How To Replacing your Rocker Boxes and/or gaskets

[Gas Man]

This is a HOW TO that I'm posting for another member. That member is concerned with warrenty issues and doesn't want it to be known. So the props go to that member, not I.

I had to replace the gasket between the Head and the Rocker Box because I had a small oil leak at the back left corner of the rear Head. From the looks of it the OEM gasket failed because of a problem during assembly. Now this isn't a hard job but, you must pay attention to where bolts come from so they can go back in the same spot. Now, with that said, on to the job at hand.

1: Remove Rocker Box Cover by loosening the 6(six) allen head bolts and carefully lifting the cover off. Place on bench out of way.

2: Remove tension from the pushrod by following ChaCha's pushrod adjustment "how-to" steps 1-7. http://www.bigdogbiker.com/forums/how/463-pushrod-adjustment-how-pics.html

3: This is what you will see once you take the Rocker Box Cover off. Loosen the 6(six)bolts that hold the Rocker Arm Assembly to the Head.

4: Loosen the 6(six) bolts that hold the Rocker Box to the Head. Carefully lift Rocker Box and Rocker Arm Assembly off of Head in one piece.

5: This is what you will see with the Rocker Box removed. As you can see, I have the "Red Stripe" valve springs which are good enough for the S&S 600 Camshaft or comparable.

6: This is what you will see with the Rocker Box and Rocker Arms apart.
Rocker Box

Rocker Arm and new Gasket

7: Clean both mating surfaces and all bolt holes.

8: Place new Gasket on head. I don't think it matters which side is up in this case but, The printed side was facing up at this point originally so I put it on that way.

9: Place Rocker Box on top of Gasket and start the 6(six) bolts for the Rocker box. Remember to use BLUE THREAD LOCKER! Make sure the rubber o-ring is in the center of the Rocker Box. Mine was stuck to the bottom of the Rocker Arm Assembly.

10: Place Rocker Arm Assembly in Rocker Box with the 6(six) bolts in place. Remember to use BLUE THREAD LOCKER! Start the 6(six) bolts holding the Rocker Arm Assembly to the Head.

11: Torque the 4(four) main bolts on the Rocker Arm Assembly to 18 ft-lbs. Doesn't say what order but I criss-crossed. Make sure the Push rods are in the cups in the rocker arms.

12: Torque the 6(six) allen head bolts to 23 ft-lbs in order shown in picture.

13: Torque the 2(two) remaining bolts in the center of the Rocker Arm Assembly right next to the Compression Release to 11 ft-lbs.

14: Adjust push rods following the rest of ChaCha's "how-to".
http://www.bigdogbiker.com/forums/how/463-pushrod-adjustment-how-pics.html

15: Replace Rocker Box Cover and go for a ride.

 

[lee]

great how to - presumably if I change my TP boxes for S&S its the exact same procedure, without having to remove the rocker assembly?

 

[kickstart]

Nice Job Mystery Man!

 

[narow37]

If you were to change out your TP's, it would be everything from the head up I believe.

 

[woodbutcher]

way to go, "mysteryman". :2thumbs: :2thumbs: :choppersmiley:

 

[choppersforlife]

Thanks Gas

You never cease to amaze me. Thank you for all of the info.

Ride safe:2thumbs:

 

[ChuckRB05]

re

Another good one...thnx

 

[BIG HOUSE]

FRAME IS IN THE WAY :bang: :bang:

 

[T Mack]

Gas what motor was this?
I just seen a little oil on my rear cyc. on left rear side to...?
mine is a 06 just curious what year his was? is this a common prob?
I seen it, just going to keep an eye on it to see if it gets worse. Or even if there is a leak or not. just seen a "spot" there....

 

[woodbutcher]

bighouse, sorry but probably wouldn't work on a pro-street. T-mack, this was on a K9 with a 117. the gasket apparently had a small tear from the dog pound.

 

[BIG HOUSE]

Got the same small leak was gonna fix it saw the delema and decided its goin to full throttle after myrtle:angry:

 

[narow37]

Big House, the service manual doesn't say anything about not being able to do the job. It does say that you would have to remove the gas tank on Pitbulls and Mastiffs. Nothing said about Bulldogs.

 

[BIG HOUSE]

Thanks Narrow maybe I will takle it if I dont have to pull the motor that would be bs

 

[justinridgeback]

So I have a small leak from exact same back left corner of the rear cylinder...am assuming it is the same gasket as this post referes to. My question is will I will be able to do this on an 05 ridgeback with the engine still in the frame? The chrome rocker box cover appears to be very close to the frame above it. Once the allens are out of, can it be slid out of the way, or actually has to come "up" and off?

 

[Gas Man]

I would say yes. You can see in the pics the original person still had everything in the bike...

 

[Beastman1652]

Question about this job

The S&S part # I found is DS-174501. The picture showes a bunch of gaskets. Does the contents of this kit have everthing you need to do both cylinders, or is this just for one cylinder? Also the kit says it is For 84-99 S&S Evolution style billet rocker boxes. Will this fit a '03 107 cubic inch?

 

[MARV]

The S&S part # I found is DS-174501. The picture showes a bunch of gaskets. Does the contents of this kit have everthing you need to do both cylinders, or is this just for one cylinder? Also the kit says it is For 84-99 S&S Evolution style billet rocker boxes. Will this fit a '03 107 cubic inch?

the kit will be for both boxes. your 107 is a true evo style so the blue kevlar lower box gasket will be a 2 piece for each box. unlike the TC style which is a 1 piece. i'd buy through a dealer if your not sure what you have.

 

[Beastman1652]

I appreciate the info. and That part number came from a dealer down here in Texas. I just did a google search for it so I could see a picture of what all came in the kit. Thanks again!

 

[BadBrad]

Just one note on this how-to. After removing the rocker boxes on my '05 Pitbull, I had to modify 2 tools in order to remove it. The frame of the bike lies directly over 2 bolts that have to be removed. First, the rocker box lid has an allen bolt under the frame. I had to cut the short end of the allen wrench by about 1/2" for it to fit under the frame into to allen bolt head. Second, once the rocker box lid is removed, there is a 1/2" hex head bolt that is directly under the frame. I had to cut 1/2" socket in half and used the small 1/4" drive wratchet wrench in order to get onto the bolt. They may have both of these tools for sale somewhere, but it was an easy modification.