How difficult is it to change rocker boxes : V-Twin Forum: Harley Davidson Forums

starfire · 09-25-2009, 12:11 PM

I have a 01 Eglide and the chrome on my front rocker box is peeling. I got a good deal on some take off boxes and am wondering how hard it is to change these out? I am not a skilled mechanic. Thanks for any input.

blackfxd · 09-25-2009, 05:48 PM

Quote:

Originally Posted by starfire

I have a 01 Eglide and the chrome on my front rocker box is peeling. I got a good deal on some take off boxes and am wondering how hard it is to change these out? I am not a skilled mechanic. Thanks for any input.

It's pretty simple. You'll need to take off the gas tank. The rear cylinder is a pain in the butt because there's not a lot of room to work. But be patient and you can do it. I'd recommend a fresh set of gaskets.

Get a service manual before you start. Also, make sure you put the pushrods back the same way they came out (same hole). And use a torque wrench when you button everything back up.

I'm probably missing some pointers. Anyone else?

Smokedyvr · 09-26-2009, 12:04 PM

Just to add, Don't use any silicone. Many oil return lines have been plugged from it's use. As blackfxd stated the back rocker box may require you to cut down an allen head wrench to be able to tighten the rocker box bolts due to the lack of room. I would also bring each cyclinder to top dead before removing or replacing the head bolts. The boxes can be warped easily. All in all it's an easy job.

YankeeBob · 09-26-2009, 01:01 PM

You will need two "dogbone" torque adapters. 1/2" and 7/16". You could use a 3/8" also, but I used a 3/8" box/open end wrench.
These can be found at McMaster-Carr tools.

starfire · 09-29-2009, 04:23 PM

Thanks guys for your input. I didn't mention that I am lucky because I only need to replace the front box. This bike lived a short while in Corpus Christi and the sand that would get kicked up deteriorated the chrome on the front of the rocker box. I got a great deal on set of take off boxes on fleabay and just need to get the front one done. Thanks again and any other input is appreciated.

1949shoebox · 09-30-2009, 04:40 PM

its easy.... 1. plug fuel lines & remove tank/electrical 2. break bolts loose cross patern, loosen each bolt 1/4 turn til out and remove top cover 3. unload pushrods, to do this remove spark plug from cylinder put bike in 5th gear, have someone spin tire while you hold a pencil in spark plug hole- your goal is to get the piston all the way up the pencil is a guide. 4. break bolts loose cross patern to rocker arms 1/4 turn til out and remove 4. break head bolts cross patern 1/4 turn til out remove push rods rocker arm supprt and head if needed. 5. reverse the process to rebuild for torque see manual or its about a half turn past snug for the bolts. tip: if you remove the head USE new head bolts. always new gaskets and such -rememember which rod came from which hole, one is slightly longer than the other

kemo · 09-30-2009, 05:21 PM

Shoebox why are you loosening the head bolts? You are going to scare the guy.

1949shoebox · 09-30-2009, 05:36 PM

dont know how far he wants to go - for reference only bro. - just saying if he goes that far, he should replace the bolts. once theyve been torqued, they lose strentgh.

'05Train · 10-01-2009, 09:56 AM

There's actually a special tool for the rocker box bolts. Makes it an easy job.

starfire · 10-01-2009, 12:10 PM

Thanks Shoebox and Kemo. That did kinda scare me for a minute but I don't think I need to loosen/remove the headbolts just to change the box. I would assume there is a set torque for the rocker bolts too, or is that more by feel?
05Train, where do you get the special tool?
Also, since I am just replacing the front rocker box do I need to remove tank completely for can I just loosen and raise it up? Thanks

1949shoebox · 10-01-2009, 05:30 PM

remove the tank makes it easier and yeah, its about 17 and 30 ft.lbs. soak bolt in gas until your ready to reassemble then put a tiny bit of clean oil on the threads when you put it back together - a good habit so bolts don't seize later on. good luck brotha.

starfire · 10-02-2009, 12:13 PM

Thanks Shoebox. Damn sure wouldn't have known to do these things.

Mtclassic · 10-02-2009, 11:00 PM

I gotta jump in and say never stick a pencil in the plug hole. A straw maybe. Also all you need to do is watch that both pushrods are at their lowest point.

starfire · 10-05-2009, 10:56 AM

Got it Mtclassic, thanks

BigSwede · 10-05-2009, 12:42 PM

Quote:

Originally Posted by starfire

Thanks Shoebox and Kemo. That did kinda scare me for a minute but I don't think I need to loosen/remove the headbolts just to change the box. I would assume there is a set torque for the rocker bolts too, or is that more by feel?
05Train, where do you get the special tool?
Also, since I am just replacing the front rocker box do I need to remove tank completely for can I just loosen and raise it up? Thanks

You can get the rocker box wrenches from HD or a discount HD dealer online. They worked wonders. You can raise the front of the tank and get the front box replaced pretty easy, that's what we did with '05Train's rocker boxes. New gaskets are a no-brainer. Don't touch the head bolts......