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techtalk:ref:svcproc17 [2021/07/10 03:05] hippysmack |
techtalk:ref:svcproc17 [2024/01/21 21:19] (current) hippysmack |
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| New rocker arms come with new bushings that have already been properly sized for the rocker arm shafts. \\ | New rocker arms come with new bushings that have already been properly sized for the rocker arm shafts. \\ | ||
| - | A helpful suggestion is to mic the bushings closely and several times to be sure you need to before replacing them. ((Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072192)) \\ | + | A helpful suggestion is to mic the bushings closely and several times to be sure you need to before replacing them. ((Hippysmack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/195784-replacing-rocker-arm-bushings?t=2072192)) \\ |
| If the rocker arm pads or the pushrod cups are worn badly, it'd probably be best to just replace the arms instead. \\ | If the rocker arm pads or the pushrod cups are worn badly, it'd probably be best to just replace the arms instead. \\ | ||
| New rocker arms come with the bushings installed and pre-sized. \\ | New rocker arms come with the bushings installed and pre-sized. \\ | ||
| Line 14: | Line 14: | ||
| Service Limit: .0035” (.089 mm) \\ | Service Limit: .0035” (.089 mm) \\ | ||
| - | It's not common to have to replace the rocker arm bushings. ((Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?t=1712024&highlight=rocker+arm+bushings)) \\ | + | It's not common to have to replace the rocker arm bushings. ((Scuba10jdl 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/159640-rocker-arm-life?t=1712024&highlight=rocker+arm+bushings)) \\ |
| Unless you run them dry or put high lift cams in causing them to hit the boxes, you shouldn't have an issue with them. \\ | Unless you run them dry or put high lift cams in causing them to hit the boxes, you shouldn't have an issue with them. \\ | ||
| The bushings may wear eventually, but that should be well in to the 100k territory. \\ | The bushings may wear eventually, but that should be well in to the 100k territory. \\ | ||
| - | As far as rocker arm bushings, where they're made isn't nearly as important as having them installed and fitted correctly. ((rivethog of the XLFORUM http://xlforum.net/forums/showthread.php?t=1890998&highlight=rocker+arm+bushings)) \\ | + | As far as rocker arm bushings, where they're made isn't nearly as important as having them installed and fitted correctly. ((rivethog of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/176164-rocker-bushings?t=1890998&highlight=rocker+arm+bushings)) \\ |
| Replace the rocker arm bushings one at a time. \\ | Replace the rocker arm bushings one at a time. \\ | ||
| + | |||
| + | ===== Bushings ===== | ||
| + | |||
| + | * Superior Dixie Distributing makes a set of 4 bushings (17428-57). | ||
| ===== Tools ===== | ===== Tools ===== | ||
| Line 45: | Line 49: | ||
| * (1) 3/4" box end wrench | * (1) 3/4" box end wrench | ||
| * **Arbor Press or Shop Press**: | * **Arbor Press or Shop Press**: | ||
| - | * You can make an arbor button that will fit the bushing with a stop shoulder, could be any length. ((bustert of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072192&page=3)) \\ That way, the ID is protected from the threads and with the stepped shoulder, press it home until it stops. \\ The arbor button could be a right sized bolt with a long shank with the threads cut off. This would negate the need for turning one on a lathe. | + | * You can make an arbor button that will fit the bushing with a stop shoulder, could be any length. ((bustert of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/195784-replacing-rocker-arm-bushings/page3?t=2072192&page=3)) \\ That way, the ID is protected from the threads and with the stepped shoulder, press it home until it stops. \\ The arbor button could be a right sized bolt with a long shank with the threads cut off. This would negate the need for turning one on a lathe. |
| * **Using a Bench Vise**: | * **Using a Bench Vise**: | ||
| - | * A standard bench vise isn't the best idea, but if your vise opens wide enough, you could try it as a press with an arbor button as mentioned above. ((bustert of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072192&page=3)) \\ | + | * A standard bench vise isn't the best idea, but if your vise opens wide enough, you could try it as a press with an arbor button as mentioned above. ((bustert of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/195784-replacing-rocker-arm-bushings/page3?t=2072192&page=3)) \\ |
| - | * However, keep in mind that most bench vises do not have a dedicated flush pull though. ((Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072192&page=3)) \\ The jaws will pull closer together on the opposite side of where the piece is clamped. \\ So the rocker arm would need to be placed in the center of the vise to help ensure a center pull on the bushing to keep it from binding / distorting. \\ Then pull the bushing in slowly checking for binding as you go. It will get tight once the bushing gets about halfway home. | + | * However, keep in mind that most bench vises do not have a dedicated flush pull though. ((Hippysmack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/195784-replacing-rocker-arm-bushings/page3?t=2072192&page=3)) \\ The jaws will pull closer together on the opposite side of where the piece is clamped. \\ So the rocker arm would need to be placed in the center of the vise to help ensure a center pull on the bushing to keep it from binding / distorting. \\ Then pull the bushing in slowly checking for binding as you go. It will get tight once the bushing gets about halfway home. |
| ==== For bushing reaming / sizing ==== | ==== For bushing reaming / sizing ==== | ||
| Line 64: | Line 68: | ||
| | "Jims" reamer for the rocker arm bushings. \\ It's referenced to HD part number (94804-57) ((photo by Hippysmack)) | Other tools ((photo by Hippysmack)) | Wooden dowel lapping tool ((photo by Hippysmack)) | | | "Jims" reamer for the rocker arm bushings. \\ It's referenced to HD part number (94804-57) ((photo by Hippysmack)) | Other tools ((photo by Hippysmack)) | Wooden dowel lapping tool ((photo by Hippysmack)) | | ||
| |{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_arm_bushing_tools_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:wooden_dowel_lapping_tool_3_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_arm_bushing_tools_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:wooden_dowel_lapping_tool_3_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| - | ===== Bushings ===== | ||
| - | |||
| ===== Procedure ===== | ===== Procedure ===== | ||
| Line 115: | Line 116: | ||
| * The 1/2"x13x5" bolt was used below to pull the new bushing into the rocker arm bore. | * The 1/2"x13x5" bolt was used below to pull the new bushing into the rocker arm bore. | ||
| - | | Clean the bore of all oil and debris. Actetone or brake cleaner works well. ((photos by Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?p=5724098#post5724098)) || | + | | Clean the bore of all oil and debris. Actetone or brake cleaner works well. ((photos by Hippysmack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/195784-replacing-rocker-arm-bushings#post4267263)) || |
| |{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_16_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_17_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_16_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_17_by_hippysmack.jpg?direct&300|}}| | ||
| - | |Standard 1/2" washers were cut down on one side to clear the rising edges of the arms to get a flat pull on the bushing. \\ Then the bolt hex was stood up into a bench vise. ((photos by Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?p=5724098#post5724098)) ||| | + | |Standard 1/2" washers were cut down on one side to clear the rising edges of the arms to get a flat pull on the bushing. \\ Then the bolt hex was stood up into a bench vise. ((photos by Hippysmack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/195784-replacing-rocker-arm-bushings#post4267263)) ||| |
| |{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_18_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_19_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_42_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_18_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_19_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_42_by_hippysmack.jpg?direct&300|}}| | ||
| Line 135: | Line 136: | ||
| |If needed, the end of the bushing can be filed down flush to the rocker arm. Place a straightedge across the assembly to ensure it's flat end to end. \\ The file will cut down the bushing before harming the hardened rocker arm. ((photos by Hippysmack))||| | |If needed, the end of the bushing can be filed down flush to the rocker arm. Place a straightedge across the assembly to ensure it's flat end to end. \\ The file will cut down the bushing before harming the hardened rocker arm. ((photos by Hippysmack))||| | ||
| |{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_44_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_45_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_46_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_44_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_45_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_46_by_hippysmack.jpg?direct&300|}}| | ||
| + | |||
| ==== Ream the New Bushing to Size ==== | ==== Ream the New Bushing to Size ==== | ||
| - | The proper way to ream rocker shaft bushing's is to come in from the opposite bushing with the reamer. ((brucstoudt of the XLFORUM http://xlforum.net/forums/showthread.php?p=5189428&highlight=rocker+arm+bushings#post5189428)) \\ | + | The proper way to ream rocker shaft bushing's is to come in from the opposite bushing with the reamer. ((brucstoudt of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/176872-rocker-arm-binding?highlight=rocker+arm+bushings#post5189428)) \\ |
| That way the existing bushing acts as a guide for the bushing being reamed. \\ | That way the existing bushing acts as a guide for the bushing being reamed. \\ | ||
| - | **Factors for a good reaming job include**; ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?p=4680325#post4680325)) ((Hippysmack)) | + | **Factors for a good reaming job include**; ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated#post3406969)) ((Hippysmack)) |
| - | - **Alignment**: The bushing needs to be in perfect alignment when pulled into the rocker arm. \\ You'll also be using a wider bore (existing used bushing)than the reamer as a base line. \\ Choose the best bushing of the two to replace last. \\ The reason for line boring is to get a straight line thru for the shaft. \\ What is bad about a reamer and going free hand is bell mouth. ((bustert of the XLFORUM http://xlforum.net/forums/showthread.php?p=5719526&highlight=rocker+arm+bushings#post5719526)) Slight wiggles can create a wider opening on the outside of the bushing. \\ Using the existing bushing thru to the new one 'helps' to keep the reamer centered in the rocker arm. | + | - **Alignment**: The bushing needs to be in perfect alignment when pulled into the rocker arm. \\ You'll also be using a wider bore (existing used bushing)than the reamer as a base line. \\ Choose the best bushing of the two to replace last. \\ The reason for line boring is to get a straight line thru for the shaft. \\ What is bad about a reamer and going free hand is bell mouth. ((bustert of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/195620-changing-rocker-arm-bushings?highlight=rocker+arm+bushings#post4260418)) Slight wiggles can create a wider opening on the outside of the bushing. \\ Using the existing bushing thru to the new one 'helps' to keep the reamer centered in the rocker arm. |
| - | - **Size**: You have little, if any, control over the finished size the reamer gives while doing this at home. \\ You basically get what the reamer gives. Finished over size or under size is not a good thing. \\ Sizing needs to be done to fit each rocker shaft to it's corresponding bushing. I.E. A to A, B to B, etc. along with trial fitting with zero burrs or high spots on the shafts. ((hcrashster of the XLFORUM http://xlforum.net/forums/showthread.php?p=5189428&highlight=rocker+arm+bushings#post5189428)) | + | - **Size**: You have little, if any, control over the finished size the reamer gives while doing this at home. \\ You basically get what the reamer gives. Finished over size or under size is not a good thing. \\ Sizing needs to be done to fit each rocker shaft to it's corresponding bushing. I.E. A to A, B to B, etc. along with trial fitting with zero burrs or high spots on the shafts. ((hcrashster of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/176872-rocker-arm-binding?highlight=rocker+arm+bushings#post5189428)) |
| - | - **Position**: Each bushing should be installed straight, not cocked or collapsed. ((hcrashster of the XLFORUM http://xlforum.net/forums/showthread.php?p=5189428&highlight=rocker+arm+bushings#post5189428)) \\ If the new bushing installs at a slight angle, this will throw the position of the reamer off. \\ Then the reamer will have to cut at the same time it's fighting a non straight path toward the end of the bushing. \\ The bushing will shrink when it is squeezed into the arm bore. \\ The slit in the bushing may also distort to an 'out of round' condition when installed creating a bumping condition while reaming. | + | - **Position**: Each bushing should be installed straight, not cocked or collapsed. ((hcrashster of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/176872-rocker-arm-binding?highlight=rocker+arm+bushings#post5189428)) \\ If the new bushing installs at a slight angle, this will throw the position of the reamer off. \\ Then the reamer will have to cut at the same time it's fighting a non straight path toward the end of the bushing. \\ The bushing will shrink when it is squeezed into the arm bore. \\ The slit in the bushing may also distort to an 'out of round' condition when installed creating a bumping condition while reaming. |
| - **Surface finish**. Again you have little, if any, control over this at home. You basically get what the reamer gives. Too course isn't good for bushing life. | - **Surface finish**. Again you have little, if any, control over this at home. You basically get what the reamer gives. Too course isn't good for bushing life. | ||
| - **Machining conventions**. This is the method for replacing the bushings in the rocker arm as explained in the FSM. \\ The process is slow, not to mention the variances in accuracy. \\ Chances are the MoCo used dedicated machinery to handle this task. \\ This method is an answer to a field tech or home mechanic needing to change the bushings. \\ Chances are the results will not be as good as the factory machining hence the wide spec range for a new installed bushing job. | - **Machining conventions**. This is the method for replacing the bushings in the rocker arm as explained in the FSM. \\ The process is slow, not to mention the variances in accuracy. \\ Chances are the MoCo used dedicated machinery to handle this task. \\ This method is an answer to a field tech or home mechanic needing to change the bushings. \\ Chances are the results will not be as good as the factory machining hence the wide spec range for a new installed bushing job. | ||
