Differences

This shows you the differences between two versions of the page.

--- techtalk:evo:engmech04 [2021/07/15 05:00]
hippysmack [Sub Documents]
+++ techtalk:evo:engmech04 [2022/10/10 23:19]
hippysmack [Rocker Box Gaskets]
@@ Line 2: / Line 2: @@
 ====== EVO: Engine Mechanicals ======
 ====== Rocker Box ======
- ===== Sub Documents =====
+===== Sub Documents =====
   * [[techtalk:evo:engmech04a|Removing the Rocker Boxes]]
   * [[techtalk:evo:engmech04b|Rocker Box Inspection and Servicing]]
   * [[techtalk:evo:engmech04c|Installing the Rocker Boxes]]
-  * [[techtalk:evo:engmech04e|Pics of Evo Sportster Rocker Boxes]]
+  * [[techtalk:evo:engmech04e|Pics and Information on Evo Sportster Rocker Boxes]]
   * [[techtalk:evo:engmech04j|Rocker Arm Inspection and Servicing]]
   * [[techtalk:evo:engmech04l|Stabilizing Noisy Rocker Arm Shafts]]
   * [[techtalk:evo:engmech04q|Removing / Installing Pushrods and Tubes]]
+  * [[techtalk:evo:engmech04s|Top End Oiling]]
+===== Rocker Box Part Numbers =====
-^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&830|}}||||||||
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&840|}}|||||||
-|  Rocker Box Part Numbers  ||||||||
+|  1986-Up Sportster Rocker Box Part Numbers \\ (Note: an asterisk (*) next to a number indicates that part number is an updated version and not the original part number)  |||||||
-|Year Model|Lower Box \\ Part#|Lower Box \\ Casting#|Middle Spacer \\ Part#|Middle Spacer \\ Casting#|Upper Cover \\ Part#|Upper Cover \\ Casting#|Notes|
+|Year Model|Lower Box \\ Part#|Lower Box \\ Casting#|Middle Spacer \\ Part#|Middle Spacer \\ Casting#|Upper Cover \\ Part#|Upper Cover \\ Casting#|
-|1986-1988 All|17532-86|17554-86|17533-86|17555-86|17501-86|17556-86|Chrome set|
+|1986-1988 All|17532-86 \\ *17532-86A|17554-86 \\ *17555-86A|17533-86 \\ *17533-86B|17555-86 \\ *17580-95|17501-86 \\ *17501-86A|17556-86 \\ *17556-86A|
-|1989 All|17532-86A|17554-86A|17533-86A|17555-86A|17501-86A|17556-86A|L89 see \\ {{ pdf-bulletin:tsb0984.pdf |TSB M-984}}|
+|  Notes:|17532-85 lower box does not have oval shaped holes on the pushrod side. \\ (crankcase air escape route to heads) \\ 17554-86 middle spacer doesn't have provisions for head breather umbrellas. \\ None of this is needed since 86-90 models breath through the cam cover. \\ But it's important to note that these parts can only be used on 86-90 models.||||||
-|1990 All|17532-86A|17554-86A|17533-86B|  |17501-86A|17556-86A|Polished set|
+|1989 All|17532-86A|17554-86A|17533-86A|17555-86A|17501-86A|17556-86A|
-|1991 All|17532-86A|17554-86A|17533-89|  |17501-86A|17556-86A|
+|  Notes:|On L89 lower boxes, {{ pdf-bulletin:tsb0984.pdf |Click Here to view TSB M-984}} regarding sealing area around middle spacer.||||||
-|1992-1994 All|17532-86A|17554-86A|17533-90|17555-90|17501-86A|17556-86A|Polished set|
+|1990 All|17532-86A|17554-86A|17533-86B|17580-95|17501-86A|17556-86A|
-|1995-2003 All except \\ 883R, 1200C, 1200S)|17532-86B|17579-95|17533-90A|17580-95|17501-86B|17581-95|Chrome set|
+|  Notes:|Polished set.  ||||||
-|1996-2003 1200C|17537-96 \\ 17537-96C|17579-95 \\ 17579-95C|17538-96|17580-95|17551-96|17581-95|Chrome set|
+|1991 All|17532-86A \\ *17532-86E|17554-86A|17533-89 \\ *17533-90A|  |17501-86A \\ *17501-86B|17556-86A|
-|1998-2003 1200S|17614-98 \\ 17614-98C|17579-95 \\ 17579-95C|17533-90A|17580-95|17527-98|17581-95|Silver top \\ Silver bottom|
+|  Notes:|  ||||||
-|2002-2003 883R|17532-86B|17579-95|17535-02|  |17501-86B|
+|1992-1994 All|17532-86A \\ *17532-86E|17554-86A|17533-90 \\ *17533-90A|17555-90 \\ *17580-95|17501-86A \\ *17501-86B|17556-86A \\ *17581-95|
-|2004-2006 883, 883C, 883L|17532-86C|  |  N/A  ||17501-04|17581-04|Polished set|
+|  Notes:|Polished set.||||||
-|2004-2006 1200C|17537-96A|17579-95B|  N/A  ||17551-04|17581-04|Chrome|
+|1995-2003 All except \\ 883R, 1200C, 1200S)|17532-86B \\ *17532-86E|17579-95|17533-90A|17580-95|17501-86B|17581-95|
-|2004-2005 883R, 1200R|17614-98A \\ 17614-98B|17579-95A \\ 17579-95B|  N/A  ||17527-04|  |Silver set|
+|  Notes:|Polished set.||||||
-|2006 883R|17614-98A \\ 17614-98B|17579-95A \\ 17579-95B|  N/A  ||17655-05|  |Silver bottom, black top|
+|1996-2003 1200C|17537-96 \\ *17537-96C|17579-95 \\ *17579-95C|17538-96|17580-95|17551-96|17581-95|
-|2006 1200R|17645-06|  |  N/A  ||17655-05|  |Black bottom, black top|
+|  Notes:|Chrome set.||||||
-|2007-2009 883, \\ 883C, 883L, 1200N|17532-07|17579-07|  N/A  ||17501-04|17581-04|Polished set|
+|1998-2003 1200S|17614-98 \\ *17614-98C|17579-95 \\ *17579-95C|17533-90A|17580-95|17527-98|17581-95|
-|2007-2009 1200C, \\ 1200L, XL50|17537-07|17579-07|  N/A  ||17551-04|  |Chrome set|
+|  Notes:|Silver powder coated set.||||||
-|2007-2009 883R, 883N|17614-07|17579-07|  N/A  ||17655-05|  |Silver bottom, black top|
+|2002-2003 883R|17532-86B \\ *17532-86E|17579-95|17535-02|  |17501-86B|  |
-|2007-2009 1200R|17645-07|  |  N/A  ||17655-05|  |Black set|
+|  Notes:|Polished set.  ||||||
-|2009 XR1200|17590-08|  |  N/A  ||17585-08|  |Silver set|
+|2004-2006 883, \\ 883C, 883L|17532-86C \\ *17532-86E|17579-95B|  N/A  ||17501-04|17581-04|
-|2010-2016 883C, 883L, \\ 1200N, 1200X|17532-07A|17579-07A|  N/A  ||17501-04|17581-04|Polished set|
+|  Notes:|Polished set.||||||
-|2010-2016 1200C, 1200L, \\ 1200CP, 1200V, 1200T|17537-07A|17579-07A|  N/A  ||17551-04|  |Chrome set|
+|2004-2006 1200C|17537-96A \\ *17537-96C|17579-95B \\ *17579-95C|  N/A  ||17551-04|17581-04|
-|2010-2014 883R, 883N, \\ 1200CP, 1200CA, 1200CB|17614-07A|  |  N/A  ||17655-05|17581-04|Silver bottom, black top|
+|  Notes:|Chrome set. \\ 17537-96A and 17537-96B lower boxes have slots in the gasket channel on the valve side of the box. \\ The slots can cause gasket leaks and lower box ..537-96C (no slots) replaced them both. \\ {{ pdf-bulletin:tsb1168A.pdf |Click Here to view TSB M-1168A}} in the Sportsterpedia.||||||
-|2010 XR1200|17590-08A|  |  N/A  ||17585-08|  |Silver set|
+|2004-2005 \\ 883R, 1200R|17614-98A \\ *17614-98B \\ *17614-98C|17579-95A \\ *17579-95B \\ *17579-95C|  N/A  ||17527-04|  |
-|2010-2013 XR1200X|17591-10|  |  N/A  ||17615-10|  |Black set|
+|  Notes:|Silver powder coated set.||||||
-|2015-2016 883R, 883NN, \\ 1200CP, 1200CA, 1200CB|17598-07A|  |  N/A  ||17655-05|  |Silver bottom, black top|
+|2006 883R|17614-98A \\ *17614-98B \\ *17614-98C|17579-95A \\ *17579-95B \\ 17579-95C|  N/A  ||17655-05|  |
+|  Notes:|Silver powder coated bottom, black powder coated top.||||||
+|2006 1200R|17645-06 \\ *17645-06A|  |  N/A  ||17655-05|  |
+|  Notes:|Black powder coated set.||||||
+|2007-2009 883, 883C, \\ 883L, 1200N|17532-07|17579-07|  N/A  ||17501-04|17581-04|
+|  Notes:|Polished set.  ||||||
+|2007-2009 1200C, \\ 1200L, XL50|17537-07|17579-07|  N/A  ||17551-04|  |
+|  Notes:|Chrome set.||||||
+|2007-2009 883R, 883N|17614-07|17579-07|  N/A  ||17655-05|  |
+|  Notes:|Silver powder coated bottom, black powder coated top.||||||
+|2007-2009 1200R|17645-07 \\ *17645-07A|  |  N/A  ||17655-05|  |
+|  Notes:|Black powder coated set. -07A is wrinkle black powder coat.||||||
+|2009 XR1200|17590-08|  |  N/A  ||17585-08|  |
+|  Notes:|Silver powder coated set.||||||
+|2010-2016 883C, 883L, \\ 1200N, 1200X|17532-07A|17579-07A|  N/A  ||17501-04|17581-04|
+|  Notes:|Polished set.||||||
+|2010-2016 1200C, 1200L, \\ 1200CP, 1200V, 1200T|17537-07A|17579-07A|  N/A  ||17551-04|  |
+|  Notes:|Chrome set.||||||
+|2010-2014 883R, 883N, \\ 1200CP, 1200CA, 1200CB|17614-07A|  |  N/A  ||17655-05|17581-04|
+|  Notes:|Silver powder coated bottom, black powder coated top.||||||
+|2010 XR1200|17590-08A|  |  N/A  ||17585-08|  |
+|  Notes:|Silver powder coated set.||||||
+|2010-2013 XR1200X|17591-10|  |  N/A  ||17615-10|  |
+|  Notes:|Black set.||||||
+|2015-2016 883R, 883NN, \\ 1200CP, 1200CA, 1200CB|17598-07A|  |  N/A  ||17655-05|  |
+|  Notes:|Silver powder coated bottom, black powder coated top.||||||
 ===== Rocker Box Gaskets =====
-\\
+[[techtalk:evo:engmech07|Click Here]] to reference breather valves/installation/sealing in the Sportsterpedia. \\
-==== Top cover gaskets ====
-|91-03|17353-89C|rocker cover gasket (includes cutouts for the breather to fit into). \\ Gasket 17353-89B also usable. No breather seal required. |
+Below is a list of factory gaskets used on Sportster rocker boxes. \\
-|04-06|17353-89C|rocker cover gasket (includes cutouts for the breather to fit into). \\ Only use -89C gasket. No breather seal required. See [[http://sportsterpedia.com/lib/exe/fetch.php/pdf-bulletin:tt0253.pdf|TT#253]].|
+Original part numbers are listed first with known superseded part numbers below the original ones. \\
-|07-16|17362-07|rocker cover gasket (does not include cutouts for the breather to fit into). \\ 17393-07 breather seal (required with rocker cover gasket 17362-07)|
+Pics of the different part numbers are listed to the right in the chart. Click on the link to open a picture of the part. \\
+While a complete updated list is difficult to maintain, this list may help find updated as well as NOS gaskets. \\
+Check the notes section for particulars as gaskets have changed over the years. \\
-===== Pushrods =====
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&840|}}|||||
+|  Sportster Rocker Box Gaskets  |||||
+|Year Model|Position|Part#|Notes|Pics|
+|1986-1990|Upper (cover gasket)|17354-86 \\ 17354-86A|-86 - cork gaskets replaced in 1989 by -86A. \\ -86A - rubber gaskets.|{{techtalk:evo:engmech:1986-1988_sportster_rocker_box_cover_gasket_17354-86_by_deep_south_cycles.jpg?linkonly|-86}} ((photo courtesy of Deep South Cycles, [[https://www.ebay.com/str/deepsouthcycles|Link to Eaby Store]] )) \\ {{ :techtalk:evo:engmech:1986-1990_sportster_rocker_box_cover_gasket_17354-86a_by_harleyguys.jpg?linkonly |-86A}} ((photo courtesy of Ebay seller, harleyguys [[https://www.ebay.com/str/used2bviperizer2?_trksid=p2047675.l2563|Link to Ebay Store]] ))|
+|:::|Lower (middle section)|17353-86 \\ 17353-86A|-86 - cork gaskets replaced in 1989 by -86A. \\ -86A - rubber gaskets.|{{ :techtalk:evo:engmech:1986-1988_sportster_rocker_box_middle_section_gasket_17353-86_by_robison_motorcycles.jpg?linkonly |-86}} ((photo courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] )) \\ {{ :techtalk:evo:engmech:1986-1990_sportster_rocker_box_middle_section_gasket_17353-86a_by_fox_cycle_works.jpg?linkonly |-86A}}  ((photo courtesy of Fox Cycle Works, [[https://www.ebay.com/str/foxcycleworks?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))|
+|:::|Inner (bottom section)|17358-84 \\ 17358-84A|Small rectangle gasket on top of bottom section. \\ -84 - cork gaskets replaced in 1989 by -84A. \\ -84A - rubber gaskets.|{{ :techtalk:evo:engmech:1986-1988_sportster_inner_rocker_box_gasket_17358-84_by_jrsvintageharley1990.jpg?linkonly |-84}} ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://www.ebay.com/str/jrsvintageharleyparts?_trksid=p2047675.l2563|Link to Ebay Store]]  ))|
+|:::|Head (bottom section)|(L) 16779-84A \\ (R) 16778-84|Beaded gaskets between lower section and heads.| \\ {{ :techtalk:evo:engmech:1986-1990_rocker_box_bottom_section_right_gasket_16778-84_by_jrsvintageharley1990.jpg?linkonly |-84}} ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://www.ebay.com/str/jrsvintageharleyparts?_trksid=p2047675.l2563|Link to Ebay Store]]  ))|
+|:::|Cover screw washer|6114 \\ 63858-49|Washer seals against air intake or exhaust. \\ 6114 - Reusable copper, replaced by fiber (1987) \\ -49 - Fiber washer, reusable unless breaks or erodes.|{{ :techtalk:evo:engmech:1986-2003_sportster_rocker_box_cover_washer_6114_by_57harleyrider.jpg?linkonly |6114}} ((photo courtesy of Ebay seller, 57harleyrider. [[https://www.ebay.com/str/57harleyrider|Link to Ebay Store]] )) \\ {{ :techtalk:evo:engmech:1986-2003_sportster_rocker_box_cover_washers_63858-49_by_robisonmotorcycles.jpg?linkonly |-49}} ((photo courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] ))|
+|1991-2003|Upper (cover gasket)|17354-89|  |{{ :techtalk:evo:engmech:1991-2003_rocker_box_cover_gasket_17354-89_by_rusty_dusty_motorocycle_parts.jpg?linkonly |-89}} ((photo courtesy of Ebay seller, Rusty Dusty Motorcycle Parts. [[https://www.ebay.com/str/bialystreasures|Link to Ebay Store]] ))|
+|:::|Lower (middle section)|17353-89 \\ 17353-89A \\ 17353-89B \\ 17353-89C|-89 is black, has round breather holes \\ -A, -B, -C gaskets redesigned \\ several times for 04-06 models. \\ Original -89 Ok to use on 91-03 models.|{{ :techtalk:evo:engmech:1991-2003_sportster_rocker_box_middle_section_gasket_17353-89_by_hudsonvalleymotorcycleparts.jpg?linkonly |-89}} ((photo courtesy of Northway Motorcycle Parts. [[https://www.ebay.com/str/northwayparts?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] )) \\ {{ :techtalk:evo:engmech:1991-2006_sportster_rocker_box_middle_section_gasket_17353-89c_by_harleyguys.jpg?linkonly |-89C}} ((photo courtesy of Ebay seller, harleyguys [[https://www.ebay.com/str/used2bviperizer2?_trksid=p2047675.l2563|Link to Ebay Store]] ))|
+|:::|Inner (bottom section)|17358-84A|Small rectangle gasket on top of bottom section.|
+|:::|Head (bottom section)|(L) 16779-84A, \\ (R) 16778-84A|Gasket between lower box and heads.|  |
+|:::|Cover screw washer|63858-49|Fiber washer seals against air intake. \\ Reusable unless breaks or erodes. \\ Copper washer (6114) Ok to use as well.|{{ :techtalk:evo:engmech:1986-2003_sportster_rocker_box_cover_washers_63858-49_by_robisonmotorcycles.jpg?linkonly |-49}} ((photo courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] ))|
+|:::|Umbrella valve|26856-89|Not a gasket but rather a breather valve. \\ Good maintenance to replace when cover is off.|See \\ [[techtalk:evo:engmech07|Breather page]]|
+|:::|Full gasket kit|17036-91|Includes all original gaskets above.|  |
+|2004-2006|Lower (cover gasket)|17353-89A \\ 17353-89B \\ 17353-89C|Cover gasket (includes cutouts for breather valve). \\ -89A has slots and locating tabs over breather holes. \\ The edges are also rounded. \\ -89B (2-15-05) has slots but no locating tabs. \\ It's black and the edges are cut square. ((HD TSB #M-1168A dated 11-10-2005)) \\ **Only use -89C gasket**. No breather seal required. \\ It's brown with slots and locating tabs. \\ See [[http://sportsterpedia.com/lib/exe/fetch.php/pdf-bulletin:tt0253.pdf|TT#253]].|{{ :techtalk:evo:engmech:1991-2006_sportster_rocker_box_middle_section_gasket_17353-89c_by_harleyguys.jpg?linkonly |-89C}} ((photo courtesy of Ebay seller, harleyguys [[https://www.ebay.com/str/used2bviperizer2?_trksid=p2047675.l2563|Link to Ebay Store]] ))|
+|:::|Inner (bottom section)|17358-84A|Small rectangle gasket on top of bottom section.|
+|:::|Head (bottom section)|16800-84|One piece gasket between lower box and head.|  |
+|:::|Breather valves|(F) 26010-04|Directional and cannot be installed backwards.|See \\ [[techtalk:evo:engmech07|Breather page]]|
+|:::|:::|(R) 26011-04|:::|:::|
+|2007-Present|Upper (cover gasket)|17362-07 \\ 17362-07B \\ 17362-07C|Does not include cutouts for the breather valve. \\ 17393-07 breather seal required. \\ -07, thin orange rubber. \\ -07A, thin orange crush dimpled rubber.\\ -07B, thin black rubber. \\ -07C, thin crush dimpled black rubber.| |
+|:::|Inner (bottom section)|17695-07 \\ 17695-07A \\ 17695-07B \\ 17695-07C|-07 thin orange rubber, top of bottom section. \\ -07A, orange rubber with crush dimples. \\ -07B, thin black rubber, \\ -07C, thin black rubber with crush dimples.| \\ {{ :techtalk:evo:engmech:2007-up_sportster_inner_rocker_box_gasket_17695-07a_by_mg000000.jpg?linkonly |-07A}} ((photo courtesy of Royal Motorworks Citroen Parts Plus, [[https://www.ebay.com/str/royalmotorworkscitroenpartsplus?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] )) \\ {{ :techtalk:evo:engmech:2007-up_sportster_rocker_cover_inner_gasket_17695-07b_by_on_any_sunday_1961.jpg?linkonly |-07B}} ((photo courtesy of
+Vintage Acquisitions, [[https://www.ebay.com/str/onanysunday1961?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] )) \\ {{ :techtalk:evo:engmech:2007-up_sportster_rocker_box_inner_cover_gasket_17695-07c_by_1rosesofwood.jpg?linkonly |-07C}} ((photo courtesy of Ebay seller,1rosesofwood, [[https://www.ebay.com/str/rosesofwood?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))|
+|:::|Head (bottom section)|16800-84A|One piece gasket between lower box and head.|  |
+|:::|Breather valves \\ (plastic units)|(F) 26012-07|Not a gasket but rather a breather valve. \\ Good maintenance to replace when cover is off. \\ Directional and cannot be installed backwards. \\ Same breather units as 04-06, seal included.|See \\ [[techtalk:evo:engmech07|Breather page]]|
+|:::|:::|(R) 26020-07|:::|:::|
+|:::|Breather valve seal|17393-07|Required to seal the breather valve into their holes \\ in the lower rocker box section.|{{:techtalk:evo:engmech:2007-present_sportster_breather_seal_gasket_17393-07_by_fox_cycle_works.jpg?linkonly|-07}} ((photo courtesy of Fox Cycle Works, [[https://www.ebay.com/str/foxcycleworks?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))|
+====== Pushrods ======
 Pushrod lean angle on 91-up engines.
 The lifters are square to the lifter bore but they're not quite square to the rocker arm slot for the pushrod. \\

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