I am getting ready to install a set of SE cams in my 04 1200. I have ordered a service manual, but have not recieved it yet.

But, I have a question:

Certainly the lifters will need to be removed in order to make a cam change ... Can the lifters be removed without removing the rocker boxes (upper and lower)?
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I ask this because I read a how-to that said ...

"First, remove your lifters. To do this you'll need a small paper clip straightened out with just a little bend at the very end. You can use a paper clip or some other means and stick it down into the tiny hole in the center of the top of the lifter. Don't scratch the surface trying to stick it into the hole. Hook it, then slowly lift the lifter out of its bore. Repeat this for the rear cylinder lifters".

"Next, remove the Allen screws holding the plate that holds the lower pushrod tube seals and the pushrod tubes onto the case. These are VERY tight.
Now remove the smaller Allen screws that are 90 degrees to the one you just removed (These aren't so tight). It secures a small triangular plate to the case. Behind the plate are two guide pins with tiny o-rings on their ends. Remove the plate, guide pins and o-rings."
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Ok ... Seems like they have it all backwards; Wouldn't you have to remove the pushrod tubes before removing the lifters?

Also, they don't mention a thing about removing the actual pushrods in this 'how-to'. I just can't see how lifters can be removed without first removing the rocker arms and pushrods first ... And certainly if the rocker arms need to be removed, you are going to have to remove the rocker boxes first.

Am I wrong?
What am I missing here?

Thanks,
Ron

If your Stock then ya gotta pull the rocker boxes.....
I think the "How to" was refering to adjustable pushrod setups,with 2pc tubes. And then some adjustable pushrods wont collapse enough to do it anyway....Mine wont....hope this helps.
Chris

That makes sense.

The Sporster cam change how-to that I posted above came from the Nightrider / V-Twin Cafe' web site.

http://www.nightrider.com/biketech/xl883_to_1200_page03.htm

It is confusing to say the least ... And they don't mention anything about adjustable pushrods ... Oh well

Yeah, you got to pull the push rod tubes before you can remove the lifters. My 883->1200 conversion doc details my cam swap.

Hey Turbo...This is the paragraph preceding the instructions on that link you posted.

"This procedure assumes you've already removed all three of your rocker boxes and push rods, push rod tubes, removed your brake pedal from the pushrod going into the master brake cylinder, and removed your front exhaust muffler."

I almost missed it too.....

wabiker ...

Jeeeze, I must be going blind!

Thanks,

Ya need to remove both rocker boxes

remove all 4 pushrods

On the pre'04's ya could the undo the allen bolts that held the bottom of the pushrod tubes in place and lift the plates and pull the tubes out from the bottom.

The service manual said remove the heads!!!!!!!

remove the 2 allen bolts on the sides and remove the covers and the pins

THEN remove the lifters takin care to keep them in the same order and orientation

Then ya into ya cams

Turbota,
I am doing the same and found a couple of sites where guys have documented the process with some pics. I thought it was interesting to read about their swaps...
I have read through the manual and the Andrews instructions. A few things stand out for me.
Keeping the hardware straight using the cardboard cutout.
Having the #1 on TDC so the marks line up better for ya'
Setting the cams in the case cover and rotating them to check for binding.
Lubing the bushing and lobes real good.

One of those guys left the pushrod tubes installed and pulled the lifters up with a magnet to fit each gear. The down side of that is not being able to check end play. He was using HD parts and the bushing are seated well, he had no problems. Your call...

You know the deal... Just make sure your checklist is complete before you pull into that hover...
Good luck...


http://home.sandiego.edu/~ekim/harley/tstorm/thud.html
http://www.mklsportster.com/xlcams.htm