I can't tell the difference between the exhaust and intake pushrods... one is lighter than the other. Is the light one the exhaust pushrod?

The intake valve pushrods measure 144 mm (5.75 in) long.
Exhaust valve pushrods measure 152.5 mm (6.0 in) long

All Harley's have different length pushrods in it's engines, because the distance from the lifters to the rocker arms are different.

The two shortest ones go to both intake valves.
The next longest goes to the rear cylinder exhaust.
The longest one goes to the front cylinder exhaust.

The intake pushrods and exhaust pushrods are different lengths. To distinguish the different pushrods, paint has been used, although this paint may be hard to identify after prolonged use. The intake pushrods are color-coded orange and are 6 in. (152mm) long. The exhaust pushrods are color-coded blue and are 63/8in. (162mm) long.

Here is a picture of the cylinder marking:

The latest book I have is a 2002 model book and it says that the pushrods marked with three pink bands and are 10.800" (274.32mm) are exhaust pushrods. The intake pushrods are marked with a single brown band and are 10.746" (272.94mm) long. Lay all the pushrods side by side and check the lengths. The long pushrods are the exhaust pushrods.

Good Luck
Steve

On a 3.1L and 3.4L engine the Intake pushrods are 5 3 / 4 inches long and exhaust pushrods are 6 inches long.

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.

Now, if you are working on something other than an Evolution engine or you have aftermarket pushrods, please repost and I'll tell you what I know about the valve adjustment for your engine.

Steve

Uhh, if the pushrods in your 1994 model bike were stock, they are not adjustable. They should be color coded at to where they go. If this is what you have, they go in the following positions:
Purple - Rear Exhaust
Blue - Rear Intake
Yellow - Front Intake
Green - Front exhaust

Now, if they have been changed to adjustable push rods by you or some previous owner, the first thing you have to do is figure out how many turns of the adjuster it takes to make the pushrod 0.100" longer. Turn the adjuster all the way inward making the pushrod as short as possible. Now, using a caliper, turn the adjuster outwards until you get a measurement of threaded rod that is exactly one hundred thousandts long. Then turn the adjust all the way back inward while counting the number of "flats" on the hex adjuster that you turn until it bottoms out. You must do it this way because different manufacturers of the pushrods use different thread pitches on their adjusters.

Once you know how many "flats" it takes to make the pushrods 0.100" longer install the pushrod into a position with the tappet all the way down. Adjust the pushrod out using your fingers until you get all the slack out of the pushrod. Then turn the pushrod adjuster outwards the number of turns that it takes to make the pushrod exactly 0.100" longer.

Once this is done, you will not be able to turn the pushrod. You must wait for the hydraulic tappet to bleed down before you can turn the engine. If you do turn the engine before the tappet bleeds down, you may bend the valve. Do not turn the engine until you can turn the pushrod with your fingers. Proceed until you get all pushrods installed and adjusted in this manner.

Ride Safe,
Steve

If the engine oil was full of antifreeze when the intake gasket went bad, then there is a good chance that there may be some cam and/or lifter damage. A more likely cause of your problem would be that the push rods got mixed up when you put it back together. The intake and exhaust rods are different lengths. If this is the case, and you have turned the engine over, there is a good chance that you now also have a bent pushrod and intake valve. The exhaust pushrod is the longer one and if you mix them up, the piston will contact the intake valve because it will not be able to close due to the longer pushrod. This will bend or break the pushrod and bend the valve stem.

the euro sport is the same as the lumina base just with a body kit, stiffer suspension, and dual exhaust.

but on the 3.1 engine the pushrods are all the same length, but depending on the stroke each cylinder is on the pushrod may be in a different position.

you are assuming that every pushrod should be in the rest state. that is not true. if the cylinder you are installing the pushrod for is on the intake stroke when you install the intake valve pushrod and tighten the rocker arm nut the valve will procede to open like it should be open for the intake stroke.

this is normal and its nothing wrong with it.