Tappet dropped while removing Gearcase

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Jul 19, 2013 | 05:16 PM

gabarnes28

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Tappet dropped while removing Gearcase

I removed my Harley Sportster 2003 XL1200C gearcase in order to replace my gearcase gasket. Unfortunately three of my cam gears came out with it thus the tappets of all three have dropped. Do I just remove the cylinder heads to loosen the pushrod and that will relieve pressure from the tappets in order for me to reinstall the cam gears or is there something else I should do. Help would be greatly appreciated.

Thanks,

Gary

Jul 19, 2013 | 08:11 PM

Dan89FLSTC

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From: South Carolina

Remove the rocker covers, not the cylinder heads. When you re assemble, follow the manual closely. It`s a simple process, but if done wrong you can bend a valve, or worse.

Jul 20, 2013 | 12:40 PM

gabarnes28

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Having trouble taking off the back rocker cover. Also what do I do after I get the covers off. I have the front rocker cover off, but the dropped tappet is not budging. What do you suggest?

Gary

Jul 21, 2013 | 01:30 PM

Dan89FLSTC

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From: South Carolina

All three sections of the rocker covers must be removed, the lower part is the rocker arm support. Once the lower cover/rocker arm support is removed, the pressure will be off the tappet.

Now you see why the first thing you should have done was to remove the rocker covers and pushrods. They will also be the last thing you do when you re assemble.