Question about Harley Davidson XLH Sportster 883 Motorcycles
To replace the rocker box gaskets, you'll have to remove the bolts on top of the rocker boxes to get them off. You may have to remove the fuel tank(s) and seat. You didn't tell me what year and model bike you're working on. Once you have these bolts off, you can replace the gaskets between the center and the upper parts, the inner gasket and the umbrella if your bike is equipped with them.
To replace the gaskets under the lower plate, work with one plate at the time. Remove the spark plugs and jack the rear wheel off the ground. Put the transmission in high gear and bump the engine over until the piston is at top dead center in the cylinder your working on with both vavles closed. Start by removing the three 1/4" hex head bolts and the two 1/4' socket head bolts. Then, remove the 5/16" bolts on the pushrod side of the engine. Tap the rocker shafts out and remove the rocker arms. Remove the other two 5/16" bolts. Lift the lower plate and replace the gaskets. Do not mix up the pushrods. They are usually color coded as to which position they go in.
To reinstall the lower plate, place the rocker box on top of the cylinder and start all bolts except the two 5/16" bolts on the push rod side of the engine. Put the rocker arms in place and push the shafts through them. Start the remaining two bolts. At this point, your lower rocker box plate is "floating" above the cylinder head. Tighten the four large bolts down until they are all flush with the top of the plate. Then, tighten them down 1/4 turn at the time until they are snug. Then, tighten the six smaller bolts down until they are barely snug. Torque the larger bolt to 15-18 foot pounds and the smaller bolts to 10-13 foot pounds. Wait for the tappest to bleed down to where you can turn them by hand to do the other cylinder. Do it the exact same way as you did the first one.
To install the middle and upper plates, put the center gasket and all other gaskets in place and align the plate. Install the socket head bolts in the top and torque to 100 Inch pounds.
Put the transmission in neutral and lower the bike. Reinstall the spark plugs, the tank(s) and the seat.
Posted on Sep 05, 2010
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Posted on Jan 02, 2017
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