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

 

You don't have to remove the jugs, just the rocker boxes will suffice. HOWEVER the cam gears con only go back in 1 way! There are lines on each gear that ALL have to be lined up properly. I've got a picture somewhere and will post it when I find it. Here you go...

 

No need to remove the cylinder heads, but rocker covers will need to come off.

FYI - You must perform this reinstallation correctly. Do you have a service manual for reference?

 

Yes I have the manual with the timing picture. I wish I would have read it in the beginning.

Thanks,

Gary

 

Your not the first one,if this link works it might be some help.
https://www.hdforums.com/forum/sport...oes-it-go.html

 

What did you do after removing the rocker covers. I mean what else did you have to do to get the tappets to go up in order to reinstall the cam gears.

Thanks,
Gary

 

Pull the plugs in order to rotate the motor more easily. Rotate until both valves are closed on one cylinder, then loosen the rocker arms in increments until there is no tension on the pushrods. Better to turn the motor over by hand using the rear wheel in gear than using the starter. Repeat for the other cylinder.

 

I panicked when I opened her up and all the gears fell to the ground but with a little persistence it's not that difficult getting it back together. Just make sure you clean all of the parts, put all of the washers back in their correct positions and use new gaskets. It is also mandatory to tighten the rockerbox bolts in order and torque.

 

Alright. Didn't have to remove the cylinder head. Did the first cylinder closest to the front. Just had to loosen all of the bolts in the sequence provided in the manual. This loosened the pushrods thus allowing me to be able to push up the tappet. Will do the other cylinder tomorrow and possibly line up all the cams tomorrow as well if time permits since I have to work. I appreciate everyone's help in this matter.

Thanks,

Gary

Will let you know how it all turns out when I'm done. Most likely in the next two to three days.

 

Just one more thing, make sure there is no pressure on the valves while torquing the head/rockerbox, you'll have to rotate the rear wheel and do one head at a time. It sounds like you're not removing the rockerbox...probably not a good Idea since I highly recommend replacing the any of the gasket you mess around with.