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[Air-Cooled]

I have read about milling the '07 & '08 rocker covers for clearance. Although not part of the recall, dealers are doing this. I have an '07 and I've had the recall done. I never had the ticking sound, and I'm wondering why some bikes need the milling, and others like mine may or may not need it. Should all of these bike have it done?  I'm inclined to just leave well enough alone.

[mr_magoo]

Differences in mass production.

[Air-Cooled]

I considered that, but I don't buy it. I've seen the pics, and these things are precision milled. If it is that close, that some need it and some don't then I would think that all should have it done. Perhaps there is a Harley mechanic here that has worked on these things and can help clarify the situation.

[Hoist!]

I considered that, but I don't buy it. I've seen the pics, and these things are precision milled. If it is that close, that some need it and some don't then I would think that all should have it done. Perhaps there is a Harley mechanic here that has worked on these things and can help clarify the situation.

I agree that it's the design, not the manufacturing process. In the later 110's this was supposedly corrected. '07's & earlier '08's have the issue. Supposedly!

Hoist!

[AZSSE]

I've got an 07 and it clicks since I had the upgrade done. Maybe I'll ask my HD mechanic about it. Thanks.

[Hoist!]

I've got an 07 and it clicks since I had the upgrade done. Maybe I'll ask my HD mechanic about it. Thanks.

They wouldn't normally do it as part of the upgrade. Only if you complain about it. Then they hem and haw and say it's normal, until you complain so much they finally take care of it!

Hoist!

[sadunbar]

I considered that, but I don't buy it. I've seen the pics, and these things are precision milled. If it is that close, that some need it and some don't then I would think that all should have it done. Perhaps there is a Harley mechanic here that has worked on these things and can help clarify the situation.

For those of us that had the interference, the witness marks indicate just slight contact - enough to create the clatter noise - but slight none the less.  It is likely the tolerance stack of the various components.  Every machined part involved in whether or not there is contact - has a manufacturing tolerance.  The assemblies that result with contact likely have a combination of parts using the extremes of the manufacturing tolerances.  Of course, this would be an engineering error - because even using the extreme of the allowable engineered tolerances, there should be no contact.  It could be that they improperly allowed for heat, or improperly allowed for an assembly tolerance - or they just made a mistake when stacking tolerances.  End result is some assemblies have contact and others don't have contact.  All of the individual parts, if inspected, could measure within tolerance - but the stack of these combined parts are not within tolerance.

[the barber]

Is this just a mild ticking sound?

[grc]

One reason for the issue, other than manufacturing tolerances, is the amount of "slop" designed into the mounting holes.  That is why a part that didn't touch originally can now be touching after the dealer removed and reinstalled it.

IMHO, rather than mess around grinding the original I would just get the latest design which has much more clearance.

Jerry

[Air-Cooled]

I feel stupid now. I should have asked for it when they did my upgrade recall. I don't want to risk them taking it apart now since it's not  ticking.

[Talon]

.

[Air-Cooled]

Thanks for posting the pic. Is this a pic of what happens when the contact is made, or is it a pic after the milling?  If it is the former, then this is considerably more than "witness marks" showing "slight contact." If it is the latter, I don't want that guy milling my parts!

[sadunbar]

Thanks for posting the pic. Is this a pic of what happens when the contact is made, or is it a pic after the milling?  If it is the former, then this is considerably more than "witness marks" showing "slight contact." If it is the latter, I don't want that guy milling my parts!

I looks like some dremel work...  clearance is clearance...      

The 'witness' mark is small enough it is easy to overlook unless you are looking specifically for it.  If you search the site, you will find some pictures of witness marks that others have posted.   

[Air-Cooled]

OK, thanks. I searched but didn't find pics. I did find a post that said to check for it, fire up a cold engine and put your hand on the rocker cover to feel it. I did that—no tapping feeling. But when I put my ear within 3 inches of the head, I could hear a faint ticking from the left rear side, rear cylinder. Any farther away, and I can't even detect it (I have stock exhaust system). On any other bike, I would normally attribute that to a normal tappet sound. In fact on some bikes (Guzzis), if you don't hear some tapping, it is said that your tappet-valve clearance is too tight.

I don't want to beat this topic to death, but I'm hoping we'll all be a little clearer as to what constitutes a normal tapping sound vs. abnormal, and whether any tapping sound should warrant a rocker frame upgrade/replacement. After seeing the dremel job above, that is not going to be an option for me. Yes, I know it is functionally fine, but it's a hack-job from an engineering point of view. I would only accept a mod that was done with a jig. That's what Harley sells for reboring cases for larger piston, even though a hand grinder and a file would yield the same functional result.

[sadunbar]

OK, thanks. I searched but didn't find pics. I did find a post that said to check for it, fire up a cold engine and put your hand on the rocker cover to feel it. I did that—no tapping feeling. But when I put my ear within 3 inches of the head, I could hear a faint ticking from the left rear side, rear cylinder. Any farther away, and I can't even detect it (I have stock exhaust system). On any other bike, I would normally attribute that to a normal tappet sound. In fact on some bikes (Guzzis), if you don't hear some tapping, it is said that your tappet-valve clearance is too tight.

I don't want to beat this topic to death, but I'm hoping we'll all be a little clearer as to what constitutes a normal tapping sound vs. abnormal, and whether any tapping sound should warrant a rocker frame upgrade/replacement. After seeing the dremel job above, that is not going to be an option for me. Yes, I know it is functionally fine, but it's a hack-job from an engineering point of view. I would only accept a mod that was done with a jig. That's what Harley sells for reboring cases for larger piston, even though a hand grinder and a file would yield the same functional result.

Check this thread for pictures...

http://www.cvoharley.com/smf/index.php?topic=20687.msg330150#msg330150