Had a simple leak on the front jug, so it was time to tear into the rocker box and replace the gaskets. This is a really simple job and if you have tools and a torque wrench, you can do it in a couple of hours.
The real thing you want to have (Hell, MUST have!) is a motor manual--it has the procedures AND the torque values for anything you'll be doing on the motor.
ON the Prosport models, you'll want to pull the fuel tank. The K-9s and Choppers could do the front without pulling the tank. These same steps work for the rear jug of course and you will definitely need to pull the tank then.
Start by loosening the top six bolts in an X-pattern. This is bolt #1 in the pattern.
Once all six bolts are loose, you can use an air-wrench to remove them.
The cover will come right off--you may need to rap it with a rubber mallet, but it lifts right off. You'll see the first gasket and the rockers.
Before ANYTHING else, you need to put the cylinder (in this case the front) at top dead-center. Easiest thing is to pull the pushrod cover keepers and rotate the motor to have the pushrods at their lowest position. Search the pushrod adjustment How-Tos for how to do this.
Once the pushrods are in the right place, then the valves are unloaded and you can safely remove the rocker assembly. Five fasteners of three different types so you have three different fittings to work and they have to be loosened in the right sequence, so you'll be swapping alot.
Once the rocker assembly is out, then you have access to the last four bolts to remove the lower rocker box.
With the lower rocker box removed, we can see the original OEM gaskets are a two piece affair. New gaskets are one piece and make installation much better.
Here is the other gasket stuck to the bottom of the lower rocker box. Notice the curve in the gasket on the top right side. That ain't right and that's where my leak was coming from. Also note the crud build-up against the gasket on the lower right...that ain't normal either, but you can't see that section when it's on the motor.
Next you'll want to clean all of the parts and replace the gaskets 1) one for the head/lower, 2) two o-rings, and 3) one for the lower/top rocker cover.
Last, put it all back together. USE A TORQUE WRENCH! You'll want an in-lbs and ft-lbs version.
Good luck!
The real thing you want to have (Hell, MUST have!) is a motor manual--it has the procedures AND the torque values for anything you'll be doing on the motor.
ON the Prosport models, you'll want to pull the fuel tank. The K-9s and Choppers could do the front without pulling the tank. These same steps work for the rear jug of course and you will definitely need to pull the tank then.
Start by loosening the top six bolts in an X-pattern. This is bolt #1 in the pattern.
Once all six bolts are loose, you can use an air-wrench to remove them.
The cover will come right off--you may need to rap it with a rubber mallet, but it lifts right off. You'll see the first gasket and the rockers.
Before ANYTHING else, you need to put the cylinder (in this case the front) at top dead-center. Easiest thing is to pull the pushrod cover keepers and rotate the motor to have the pushrods at their lowest position. Search the pushrod adjustment How-Tos for how to do this.
Once the pushrods are in the right place, then the valves are unloaded and you can safely remove the rocker assembly. Five fasteners of three different types so you have three different fittings to work and they have to be loosened in the right sequence, so you'll be swapping alot.
Once the rocker assembly is out, then you have access to the last four bolts to remove the lower rocker box.
With the lower rocker box removed, we can see the original OEM gaskets are a two piece affair. New gaskets are one piece and make installation much better.
Here is the other gasket stuck to the bottom of the lower rocker box. Notice the curve in the gasket on the top right side. That ain't right and that's where my leak was coming from. Also note the crud build-up against the gasket on the lower right...that ain't normal either, but you can't see that section when it's on the motor.
Next you'll want to clean all of the parts and replace the gaskets 1) one for the head/lower, 2) two o-rings, and 3) one for the lower/top rocker cover.
Last, put it all back together. USE A TORQUE WRENCH! You'll want an in-lbs and ft-lbs version.
Good luck!
