Differences

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--- techtalk:ref:tools124 [2018/05/21 07:56] – [REF: Tools - Sub-024] ixl2relax
+++ techtalk:ref:tools124 [2024/01/24 01:49] (current) – hippysmack
@@ Line 3: / Line 3: @@
 ====== Rocker Box Tools ======
-===== Ironhead Engine =====
+====== Ironhead Engine ======
-  * Keep the extender straight out in front of the wrench. Don't let it move out of line more than a ratchet click or two, otherwise it can affect the torque reading. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2)) \\ [[techtalk:ref:tools123#torque_socket_wrench_extensions_horizontal_with_the_wrench|Read more about torque value changes with the use of extensions here]].
+  * Keep the extender straight out in front of the wrench. \\ Don't let it move out of line more than a ratchet click or two, otherwise it can affect the torque reading. ((Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586&page=2))
+  * If the extension is not used at a 90° angle from the wrench (as in the pics below), you'll need to recalculate torque before using. \\ [[techtalk:ref:tools123#torque_socket_wrench_extensions_horizontal_with_the_wrench|Read more about torque value changes with the use of extensions here]].
 |Torque rocker box bolts to 20 ft lbs. You can use a wrench cut down to 3 inches long and welded to a 3/8 drive socket to get in under the frame and torque those \\ rocker bolts to show 185 inch pounds on a 10 inch torque wrench, to give 240 at the bolt.|||
 |{{techtalk:ref:tools:torque_wrench_extension_1_by_hopper.jpg?direct&300|}}|{{techtalk:ref:tools:torque_wrench_extension_2_by_hopper.jpg?direct&300|}}|{{techtalk:ref:tools:torque_wrench_extension_5_by_hopper.jpg?direct&300|}}|
-|1/2" wrench cut down (box also ground down to fit \\ confined areas)  3/4" socket notched with an angle \\ grinder. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))|Torque wrench extender welded and ready to use. \\ Extension Length: 3" from the center of the drive \\ square to the center of the (intended) bolt. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))|Torquing rear rocker box bolts with torque wrench \\ extender. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))|
+|1/2" wrench cut down (box also ground down to fit \\ confined areas)  3/4" socket notched with an angle \\ grinder. ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586&page=2))|Torque wrench extender welded and ready to use. \\ Extension Length: 3" from the center of the drive \\ square to the center of the (intended) bolt. ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586&page=2))|Torquing rear rocker box bolts with torque wrench \\ extender. ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586&page=2))|
-|{{techtalk:ref:tools:torque_wrench_extension_4_by_hopper.jpg?direct&400|}}|{{techtalk:ref:tools:torque_wrench_extension_3_by_hopper.jpg?direct&300|}}|
+|{{techtalk:ref:tools:torque_wrench_extension_4_by_hopper.jpg?direct&300|}}|{{techtalk:ref:tools:torque_wrench_extension_3_by_hopper.jpg?direct&300|}}|{{:techtalk:ref:tools:torque_with_a_crows_foot_by_hippysmack.jpg?direct&300|}}|
-^  A little cutting, a little welding and you have a special wrench to reach the bolts under the frame. ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=2))  ^^
+^  A little cutting, a little welding and you have a special wrench to reach the bolts under the frame. ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page2?t=395586&page=2))  ^^  T recalculate or not. ((photo by Hippysmack))  ^
-===== Evo Engine =====
+====== Evo Engine ======
+Cutting down Allen wrenches to make them shorter on the end will allow you to get into tight places easier. \\
+It also helps when the ends get rounded which allows the tool to slip in the socket head. \\
+Using a Dremil tool or a file on the end can get rid of the round and help to keep it from slipping. \\
 |{{techtalk:ref:tools:cut_down_allen_1_wrenches_by_hippysmack.jpg?direct&400|}}|{{techtalk:ref:tools:cut_down_allen_3_wrenches_by_hippysmack.jpg?direct&400|}}|
 ^  Allen wrench end cut shorter with a Dremil cut-off blade ((photos by Hippysmack))  ^^
+You can also use a 1/4" ratcheting wrench with 1/4" attachments (cheap attachments are easy to replace). \\
+It's easier to get at Allen heads such as the speedo sender and the rear left rocker cover bolts easy to remove/replace. \\
+It's a slimmer profile ratchet that can be useful at times. ((Sportsterpaul of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/191480-replace-torx-with-conventional/page3#post4135041)) \\
+This is a 'Snap On Blue Point' brand 1/4" and 5/16" offset/reversible wrench ($32 delivered). \\
+|{{:techtalk:ref:tools:offset_wrench_by_aussiegazza.png?direct&300|}}|
+^  Offset wrench for rocker box cover. ((photo by AussieGazza of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-buell-motorcycle-forum-general-discussion/product-reviews/48227-a-hd-toolkit-must-have?postid=1181033#post1013644))  ^
+\\
+Lower inner rocker box bolts (circled in red in the pic below) leave little room between the frame and the bolts for a wrench. \\
+And sometimes you have to turn the bolt one flat at a time due to little space so it takes longer to remove/install those three bolts. \\
+You can buy (or make) tools with a shorter profile to help out with the space issue. \\
+However, it's best to only install the bolts to "snug", then use a 1/4" beam type torque wrench to finish bolt installation. \\
+  * You can buy a three pack of gear ratchet inserts,(1/4”-3/8”-1/2”). \\ That turns the appropriate size gear ratchet into a “slimmer profile" ratchet that can be useful at times. ((sportsterpaul of the XLFORUM))
+  * A company called KATAR makes a wrench specifically for the Evo lower rocker box bolts. Made in the USA. \\ It's a reversible ratcheting box wrench with a deep well 7/16" socket. \\ This allows for removal or installation of the lower rocker box hex nut bolts (5/16" bolts with 7/16" hex heads). \\ It has a long handle and a short profile making it easier to get to the bolts.
+{{:techtalk:evo:oil:91-03_lower_rocker_box_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\
+====== Rocker Arms ======
+See also [[techtalk:evo:engmech04b#rocker_arm_bushing_replacement|Rocker Arm Bushing Replacement]] in the Sportsterpedia. \\
+===== Rocker Arm Bushing Remover =====
+  * (1) 9/16"x18 tapered thread tap
+  * (1) 9/16"x18x1" grade 8 bolt (3/4" to 1-1/2" length will work)
+  * (1) tap wrench to fit the 9/16" tap
+  * (1) drift or punch
+  * (1) Hammer
+{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_14_by_hippysmack.jpg?direct&300|}}
+|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_7_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_9_by_hippysmack.jpg?direct&300|}}|
+|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_11_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_rocker_arm_bushings_12_by_hippysmack.jpg?direct&300|}}|
+===== Rocker Arm Bushing Installer =====
+  * (1) 1/2"x13x5" grade 8 bolt
+  * (2) 1/2" grade 8 washers
+  * (1) 1/2" grade 8 nut
+  * (1) 3/4" box end wrench
+{{:techtalk:evo:engmech:rocker_arm_bushing_tools_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack of the XLFORUM)) {{:techtalk:evo:engmech:replacing_rocker_arm_bushings_22_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack))
+===== Rocker Arm Bushing Reamer (94804-57) =====
+See also [[techtalk:evo:engmech04b#rocker_arm_bushing_replacement|Rocker Arm Bushing Replacement]] in the Sportsterpedia. \\
+This reamer is specially designed for reaming the rocker arm bushings from 1957 to present. \\
+It is the right length and cut to fit into the old bushing on one end of the rocker arm and ream the new bushing in the other end.
+|  "Jims" makes this reamer referenced to HD part number (94804-57) ((photos by Hippysmack))  ||
+|{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:jims_94804-57_rocker_bushing_reamer_2_by_hippysmack.jpg?direct&300|}}|
+===== Lapping Tool for Rocker Arm Bushings =====
+A lapping tool can be made from a 1/2" wooden dowel and a small piece of sandpaper. ((photos by Hippysmack)) \\
+Make the dowel long enough to run the full length of the rocker arm plus enough to get a hand on to turn it (12" or so). \\
+Use a hacksaw blade cut a slot down the middle of one end to hold the sandpaper. \\
+Make the slot longer than the bushing so you can be sure to have contact on the full length of the bushing. \\
+|{{:techtalk:ref:tools:wooden_dowel_lapping_tool_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:wooden_dowel_lapping_tool_2_by_hippysmack.jpg?direct&300|}}|
+Initially cut a piece of sandpaper to go one full revolution around the dowel. ((photos by Hippysmack)) \\
+Too many wraps will not slide into the bushing as it will then be too thick. \\
+You just need to turn or lap the bushing slowly and evenly. \\
+Grit of sandpaper will be determined by the condition of the bore and clearance desired. \\
+Insert the bare end of the dowel into the bushing to lap and exit the dowel out the non lapped bushing. \\
+This will allow you to basically line lap the intended bushing to help keep center between the two. \\
+|{{:techtalk:ref:tools:wooden_dowel_lapping_tool_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:wooden_dowel_lapping_tool_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:wooden_dowel_lapping_tool_5_by_hippysmack.jpg?direct&300|}}|

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