Drop Engine for Rocker Box Gasket Replacement
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Novice
Joined: Jan 2014
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From: Atlanta, GA
Drop Engine for Rocker Box Gasket Replacement
Harley 2002 FLHRSEI. Need to replace rocker box gaskets. Want to do this myself but need some tech advice. Dealer mentioned that front of engine needs to be dropped about 2 inches. Can't find this procedure in the service manual. Can anybody talk me through this step by step. Thanks in advance.
Outstanding HDF Member
Joined: May 2013
Posts: 3,427
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From: Home
You don't need to drop the engine to remove the rocker boxes.
Either the dealer does not have the proper tools or they are ripping people off by charging more labor hours if they drop all the engines by 2".
Either the dealer does not have the proper tools or they are ripping people off by charging more labor hours if they drop all the engines by 2".
Tourer
Joined: Sep 2014
Posts: 461
Likes: 119
From: North Dakota
I just replaced the rear on my 04 ultra classic. It is tight a couple rear bolts, but it covers that in the manual. I just unbolted the tank and stuck a 2x4 under it and had (just) enough room. The front looked much easier (more room), but it wasn't leaking so I didn't mess with it.
Seasoned HDF Member
Joined: Feb 2006
Posts: 6,680
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From: South Florida
The manual states remove the tank.Depending on the technician or owner doing the work,sometimes its faster to drop engine down than fool with tank.But depending on what you are doing after the upper rocker box is removed,sometimes you need the tank out of the way to access bolts.I always go with the service manual.
HDF Community Team
Joined: Jun 2006
Posts: 12,776
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From: san antonio
Remove the tank, takes all of five minutes. The only messy part is dealing with the fuel if the tank is not near empty. While you have the tank off, fit a quick disconnect cross over to facilitate tank removal in the future. How much fuel is in the tank won't make any difference.
The front is easy, no drama. However, there are a couple of rocker box cover fasteners on the left side that are tough to get to and I have had to use a 2x4 to push the motor down to R/R those fasteners. You will swear that the breather assembly on the rear will not come out but it will. Do yourself a favor and replace the breathers with the later stamped breather. The bolts are shorter and it is easily removed and installed; they are cheap and make life simple.
One of my bikes is an '02 FLHT and I have had that motor apart more times than I can remember.
The front is easy, no drama. However, there are a couple of rocker box cover fasteners on the left side that are tough to get to and I have had to use a 2x4 to push the motor down to R/R those fasteners. You will swear that the breather assembly on the rear will not come out but it will. Do yourself a favor and replace the breathers with the later stamped breather. The bolts are shorter and it is easily removed and installed; they are cheap and make life simple.
One of my bikes is an '02 FLHT and I have had that motor apart more times than I can remember.
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