| Author | Message | ||
     Jetlee |
I picked up a 2001 P3, 4900 miles. It needed rocker box gaskets, carb coupler, filter, spark plug. All was fine until I changed the rocker box gaskets. First question, before I go further, the gasket I got from the local HD/Buell dealer has two single-piece gaskets in it; was I supposed to put both on, or just one? I did one. Now there's a click that seems to come from the rocker box area of the engine. I thought it might be deto as it only happens after warm-up, but changing from 87 to 91 octane has no effect. Occasionally, while cruising, it will lose power for about .5-1 second. My biggest concern is the click/tap. It's faint. You can really only hear it when you're holding speed, not lugging/loading or on decel, just cruising/maintaining speed. Also, when letting out the clutch too fast it clicks pretty loud, but that doesn't bother me as much cause, well, it's a Harley, they do that. Help on the click/tap? I'm very mechanically inclined. I've built engines from scratch, so I know my way around them pretty well. Motorcycles are a new frontier; I may not know where something is, but I know I can do anything to it once located. So, again, help please? lol Thanks! Lee (Message edited by Jet-Lee on October 17, 2008) | ||
| Jetlee |
Oh crap, I remember a tiny piece of paper gasket falling in one of the pushrod tubes, and I forgot to fish it out. Could that cause it? Crap crap crap! lol | ||
| Jetlee |
aaannnd reading some more, I see that I may have two different length pushrods? Is this true? Would having them switched cause this? Yeah...live and learn, eh? | ||
| Jlnance |
Yes, you only need one gasket, so you're good there. The pushrod tubes are different lengths, but only slightly. It will not run right if you switched them. They are also hydrolicly adjusted so if you've got gasket in there, that can't be good. | ||
| Jetlee |
Well, it feels to run right, and I'm about 95% sure I put the pushrods in the right tubes (didn't know they were marked!). It was dark, maybe the gasket missed and just blew elsewhere? I know I didn't feel anything unusual when putting the pushrod back. Could incorrect spark gap cause this noise? What about timing? Thanks! | ||
| Bombardier |
Sounds like your extra piece of gasket has found its way into the oil gallery of one of the lifters. | ||
| Bluzm2 |
If you pull it apart again the exhaust pushrod should have a black band on it. The intake has orange. The exhaust is about .050 longer than the intake. If you got the paper two piece gasket, your dealer should be slapped upside the head. They were obsoleted long ago. The correct gasket is a single piece rubber coated steel unit. This is for the lower gasket. The upper is a two piece o-ring type deal. One for the outer part and a smaller inner one for the chimney. If the piece of old gasket fell into the pushrod tube while the pushrod was out, it may be covering the oil hole on the top of the lifter that lets oil go up the pushrod into the rockerbox. I'd seriously consider pulling it apart to check. Bad things can happen if you don't get proper oiling on the top... Brad | ||
| Jetlee |
Ok, pulled apart again. No bands on the pushrods, but I put the longer one on the exhaust side, I did it right the first time. No gasket in the pushrod tube. The cutting out at cruise is the spark plug. Running the old Champion at the moment. Next? Thanks guys! | ||
| Jetlee |
Now that I have more time... Bluzm, it's an '01 with 4900 miles, it came stock with the paper gasket. I yanked it all apart to find that there were no bands on the pushrods. I looked those things over good, still nothing. I compared lengths, I had the longer on the exhaust side, just like s'posed to, so I put them back. Well, not before pullin the head, and pushrod cover in search of that gasket piece; not found. Put all back together (new gaskets of course), changed spark plug from H-D one from dealer (gapped at .038") back to the one that came in it (some Champion plug, gapped @ .038"). Took it out for a spin. No more occasional cutting out (cough) at cruise, although there was some stutter down low when cold. Brought it back in, made a .010" shim for the needle and switched back to the HD plug. cough was back, but no stutter. Back to Champion plug, no stutter, no cough. Click's still there, throughout. Hasn't gotten any worse. Even ran the bike up to ~92mph (Interstate), not any louder afterwards. My plug is scorched, though. Not charred, from too rich, but scorched like it's too lean. The jets are stock. Could the idle needle need adjusting? Is the engine pinging? Take a wrench and tap the rocker box, that's what it sounds like. (Message edited by jetlee on October 18, 2008) | ||
| Bombardier |
Is the plug white on the electrode? If yes then it is running lean. If no then its not. Try idling the bike and spraying the rubber intake with butane. The gas that is used in lighters. This is the recommended test for a leaking intake gasket/boot. If the revs change chances are the intake boot needs replacing and the clicking you are getting is pre-ignition. Not a good thing. Good way to hole a piston. | ||
| Jetlee |
plug = white-ish Tried carb cleaner and starter fluid on the boot last night, no beans. I pulled the shim off the needle. Backed out the idle screw 1/2 turn (it's at 3 total now). It's still on the stock jets (165/42). No difference in click after changes. So far it's had... Cough/stutter/cut-out Click Gasket fell in pushrod tube (I thought) but cannot be located since tearing down engine. Stutter goes away when NOT using H-D plugs. Stopped oil leak by changing rocker box gaskets. Stopped fuel leak by changing carb coupler Click is unaffected by .010" shim on needle, 1/2 turn out of idle mixture screw, spark plug, fuel octane rating, riding style. I've got an oil change coming up, maybe that'll yield something. | ||
| Ezblast |
Sounds like a lifter not fully pumped up. Jetting for stock so as not too lean - 45/170, shim needle and air screw 2 1/2 turns out. EZ | ||
| Jetlee |
How far to shim needle? It's currently back at .010" on the 165 jet. Goin' by dealer today to see about new jets. How do I verify the lifter? Thanks for the input, EZ. (Message edited by Jet-Lee on October 20, 2008) | ||
| Ezblast |
.05 has been the best general result. buy a set and replace - its not like they are pricey, but I can't think of anything else, if your primary is adjusted properly. EZ | ||
| Jetlee |
I guess I'll grab a primary gasket and go ahead and yank that and find out. I'll search the vault for a how-to on that process. Thanks again! Lee | ||
| Jetlee |
I've got the 170 main and the 45 slow on order, should be about a week. Will put the main in this evening and shim it to .050" and see how it does. (Message edited by jet-lee on October 22, 2008) | ||
| Bombardier |
The plugs not too long in the reach or the leads shorting out? | ||
| Jetlee |
The plug is identical (in size/shape) to the plug from the dealer, just a different brand (Champion). I'll get the number off it when I pull the tank off this evening. I haven't checked if the lead is shorting or not. Will update this evening. |
