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  #1  
Old 4 Weeks Ago
94XLH 94XLH is offline
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Default Re-installing rocker boxes

Hi folks,

I got my rocker boxes powder coated (94 XLH 1200) and now I'm going to re-install them and the pushrod covers. Got all new gaskets. Read a bunch of stuff here and on the Sporsterpedia site. Also read the FSM which didn't really have much besides the order to tighten the bolts. Doesn't look too complicated but I wanted to check with the experts here if there are any tips, tricks, or gotchas I need to be aware of while putting this all back together. Trying to avoid any leaks down the road, or worse like a bent pushrod. Thanks.
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OCRyder OCRyder is offline
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These videos were very helpful to me on the subject. There is a video for both installing the rocker boxes and another for installing the pushrod tubes.

http://www.hammerperf.com/ttvideos.shtml

And these instructions are also very detailed.

http://www.hammerperf.com/ttinstallkit.shtml

Hammer performance pushrod tube base kit is an awesome upgrade as well. If you don't have it I would recommend installing one while you have it all the apart already.

http://www.hammerperf.com/xlvalvetrain.shtml
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Anyone else have an opinion on the Hammer pushrod tube base kit? It looks like a beotch to install, but is it worth it? I'm about to get set to put in some rocker lockers, so this would be a good time to hit it.
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Default

Stock is fine and the Hammer parts are fine too.
If you follow Hammer's video on installing the tubes, shouldn't have any problems.
The only worth it factor unless the stock ones are bent/broke is the construction and graphic.
I have the Hammer ones and installation isn't really that hard.
My 2 cents.
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I have no issue with my stock ones as they sit, no leaks or anything. Would prefer to just leave them be, frankly. But Hammer calls them inferior pot metal, and a previous post suggests doing it as an upgrade.

So input is good. At $50+ to change out a clamp and seals that aren't a problem, well....
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I wouldn't go out of my way to change them. If you have the bike apart already and are goung to have to do the install anyway it's totally worth it, but otherwise no way. When you look at the stock bases after removing them they really do seem pretty flimsy.
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Thanks for posting these vids. Very helpful!


Quote:
Originally Posted by OCRyder View Post
These videos were very helpful to me on the subject. There is a video for both installing the rocker boxes and another for installing the pushrod tubes.

http://www.hammerperf.com/ttvideos.shtml

And these instructions are also very detailed.

http://www.hammerperf.com/ttinstallkit.shtml

Hammer performance pushrod tube base kit is an awesome upgrade as well. If you don't have it I would recommend installing one while you have it all the apart already.

http://www.hammerperf.com/xlvalvetrain.shtml
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I did not have any issues with my stock push rod tube bases. I used some motor oil on the tubes so the seals and bases slid down easy. Make sure you get them on the alignment pins, use your hands to push them down, then go to the allen wrench. Mine are tight and dry.

John
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I had a leakage problem at the forward tube after installing the 1250 kit.
Drove me nuts until I found the base was bent a little.
Looked like I tightened it down without the guide pin in the hole.
I put it in the vise with a couple thin pieces of wood and "re-curved" it.
Been great since.

That being said, swapping in the Hammer bases involves pulling the gas tank, cylinder covers, rocker boxes, push rods and tubes.
If it's leaking, you're pulling that anyway.
If it's not it's a lot of work for a shiny part.
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I was one that had leak issues on my 2000. This was many years ago and the collected knowledge was still accumulating. I went to the one piece bases and life was much easier. If yours is together and don’t leak then don’t kick a sleeping dog. If not together then consider it for piece of mind.
On the rocker box covers the key for me was keeping perfect vertical alignment and tighten slightly doing a criss cross pattern a little bit at a time. Keep it safe!
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