| Both sides previous revisionPrevious revision |
techtalk:evo:engmech04a [2019/02/17 15:39]
– [About Relieving Valve Pressure] hippysmack |
|---|
|
techtalk:evo:engmech04a [2024/01/03 21:29] (current)
– hippysmack |
|---|
|
|
|
First, it is suggested to acquire a Factory Service Manual (FSM) before doing any work on your bike. ((Screw Loose Dan of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?t=1488750)) \\ |
Installing or removing the rocker boxes is not complicated. ((Screw Loose Dan of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?s=c412e43a4339648eaaa7872371a84820&p=4008995#post2932234)) \\ |
| But, it could very easily be done the wrong way with bad results. \\ |
| While it is mostly just unbolting parts and bolting them back on, some care should be taken. \\ |
|
|
| ======= Plan Ahead ======= |
Mark all valve train components as they are removed so they will be re-installed in there original locations. ((Turbota of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/763-04-05-cam-install-how-to-complete-with-pics?t=870)) \\ |
| Remove one rocker cover / box assembly at a time. |
|
| ===== Make Room for Parts ===== |
|
| Plan ahead to have a place to store bolts and parts. \\ |
| This way they won't get mixed up or lost and it'll make reassembly go smoother. \\ |
| You can use a Ziplock bag or an old piece of cardboard for each set of rocker bolts and parts. \\ |
{{:techtalk:evo:engmech:06_rocker_box_removal_3_by_jackattack.jpg?direct&300|}} ((photo by JackAttack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4435889sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) {{:techtalk:ref:tools:cardboard_rocker_box_screw_holder_by_sep69.jpg?direct&300|}} ((photo by sep69 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion/page4?t=1332901&page=4)) |
|
| ===== Keeping / Discarding Gaskets ===== |
|
| This is a judgment call. \\ |
| Most gaskets can be easily replaced if you have a leak from re-using the old ones (except the lower cover gasket). \\ |
If installing new gaskets, the old ones can be stored for spares if needed. ((photos by JackAttack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4435889sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) \\ |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_10_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_11_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_18_by_jackattack.jpg?direct&300|}}| |
|
|
| ====== Make Room to Work ====== |
|
Disconnect and remove the fuel tank: ((Turbota of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/763-04-05-cam-install-how-to-complete-with-pics?t=870)) \\ |
| The tank will be cumbersome to work around if left on. \\ |
| Turn the petcock valve off. Remove the fuel line and vacuum line (if applicable) attaching to the petcock. \\ |
|
| Then you can nudge the harness out of the way for removal of the rear left rocker bolts. \\ |
|
|Fuel tank and other appurtenances removed. ((photos by JackAttack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4435889sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003))|| |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_2_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_5_by_jackattack.jpg?direct&300|}}| |
|
|
| And the inner cover (aka lower cover). \\ |
|
|Rocker box on a 95 883R ((photo by sep69 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901))|Rocker box on an 09 883C ((photo by willypscustoms of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/148798-black-top-engine-covers?t=1615475))| |
| |{{:techtalk:evo:engmech:1995_rocker_boxes_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_boxes_bywillypscustoms.jpg?direct&300|}}| |
| **Remove the 4 screws with captive steel washers and fiber washers on the top section**. \\ |
|
| However, new ones are cheap enough to have some on hand as spares when needed also. \\ |
|
|These two screws can be more difficult to get to with \\ the wiring harness attached to the frame. ((photo by JackAttack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4435889sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003))|Put the screws and washers safely away. ((photo by sep69 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901))| |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_4_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_3_by_sep69.jpg?direct&300|}}| |
|
| | An Allen wrench end cut shorter with a Dremil cut-off blade works good. ((photos by Hippysmack)) || |
| |{{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|}}| |
|
|
|
| **Then remove the outer cover and put it safely away**. \\ |
|Most of the time, it will be easy to lift off. \\ However, you may have to nudge it a bit with a rubber mallet to break it loose to lift it. ((photo by daggar rider of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/68286-bottom-and-top-rocker-gasket-replacement-step-by-step?t=453930)) ((photo by sep69 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901))|| |
| |{{:techtalk:evo:engmech:04_rocker_box_removal_1_by_daggar_rider.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_4_by_sep69.jpg?direct&300|}}| |
|
|
| Remove and replace them now so they don't cause you problems later. \\ |
|
| Middle rocker box spacers on a 95 model ((photos by sep69 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901)) || |
| |{{:techtalk:evo:engmech:1995_rocker_boxes_6_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:engmech:1995_rocker_boxes_5_by_sep69.jpg?direct&300|}}| |
|
|
| You are not actually doing anything but allowing the oil time to leave the lifter body out of the holes in the each lifter before removing the lower rocker mounting bolts. \\ |
| Due to viscosity of the oil and hole locations, it usually takes 20-30 minutes. |
Internal clearance and parts determine bleed rates. ((bustert of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/191107-tappets-testing-and-change?t=2039673&highlight=bleed+lifters)) |
|
| **The 86-03 FSMs state to rotate the crankshaft so both valves are closed on the head being repaired**. \\ |
|
| **But they changed the sequence of removing the bolts**. \\ |
|
Removing them in the proper order also prevents potentially warpage of the cover(s). ((Screw Loose Dan of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?t=1488750)) \\ |
| It also mentions making sure that both valves are closed prior to removal for each cylinder (separately) of the rocker box you're removing. \\ |
|
|
| |Photos of a dry lifter. (L) assembled - (R) with spring pressure at rest. On dry assembly, the pushrod cup is \\ relatively easy to push in with you finger to install the retainer clip. If oil was poured into the lifter body and \\ then the cup was compressed, it would be more difficult to push the cup down to install the retainer. ((photos by Hippysmack)) || |
| |{{:techtalk:ref:svcproc:lifter_disassembly_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:svcproc:lifter_disassembly_6_by_hippysmack.jpg?direct&300|}}| |
|
|
| **Cam lobe positions**: |
Rocker boxes should really only be removed and installed when the cams are positioned such that the lifters are let all the way down. ((aswracing of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/171860-intake-valve-issues?p=5041422&highlight=rocker+box#post5041422post3669740)) \\ |
| Compression TDC is the best place to do this, because it's just about exactly halfway through the valve-closed window. \\ |
| If you install the rocker boxes at overlap TDC instead, both valves are slightly open. So it's important to be able to tell compression TDC from overlap TDC. \\ |
|
| But if you're sitting at overlap TDC, you may never see the valves close because the lifter will shorten as far as it goes and still be too long. \\ |
|
**There are two TDC's for EACH cylinder**. ((aswracing of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/174732-finding-top-dead-center?t=1874585)) \\ |
| The reason there are two TDC's for each is that a 4-stroke motor requires two full revolutions of the crank to complete it's 4 cycles. \\ |
| Therefore the piston passes through TDC twice; \\ |
|
| It doesn't have to be precise. Both valves are fully closed from about halfway up the compression stroke to about halfway down the following power stroke. \\ |
| Compression TDC is about halfway between those events, so it's a good reference point, but the window is fairly wide. \\ |
|
| ===== Bolt Removal Sequence ===== |
|
|
| The circled areas are where the bolts would be: \\ |
|
**On disassembly**: ((Screw Loose Dan of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?s=c412e43a4339648eaaa7872371a84820&p=4008995#post2932234)) \\ |
|
| Remove each color set below in slight increments while moving back and forth between them: \\ |
|
| * An easy way to remember the order is to work on the smaller bolts first and then the larger ones. |
|
|91-03 style lower rocker box ((photo by Hippysmack))|04 and up style lower rocker box ((photo by Screw Loose Dan of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?s=c412e43a4339648eaaa7872371a84820&p=4008995#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|}}| |
|
|
|
| Or for a better visual: \\ |
| Loosen these two bolts first. ((photos by JackAttack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4435889sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) || |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_12_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_13_by_jackattack.jpg?direct&300|}}| |
|
| Then these three. ((photo by JackAttack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4435889sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) | And finally these four. ((photo by JackAttack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4435889sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) | |
| |{{:techtalk:evo:engmech:06_rocker_box_removal_15_by_jackattack.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_16_by_jackattack.jpg?direct&300|}}| |
|
|
| Mark each one so you can replace them back in the same locations upon installing the rocker boxes. \\ |
| Each one has it's own wear patterns in the rocker arm cups. \\ |
If yours are not painted or labeled, check the lengths. The exhaust pushrods are longer than the intake pushrods. ((Turbota of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/18835-installing-cams-how-to-with-pics/page3?t=31258&page=3)) \\ |
| Mixing intake and exhaust pushrods can result in bent pushrods,damaged valves, pistons and more. \\ |
| **Note**: The intake pushrods have an colored painted bands. Newer pushrods may be labeled instead of painted. \\ |
|
| The hole for the breather is also threaded on the correct side for installation. \\ |
|
|91-03 Inner Rocker Cover ((photo by Hippysmack))|04 an Up Inner Rocker Cover ((photo by JohnK of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/132786-fixing-a-leaky-top-end-with-pics/page9?t=1422877&page=9))| |
| |{{:techtalk:evo:engmech:lower_rocker_box_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:05_rocker_box_removal_1_by_johnk.jpg?direct&300|}}| |
|
| ====== Remove the Crankcase Breather ====== |
| ===== 86-90 ===== |
| 86-90 engines do not have a crankcase breather valve incorporated into the rocker boxes. \\ |
| ===== 91-03 ===== |
| \\ |
| ===== 04 and Up ===== |
Remove the plastic crankcase breather from the already removed lower rocker cover. It’s attached with 1 screw. ((Turbota of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/763-04-05-cam-install-how-to-complete-with-pics?t=870)) \\ |
| Once the breather is removed, the rubber upper rocker cover gasket can be removed and discarded. \\ |
| Mark the breather, as it needs to be installed back to it’s original rocker cover. \\ |
| (The breathers are not interchangeable between front and rear lower rocker covers) \\ |
|
| Breather screw takes a T20 Torx driver or bit ((photo by chris_b_owens of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-styles/cafe-racer-sportster-motorcycle-talk/170788-my-2013-iron-883-cafe-build/page47?t=1832762&page=47)) | Remove the screw holding the breather valve. ((photos by daggar rider of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/68286-bottom-and-top-rocker-gasket-replacement-step-by-step?t=453930)) | |
| |{{:techtalk:evo:oil:2013_crankcase_breather_2_by_chris_b_owens.jpg?direct&300|}}| {{:techtalk:evo:engmech:04_rocker_box_removal_4._by_daggar_rider.jpg?direct&300|}}| |
|
| Lift the breather up and place it safely away. ((photo by chris_b_owens of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-styles/cafe-racer-sportster-motorcycle-talk/170788-my-2013-iron-883-cafe-build/page47?t=1832762&page=47)) ((photo by daggar rider of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/68286-bottom-and-top-rocker-gasket-replacement-step-by-step?t=453930)) || |
| |{{:techtalk:evo:oil:2013_crankcase_breather_3_by_chris_b_owens.jpg?direct&300|}}| {{:techtalk:evo:engmech:04_rocker_box_removal_5_by_daggar_rider.jpg?direct&300|}}| |
|
|
|
| ====== Remove the Rocker Arm Shafts ====== |
|
| **Be careful when handling the inner rocker box (cover) so that the rocker arm shaft does not slide out and hit the floor**. \\ |
| This could result in dings on the shaft and scarred bushings later. \\ |
It is held in place by one of the assembly screws and can fall out with the screw removed. ((Left photo by JohnK of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/132786-fixing-a-leaky-top-end-with-pics/page9?t=1422877&page=9)) ((Right photo by JackAttack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4435889sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/151682-2006-top-end-disassembly-pic-heavy#post3232003)) |
| |{{:techtalk:evo:engmech:05_rocker_box_removal_2_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:engmech:06_rocker_box_removal_17_by_jackattack.jpg?direct&300|}}| |
|
|
| These rubber parts will become brittle over time and will be rendered useless. \\ |
| It's best to replace them while you have them apart. \\ |
|
| ====== Inspect the Rocker Box and Rocker Arms ====== |
| The rocker box, rocker arms, bushings and shafts should be inspected for wear, pitting and proper clearances per the FSM. \\ |
