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techtalk:evo:engmech04 [2021/07/16 04:31] hippysmack [Sub Documents] |
techtalk:evo:engmech04 [2022/10/09 14:56] hippysmack [Rocker Box Gaskets] |
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====== EVO: Engine Mechanicals ====== | ====== EVO: Engine Mechanicals ====== | ||
====== Rocker Box ====== | ====== Rocker Box ====== | ||
- | ===== Sub Documents ===== | + | ===== Sub Documents ===== |
* [[techtalk:evo:engmech04a|Removing the Rocker Boxes]] | * [[techtalk:evo:engmech04a|Removing the Rocker Boxes]] | ||
* [[techtalk:evo:engmech04b|Rocker Box Inspection and Servicing]] | * [[techtalk:evo:engmech04b|Rocker Box Inspection and Servicing]] | ||
* [[techtalk:evo:engmech04c|Installing the Rocker Boxes]] | * [[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:engmech04j|Rocker Arm Inspection and Servicing]] | ||
* [[techtalk:evo:engmech04l|Stabilizing Noisy Rocker Arm Shafts]] | * [[techtalk:evo:engmech04l|Stabilizing Noisy Rocker Arm Shafts]] | ||
* [[techtalk:evo:engmech04q|Removing / Installing Pushrods and Tubes]] | * [[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&840|}}||||||| | ^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&840|}}||||||| | ||
- | | 1986-Up Sportster 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#| | |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 \\ 17532-86A|17554-86 \\ 17555-86A|17533-86 \\ 17533-86B|17555-86 \\ 17580-95|17501-86 \\ 17501-86A|17556-86 \\ 17556-86A| | + | |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| |
- | | Notes:| |||||| | + | | 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.|||||| |
|1989 All|17532-86A|17554-86A|17533-86A|17555-86A|17501-86A|17556-86A| | |1989 All|17532-86A|17554-86A|17533-86A|17555-86A|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.|||||| | | Notes:|On L89 lower boxes, {{ pdf-bulletin:tsb0984.pdf |Click Here to view TSB M-984}} regarding sealing area around middle spacer.|||||| | ||
|1990 All|17532-86A|17554-86A|17533-86B|17580-95|17501-86A|17556-86A| | |1990 All|17532-86A|17554-86A|17533-86B|17580-95|17501-86A|17556-86A| | ||
| Notes:|Polished set. |||||| | | Notes:|Polished set. |||||| | ||
- | |1991 All|17532-86A \\ 17532-86E|17554-86A|17533-89 \\ 17533-90A| |17501-86A \\ 17501-86B|17556-86A| | + | |1991 All|17532-86A \\ *17532-86E|17554-86A|17533-89 \\ *17533-90A| |17501-86A \\ *17501-86B|17556-86A| |
| Notes:| |||||| | | Notes:| |||||| | ||
- | |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| | + | |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| |
| Notes:|Polished set.|||||| | | Notes:|Polished set.|||||| | ||
- | |1995-2003 All except \\ 883R, 1200C, 1200S)|17532-86B \\ 17532-86E|17579-95|17533-90A|17580-95|17501-86B|17581-95| | + | |1995-2003 All except \\ 883R, 1200C, 1200S)|17532-86B \\ *17532-86E|17579-95|17533-90A|17580-95|17501-86B|17581-95| |
| Notes:|Polished set.|||||| | | Notes:|Polished set.|||||| | ||
- | |1996-2003 1200C|17537-96 \\ 17537-96C|17579-95 \\ 17579-95C|17538-96|17580-95|17551-96|17581-95| | + | |1996-2003 1200C|17537-96 \\ *17537-96C|17579-95 \\ *17579-95C|17538-96|17580-95|17551-96|17581-95| |
| Notes:|Chrome set.|||||| | | Notes:|Chrome set.|||||| | ||
- | |1998-2003 1200S|17614-98 \\ 17614-98C|17579-95 \\ 17579-95C|17533-90A|17580-95|17527-98|17581-95| | + | |1998-2003 1200S|17614-98 \\ *17614-98C|17579-95 \\ *17579-95C|17533-90A|17580-95|17527-98|17581-95| |
| Notes:|Silver powder coated set.|||||| | | Notes:|Silver powder coated set.|||||| | ||
- | |2002-2003 883R|17532-86B \\ 17532-86E|17579-95|17535-02| |17501-86B| | | + | |2002-2003 883R|17532-86B \\ *17532-86E|17579-95|17535-02| |17501-86B| | |
| Notes:|Polished set. |||||| | | Notes:|Polished set. |||||| | ||
- | |2004-2006 883, \\ 883C, 883L|17532-86C \\ 17532-86E|17579-95B| N/A ||17501-04|17581-04| | + | |2004-2006 883, \\ 883C, 883L|17532-86C \\ *17532-86E|17579-95B| N/A ||17501-04|17581-04| |
| Notes:|Polished set.|||||| | | Notes:|Polished set.|||||| | ||
- | |2004-2006 1200C|17537-96A \\ 17537-96C|17579-95B \\ 17579-95C| N/A ||17551-04|17581-04| | + | |2004-2006 1200C|17537-96A \\ *17537-96C|17579-95B \\ *17579-95C| N/A ||17551-04|17581-04| |
- | | Notes:|Chrome.|||||| | + | | 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.|||||| |
- | |2004-2005 \\ 883R, 1200R|17614-98A \\ 17614-98B \\ 17614-98C|17579-95A \\ 17579-95B \\ 17579-95C| N/A ||17527-04| | | + | |2004-2005 \\ 883R, 1200R|17614-98A \\ *17614-98B \\ *17614-98C|17579-95A \\ *17579-95B \\ *17579-95C| N/A ||17527-04| | |
| Notes:|Silver powder coated set.|||||| | | Notes:|Silver powder coated set.|||||| | ||
- | |2006 883R|17614-98A \\ 17614-98B \\ 17614-98C|17579-95A \\ 17579-95B \\ 17579-95C| N/A ||17655-05| | | + | |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.|||||| | | Notes:|Silver powder coated bottom, black powder coated top.|||||| | ||
- | |2006 1200R|17645-06 \\ 17645-06A| | N/A ||17655-05| | | + | |2006 1200R|17645-06 \\ *17645-06A| | N/A ||17655-05| | |
| Notes:|Black powder coated set.|||||| | | Notes:|Black powder coated set.|||||| | ||
|2007-2009 883, 883C, \\ 883L, 1200N|17532-07|17579-07| N/A ||17501-04|17581-04| | |2007-2009 883, 883C, \\ 883L, 1200N|17532-07|17579-07| N/A ||17501-04|17581-04| | ||
Line 49: | Line 51: | ||
|2007-2009 883R, 883N|17614-07|17579-07| N/A ||17655-05| | | |2007-2009 883R, 883N|17614-07|17579-07| N/A ||17655-05| | | ||
| Notes:|Silver powder coated bottom, black powder coated top.|||||| | | Notes:|Silver powder coated bottom, black powder coated top.|||||| | ||
- | |2007-2009 1200R|17645-07 \\ 17645-07A| | N/A ||17655-05| | | + | |2007-2009 1200R|17645-07 \\ *17645-07A| | N/A ||17655-05| | |
| Notes:|Black powder coated set. -07A is wrinkle black powder coat.|||||| | | Notes:|Black powder coated set. -07A is wrinkle black powder coat.|||||| | ||
|2009 XR1200|17590-08| | N/A ||17585-08| | | |2009 XR1200|17590-08| | N/A ||17585-08| | | ||
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===== Rocker Box Gaskets ===== | ===== Rocker Box Gaskets ===== | ||
- | \\ | + | [[techtalk:evo:engmech07|Click Here]] to reference breather valves/installation/sealing in the Sportsterpedia. \\ |
- | ==== Top cover gaskets ==== | + | |
- | ^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&840|}}||| | + | Below is a list of factory gaskets used on Sportster rocker boxes. \\ |
- | |91-03|17353-89C|Rocker cover gasket (includes cutouts for the breather to fit into). Gasket 17353-89B also usable. \\ No breather seal required. | | + | Original part numbers are listed first with known superseded part numbers below the original ones. \\ |
- | |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]].| | + | 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. \\ |
- | |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)| | + | 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. \\ | ||
+ | |||
+ | ^{{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 black rubber. \\ -07B, \\ -07C, thin crush dimpled black rubber.|{{ :techtalk:evo:engmech:2007-up_sportster_rocker_box_cover_gasket_17362-07_by_bikersnos.jpg?linkonly |-07}} ((photo courtesy of BIKERSNOS.com. [[https://www.ebay.com/str/bikersnos?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))| | ||
+ | |:::|Inner (bottom section)|17695-07 \\ 17695-07A \\ 17695-07B \\ 17695-07C|-07 orange gasket top of bottom section. \\ 07A is orange with crush dimples, \\ 07B is black, \\ 07C is black 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_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 ===== | + | ====== Pushrods ====== |
Pushrod lean angle on 91-up engines. | 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. \\ | The lifters are square to the lifter bore but they're not quite square to the rocker arm slot for the pushrod. \\ |