5/16" offset/reversible wrench ($32 delivered). \\ | ||
+ | |||
+ | |{{:techtalk:ref:tools:offset_wrench_by_aussiegazza.png?direct&300|}}| | ||
+ | ^ Offset wrench for rocker box cover. ((photo by AussieGazza of the XLFORUM http://xlforum.net/forums/showthread.php?postid=1181033)) ^ | ||
+ | \\ | ||
+ | |||
+ | Lower inner rocker box bolts (circled in red in the pic below) leave little room between the frame and the bolts for a wrench. \\ | ||
+ | And sometimes you have to turn the bolt one flat at a time due to little space so it takes longer to remove/install those three bolts. \\ | ||
+ | You can buy (or make) tools with a shorter profile to help out with the space issue. \\ | ||
+ | However, it's best to only install the bolts to "snug", then use a 1/4" beam type torque wrench to finish bolt installation. \\ | ||
+ | |||
+ | * You can buy a three pack of gear ratchet inserts,(1/4”-3/8”-1/2”). \\ That turns the appropriate size gear ratchet into a “slimmer profile" ratchet that can be useful at times. ((sportsterpaul of the XLFORUM http://xlforum.net/forums/showthread.php?p=5924506#post5924506)) | ||
+ | * A company called KATAR makes a wrench specifically for the Evo lower rocker box bolts. Made in the USA. \\ It's a reversible ratcheting box wrench with a deep well 7/16" socket. \\ This allows for removal or installation of the lower rocker box hex nut bolts (5/16" bolts with 7/16" hex heads). \\ It has a long handle and a short profile making it easier to get to the bolts. | ||
+ | |||
+ | |||
+ | {{:techtalk:evo:oil:91-03_lower_rocker_box_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
+ | ====== Rocker Arms ====== | ||
+ | See also [[techtalk:evo:engmech04b#rocker_arm_bushing_replacement|Rocker Arm Bushing Replacement]] in the Sportsterpedia. \\ | ||
+ | ===== Rocker Arm Bushing Remover ===== | ||
+ | * (1) 9/16"x18 tapered thread tap | ||
+ | * (1) 9/16"x18x1" grade 8 bolt (3/4" to 1-1/2" length will work) | ||
+ | * (1) tap wrench to fit the 9/16" tap | ||
+ | * (1) drift or punch | ||
+ | * (1) Hammer | ||
+ | |||
+ | {{:techtalk:evo:engmech:replacing_rocker_arm_bushings_14_by_hippysmack.jpg?direct&300|}} | ||
+ | |||
+ | |{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_7_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_9_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | |{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_11_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_12_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | ===== Rocker Arm Bushing Installer ===== | ||
+ | |||
+ | * (1) 1/2"x13x5" grade 8 bolt | ||
+ | * (2) 1/2" grade 8 washers | ||
+ | * (1) 1/2" grade 8 nut | ||
+ | * (1) 3/4" box end wrench | ||
+ | |||
+ | {{:techtalk:evo:engmech:rocker_arm_bushing_tools_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack of the XLFORUM)) {{:techtalk:evo:engmech:replacing_rocker_arm_bushings_22_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
+ | |||
+ | ===== Rocker Arm Bushing Reamer (94804-57) ===== | ||
+ | See also [[techtalk:evo:engmech04b#rocker_arm_bushing_replacement|Rocker Arm Bushing Replacement]] in the Sportsterpedia. \\ | ||
+ | |||
+ | This reamer is specially designed for reaming the rocker arm bushings from 1957 to present. \\ | ||
+ | It is the right length and cut to fit into the old bushing on one end of the rocker arm and ream the new bushing in the other end. | ||
+ | |||
+ | | "Jims" makes this reamer referenced to HD part number (94804-57) ((photos by Hippysmack)) || | ||
+ | |{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_2_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | ===== Lapping Tool for Rocker Arm Bushings ===== | ||
+ | |||
+ | A lapping tool can be made from a 1/2" wooden dowel and a small piece of sandpaper. ((photos by Hippysmack)) \\ | ||
+ | Make the dowel long enough to run the full length of the rocker arm plus enough to get a hand on to turn it (12" or so). \\ | ||
+ | Use a hacksaw blade cut a slot down the middle of one end to hold the sandpaper. \\ | ||
+ | Make the slot longer than the bushing so you can be sure to have contact on the full length of the bushing. \\ | ||
+ | |||
+ | |{{:techtalk:ref:tools:wooden_dowel_lapping_tool_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:wooden_dowel_lapping_tool_2_by_hippysmack.jpg?direct&300|}}| | ||
+ | |||
+ | Initially cut a piece of sandpaper to go one full revolution around the dowel. ((photos by Hippysmack)) \\ | ||
+ | Too many wraps will not slide into the bushing as it will then be too thick. \\ | ||
+ | You just need to turn or lap the bushing slowly and evenly. \\ | ||
+ | Grit of sandpaper will be determined by the condition of the bore and clearance desired. \\ | ||
+ | Insert the bare end of the dowel into the bushing to lap and exit the dowel out the non lapped bushing. \\ | ||
+ | This will allow you to basically line lap the intended bushing to help keep center between the two. \\ | ||
+ | |||
+ | |{{:techtalk:ref:tools:wooden_dowel_lapping_tool_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:wooden_dowel_lapping_tool_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:wooden_dowel_lapping_tool_5_by_hippysmack.jpg?direct&300|}}| | ||