Started with a Broken Speedo Cable...lots of pics.
Thread Starter
|
Road Captain
Joined: Aug 2009
Posts: 592
Likes: 0
From: Southside CT
Started with a Broken Speedo Cable...lots of pics.
So I was laying down on my driveway unscrewing a broken speedo cable at the drive on the front wheel when I look up and see this:
So I decided to fix the leaky rocker boxes since I was going to be wrenching:
Since I was taking things apart I might as well paint some parts that have been bothering me bc they're all faded.
I bought a mc jack and a set of tools and got to it.
While I was replacing the gaskets on the rocker boxes I hit them with a compound because they looked like crap:
Then I decided since I was going to be doing painting I might as well paint the motor since the carb, intake and accessories were already dismantled:
And then I put it all back together:
...all in two days.
(yeah I know I put rusty nuts back on the back of the gauges, but I haven't gotten around to replacing them yet. Maybe I'll paint those too.)
So I decided to fix the leaky rocker boxes since I was going to be wrenching:
Since I was taking things apart I might as well paint some parts that have been bothering me bc they're all faded.
I bought a mc jack and a set of tools and got to it.
While I was replacing the gaskets on the rocker boxes I hit them with a compound because they looked like crap:
Then I decided since I was going to be doing painting I might as well paint the motor since the carb, intake and accessories were already dismantled:
And then I put it all back together:
...all in two days.
(yeah I know I put rusty nuts back on the back of the gauges, but I haven't gotten around to replacing them yet. Maybe I'll paint those too.)
Thread Starter
|
Road Captain
Joined: Aug 2009
Posts: 592
Likes: 0
From: Southside CT
Sorry I don't. They're fairly easy to get off and back on. You'll need a ft/lb and an inch/lb torque wrench. The jug underneath the seat has very little clearance for the bolts, so be prepared to battle it out with those two. I'd do that one first and get it out of the way. The forward one will be cake after that. Just be really careful about the torque settings. You tighten them too much and you'll break the gaskets.
Thread Starter
|
Road Captain
Joined: Aug 2009
Posts: 592
Likes: 0
From: Southside CT
The four for the top cover and my '87 had 9 mounting the lower assembly to the jugs. (4) 1/2 bolts and (5) hex. I had to take the pushrods out of the back jug to get the lower cover off, the front one came off. Make sure you label which end and where the pushrods came from. Also, if your bike is old as mine, get a good knife, razor blade and scraper because your gaskets are going to be glued onto the rocker box. Not fun.
Outstanding HDF Member
Joined: Jul 2009
Posts: 2,447
Likes: 0
From: Danville Va, Providence NC
I have never seen the inside of the valve assembly on one of these engines. I have no idea what I am getting into today. But it has to be done, and now is the time before I get the tank and fenders back from the painter. If I get in too deep, I will just have to pay someone to bail me out. I am determined to learn this stuff, and no time like the present.
What are the torque values? Is it vital to torque the rocker covers to spec? I do have an inch pound and foor pound torque wrench, but they were left loaded 7 years ago or so. lmao.
Thanx guyz. RD
What are the torque values? Is it vital to torque the rocker covers to spec? I do have an inch pound and foor pound torque wrench, but they were left loaded 7 years ago or so. lmao.
Thanx guyz. RD
Thread Starter
|
Road Captain
Joined: Aug 2009
Posts: 592
Likes: 0
From: Southside CT
I don't have the book in front of me but I think the 4 1/2inch bolts were 25-30ft/lbs and the allens were 125-140 inch/lbs. You should DEFINITELY get yourself a Clymer repair book or a HD one if you don't have on already. If your is motor is solid mounted it'll also be easier to take off the top mount,(makes a lot more room for wrenching which also requires certain torque settings to put back together.
I got a plastic bag, wrapped the horn/ignition key housing and whatever else was hanging and zip tied it up and out of the way.
Definitely wouldn't go at this job without a book though. It's pretty simple, except if you have a Clymer, they don't tell you about all of the bolts in the lower rocker housing in the installation steps. They mention 4...of 9. So I just tightened them in a crisscross pattern according to the specs for the 1/2 bolts or the allen head bolts & it worked out for me.
I got a plastic bag, wrapped the horn/ignition key housing and whatever else was hanging and zip tied it up and out of the way.
Definitely wouldn't go at this job without a book though. It's pretty simple, except if you have a Clymer, they don't tell you about all of the bolts in the lower rocker housing in the installation steps. They mention 4...of 9. So I just tightened them in a crisscross pattern according to the specs for the 1/2 bolts or the allen head bolts & it worked out for me.
Trending Topics
Outstanding HDF Member
Joined: Jul 2009
Posts: 2,447
Likes: 0
From: Danville Va, Providence NC
I don't have the book in front of me but I think the 4 1/2inch bolts were 25-30ft/lbs and the allens were 125-140 inch/lbs. You should DEFINITELY get yourself a Clymer repair book or a HD one if you don't have on already. If your is motor is solid mounted it'll also be easier to take off the top mount,(makes a lot more room for wrenching which also requires certain torque settings to put back together.
I got a plastic bag, wrapped the horn/ignition key housing and whatever else was hanging and zip tied it up and out of the way.
Definitely wouldn't go at this job without a book though. It's pretty simple, except if you have a Clymer, they don't tell you about all of the bolts in the lower rocker housing in the installation steps. They mention 4...of 9. So I just tightened them in a crisscross pattern according to the specs for the 1/2 bolts or the allen head bolts & it worked out for me.
I got a plastic bag, wrapped the horn/ignition key housing and whatever else was hanging and zip tied it up and out of the way.
Definitely wouldn't go at this job without a book though. It's pretty simple, except if you have a Clymer, they don't tell you about all of the bolts in the lower rocker housing in the installation steps. They mention 4...of 9. So I just tightened them in a crisscross pattern according to the specs for the 1/2 bolts or the allen head bolts & it worked out for me.
You have me worried now. I am going to take it apart tomorrow. How many pieces are there to the rocker setup?
Thanx, RD
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
