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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Engine » Big Mechanicals: Head, Cyl, Piston, Rod, Crank, Flywheel, Cases, Bearings » Archive through October 22, 2006 » M2 Rear Rockerbox Bolt Access « Previous Next »

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Greycyclone
Posted on Wednesday, May 14, 2003 - 07:51 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I am in the process of replacing the rockerbox gaskets on my M2. I cannot access the right rear bolt on the rear cover because the frame is in the way.

Is there a trick or tool that I can use? The only thing I can think of is to "shorten" my allen wrench to fit it between the frame and cover.
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Reepicheep
Posted on Wednesday, May 14, 2003 - 09:28 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Grey... thats exactly what to do, trim down an old wrench with a hacksaw and keep it handy for future tasks. Since you trim down the short side, it will still be perfectly useful, the one I use all over the bike is the trimmed one, and if anything it works better then when it was "long".

Setting torque when you put it back on is fuzzy. I simply torqued down the remaining accessible bolts with the torque wrench, reached over to one of them with the trimmed allen wrench and loosened it about half a turn, then retightend it about half a turn to get the feel, then did the last bolt purely by feel. Has worked well for two rocker box jobs.

If you want to get fancier about it, you can get a crows foot attachment for your torque wrench, and do some calculations for the offset multiplier for the torque setting. I think American Sportbike also sells a flat top allen wrench for the job if you are a tool junkie.

If you want to get totally basic about it, the correct torque was about as hard as I could comfortably push with a (normal) short allen wrench and my thumb, the wrench was just beginning to deflect.

You do have the new metal lower gaskets, right? And depending on your milage, while you have the rocker boxes off, it would be a good time to check your oil pump drive gear. It is a 20 minute check (one extra gasket replacement), and if it needs to be refreshed, you have to pull the rocker boxes anyway to do it.

I would be inclined to check the oil pump drive gear on any bike with more then 10k miles on it anytime I have the rocker box gaskets off for any other reason. If it fails, you are looking at problems with approaching $1000. If you replace it before then, you are looking at 5 hours work and $15 worth of parts, and you get to see your cams (which in my opinion, is a totally cool experience).
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