Anyone in MD replace their own Rocker Box
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Road Captain
Joined: Apr 2006
Posts: 698
Likes: 0
From: Hanover, PA
Anyone in MD replace their own Rocker Box
I bought a set of chrome rocker box covers and lowers. I looked in the service manual, looks alot harder than I expected. Anyone close to Baltimore have experience with this? Trying to avoid paying the dealer to do it, and I'd like to learn.
Outstanding HDF Member
Joined: Jan 2007
Posts: 3,438
Likes: 3
From: Chesterfield, VA
I did mine about six months ago and did it only possessing the finely tuned skills of a shade-tree jack-leg.
It was time consuming, but overall, wasn't bad at all. Follow the manual step-by-step. There is a dogbone adapter which would make the job easier, but I was able to do it without. The hardest part was accessing several of the allen head bolts because of where they are positioned in relationship to the frame.
I have read posts here where some have done it only loosening the tank and propping it up. I highly recommended removing the tank.
Go for it. Have a chair handy so you can sit back, drink a beer, and admire the work when you are done.
It was time consuming, but overall, wasn't bad at all. Follow the manual step-by-step. There is a dogbone adapter which would make the job easier, but I was able to do it without. The hardest part was accessing several of the allen head bolts because of where they are positioned in relationship to the frame.
I have read posts here where some have done it only loosening the tank and propping it up. I highly recommended removing the tank.
Go for it. Have a chair handy so you can sit back, drink a beer, and admire the work when you are done.
Road Warrior
Joined: Apr 2008
Posts: 1,899
Likes: 8
From: Aurora, IL
I never worked on the engine of a harley before this one. You can do it, just take your time and pay attention to how it comes apart. With the resource of the internet, you can do just about anything if you have the right tools, time and patience.
Here is a good write up on what I did. The information you need is included in there.
http://www.harleyhog.co.uk/1550/bb6online.htm
FYI I have been wrenchin on Jeeps, Mustangs, and rice rockets for years.
Here is a good write up on what I did. The information you need is included in there.
http://www.harleyhog.co.uk/1550/bb6online.htm
FYI I have been wrenchin on Jeeps, Mustangs, and rice rockets for years.
Last edited by redrubicon2004; Feb 20, 2009 at 06:03 AM.
Road Master
Joined: Sep 2008
Posts: 799
Likes: 25
From: Milan,Tennessee
its fairly easy....the back rocker box bolts ,you can see them,are the hardest..take a allen wrench and cut about a inch off and use a open/box end wrench..take your time,use blue locktite and clean the threads off the bolts.also you need to make sure the cylinder your working on is on the compression stroke and piston all the way up...this is if you are changing the lower box,because you have to take the rocker arm cradle off to change the lowr box..get a manual and take your time....
Road Master
Joined: Sep 2008
Posts: 799
Likes: 25
From: Milan,Tennessee
easiest way is to get the rear tire off the ground,remove the spark plug of the cylinder your working on...ok go ahead and remove both plugs,make a note as to wich plug wire goes where,put the trans in high gear,turn the rear wheel in forward rolling direction,takes a little effort,have some one put their finger over spark plug hole,dont turn the motor over with the starter,when you feel air coming out you are on the compression stroke,now,get a straw,drinking straw like the long red ones from fast food places,make sure it doesnt have any soda left in it.put it in the hole,make sure the straw is at least 8 in long,now turn the wheel ,the straw should be coming up,watch it and it will stop for a second,that is top dead center...if you go past a little bit you can bump the wheel backwards....do this for each cylinder.........if this is over your head,get some help,everyone has learned with a little help...
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Elite HDF Member
Joined: May 2008
Posts: 4,579
Likes: 10
From: S.E. MO
I did mine this last summer and your right its a bigger job than what you think.
All in all there is nothing to difficult though it just takes some time and patience to get through it. It took me I think about 5 to 6 hours to do the rocker covers and the tappet covers. It was hotter than hell that day and I took lots of breaks.
If you have pretty good mechanical ability and a service manual you can do it but its not a job for everyone.
Like others have said make sure you are at TDC for each cylinder. Also make sure your push rods spin freely when putting the lower covers back on.
All in all there is nothing to difficult though it just takes some time and patience to get through it. It took me I think about 5 to 6 hours to do the rocker covers and the tappet covers. It was hotter than hell that day and I took lots of breaks.
If you have pretty good mechanical ability and a service manual you can do it but its not a job for everyone.
Like others have said make sure you are at TDC for each cylinder. Also make sure your push rods spin freely when putting the lower covers back on.
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