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How do I Install 2001 883 Harley Sportster Push Rods

Pushrods, on the exterior of the cylinders on the right side of the engine, are part of an old-fashioned connection between the cam shaft and the exhaust and intake valves on your 2001, 883 cubic centimeter, V-twin Harley engine. Pushrods are specific to 883 and 1200 Sportster engines and Big Twins, but their operation, installation and removal is identical in all 2001 Harley V-Twin engines. Adjustable pushrods can conveniently be adjusted without having to first partially disassemble the top end of the engine. The initial top end job needed to install replacement pushrods is not for novices as clearances are tight, and many tools and some skill are required.

Instructions

1

Close the petcock. Put the motorcycle in fifth gear.

2

Loosen the fender tab screw with an Allen wrench. Remove the seat.

3

Loosen the battery cable from the negative terminal with an open end wrench. Disconnect the cable.

4

Raise the motorcycle on a motorcycle jack until the rear tire clears the ground. Ensure the bike is stable.

5

Remove the front and rear spark plugs with a spark plug socket and a socket wrench.

6

Rotate the engine by rotating the rear wheel. Rotate the engine until the front piston, as viewed through the spark plug hole, is at the top of its stroke and both front lifters are at their lowest point in the compression cycle.

7

Remove the front rocker box cover by loosening the rocker cover bolts with a rocker cover wrench. Remove the metal D-ring. Remove the gasket and discard.

8

Insert a small, flat head screwdriver blade into the cast loop of the spring cap retainer at the top of the rear pushrod cover for the front cylinder.

9

Rotate the screwdriver bottom toward the outboard side while pushing down. Remove the spring cap cover. Repeat the procedure for the other front cylinder pushrod.

10

Collapse the upper and lower push rod covers.

11

Alternately loosen each of the four rocker arm support plate bolts in 1/4 turn increments until all four bolts are loose. Remove the rocker arm support plate assembly.

12

Remove the push rod covers from the cylinder head and lifter cover bores. Remove the three O-rings from the push rod covers and discard.

13

Remove the pushrods by hand.

14

Assemble the new pushrod covers. Insert the pushrod cover adapters in the cover retainers.

15

Insert the new pushrods in the cylinder head and lifter cover bores. Install the new cover O-rings included with the new pushrods.

16

Replace the rocker arm support plate into the rocker housing. Loosely install the four rocker arm support plate bolts.

17

Tighten the four rocker arm support plate bolts in a cross pattern by tightening each bolt 1/4 turn at a time. Final tighten the bolts to 18 to 22 foot pounds of torque with a torque wrench and a "dog bone" torque adapter.

18

Install a new rocker box cover gasket. Replace the D-ring.

19

Replace the rocker box cover. Tighten the rocker box cover bolts in a cross pattern to 20 foot pounds of torque with a torque wrench.

20

Extend the adjusting screws to remove lash in the pushrods.

21

Compress the hydraulic unit in the exhaust lifter four complete turns and tighten the lock nut.

22

Adjust slack in the pushrod with your fingers after waiting five minutes. Repeat all procedures for the rear cylinder.

23

Replace the spark plugs and tighten them with a spark plug socket and socket wrench.

24

Lower and remove the motorcycle jack. Shift the motorcycle into neutral.

25

Start the motorcycle and check for leaks.

Posted by Unknown at 11:45 AM

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Labels: 2001, 883, do, harley, how, i, install, push, rods, sportster