In the Clymer book 1986 to 2003 page 154, line 1B, item H., it says to torque down the bolts for the center rocker cover. Then it says "CAUTION" On all models, make sure the pushrods can be hand-turned before rotating the engine.
My question is how do I acccess the pushrods to hand turn them with the rocker cover mounted over top of them? I would like to understand this before I start disassembly of the covers. Can anyone please explain?

 

you check them before you put the rocker cover back on?

 

i'm sorry to say this but......BURN THAT MANUAL!!!!!!!!

seriously, its a good manual if yr gonna do small stuff but if your gonna be doin some serious work, ya gotta just buck up and buy the manual from HD, i know it sucks and it seems like to much $$ but i did the same thing (bought the clymer tryin to save $$) and ended up gettin the HD one, they built the bike and the manual is soooooo much more detailed than a clymer.

trust me you won't regret it

 

Midnight, I am sure they will rotate quite easily prior to installing the rocker cover as they are just going to be sitting there in a hole with nothing holding them in place. Am I missing something.

Old school, I have the factory manual. It gives little more clarification than the Clymer. Surely someone on this forum has been there and done that!

 

As I read & interpret the instruction from the HD manual, you are to check push rod rotation after installing the inner rocker assembly and prior to installing the outer rocker cover. At this point the push rods and rockers are accessible.

I don't like passing on bad tech info (guessing) so this is just my interpretation.

 

Thanks cHarley I just needed to have someone tell me that. Can't really tell from the pictures if the pushrods were still finger accessable or not. Just so we are all on the same page I have rechecked and they are referring to the first box to be installed over the head. The manuals both call it the lower rocker arm cover not the center cover as I had referred to it.

 

Good catch: funny never noticed that in the manual since EVO and up XL's use solid pushrod tubes! I hate Chapter 3 since it jumps around so much, but I digress... The CAUTION is to prevent damage from rotating the valve train with tappets not bleed down or assembling at their incorrect cam points. Paraphrasing from manual: When torquing the rocker assembly (and therefore putting stress on the pushrod and tappets) the cams should be at TDCC (in other words, thecams lowest points or base circle) for that cylinder you are assembling (torqued in increments). Then wait approximately ten minutes (safe zone) for the tappets to bleed out or "adjust out" (point where rods will spin as described) before rotating the engine to assemble the next cylinder at it's base circle (a TDCC for each cylinder= means rotating the engine to it's TDCC). Then another ten minute wait before rotating for anything else esp. STARTING it. Seen results of doing wrong: it's UGLY! Whole process is even worse with adjustable pushrods!

 

PS Wingman: you uncannily look my Army SFC Dad! LOL