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techtalk:evo:engmech04c [2019/02/02 03:08] – [Installing the Rocker Boxes] hippysmacktechtalk:evo:engmech04c [2024/01/04 01:22] (current) – hippysmack
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 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]] [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
-====== EVO: Engine Mechanicals - Sub-04A ======+====== EVO: Engine Mechanicals - Sub-04C ======
 ====== Installing the Rocker Boxes ====== ====== Installing the Rocker Boxes ======
 See also in the Sportsterpedia; See also in the Sportsterpedia;
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   * [[techtalk:evo:engmech04b#rocker_box_rocker_arm_inspection_and_servicing|Rocker Box / Rocker Arm Inspection and Servicing]]   * [[techtalk:evo:engmech04b#rocker_box_rocker_arm_inspection_and_servicing|Rocker Box / Rocker Arm Inspection and Servicing]]
 \\ \\
-One issue in installing the rocker box is that it has no alignment method. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1933342&page=13)) \\+One issue in installing the rocker box is that it has no alignment method. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/179904-s-s-hl2t-and-jims-hydrosolid-question/page13?t=1933342&page=13)) \\
 Basically, every time you put it on, it's in a different place. \\ Basically, every time you put it on, it's in a different place. \\
  
-When installing the rocker boxes, be sure to put them on with the engine positioned such that the cams aren't trying to open the valves. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=322680&page=3)) \\+When installing the rocker boxes, be sure to put them on with the engine positioned such that the cams aren't trying to open the valves. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/59164-i-think-i-screwed-up-with-new-cam-install/page3?t=322680&page=3)) \\
 Else you can damage parts. \\ Else you can damage parts. \\
 +
 +===== Compatibility =====
 +Middle rocker box: \\
 +The 86-90 doesn't incorporate the area were the umbrella flapper valve would go. ((dave76 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/90479-rocker-box-difference?t=732143)) \\
 +So due to functionality, the 86-90 mid section won't fit 91-03 boxes. \\
 +But the 91-03 middle cover will fit 86-90 boxes. \\
 +
 +===== Gaskets =====
 +Clean the mating surfaces of all oil / trash before setting the gaskets in place. \\
 +With the bolts 'lightly' hand seated, check all around the box for a gasket squirting out the side before tightening the bolts. \\
 +It's easy to 'just nudge' the top section and squeeze a portion of the rubber gasket out while positioning it. \\
 +See [[http://sportsterpedia.com/lib/exe/fetch.php/pdf-bulletin:tt0253.pdf|TT#253]] regarding the top rocker box gasket.
 +
 +{{:techtalk:evo:engmech:pinched_rocker_box_gasket_1_by_sep69.jpg?direct&300|}} ((photo by sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion/page5#post2761096)) {{:techtalk:evo:engmech:pinched_rocker_box_gasket_2_by_sep69.jpg?direct&300|}} ((photo by sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion/page5#post2761096)) \\
 +
 ===== Bolt Installation Sequence ===== ===== Bolt Installation Sequence =====
 The FSM details the proper installation sequence of the bolts. \\ The FSM details the proper installation sequence of the bolts. \\
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 The circled areas are where the bolts would be: \\ The circled areas are where the bolts would be: \\
  
- **On assembly**: ((Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?s=c412e43a4339648eaaa7872371a84820&p=4008995)) \\+ **On assembly**: ((Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?s=c412e43a4339648eaaa7872371a84820#post2932234)) \\
  
   * Work in this order. Blue->red->yellow. \\ It is suggested to do this slowly (one turn at a time) and for the blue ones to do it in a cross pattern. \\ This is to bleed the lifters properly.   * Work in this order. Blue->red->yellow. \\ It is suggested to do this slowly (one turn at a time) and for the blue ones to do it in a cross pattern. \\ This is to bleed the lifters properly.
   * An easy way to remember the order is to work from the larger bolts to the smaller ones.   * An easy way to remember the order is to work from the larger bolts to the smaller ones.
 +  * If you start with the red ones, you can easily strip the threads in the heads.
  
 **Torque values**: \\ **Torque values**: \\
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     * Yellow - 135-155 in-lbs     * Yellow - 135-155 in-lbs
  
-|91-03 style lower rocker box ((photo by Hippysmack))|04 and up style lower rocker box ((photo by Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?s=c412e43a4339648eaaa7872371a84820&p=4008995))|+|91-03 style lower rocker box ((photo by Hippysmack))|04 and up style lower rocker box ((photo by Screw Loose Dan of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-custom-finishing/137154-how-to-paint-top-lifter-covers-for-07-sportster?s=c412e43a4339648eaaa7872371a84820#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|}}|  |{{: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|}}| 
 +
 +===== Check Pushrod Length =====
 +A hydraulic lifter has a plunger in it's body that has about .200" of movement. ((http://www.hammerperf.com/ttpushrodlength.shtml)) Oil sits under the plunger and pushes it up to take the slack out of the valve train. \\
 +In the ideal world, the plunger is approximately centered in it's travel, meaning it's preloaded about .100". \\
 +So in theory,\\
 +It could move up, thus lengthening the effective length of the lifter to compensate for a pushrod that's up to .100" too short. \\
 +And likewise, it could move down, thus shortening the effective length of the lifter to compensate for a pushrod that's up to .100" too long. \\
 +This self adjusting action is also useful for compensating for changes in needed pushrod length due to engine temp variations. \\
 +As the motor heats up, the top end grows and the lifter automatically takes up the slack. \\
 +In reality, \\
 +The useful operating range of the lifter plunger is only about .050" in either direction away from centered (.050" to .150" of preload). \\
 +Outside of this range, the self adjusting function doesn't work nearly as well. 
 +
 +You can measure lifter pre-load to determine if the pushrods are in the size range needed. This method will get you close. ((http://www.hammerperf.com/ttpushrodlength.shtml)) \\
 +The cam lobes should be down (as they should be when installing a rocker box). \\
 +Set the pushrods in place (the longer one goes on the exhaust) and then place the gasket and rocker box on top installing the four big screws only. \\
 +Finger tighten the left (spark plug) side, while making sure the right side is resting with the upper pushrod ends sitting in the cups on the rocker arms. \\
 +Use a caliper to measure how much gap you have between the rocker box and the rocker box gasket. \\
 +The lifter preload should be app. .100" but anywhere between .050" and .150" should work. \\
 +Aftermarket pushrods can be purchased in longer or shorter lengths than stock ones to get the measurement within .100".
 +
 +{{:techtalk:evo:engmech:lifter_preload_by_aswracing.jpg?direct&200|}} ((photo by aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/59164-i-think-i-screwed-up-with-new-cam-install/page5?t=322680&page=5)) \\
  
 \\ \\

Trace: • EVO: Engine Mechanicals - Sub-04C