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EVO: Engine Mechanicals - Sub-04D

Removing / Installing Pushrods and Tubes

See also in the Sportsterpedia;

91-99 Engines

Removal

The lower rocker box has to be removed first to be able to get the pushrod tubes out (see link above).
It's also easier to remove the pushrods so they won't get hung up while removing the tubes.

91-99 pushrod bases. 1)

A standard Allen wrench can be used to remove or install the tube base bolts.
But it won't help to properly torque the bolts on installation.
A short Allen wrench adapter, short extension and a 3/8“ socket wrench works well for removing / installing the bolts.
With the bolt removed, you can swing the front end around a bit to get a hold on the base to lift it up on the pushrod tube.
Refrain from using a screwdriver to wedge under it as that can scratch the sealing surface.

The short Allen adapter and extension brings the wrench to the smaller OD area of the tube. 2)

You just want to bring the base up enough to clear the roll pin it's sitting on to give more room when maneuvering the tube up.
Push the base up slightly, then grab and pick up on the pushrod tube while pulling the bottom outward.

There is enough room to pick up on it and then pull the bottom out to clear the lifter block and then down to remove it from the head. 3)

Installation

  • Clean the lifter block, pushrod tubes and O-ring sockets in the heads.
    • Any grease, debris, grit etc. can cause a leak.
  • Lightly oil the O-rings and install them into the heads (do not install them on the tubes first).
  • Install the seal on the tube with the chamfer facing up. Then slide the base onto it.
Lifter block can be cleaned with brake cleaner or
Acetone poured onto a rag and wiped across the
surface. 4)
Make sure the O-rings are seated all the way in the
sockets. 5)
Install gasket and base. Intake and Exhaust side
bases are directional. 6)


1) , 2) , 3)
photos by Hippysmack
4)
phoyo by Hippysmack
5) , 6)
photo by Hippysmack
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