Just curious - how big of a job is replacing the rocker box gaskets on a 2016 Deluxe with TC103HO engine? It seems like something that is not too bad if you take your time, just wondering if there are any particular issues I may run into

 

If you've done it several times, about three hours.

If you've never done it, about six.

It's not bad. Just follow the book. It's easier if you have a fuel tank crossover line quick disconnect. And it's even easier if you have adjustable pushrods.

 

It's not that difficult of a job, but I urge you to have a factory HD service manual, even if you have done this before. I always feel like getting the gas tank off is the most tedious part, primarily because I would not want to damage the paint etc, so before you start prepare a nice safe place to store the gas tank and any other delicate parts while you complete the work. You will also need a good quality torque (inch and ft lbs) wrench along with the correct sockets and wrenches. I would use Cometic gaskets and seals as replacent gaskets. Keep things organized and makes notes as you take it apart so hopefully it will be easier to put it back together correctly.

Depending on mileage there may be other things to check and possible replace. I'd look closely at the breathers and consider replacing them. Also depending on miles, I'd consider replacing the factory hydraulic lifters with high quality aftermarket lifters, like ones WFO Larry (w / pin oiler and slow leak down) or S&S. Possibly others depending on the history of the bike and mileage.

http://www.larrysmotorcyclemachine.com/lifters.html

Paul

 

I am one of the few that doesn't mind going through the top (rocker boxes) anytime I go into the cam chest of an air cooled Twin Cam... I just don't see it as a terrible job.

I have yet to own a Twin cooled engine or an M8 oil cooled engine, so I have no experience or opinion on the difficulty of removing the rockers on those engines. I have HEARD that it makes the job more time consuming, complicated, and a pain in the butt... but that is all heresay...

I have done it about eight times between my bikes and friend's bikes... all air-cooled Twin Cams

As often as I have done it, I always have my factory service manual for the year/model bike I am working on for reference... every time...

If your rocker cover gasket (top one) needs replacing, it's way easy. Removing the tank is the biggest job, but I have that down.

If you need to replace the rocker housing gasket (bottom one), that is not hard, just takes a little more time. You will need to remove the breather assemblies, and rocker arms/rocker arm supports to remove that rocker housing & replace the gasket.

The biggest thing to look out for, IMHO, involves reassembly. I always clean all fasteners and screws/bolt threads with a thread chaser. The important part to remember is that any blind hole in the head/covers needs to be clean before reassembly. If you leave oil in the bottom of the blind hole(s), when you install the fastener you run the risk (very high risk on some of the blind holes) of breaking the head casting. It would suck to start a gasket replacement job, and then ending up needing a new head(s)...

Each and every threaded hole gets blasted with a good shot of air from my compressor, after the threads are cleaned, before reassembly. I shield the top of the hole with a rag to catch the debris and/or oil blown out from the blind holes. But I make sure every blind hole is empty & contains no oil, before reassembly...


As for gaskets, the HD OEM rocker cover gaskets are really nice. I have reused an undamaged OEM HD rocker cover gasket before with good results. If you have a dealership nearby, no real reason NOT to buy/use the OEM gaskets. They are #16719-99B for the Rocker Housing gasket (bottom) and #17386-99A for the Rocker Cover gasket (top).

When the MoCo haulted online discount sales, I stopped buying their gaskets and use gaskets made by Cyco Gaskets. Their foamet gaskets work well, as do their silicone bead gaskets.

I have not tried to reuse a Cyco Gasket, as I choose to replace them every time. I never had one leak. The bad part is, they supply a lot of independent Harley shops. To buy the gaskets at a great price from Cyco Gasket, you need a minimum order of $50 and they are cheaper in a multi-pack. Since I care for four of my own Twin Cams, and occasionally work on a good friend's bike, I keep numerous gaskets on hand. I have no issue making a $50 order when I need to get more gaskets.

Go slow, referring to the manual frequently, on your first time... and the subsequent times you go into the rocker boxes will become faster without even trying...

Good luck with the repair.

 

How does having adjustable pushrods help anything?

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Good catch...

 

Not sure clearance on softail frame, I have only done touring. And you don't need this tool, I have done without, but it is handy. Dogbone to use on tq adapter might be handy. I got the chance to work with a pro. He was just for bleep sake its just a cover, when I started getting fussy about the rear. Again on touring, not sure how softail frame is.

 

In this work, you can install the rocker lockers also.

 

I've opened rocker boxes on a 2001, 2003, & 2004 Softails. On those years the main wiring harness along the backbone of the frame, and the backbone itself, can make things tight on the primary side rocker cover bolts. Especially on the rear cylinder.

Due to the limited clearance, I use ratcheting box wrenches to remove the bolts, and torque adapters at 90°, to torque them down during reassembly.

The primary side, rear two rocker cover bolts need some manuvering to get out... You just need to "wiggle it" a bit to get them out past the harness.

 

FWIW, I would use "Rockouts" because of the internal drama between the two