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On a evo Harley Davidson how do I get my pushrods lowered so I can install my rocker boxes

Posted by Anonymous on

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  • Harley Davidson Master
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Hi Anonymous, you can purchase a set of adjustable push rods making lower rocker box installastion easier, other wise if you are using stock factory solid push rods all four of them are different lengths. The shortest goes in the RI ( rear intake ) the next shortest goes in the FI the next shortest goes in the RE and the longest goes in the FE. Rotate the engine until the lifters are at their lowest point of the cylinder you are working on and install push rods, tubes, o or quad seals, gaskets, and lower rocker box. In increments of 5 ft lbs. and in a criss cross pattern, torque 5/16" bolts to 20 ft lbs. and 1/4" bolts to 10 ft lbs. WARNING!!!!! Wait a couple minutes for lifters to bleed down untill you can spin push rods freely with your fingers before moving on to the remaing cylinder.Then rotate the engine untill the other cylinders lifters are at their lowest point and repeat the process. Good luck

Posted on Apr 20, 2015

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  • Harley Davidson Master
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The push rods are at a required length to activate the rocker gear
by shortening the push rods the valves will not open and the engine will not go

if the original rocker covers will not fit after work has been done then I would go back to square one and find out what has been assembled incorrectly

Posted on Apr 19, 2015

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Posted on Jan 02, 2017

wd4ity
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SOURCE: NEED TORUQU SETTINGS FOR ROCKERS HARLEY 96 EVO

The 5/16" bolts torque to 15-18 foot pounds.
The 1/4" bolts torque to 10-13" foot pounds.
The socket head bolts on the upper cover torque to 80-110 inch pounds.

Posted on Sep 24, 2009

wd4ity
  • 4565 Answers

SOURCE: i have a loud tapping in my front rocker box on my

I could be the bushings in the rocker arms and the rocker arm shafts. Bring the piston to top dead center on the cylinder that has the noise. Both valves should be closed. Allow about five minutes for the tappets to bleed down on that cylinder. When you can spin both of the pushrods with your fingers, remove the 5/16 inch bolts on the right hand side (pushrod side) of the head. This should allow you to push the rocker arm shaft out and remove the rocker arm. You may have to gently tap the rocker arm shafts out but it should not be difficult to get them out. Do not mix the rocker arms and their shafts up. Keep them together. Check the bushings in the rocker arms and the rocker arm shafts for wear. The bushings can be replaced and use new rocker arm shafts if this turns out out to be the problem. Check the face of the rocker arm where it pushes down on the valve stem for wear as well.

http://www.bikebandit.com/2002-harley-davidson-sportster-1200-custom-xl1200c/o/m18657#sch625617

Good Luck
Steve

Posted on Sep 06, 2011

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Hi, Robert that would probably be a failed lower rocker box gasket for this scenario you will need your service/owners manual if you can not find the best tool you ever bought for your Harley, despair not, for a mere zero $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
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Rocker arms have to be removed, BUT newer push rods are NOT adjustable, so you just can't loosen the push rods.

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Since the EVO engines (before yours) onward, the stock factory pushrods are non-adjustable, so the only way to bleed the lifters down (a little bit) is to rotate the engine until the lifter is at it's topmost position (one lifter at a time) and let it set for 30 minutes to an hour.

Bring the cylinder (one cylinder at a time can be worked) to TDC on the compression stroke.
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Once the rocker box is opened up loosen the rocker arm mount slowly, each bolt a little at time, until you can remove them.

If you are going to work on the other cylinder at the same time, remove pushrods, marking them for location, as they are different lengths.

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If your bike is equipped with the Evolution engine there is no adjustment on the rocker arms, the engine is equipped with hydraulic tappets. The pushrods on the Big Twin Evo engine are color coded and go in a particular position. They are different lengths. The blue color coded pushrod is the rear intake pushrod, the purple color coded pushrod is the exhaust pushrod. The pushrods for the Evo Sportster are all the same and there is no adjustment on those eiher provided they are stock.

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Simple fix. Take the fuel tank off and remove the four bolts that hold the rocker box covers on. If the rocker box is leaking there, simply put a new gasket in place, carefully align the top plate and put the bolts back in. Torque them to 100 inch pounds.

If the lower rocker is leaking remove the smaller 1/4" bolts and then remove the larger 5/16 inch bolts. Remove the larger bolts a turn at a time until they are completely loose. Lift the lower rocker plate and replace the gaskets. Reposition the lower plate and align the pushrods in the rocker arms. Do not mix up the push rods, mark them if necessary. Tighten the 5/16" bolts down evenly until just seated. Then put the 1/4" bolts in. Torque the 5/16" bolts to 15-18 ft. lbs and 1/4" 10-13 ft. pounds. Reinstall the middle and upper rocker boxes and torque those bolts.

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