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Mark the breather, as it needs to be installed on its original rocker cover. _______________________________________________ Removing the Cam Gear Case Cover: Note: The cam gear case has 11 Allen screws of various lengths.(The breathers are not interchangable between lower rocker covers). They will need to be replaced back in the same holes from which they were removed.We will be removing one rocker cover / box assembly at a time. Remove all the small bolts except for the 4 larger black colored rocker arm bolts that attach the lower rocker cover to the head.Remove the 4 small hex head screws that attach the upper rocker cover.. The smaller bolts will include 3 small standard type bolts and 2 small hex head bolts per cylinder.You will note that it will not come completely off because the foot peg / foot brake pedal attachment support (its painted black) will interfere with the case.Loosen the 2 large hex head bolts that attach this support. Loosening will allow the support to move outward far enough so the cam gear case can then be removed.Re-attach the rubber oil line to the cam gear case with a new worm clamp prior to installing the case. Insure all bolts are tightened to the proper torque spec.
Once these 4 bolts are removed, the lower rocker cover can be removed.
XLF Portal Forums Sportster Encylopedia XLF Angel Riders Memorial XLF Social Groups XLF Blogs XL Shout-Chat XL Arcade XL Downloads XL Links XL Photo Gallery XL Member List Contact Admin Recommend Us The CYA Legal Stuff (PLEASE READ) done on an 883 engine, however, the procedures may be the same. Cam ID numbers are different as per the Service Manual.
Parts and Supplies List: SE Cam Set, (04-05 specific) P/N 25197-04 1 ea Gasket, Cam Gearcase Cover P/N 25263-90D 1 ea Gasket, Upper Rocker Cover P/N 17353-89A 2 ea Gasket, Lower Rocker Cover (Metal) P/N 16800-84 2 ea Gasket, Center Rocker Box P/N 17358-84A 2 ea Fiber Seal, Upper Rocker Cover Screws P/N 63858-49 8 ea Anti-seize compound, blue 'Loctite', couple cans of spray brake cleaner, paper towels and shop rags _______________________________________________ Removing Seat, Fuel Tank, Air Cleaner, Spark Plugs and Coil Remove the single screw at the back of the seat.
Prior to re-installing the cam gear case, attach the new gasket to the engine case with a little contact cement. ____________________________________________ Re-Installing All Other Components: Re-assemble all other parts in reverse order of disassembly.
That will keep the gasket in place while installing the cam gear case. Note: When installing the metal lower rocker cover gasket, note that the raised bead of the gasket is facing up.