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[Spanish Flyer]

My dealer already damaged the thread on my gearbox drain during the 500 mile first service (08 Springer), so I was not prepared to leave my jewel there once more, to carry out the "Enhalcement"; I asked him instead to hand me over the kit so I could do the work. He didn't doubt for a moment and just placed it on my hands. He will still keep the bike under warranty and I guess he will also get paid for NOT doing the job    

Since my head gaskets are not leaking, I am only doing the ACR's since they are both shot and starting each time is a big effort for my engine.

Anyway, I'm half way through having done the rear ACR and my question is simple.

How come the Rocker Boxes don't have dowel pins to hold everything in place prior to tightening the bolts??  As I place the new gasket on the cylinder head and then place the rocker box lower part, the whole thing moves about and even when I have placed all bolts I can still move it A LOT due to the tolerande the bolts allow..... 

Just a couple of short dowel pins would align everything perfectly and rockers, valves and pushrods would go EXACTLY to the same place even if you removed them a thousand times.

So the question is simple, Why don't they have any? (at least my engine doesn't..... FXSTSSE2 08).

Spanish Flyer

[ice6900]

simple answer " to cut costs"   nah  seriously is there enough physical room between the engine and the framework to be able to fit and remove covers if you had to place them over the dowels?

[Spanish Flyer]

Hi ice6900,
To your question, yes there is more than enough room for the dowel pins; FYI some of the bolts cannot be removed till you have taken out the rocker covers; in my case one of the breather system top cover bolts, one lower rocker box bolts and one rocker fixing bolts, that hit the frame if you try to remove them while the box is in place. This means you have almost 1 inch clearance, so that's no excuse 

And....this means that a set of dowels on the lower rocker box and another set on the rocker's block would really do the trick. There are two issues that not having the dowels brings; one that it is difficult to hold everything in place while tightening as the gasket tends to slide or move and the worst in my opinion, that pushrods, rockers and valve stems will never align in the exact same place as they used to be and that is BAD; the contact surfaces and rod angle will vary and even if it is very slight (taking a lot of care); most important it will still vary the whole geometry of the system and new wear areas  and patterns will arise.


Spanish Flyer

[HDDOCFL]

I use tappet block alinment pins to center the bottom plate , use the holes the breather uses, after you tighten the base plate remove the alinment pins and replace the breather assy. and tighten it. Centers the base plate and nothing moves while tighting the plate.   Doc

[HILLSIDECYCLE.COM]

In regards to the ACR issues, we have requests from our clients to install manual realeses at the point of cylinder head mods.
Scott

[Spanish Flyer]

Great idea HDDOCFL! that will sort out all the alignment issues, problem is that in my case I don´t have tappet block alignment pins either, At least my bike didn't have any (I guess you are talking about the rocker blocks...). Could you please explain what part # you are talking about?

And Hillsidecycle.com, thanks for your info; I have seen very few forum members happy after replacing the ACR's, but having noticed that the replacement ones are totally different (better design and tougher looks) I thought they would  be a worthwhile replacement... 

When you mention manual releases, do you mean a small trigger on the bars with a cable system to pull and open when starting the engine?

Best Regards,
Spanish Flyer

[HILLSIDECYCLE.COM]

No,
They are located next to the spark plugs, and are pushed in prior to starting.
The engines compression then pops them closed.

[HDDOCFL]

Not really a good pic of the tappet block pin but you get the idea.   Doc

[HDDOCFL]

Better pic of the pins. Doc

[grc]

After seeing how "sloppy" H-D made this fit, is it now more evident why so many have had valve spring retainers rubbing?  The answer is to use an alignment device like the one mentioned by HDDOCFL, either the "official" ones or a homemade version.  If you wait for H-D to add dowels or just size the holes properly and use a shouldered bolt, you will be very, very old and motorcycles will probably be obsolete anyway.

Jerry

[HD Street Performance]

Use the tappet pins!
Another option is use copper pipe ferrules on screws and make your own

[Spanish Flyer]

Ok, the engine is back together and running fine, but not very pleased with the dowel pin issue; if I replace the Head gaskets at a later stage, will machine the rocker boxes to hold short dowels.

Apart from that and, Oh yes, the fact that the ACR tool is too weak and had to make myself another, everything else was OK. With the new ACR's the bike starts easier (or that's what I have made myself believe.. ).

I took a load of pics and uploaded them to my albums, so if anyone is bored or really wants to check something, please go ahead and take a look. I really love this Springer, and the first ride after the repair was just incredible.

http://imageevent.com/wforest/acrreplacementcvospringer08;jsessionid=fh008erkq1.tiger_s

Thanks for your help, and have a drink on the house; I pay 

Spanish Flyer

[HD Street Performance]

You need to make your own tool out of a mill slotted 12pt deep socket and make a wedding band on the lathe to support the opening at the bottom. The band needs to be thin enough to still fit the recess. If you want a photo I can post

[johnsachs]

Somewhere on THIS forum,I posted a picture of a tool I made(Jan - March).It'll pull 50 ft lbs. with no flex.
John

[HILLSIDECYCLE.COM]

Zipped up the same tool here.
Guess that is the glory of owning a machine shop.
Scott