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techtalk:evo:engmech04c [2019/01/06 21:11] hippysmack [Installing the Rocker Boxes] |
techtalk:evo:engmech04c [2021/11/12 22:42] hippysmack [Bolt Installation Sequence] |
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[[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | ||
- | ====== EVO: Engine Mechanicals - Sub-04A ====== | + | ====== EVO: Engine Mechanicals - Sub-04C ====== |
====== Installing the Rocker Boxes ====== | ====== Installing the Rocker Boxes ====== | ||
See also in the Sportsterpedia; | See also in the Sportsterpedia; | ||
* [[techtalk:evo:engmech04a#removing_the_rocker_boxes|Removing the Rocker Boxes]] \\ | * [[techtalk:evo:engmech04a#removing_the_rocker_boxes|Removing the Rocker Boxes]] \\ | ||
- | * [[techtalk:evo:engmech04b#rocker_box_rocker_arm_inspection_and_repair|Rocker Box / Rocker Arm Inspection and Repair]] \\ | + | * [[techtalk:evo:engmech04b#rocker_box_rocker_arm_inspection_and_servicing|Rocker Box / Rocker Arm Inspection and Servicing]] |
+ | \\ | ||
+ | One issue in installing the rocker box is that it has no alignment method. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1933342&page=13)) \\ | ||
+ | Basically, every time you put it on, it's in a different place. \\ | ||
+ | When installing the rocker boxes, be sure to put them on with the engine positioned such that the cams aren't trying to open the valves. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=322680&page=3)) \\ | ||
+ | Else you can damage parts. \\ | ||
+ | |||
+ | ===== Compatibility ===== | ||
+ | Middle rocker box: \\ | ||
+ | The 86-90 doesn't incorporate the area were the umbrella flapper valve would go. ((dave76 of the XLFORUM http://xlforum.net/forums/showthread.php?t=732143)) \\ | ||
+ | So due to functionality, the 86-90 mid section won't fit 91-03 boxes. \\ | ||
+ | But the 91-03 middle cover will fit 86-90 boxes. \\ | ||
+ | |||
+ | ===== Gaskets ===== | ||
+ | |||
+ | Clean the mating surfaces of all oil / trash before setting the gaskets in place. \\ | ||
+ | With the bolts 'lightly' hand seated, check all around the box for a gasket squirting out the side before tightening the bolts. \\ | ||
+ | It's easy to 'just nudge' the top section and squeeze a portion of the rubber gasket out while positioning it. \\ | ||
+ | See [[http://sportsterpedia.com/lib/exe/fetch.php/pdf-bulletin:tt0253.pdf|TT#253]] regarding the top rocker box gasket. | ||
+ | |||
+ | {{:techtalk:evo:engmech:pinched_rocker_box_gasket_1_by_sep69.jpg?direct&300|}} ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?p=3754227)) {{:techtalk:evo:engmech:pinched_rocker_box_gasket_2_by_sep69.jpg?direct&300|}} ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?p=3754227)) \\ | ||
===== Bolt Installation Sequence ===== | ===== Bolt Installation Sequence ===== | ||
The FSM details the proper installation sequence of the bolts. \\ | The FSM details the proper installation sequence of the bolts. \\ | ||
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* Work in this order. Blue->red->yellow. \\ It is suggested to do this slowly (one turn at a time) and for the blue ones to do it in a cross pattern. \\ This is to bleed the lifters properly. | * Work in this order. Blue->red->yellow. \\ It is suggested to do this slowly (one turn at a time) and for the blue ones to do it in a cross pattern. \\ This is to bleed the lifters properly. | ||
* An easy way to remember the order is to work from the larger bolts to the smaller ones. | * An easy way to remember the order is to work from the larger bolts to the smaller ones. | ||
+ | * If you start with the red ones, you can easily strip the threads in the heads. | ||
**Torque values**: \\ | **Torque values**: \\ | ||
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|91-03 style lower rocker box ((photo by Hippysmack))|04 and up style lower rocker box ((photo by Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?s=c412e43a4339648eaaa7872371a84820&p=4008995))| | |91-03 style lower rocker box ((photo by Hippysmack))|04 and up style lower rocker box ((photo by Screw Loose Dan of the XLFORUM http://xlforum.net/forums/showthread.php?s=c412e43a4339648eaaa7872371a84820&p=4008995))| | ||
|{{:techtalk:evo:oil:91-03_lower_rocker_box_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_box_screw_locations_by_screw_loose_dan.jpg?direct&300|}}| | |{{:techtalk:evo:oil:91-03_lower_rocker_box_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:rocker_box_screw_locations_by_screw_loose_dan.jpg?direct&300|}}| | ||
+ | |||
+ | ===== Check Pushrod Length ===== | ||
+ | A hydraulic lifter has a plunger in it's body that has about .200" of movement. ((http://www.hammerperf.com/ttpushrodlength.shtml)) Oil sits under the plunger and pushes it up to take the slack out of the valve train. \\ | ||
+ | In the ideal world, the plunger is approximately centered in it's travel, meaning it's preloaded about .100". \\ | ||
+ | So in theory,\\ | ||
+ | It could move up, thus lengthening the effective length of the lifter to compensate for a pushrod that's up to .100" too short. \\ | ||
+ | And likewise, it could move down, thus shortening the effective length of the lifter to compensate for a pushrod that's up to .100" too long. \\ | ||
+ | This self adjusting action is also useful for compensating for changes in needed pushrod length due to engine temp variations. \\ | ||
+ | As the motor heats up, the top end grows and the lifter automatically takes up the slack. \\ | ||
+ | In reality, \\ | ||
+ | The useful operating range of the lifter plunger is only about .050" in either direction away from centered (.050" to .150" of preload). \\ | ||
+ | Outside of this range, the self adjusting function doesn't work nearly as well. | ||
+ | |||
+ | You can measure lifter pre-load to determine if the pushrods are in the size range needed. This method will get you close. ((http://www.hammerperf.com/ttpushrodlength.shtml)) \\ | ||
+ | The cam lobes should be down (as they should be when installing a rocker box). \\ | ||
+ | Set the pushrods in place (the longer one goes on the exhaust) and then place the gasket and rocker box on top installing the four big screws only. \\ | ||
+ | Finger tighten the left (spark plug) side, while making sure the right side is resting with the upper pushrod ends sitting in the cups on the rocker arms. \\ | ||
+ | Use a caliper to measure how much gap you have between the rocker box and the rocker box gasket. \\ | ||
+ | The lifter preload should be app. .100" but anywhere between .050" and .150" should work. \\ | ||
+ | Aftermarket pushrods can be purchased in longer or shorter lengths than stock ones to get the measurement within .100". | ||
+ | |||
+ | {{:techtalk:evo:engmech:lifter_preload_by_aswracing.jpg?direct&200|}} ((photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=322680&page=5)) \\ | ||
\\ | \\ |