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REF: Tools - 124

Rocker Box Tools

Ironhead Engine

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.
1/2“ wrench cut down (box also ground down to fit
confined areas) 3/4” socket notched with an angle
grinder. 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. 3)
Torquing rear rocker box bolts with torque wrench
extender. 4)
A little cutting, a little welding and you have a special wrench to reach the bolts under the frame. 5)

Evo Engine

Allen wrench end cut shorter with a Dremil cut-off blade 6)

Rocker Arms

See also 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

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

7) 8)

Rocker Arm Bushing Reamer (94804-57)

See also 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) 9)

Lapping Tool for Rocker Arm Bushings

A lapping tool can be made from a 1/2“ wooden dowel and a small piece of sandpaper. 10)
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.

Initially cut a piece of sandpaper to go one full revolution around the dowel. 11)
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.


6) , 9) , 10) , 11)
photos by Hippysmack
7)
photo by Hippysmack of the XLFORUM
8)
photo by Hippysmack
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