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Author Topic: 1992 Sportster, camshafts (gears?) and pushrods - help!?  (Read 257 times)

Offline Jimbonaut

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Thought it was worth an ask here.  I'm helping a mate out with his sportster and - as is the nature of these things - one thing has led to another.  In replacing the stator we removed the right hand side engine cover which houses the camshaft gear things - getting them back in is now not possible due to downward tension in the pushrods.

Is there an easy (step by step) way that we can relieve this pushrod tension in order to be able to reinstall the cam gears (or whatever they're called)?  We've got the tank off, along with the upper and middle rocker covers.  Cheers guys, any help would be great - I need to get his bike out of my garage asap!
"I'm telling you Donnie, nuthin' but nuthin' but right"

Offline Jimbonaut

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #1 on: Jun 19, 2019, 10:18:34 »
Any ideas gents?
"I'm telling you Donnie, nuthin' but nuthin' but right"

Offline irk miller

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #2 on: Jun 19, 2019, 12:45:53 »
You're supposed to remove the pushrods when you pull the cover and to replace it.  In order to get it back on, you have to line up all four camshafts, the idler gear shaft and the pinion gear shaft- plus the dowel pins.  It's pretty much impossible to do that when you're working against the valve spring pressure.

Offline Jimbonaut

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #3 on: Jun 19, 2019, 13:16:24 »
Cheers Irk - given that all four camshafts have now been removed, what we now need to do is remove (or at least loosen the tension from) the pushrods.  What I'm trying to figure out is how to do that - is it simply a matter of removing the bolts securing the rocker arms?  Would this release pressure on the pushrods themselves, and then allow installation of the four camshafts?
"I'm telling you Donnie, nuthin' but nuthin' but right"

Offline irk miller

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #4 on: Jun 19, 2019, 13:58:12 »
It's been a minute since I built that Hugger Sportster, but if I remember right, you just pull the covers and remove them through the rocker boxes.

Offline Jimbonaut

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #5 on: Jun 19, 2019, 15:36:02 »
Thanks man, that sounds doable.  Replacing the pushrods is no biggy either? 
"I'm telling you Donnie, nuthin' but nuthin' but right"

Offline irk miller

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #6 on: Jun 19, 2019, 15:46:29 »
Thanks man, that sounds doable.  Replacing the pushrods is no biggy either?
No. In fact, S&S sells some killer adjustable pushrods for these Evo motors.  One version allows you to pull them and adjust without
 pulling the rocker cover.

Offline Jimbonaut

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #7 on: Jun 19, 2019, 16:06:04 »
Right on, thanks man, really appreciate the help as always
"I'm telling you Donnie, nuthin' but nuthin' but right"

Offline Jimbonaut

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #8 on: Jun 20, 2019, 12:23:56 »
All buttoned up, no pasa nada.  First time I've had anything to do with the internals of a Sportster - much better understanding now of how the camshaft gears and pushrods work.  Cheers mate.
"I'm telling you Donnie, nuthin' but nuthin' but right"

Offline irk miller

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Re: 1992 Sportster, camshafts (gears?) and pushrods - help!?
« Reply #9 on: Jun 20, 2019, 13:26:19 »
All buttoned up, no pasa nada.  First time I've had anything to do with the internals of a Sportster - much better understanding now of how the camshaft gears and pushrods work.  Cheers mate.
My man.